1362992205L200w-woperationwmanual,wDENSO

8/12/2019 1362992205L200w-woperationwmanual,wDENSO

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Diesel Injection Pump

Common Rail System (HP3)

for MITSUBISHI L200/TRITON

4D56/4M41Engine

(All the destinations)OPERATION

June, 2005

TG00400010E

SERVICE MANUAL

DENSO INTERNATIONAL THAILAND CO., LTD.


2/53

2005 DENSO INTERNATIONAL THAILAND

All Rights Reserved. This book may not be reproducedor copied, in whole or in part, without the writtenpermission of the publisher.


3/53

Table of Contents

Table of Contents

Operation Section

1. PRODUCT APPLICATION INFORMATION

1.1 Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 System Components Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2. OUTLINE OF SYSTEM

2.1 Common Rail System Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

2.2 Features of Injection Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

2.3 Comparison to the Conventional System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

2.4 Composition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

2.5 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42.6 Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

2.7 Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

3. SUPPLY PUMP

3.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

3.2 Exterior View Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

3.3 Supply Pump Internal Fuel Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

3.4 Construction of Supply Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

3.5 Operation of the Supply Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

4. SUPPLY PUMP COMPONENT PARTS

4.1 Feed Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

4.2 SCV ( Suction Control Valve ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

4.3 Fuel Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

5. RAIL

5.1 Outline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

6. RAIL COMPONENTS PARTS

6.1 Rail Pressure Sensor (Pc Sensor). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

6.2 Pressure limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15

7. INJECTOR (G2 TYPE)

7.1 Outline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

7.2 Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

7.3 Exterior View Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17

7.4 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

7.5 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18

7.6 QR Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19

7.7 Injector Actuation Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21


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Table of Contents

8. FUEL FILTER

8.1 Fuel Filter for Low lubricating specification.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

9. OPERATION OF CONTROL SYSTEM COMPONENTS

9.1 Engine Control System Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

9.2 Engine ECU (Electronic Control Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23

9.3 Cylinder Recognition Sensor (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

9.4 Turbo Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

9.5 Mass Air Flow Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25

9.6 Electronic Control Throttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

10. VARIOUS TYPES OF CONTROL

10.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

10.2 Fuel Injection Rate Control Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

10.3 Fuel Injection Quantity Control Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

10.4 Fuel Injection Timing Control Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

10.5 Fuel Injection Pressure Control Function (Rail Pressure Control Function) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28

11. FUEL INJECTION QUANTITY CONTROL

11.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29

11.2 Injection Quantity Calculation Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29

11.3 Set Injection Quantities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29

12. FUEL INJECTION TIMING CONTROL

12.1 Ouline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33

12.2 Main and Pilot Injection Timing Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33

12.3 Microinjection Quantity Learning Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34

13. FUEL INJECTION RATE CONTROL

13.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

14. FUEL INJECTION PRESSURE CONTROL

14.1 Fuel Injection Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37

15. DIAGNOSTIC TROUBLE CODES (DTC)

15.1 About the Codes Shown in the Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38

15.2 Diagnostic Trouble Code Details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38

16. EXTERNAL WIRING DIAGRAM

16.1 Engine ECU External Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44

16.2 Engine ECU Connector Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45


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Operation Section11

1. PRODUCT APPLICATION INFORMATION

1.1 Application

1.2 System Components Part Number

Vehicle Manufac-

ture

Vehicle Name Engine Model Specification Destination (Vol-

ume)

Line Off Period

MITSUBISHITRITON

4D562WD(MT/AT)

Thailand June ,20054WD(MT)

4M41 4WD(MT/AT)

4M41 4WD(MT) Oceania May ,2006

4D562WD(MT/AT) Middle East , Rus-

sia ,Others

July , 2006

4WD(MT)

L200 4D56 4WD (AT) Europe Dec, 2005

Parts Name DENSO P/N Manufacturer P/N Remarks

Supply pump SM294000-0331 1460A001 For 4D56 Engine model

Supply pump SM294000-0341 1460A003 For 4M41Engine model

Supply pump SM294000-0640 1460A019 For 4D56 Low lubricating model

Injector SM095000-5600 1465A041 For 4D56 Engine model

Injector SM095000-5760 1465A054 For 4M41Engine model

Rail SM095440-0640 1465A034 All

Engine ECU MA275800-4364 1860A549 For 4WD, W/O PTC for Europe market

MA275800-4374 1860A550 For 4WD W PTC for Europe market

MA275800-3574 1860A390 For 4WD/ 4M41 Thailand and Oceania

model

MA275800-4254 1860A392 For 4D56 / 4WD Thailand model

MA275800-4314 1860A523 For 4D56 / 2WD MT Thailand model

MA275800-4324 1860A524 For 4D56 / 2WD AT Thailand model

MA275800-7131 1860A767 For 4D56 Low lubricating model (Mid-

dle East , Russia , others )

MA275800-4602 1860A586 For 4WD/ 4M41 Oceania model

Turbo pressure sensor 079800-5960 MR577031 All

Cylinder recognitioin sensor

(TDC)

949979-1590 1865A074 For Thailand model 4M41

Electronic control throttle 197920-0020 1450A033 For 4M41/4D56 4WD Thailand model

Fuel temperature sensor 179730-0020 MR547077 All

Mass air flow meter VN197400-4030 1460A001 All

Fuel Filter 186000-6090 1770A048 Normal / For Low lubricating fuel spec.

186300-6240 1770A049 W/PTC heater for cold area spec./ For

Low lubricating fuel spec.


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Operation Section12

2. OUTLINE OF SYSTEM

2.1 Common Rail System Characteristics The common rail system uses a type of accumulation chamber called a rail to store pressurized fuel, and injectors that contain elec-

tronically controlled solenoid valves to inject the pressurized fuel into the cylinders. Because the engine ECU controls the injection

system (injection pressure, injection rate, and injection timing), the injection system is independent, and thus unaffected by the engine

speed or load. This ensures a stable injection pressure at all times, particularly in the low engine speed range, and dramatically de-

creases the amount of black smoke ordinarily emitted by a diesel engine during start-up and acceleration. As a result, exhaust gas emis-

sions are cleaner and reduced, and higher power output is achieved.

2.2 Features of Injection Control

(1) Injection Pressure Control

Enables high-pressure injection even at low engine speeds.

Optimizes control to minimize particulate matter and NOx emissions.

(2) Injection Timing Control

Enables finely tuned optimized control in accordance with driving conditions.

(3) Injection Rate Control

Pilot injection control injects a small amount of fuel before the main injection.

Q001223E

Common Rail System

Injection Pressure Control Injection Timing Control Injection Rate Control

Optimization, High Pressurization

Common RailSystem

ConventionalPump

ConventionalPump

Speed SpeedInjection Pressure

Optimization

Common RailSystem

Particulate

NOx

InjectionTiming

Speed

Injection Quantity Control

Cylinder InjectionQuantity Correction

Pre-Injection

Main Injection

Crankshaft AngleInjection

Rate

InjectionPressure

1 3 4 2


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Operation Section13

2.3 Comparison to the Conventional System

< NOTE >

*1 : TWV: Two Way Valve

*2 : SCV: Suction Control Valve

2.4 Composition

The common rail system consists primarily of a supply pump, rail, injectors, and engine ECU.

In-line, VE Pump Common Rail System

System

Injection

Quantity

Control

Pump (Governor) Engine ECU, Injector (TWV)*1

Injection

Timing

Control

Pump (Timer) Engine ECU, Injector (TWV)*1

Rising

Pressure

Pump Engine ECU, Supply Pump

Distributor Pump Engine ECU, Rail

Injection

Pressure

Control

Dependent upon Speed and Injection Quantity Engine ECU, Supply Pump (SCV)*2

Q001224E

High-pressure PipeMomentary

High Pressure

NozzleGovernor

Timer

In-line Pump

VE Pump Q001225E

Rail

Usually High Pressure

Supply Pump

Injector

Feed Pump SCV (Suction Control Valve)

Delivery Valve

Fuel Tank


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Operation Section14

2.5 Operation

(1) Supply Pump (HP3)

The supply pump draws fuel from the fuel tank, and pumps the high pressure fuel to the rail. The quantity of fuel discharged from the

supply pump controls the pressure in the rail. The SCV (Suction Control Valve) in the supply pump effects this control in accordance

with commands received from the engine ECU.

(2) Rail

The rail is mounted between the supply pump and the injector, and stores the high-pressure fuel.

(3) Injector (G2 type)

This injector replaces the conventional injection nozzle, and achieves optimal injection by effecting control in accordance with signals

from the engine ECU. Signals from the engine ECU determine the duration and timing in which current is applied the injector. This

in turn, determines the quantity, rate and timing of the fuel that is injected from the injector.

(4) Engine ECU

The engine ECU calculates data received from the sensors to comprehensively control the injection quantity, timing and pressure, as

well as the EGR (exhaust gas recirculation).

2.6 Fuel System

This system comprises the route through which diesel fuel flows from the fuel tank via the rail to the supply pump, and is injected

through the injector, as well as the route through which the fuel returns to the tank via the overflow pipe.

2.7 Control System

In this system, the engine ECU controls the fuel injection system in accordance with signals received from various sensors. The com-

ponents of this system can be broadly divided into the following three types: (1) sensors; (2) ECU; and (3) actuators.

Fuel Temperature

Accelerator OpeningTurbo Pressure,Atmospheric Air Pressure

Intake Airflow Rate

Rail PressureSensor

Rail

Engine ECU

Fuel Temperature Sensor

Supply PumpFuel Tank

Injectors

PressureLimiter

SCV(SuctionControl Valve)

Intake Air Temperature

Coolant TemperatureCrankshaft position

Cylinder Recognition Position

Q001226E

Engine Speed


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Operation Section15

(1) Sensors

Detect the engine and driving conditions, and convert them into electrical signals.

(2) Engine ECU

Performs calculations based on the electrical signals received from the sensors, and sends them to the actuators in order to achieve

optimal conditions.

(3) Actuators

Operate in accordance with electrical signals received from the ECU. Injection system control is undertaken by electronically control-

ling the actuators. The injection quantity and timing are determined by controlling the duration and timing in which current is applied

to the TWV (Two-Way Valve) in the injector. Injection pressure is determined by controlling the SCV (Suction Control Valve) in the

supply pump.

Q001227E

Crankshaft Position Sensor (NE)

Accelerator Position Sensor

Engine Speed

Cylider Recognition Sensor (TDC)

CylinderRecognition

Load

Injector

Supply Pump (SCV)

Injection Quantity ControlInjection Timing Control

Fuel Pressure Control

Other Sensors and Switches EGR, Air Intake Control Relay, Light

Sensor Actuator

EngineECU


10/53

Operation Section16

3. SUPPLY PUMP

3.1 Outline The supply pump consists primarily of the pump body (eccentric cam, ring cam, and plungers), SCV (Suction Control Valve), fuel

temperature sensor, and feed pump.

The two plungers are positioned vertically on the outer ring cam for compactness.

The engine drives the supply pump at a ratio of 1:1. The supply pump has a built-in feed pump (trochoid type), and draws the fuel

from the fuel tank, sending it to the plunger chamber.

The internal camshaft drives the two plungers, and they pressurize the fuel sent to the plunger chamber and send it to the rail. The

quantity of fuel supplied to the rail is controlled by the SCV, using signals from the engine ECU. The SCV is a normally open type

(the intake valve opened during de-energization).

Q001265E

InjectorRail

Discharge Valve

Regulating Valve

Feed Pump

Intake

Fuel Inlet

Fuel Overflow

Fuel Tank

Camshaft

Intake pressureFeed pressure

High pressure

Return pressure

Return

Fuel Filter (with Priming Pump)

Filter

Suction Valve

Plunger

Return Spring

SCV


11/53

Operation Section17

3.2 Exterior View Diagram

4D56 Engine Model

4M41 Engine Model

3.3 Supply Pump Internal Fuel Flow

The fuel that is drawn from the fuel tank passes through the route in the supply pump as illustrated, and is fed into the rail.

Q001253E

From Fuel Tank

Overflow to Fuel Tank

To Rail


SCV

* For Low Lubricating spec. the Exterior view same as normal spec

Normal Spec. : Injection pressure 180 MPa

Low Lubricating Spec. : Injection pressure 135 MPa

Q001228E

FromFuel Tank

Overflow to Fuel Tank

To RailFuel

Temperature

Sensor

SCV

*For Low Lubricating spec. the Exterior view same as normal spec

Normal Spec. : Injection pressure 180 MPa

Low Lubricating Spec. : Injection pressure 135 MPa


12/53

Operation Section18

3.4 Construction of Supply Pump

The eccentric cam is attached to the drive shaft. The eccentric cam is connected to the ring cam.

As the drive shaft rotates, the eccentric cam rotates eccentrically, and the ring cam moves up and down while rotating.

The plunger and the suction valve are attached to the ring cam. The feed pump is connected to the rear of the drive shaft.

Supply pump interior

Regulating valve

Feed pump

Overflow

Fuel tank

SCV (Suction Control Valve)

Intake valve

Discharge valve

Pumping portion (plunger)

Rail

QD0705E

QD0706E

Cam Shaft

Eccentric Cam Ring Cam

Q001233E

Ring Cam

Eccentric Cam

Cam Shaft

Plunger


13/53

Operation Section19

3.5 Operation of the Supply Pump

As shown in the illustration below, the rotation of the eccentric cam causes the ring cam to push Plunger A upwards. Due to the spring

force, Plunger B is pulled in the opposite direction to Plunger A. As a result, Plunger B draws in fuel, while Plunger A pumps it to the

rail.

Q001234E

Plunger A

Ring Cam

Plunger B

Feed Pump


14/53

Operation Section110

Q001235E

SCV

Plunger A: Finish Compression

Plunger B: Finish Intake

Plunger A: Finish Intake

Plunger B: Finish Compression

Plunger A: Begin Intake

Plunger B: Begin Compression

Plunger A: Begin Compression

Plunger B: Begin Intake

Suction Valve

Plunger A

Plunger B

Discharge Valve

Eccentric Cam

Ring Cam


15/53


4. SUPPLY PUMP COMPONENT PARTS

4.1 Feed Pump The trochoid type feed pump, which is integrated in the supply pump, draws fuel from the fuel tank and feeds it to the two plungers

via the fuel filter and the SCV (Suction Control Valve). The feed pump is driven by the drive shaft. With the rotation of the inner rotor,

the feed pump draws fuel from its suction port and pumps it out through the discharge port. This is done in accordance with the space

that increases and decreases with the movement of the outer and inner rotors.

4.2 SCV ( Suction Control Valve )

A linear solenoid type valve has been adopted. The ECU controls the duty ratio (the duration in which current is applied to the SCV),

in order to control the quantity of fuel that is supplied to the high-pressure plunger.

Because only the quantity of fuel that is required for achieving the target rail pressure is drawn in, the actuating load of the supply

pump decreases.

When current flows to the SCV, variable electromotive force is created in accordance with the duty ratio, moving the cylinder (inte-

grated with the armature) to the left side, and changing the opening of the fuel passage to regulate the fuel quantity.

With the SCV OFF, the return spring contracts, completely opening the fuel passage and supplying fuel to the plungers. (Full quantity

intake and full quantity discharge = normally open)

When the SCV is ON, the force of the return spring moves the cylinder to the left, closing the fuel passage (normally open).

By turning the SCV ON/OFF, fuel is supplied in an amount corresponding to the actuation duty ratio, and fuel is discharged by the

plungers.

QD0708E

Outer Rotor

FromFuel Tank

Intake Port

ToPump Chamber

Discharge

Port

Quantity Decrease

Quantity Increase

Quantity Decrease(Fuel Discharge)

Quantity Increase(Fuel Intake)

Inner Rotor

Q001113E

Valve body

Needle valve

Return Spring


16/53


(1) SCV Opening Small (Duty ON time long - Refer to the "Relationship Between Actuation

Signal and Current" Diagram.)

When the opening of the SCV is small, the fuel suction area is kept small, which decreases the transferable fuel volume.

(2) SCV Opening Large (Duty ON time short - Refer to the "Relationship Between Actuation

Signal and Current" Diagram.) When the opening of the SCV is large, the fuel suction area is kept large, which increases the transferable fuel volume.

Q001114E

Feed Pump

Needle valve Small Opening

Q001115E

Feed Pump

Needle valve Large Opening


17/53


(3) Diagram of Relationship Between Actuation Signal and Current (Magneto motive Force)

4.3 Fuel Temperature Sensor

Detects the fuel temperature and sends a corresponding signal to the engine ECU. Based on this information, the engine ECU calcu-

lates the injection volume correction that is appropriate for the fuel temperature.

Q001116E

Average Current D ifference

Small Suction Volume Large Suction Volume

ActuationVoltage

Current

ON

OFF

Q001237E

RESISTANCE(C) (k )TEMPERATURE

- 30 (25.40)

(9.16)

(1.66)

(1.15)

(0.811)

(0.584)

(0.428)

(0.240)

(0.1836)

(0.1108)

(5.74)

(3.70)

15.40 + 1.29- 1.20

+ 0.14- 0.132.45

0.318 0.008

0.1417 0.0018

- 20

- 10

10

20

30

40

50

60

70

80

90

100

110

120

0


18/53


5. RAIL

5.1 Outline Stores pressurized fuel (25 to 180 MPa) that has been delivered from the supply pump and distributes the fuel to each cylinder injector.

A rail pressure sensor and a pressure limiter valve are adopted in the rail.

The rail pressure sensor (Pc sensor) detects fuel pressure in the rail and sends a signal to the engine ECU, and the pressure limiter

controls the excess pressure. This ensures optimum combustion and reduces combustion noise.

Q001236E

Pressure SensorPressure Limiter


19/53


6. RAIL COMPONENTS PARTS

6.1 Rail Pressure Sensor (Pc Sensor) The pressure sensor detects the fuel pressure of the rail, and sends a signal to the engine ECU. The sensor is made from a semicon-

ductor that uses the Piezo resistive effect to detect changes in electrical resistance based on the pressure applied to the elemental sili-

con. In comparison to the old model, this sensor is compatible with high pressure.

6.2 Pressure limiter

The pressure limiter releases pressure when the internal pressure of the rail becomes abnormally high. The pressure limiter opens when

internal pressure reaches 221MPa (2254 kg/cm2) and closes when rail pressure reaches a given set pressure. Fuel released from the

pressure limiter is returned to the fuel tank.

Q001238E

Vout/Vc

A-VCC A-GNDPFUEL

Vc = 5V

(Mpa)Popt

2001601002000

0.20.264

0.712

0.84

0.52

Q001239E

Valve Open

Valve Close50 MPa (509.5 kg/cm2)

221 MPa (2254 kg/cm2)

From rail

To fuel tank


20/53


7. INJECTOR (G2 TYPE)

7.1 Outline The injectors inject the high-pressure fuel from the rail into the combustion chambers at the optimum injection timing, rate, and spray

condition, in accordance with commands received from the ECU.

7.2 Characteristics

A compact, energy-saving solenoid-control type TWV (Two-Way Valve) injector has been adopted.

QR codes displaying various injector characteristics and the ID codes showing these in numeric form (30 alphanumeric figures) are

engraved on the injector head. The common rail system optimizes injection volume control using this information. When an injector

is newly installed in a vehicle, it is necessary to enter the ID codes in the engine ECU using the MITSUBISHI diagnosis tool (MUT

III).


21/53


7.3 Exterior View Diagram

Q001244E


22/53


7.4 Construction

7.5 Operation

The TWV (Two-Way Valve) solenoid valve opens and closes the outlet orifice to control both the pressure in the control chamber,

and the start and end of injection.

(1) Non injection

When no current is supplied to the solenoid, the spring force is stronger than the hydraulic pressure in the control chamber. Thus, the

Q001240E

QR Codes

30 Alphanumeric Figures

Pressurized Fuel

(from Rail)

Seat

Leak Passage

Multiple Hole Filter

Pressurized Fuel

Command Piston

Nozzle Spring

Pressure Pin

Nozzle Needle

Control Chamber


23/53


solenoid valve is pushed downward, effectively closing the outlet orifice. For this reason, the hydraulic pressure that is applied to the

command piston causes the nozzle spring to compress. This closes the nozzle needle, and as a result, fuel is not injected.

(2) Injection

When current is initially applied to the solenoid, the attraction force of the solenoid pulls the solenoid valve up, effectively openingthe outlet orifice and allowing fuel to flow out of the control chamber. After the fuel flows out, the pressure in the control chamber

decreases, pulling the command piston up. This causes the nozzle needle to rise and the injection to start.

The fuel that flows past the outlet orifice flows to the leak pipe and below the command piston. The fuel that flows below the piston

lifts the piston needle upward, which helps improve the nozzle's opening and closing response.

(3) End of Injection

When current continues to be applied to the solenoid, the nozzle reaches its maximum lift, where the injection rate is also at the max-

imum level. When current to the solenoid is turned OFF, the solenoid valve falls, causing the nozzle needle to close immediately and

the injection to stop.

7.6 QR Codes

Conventionally the whole injector Assy was replaced during injector replacement, but QR (Quick Response) codes have been adopted

to improve injector quantity precision.

Q001241E

Injection Rate

ControlChamberPressure



Solenoid

TWV

Outlet Orifice

Inlet Orifice

CommandPiston

NozzleInjection Rate Injection Rate

Non-Injection Injection End of Injection

Rail

ActuatingCurrent

ActuatingCurrent

ActuatingCurrent

To Fuel TankLeak Passage

TWV


24/53


4D56 Engine Model

4M41 Engine Model

QR codes have resulted in a substantial increase in the number of fuel injection quantity correction points, greatly improving precision.

The characteristics of the engine cylinders have been further unified, contributing to improvements in combustion efficiency, reduc-

tions in exhaust gas emissions and so on.

(1) Repair Procedure

When replacing injectors with QR codes, or the engine ECU, it is necessary to record the ID codes in the ECU. (If the ID codes for

the installed injectors are not registered correctly, engine failure such as rough idling and noise will result). The ID codes will be reg-

istered in the ECU at a MITSUBISHI dealer using approved MITSUBISHI tools.

Q001243E

ID Codes (30 base 16 characters)Base 16 characters noting fuelinjection quantity correctioninformation for market service use

QR Codes ( 9.9mm)

Q001242E

ID Codes (30 base 16 characters)Base 16 characters noting fuelinjection quantity correctioninformation for market service use

QR Codes ( 9.9mm)

Q001245E

InjectionQuantityQ

180 Mpa

80 Mpa

112 Mpa

135 Mpa

48 Mpa

25 Mpa

Actuating Pluse Width TQ

InjectionQuantityQ

180 Mpa

64 Mpa

96 Mpa130 Mpa

48 Mpa

25 Mpa

Actuating Pluse Width TQ

Correction

8 Points

Correction

8 Points


25/53


Replacing the Injector

Replacing the Engine ECU

7.7 Injector Actuation Circuit

In order to improve injector responsiveness, the actuation voltage has been changed to high voltage, speeding up both solenoid mag-

netization and the response of the TWV. The EDU or the charge circuit in the ECU raises the respective battery voltage to approxi-

mately 85V, which is supplied to the injector by signal from the ECU to actuate the injector.

Q001133E

"No correction resistance, cannot be detected electrically"

Replaced injector

Engine ECU

* Injector ID code must be registered with the engine ECU

Q001134E

"No correction resistance, cannot be detected electrically"

* Injector ID code must be registered with the engine ECU

Vehicle injectors

Replaced engine ECU

Q001246E

ConstantAmperage Circuit

High Voltage Generation Circuit

ECU

Actuating Current

2WV#3 (No.4 Cylinder)


Injector

Common 1




26/53


8. FUEL FILTER

8.1 Fuel Filter for Low lubricating specification.

Item Fuel Filter (Nomal)Fuel Filter (W/PTC heater)

Heater Element

Vacuum Switch

Supply Pump

Fuel Tank Common Rail Injector

Engine

Fuel filter assy

Fuel filter assy Supply Pump

Fuel Tank Common Rail Injector

Engine

Fuel Supply route Fuel Supply route1.

Fuel Inlet

Fuel Outlet

Q001522E

: Fuel flow direction : Fuel flow direction


27/53


9. OPERATION OF CONTROL SYSTEM COMPONENTS

9.1 Engine Control System Diagram

9.2 Engine ECU (Electronic Control Unit)

This is the command center that controls the fuel injection system and the engine operation in general.

Q001247E

Rail

Rail Pressure Sensor

(Pc Sensor) Pressure limiter

injector

Engine ECU

SCV

(Sucton Control Valve)

Glow Relay

Crankshaft Position Sensor

(NE Sensor)

Cylinder Recognition

Position Sensor

(TDC Sensor)

Turbo PressureSensor

Electronic ControlThrottle

Fuel Tank

Accelerator Position Sensor

Ignition Switch Signal

Starter Signal

Vehicle Speed Signal

Mitsubishi Diagnosis Tool (MUT-III)

Battery Voltage

Other Signals

Air Mass Flow Sensor

(With Intake Air Temperature)

Fuel Temperature

Sensor

Coolant

Temperature

Sensor


28/53


9.3 Cylinder Recognition Sensor (TDC)

Outputs a cylinder identification signal. The sensor outputs 5 pulses for every two revolutions (720CA) of the engine.

9.4 Turbo Pressure Sensor

This is a type of semi-conductor pressure sensor. It utilizes the characteristics of the electrical resistance changes that occur when the

pressure applied to a silicon crystal changes. Because a single sensor is used to measure both turbo pressure and atmospheric pressure,

a VSV is used to alternate between atmospheric and turbo pressure measurement.

Q001248E

Engine ECU

Detection Calculation Actuation

Sensor Actuator

Q001249E

30CA 180CA 180CA

720CA

180CA

5V

1V

0V

Pulser

SensorSignal

Vcc

GND

OUT

Q001229E

GND PBVC


29/53


(1) Atmospheric Pressure Measurement Conditions

The VSV turns ON for 150msec to detect the atmospheric pressure when one of the conditions below is present:

Engine speed = 0rpm

Starter is ON

Idle is stable

(2) Turbo Pressure Measurement Conditions

The VSV turns OFF to detect the turbo pressure if the atmospheric pressure measurement conditions are absent.

9.5 Mass Air Flow Sensor

This air flow meter, which is a plug-in type, allows a portion of the intake air to flow through the detection area. By directly measuring

the mass and the flow rate of the intake air, the detection precision has been improved and the intake air resistance has been reduced.

This mass air flow meter has a built-in intake air temperature sensor.

Q001231E

VSV Atmosphere

Turbo Pressure Sensor

Intake Manifold

0.5

4.5

3.2

VC = 5 V

266.6

Absolute Pressure

66.6 202.7

500 20001520

PB(V)

kPa (abs)

mmHg (abs)

ECU


Pressure Sensor Device

Engine ECU

Constant VoltagePower Supply

Microcomputer

Input SignalProcessing Circuit

Vc

PB

GND


30/53


9.6 Electronic Control Throttle

(1) Outline

The suctioning of air is stopped through interlocking the intake throttle with the key switch in order to reduce engine vibration when

the vehicle is turned off.

Q001260E

Engine ECUEFI Main Relay

Airflow MeterPower Supply

VG

+B

EVG

IC

THAE2

Intake Air

Voltage Detection

Voltage Detection

PowerSupply

Intake AirTemperature Sensor

HeatingElement

Air Thermometer

5V

Temperaturesensingelement

E2 THA VG E2 G +B

Heatingelement

Temperaturesensor

Air

Air Flow-VG Characteristic

5

4

3

2

1

0

VG

(V)

1 2 5 10 20 50 100 200

Air Flow (x10-3kg/s)

-200.2

0.3

0.50.7

1

2

3

57

10

20

30

k

20 40 60 80 C0


31/53


(2) Operation

Q001256E

VTA1

VTA1 M+ M-

IC1

VC

VC

VTA2

VTA2

E2

E2

M+

M-

IC2

M

Valve Fully Opened

(Mechanical)

Valve Fully Opened

(by Control)

Valve Fully Closed

Q001232E

ON

Target Valve Opening

(Percentage)

Throttle valve fully opened

(by control)

Key switch OFF throttle valve shut.

Approx. 0.1 - 0.2 sec.

Engine OFF, valve fully opened(by control)

Valve fully opened

(mechanical)

OFF

100%

Engine Key

0%


32/53


10. VARIOUS TYPES OF CONTROL

10.1 Outline This system effects fuel injection quantity and injection timing control more appropriately than the mechanical governor and timer

used in the conventional injection pump. The engine ECU performs the necessary calculations in accordance with the sensors installed

on the engine and the vehicle. It then controls the timing and duration of time in which current is applied to the injectors, in order to

realize both optimal injection and injection timing.

10.2 Fuel Injection Rate Control Function

Pilot injection control injects a small amount of fuel before the main injection.

10.3 Fuel Injection Quantity Control Function

The fuel injection quantity control function replaces the conventional governor function. It controls the fuel injection to an optimal

injection quantity based on the engine speed and accelerator position signals.

10.4 Fuel Injection Timing Control Function

The fuel injection timing control function replaces the conventional timer function. It controls the injection to an optimal timing based

on the engine speed and the injection quantity.

10.5 Fuel Injection Pressure Control Function (Rail Pressure Control Func-

tion)

The fuel injection pressure control function (rail pressure control function) controls the discharge volume of the pump by measuring

the fuel pressure at the rail pressure sensor and feeding it back to the ECU. It effects pressure feedback control so that the discharge

volume matches the optimal (command) value set in accordance with the engine speed and the injection quantity.


33/53


11. FUEL INJECTION QUANTITY CONTROL

11.1 Outline This control determines the fuel injection quantity by adding coolant temperature, fuel temperature, intake air temperature, and intake

air pressure corrections to the basic injection quantity. The engine ECU calculates the basic injection quantity based on the engine

operating conditions and driving conditions.

11.2 Injection Quantity Calculation Method

The calculation consists of a comparison of the following two values: 1. The basic injection quantity that is obtained from the governor

pattern, which is calculated from the accelerator position and the engine speed. 2. The injection quantity obtained by adding various

types of corrections to the maximum injection quantity obtained from the engine speed. The lesser of the two injection quantities is

used as the basis for the final injection quantity.

11.3 Set Injection Quantities

(1) Basic Injection Quantity

This quantity is determined by the engine speed and the accelerator opening. With the engine speed constant, if the accelerator opening

increases, the injection quantity increases; with the accelerator opening constant, if the engine speed rises, the injection quantity de-

creases.

Q001252E

Engine Speed

Engine Speed

Accelerator Opening

Injection

Quantity

Injection

Quantity

Accelerator Opening

Engine Speed

Basic Injection Quantity

Maximum Injection Quantity

LowQuantity

Side Selected

CorrectedFinal Injection

Quantity

Injector Actuation

Period Calculation

Individual CylinderCorrection Quantity

Turbo Pressure Correction

Atmospheric Pressure Correction

Intake Air Temperature Correction

Speed Correction

Injection Pressure Correction


34/53


(2) Maximum Injection Quantity

This is determined based on the basic maximum injection quantity determined by the engine speed, and the added corrections for in-

take air pressure.

(3) Starting Injection Quantity

When the starter switch is turned ON, the injection quantity is calculated in accordance with the starting base injection volume. The

base injection quantity and the inclination of the quantity increase/decrease change in accordance with the water temperature and the

engine speed.

(4) Idle Speed Control (ISC) System

This system controls the idle speed by regulating the injection quantity in order to match the actual speed to the target speed calculated

by the engine ECU.

BasicInjec

tionQuantity

Engine Speed

Accelerator Opening

Q000888E

QB0717E

Engine Speed

BasicMaximum

InjectionQuantity

Base injectionquantity

Starter ON time

Start

Water temperature

STA/ON

QD0805E

Injectio

nq

uantity


35/53


The target speed varies, depending on the ON/OFF state of the air conditioner and the coolant temperature.

(5) Idle Vibration Reduction Control

In order to reduce vibration during idling, the angular (time difference between A and B [C and D]) speed of each cylinder is detected

using the speed pulse signal to control the injection quantity of each cylinder. As a result crank angle speed becomes more uniform

and smoother engine operation is achieved.

Q001254E

Coolant Temperature

Air Conditioner Load

Gear Position

Accelerator Opening

Vehicle Speed

Conditions for Start of Control Control Conditions

Target SpeedCalculation

Comparison

InjectionQuantityCorrection

SpeedDetection

Air Conditioner S/W

Coolant Temperature

Neutral S/W TargetSpeed

Calculation

Injection

Quantity

Determination

[Target speed]

800

20

Coolant water temperature (C)QD1172E

Engines

peed(rpm)

A/C ON/OFF


36/53


Speed Pulse

Control Diagram

Q001255E

30CA360CA

5V

0V

Pulser

SensorSignal

(Make the t for all the cylinders equal.)

( t1,4_L)A

( t1,4_H)B

( t2,3_L)C

( t2,3_H)D

Cylinder #1(#4) Cylinder #2(#3)

Q001230E

Crankshaft Angle Crankshaft AngleCorrection

#1 #1 #3 #4 #2#3 #4 #2

CrankAngleSpeed


37/53


12. FUEL INJECTION TIMING CONTROL

12.1 Ouline Fuel injection timing is controlled by varying the timing in which current is applied to the injectors.

12.2 Main and Pilot Injection Timing Control

(1) Main Injection Timing

The engine ECU calculates the basic injection timing based on the engine speed and the final injection quantity, and adds various types

of corrections in order to determine the optimal main injection timing.

(2) Pilot Injection Timing (Pilot Interval) Pilot injection timing is controlled by adding a pilot interval to the main injection timing. The pilot interval is calculated based on the

final injection quantity, engine speed, coolant temperature, ambient temperature, and atmospheric pressure (map correction). The pilot

interval at the time the engine is started is calculated from the coolant temperature and engine speed.

Top Dead Center (TDC)

Pilot Injection

Main Injection

Interval

QB0723E


38/53


(3) Injection Timing Calculation Method

12.3 Microinjection Quantity Learning Control

(1) Outline

Quantity learning control is used in every vehicle engine (injector) to preserve the accuracy of quantity (specifically, pilot injection

quantity.)

This type of control is first performed when shipped from the factory (L/O), and later is automatically performed every time the vehicle

runs a set distance (for details, see item "A".) Because of quantity learning control, the accuracy of each injector can be preserved not

only initially, but also as deterioration in injection occurs over time. As a result of this learning, correction values are recorded in the

ECU. During normal driving operations, this correction value is used to make modifications to injection commands, resulting in ac-

curate microinjection.

(2) Learning Operations

For every two no load, idle instability conditions established (See chart "A" below) quantity learning takes place.

In addition, it is also possible to perform quantity learning control manually as a diagnostic tool.

NE Pulse

Solenoid Valve Control Pulse

Nozzle Needle Lift

0 1Actual TDC

Main InjectionPilot Injection

Pilot Injection Timing Main Injection TimingPilot Interval

Basic InjectionTiming

Corrections

Engine Speed

Injection Quantity

Main InjectionTiming

AtmosphericPressureCorrection

CoolantTemperatureCorrection

IntakeAirTemperatureCorrection

IntakeAirPressureCorrection

[1] Outline of Timing Control

[2] Injection Timing Calculation Method

QB0724E

VoltageCorrection


39/53


(3) Operational Outline

Learning control sends ISC (target speed correction quantity) and FCCB (cylinder-to-cylinder correction quantity) feedback based on

engine speed to apply injection control. The correction quantity is added to each cylinder based on ISC and FCCB correction infor-

mation. The corrected injection quantity is then calculated.

Through the use of quantity learning control, injection is divided into 5 injections. In this state, the value for ISC and FCCB corrected

injection quantity that has been divided into five injections is calculated as the "learning value".

Q001250

Manual Learning Operations (as a Diagnostic Tool)

(A)

Number of IG OFF Occurrences

Vehicle Running Distance

Injection Quantity Deterioration Over Time Judgment

No Load Idle Instability Condition

Establishment of

Learning Operations

Q001251E

1st Cylinder

2nd Cylinder

3rd Cylinder

4th Cylinder

1st Cylinder

2nd Cylinder

3rd Cylinder

4th Cylinder

: ISC Correction Portion

ISC

Correction

Portion

: FCCB Correction Portion

FCCB

Correction

Portion

Learning

Value


40/53


41/53


14. FUEL INJECTION PRESSURE CONTROL

14.1 Fuel Injection Pressure The engine ECU determines the fuel injection pressure based on the final injection quantity and the engine speed. The fuel injection

pressure at the time the engine is started is calculated from the coolant temperature and engine speed.

Q000632E

Pressure

Pump Speed

Final Injection Quantity


42/53


15. DIAGNOSTIC TROUBLE CODES (DTC)

15.1 About the Codes Shown in the Table The "SAE" diagnostic trouble code indicates the code that is output through the use of the STT (WDS). (SAE: Society of Automotive

Engineers)

15.2 Diagnostic Trouble Code Details

The DTC chart below is common to the 4D56/4M41 model. However, DTC number "P1210" is only for use with the 4D56 2WD

model engine.

DTC

Number

(SAE)

Diagnostic Item Diagnostic Classifica-

tion

Malfunctioning Part Light

ON

Remarks

P0016 Speed-G phase gap

malfunction

Pulse system malfunc-

tion

Crankshaft position sen-

sor, cylinder recognition

sensor

Yes

P0072 Intake manifold tem-

perature sensor - low

Open circuit detection

(+B short, ground

short, open)

Intake temperature sensor No

P0073 Intake manifold tem-

perature sensor - high


(+B short, ground

short, open)

Intake temperature sensor No

P0088 Rail high pressure

abnormality

Fuel pressure control

system abnormality

Injector Yes

P0089 SCV stuck diagnosis Fuel pressure control

system abnormality

Supply pump Yes

P0093 Fuel leak Fuel leak Fuel piping Yes

P0102 Airflow sensor - low Open circuit detection

(+B short, ground

short, open)

Air Flow Sensor No

P0103 Airflow sensor - high Open circuit detection(+B short, ground

short, open)

Air Flow Sensor No

P0106 Turbo pressure sensor

characteristic abnor-

mality

Sensor characteristic

abnormality

Turbo pressure sensor Yes

P0107 Turbo pressure sensor -

low


(+B short, ground

short, open)

Turbo pressure sensor Yes

P0108 Turbo pressure sensor -

high


(+B short, groundshort, open)

Turbo pressure sensor

Yes


43/53


P0112 Intake temperature

sensor - low



Intake temperature sen-

sor (AFS)

Yes

P0113 Intake temperature

sensor - high


(+B short, ground

short, open)

Intake temperature sen-

sor (AFS)

Yes

P0117 Coolant temperature

sensor - low


(+B short, ground

short, open)

Coolant temperature

sensor

Yes

P0118 Coolant temperature

sensor - high


(+B short, ground

short, open)

Coolant temperature

sensor

Yes

P0122 Electronic control

throttle - low


(+B short, ground

short, open)

Electronic control throttle Yes

P0123 Intake valve sensor -

high


(+B short, ground

short, open)

Electronic control throttle Yes

P0182 Fuel temperature sen-

sor - low


(+B short, ground

short, open)

Supply Pump Yes

P0183 Fuel temperature sen-sor - high

Open circuit detection(+B short, ground

short, open)

Supply Pump Yes

P0191 Rail pressure sensor

characteristic abnor-

mality


abnormality

Rail Yes


(time) low


(+B short, ground

short, open)

Rail Yes


(time) high



Rail Yes

P0201 TWV 1 (No.1 cylin-

der) actuation system

open circuit

Injector actuation

abnormality

Injector Yes



open circui

Injector actuation

abnormality

Injector Yes



open circuit

Injector actuation

abnormality

Injector Yes



open circuit

Injector actuation

abnormality

Injector Yes

DTC

Number

(SAE)


tion


ON

Remarks


44/53


P0219 Engine overrun abnor-

mality

Engine abnormality Engine Yes

P0234 High boost abnormal-

ity diagnosis

Engine abnormality Engine Yes

P0301 Injector function (non -

injection) 1

Injector actuation abnor

malily

Injector Yes


injection) 2


malily

Injector Yes


injection) 3


malily

Injector Yes


injection) 4


malily

Injector Yes

P0335 No speed pulse input Pulse system malfunc-

tion


sor

Yes

P0336 Abnormal speed pulse

number


tio


sor

Yes

P0340 No G pulse input Pulse system malfunc-

tion

Cylinder recognition sen-

sor

Yes

P0341 Cylinder recognition

sensor pulse number

abnormality


tion

Cylinder recognition sen-

sor

Yes

P0405 EGR lift sensor - low Open circuit detection

(+B short, ground

short, open)

EGR valve No

P0406 EGR lift sensor - high Open circuit detection

(+B short, ground

short, open)

EGR valve No

P0502 Vehicle speed

abnormality - low


tion

Vehicle speed sensor Yes

P0513 Immobilizer authenti-

catuin error

Network Network Yes

P0551 Power Steering Switch

ON malfuncion

Power Steering Switch

malfuncion

Power Steering Switch Yes

P0603 EEPROM abnormality Engine ECU internal

circuit memory device

Engine ECU Yes

P0604 RAM abnormality Engine ECU Engine ECU Yes

P0605 Engine ECU flash-

ROM abnormalityEngine ECU Engine ECU

Yes

P0606 Engine ECU CPU

abnormality (main IC

abnormality)

Engine ECU Engine ECU Yes

P0607 Engine ECU abnor-

mality (monitoring IC

abnormality)


DTC

Number

(SAE)


tion


ON

Remarks


45/53


P0628 SCV actuation system

abnormality


system abnormality

Supply pump Yes

P0629 SCV +B short Fuel pressure control

system abnormality

Supply pump Yes

P0630 VIN not registered in

Engine ECU

Engine ECU write

defect

Engine ECU (VIN

rewrite)

Yes VIN stands for Vehi-

cle Identification Num-

ber. If this DTC code

is detected, rewrite the

VIN to the Engine

ECU. This does not

mean that engine ECU

is malfunctioning. Do

not replace the engine

ECU

P0638 Intake throttle valve

stuck

Actuator malfunction Electronic control throttle Yes

P0642 Sensor - voltage 1 low Engine ECU Engine ECU Yes

P0643 Sensor - voltage 1 high Engine ECU Engine ECU Yes

P0652 Sensor - voltage 2 low Engine ECU Engine ECU Yes

P0653 Sensor - voltage 2 high Engine ECU Engine ECU Yes

P1203 Low charge Engine ECU Engine ECU Yes

P1204 Over charge Engine ECU Engine ECU Yes

P1210 Throttle valve opening Actuator malfunction Throttle valve Yes Only 4D56 Engine

2WD

P1272 P/L open valve abnor-

mality


system abnormality

Rail Yes

P1273 Single pump abnor-

mality diagnosis


system abnormality

Supply pump Yes In the event that the

vehicle runs out of gas,

"P1273" may be

detected when the

vehicle is restarted.

When "P1273" is dis-

played, the user should

verify whether or not

there is gas in the vehi-

cle.

Do not replace the

pump assy. if it has

been verified that the

vehicle has run out of

gas. Remove the air

from the fuel, and erase

the code using the

MITSUBISHI MUT III

diagnosis tool.

DTC

Number

(SAE)


tion


ON

Remarks


46/53


P1274 Pump protective fill

plug


system abnormality

Supply pump Yes

P1275 Pump exchange fill

plug


system abnormality

Supply pump Yes

P1276 Fuel Filter choke Fuel filter Fuel filter and the pipings Yes For Low lubricating

model only

P1625 QR data

abnormality


P1626 QR data failure to

write to disc malfunc-

tion


P2118 DC motor over current

abnormality

Actuator malfunction Electronic control throttle Yes

P2122 Accelerator sensor-1

low


(+B short, ground

short, open)

Accelerator position sen-

sor

Yes


high final


(+B short, ground

short, open)


sor

Yes


high


(+B short, ground

short, open)


sor

No


low


(+B short, ground

short, open)


sor

Yes

P2138 Accelerator sensor -

duplicate malfunction

high


(+B short, ground

short, open)


sor

Yes

Accelerator sensor -

duplicate malfunction

low


(+B short, ground

short, open)

Accelerator Position Sen-

sor

Yes

ACCP characteristic

abnormality


abnormality

Accelerator Position Sen-

sor

Yes

P2146 Common 1 system

open circuit

Injector actuation

abnormality

Injector , Wire harness or

Engine ECU

Yes

P2147 COM1 TWV actua-

tion system ground

short

Injector actuation

abnormality

Injector, Wire harness or

Engine ECU

Yes

P2148 COM1 TWV actua-

tion system +B short

Injector actuation

abnormality

Injector, Wire harness or

Engine ECU

Yes

P2149 Common 2 system

open circuit

Injector actuation

abnormality

Yes

DTC

Number

(SAE)


tion


ON

Remarks


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P2228 Atmospheric pressure

sensor - low



Engine ECU Yes

P2229 Atmospheric pressure

sensor - high


(+B short, ground

short, open)

Engine ECU Yes

P2413 EGR feedback abnor-

mality

Actuator malfunction EGR valve No

UD073 CAN bus OFF error Network Network No

UD101 CAN time out flag

(trans)

Network Network No


(ESP)

Network Network No


(ETACS)

Network Network No


(immobilizer)

Network Network No

UD190 CAN communication Network Network No

DTC

Number

(SAE)


tion


ON

Remarks


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16. EXTERNAL WIRING DIAGRAM

16.1 Engine ECU External Wiring Diagram The wiring diagram below is common to the 4D56/4M41 model.

Q001519E

AirConditioningRelay

FAN Relay

Control (ECCS) Relay

W-B

B-W

R-Y

R

B

G

Gr

R

R

G

B-W

B-W

Y-R

L

R-W

G-W

W-L

Gr

Br

Br

Y-G

Y-G

L-R

L-R

L-W

Gr

Br-W

Y-R

B

L

L-Y

Br

Y-B

G-B

Lg-R

L

R

G-Br

B-W

B-W

B-R

Y-R

R-G

L

R-B

L-Y

P1P2

Air Conditioning 1 Switch

BATT

Glow Light

Glow Plug RelayBATT

Key ACCI

SOFF

Battery

Starter

MotorEGR

Position

Sensor

EGR

DC Motor

ElectronicThrottleControl

Body

Earth

P1

Engine Warning Light

Tacho Meter

Vihicle Speed Sensor

NE+

NE-

A46

A65

A-VCC3

A-VCC4

Crankshaft

Position

Sensor

Cylinder

Recognition

Sensor

A44

A45

BATTB40

A/C1 SWA12

WA16

GROW LA38

GROW RA37

IG-SWB26

STA-SWB18

EGR LIFT RTNA72

EGR LIFTA53

B05

EGR -A07

EGR +A08

ETC -B37

ETC +B35

A64

ETCP-M

SPDB16

TACHOB25

+BPB38

M-RELB24

C FAN RA27

A/C RA26

CAN1-H

CAN1-L

B14

B06

G+

G-

A47

A66

PS-SW Power Steering Switch

Reverse Shift Switch

1st Shift Switch

Air Temperature Sensor


Body

Earth

BATT

Accelerato rPosition Sensor

B30

MT REV SW B20

MT 1ST SW B19

A-VCC1 B01

APS1 B02

APS1 GND B03

A-VCC2 B09

APS2 B10

APS2 GND B11

A10

SCV-

SCV(Suction Control Valve)

SCV+

A29

A79

THF

THA

A50

THFRTN A69

Coolant Temperature SensorA51

THWRTN

THW

A70

PTC Control SwitchPTC SW A14

A-VCC6


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16.2 Engine ECU Connector Diagram

The connector diagram and terminal below are common to the 4D56/4M41 model.

Terminal Connections (1)

No. Pin Symbol Signal Name No. Pin Symbol Signal Name

A01 P-GND Power Ground A11

A02 A12 A/C1 SW Air Condition 1 Switch

A03 P-GND Power Ground A13 IDLUP SW IDLUP SW (For EU)

A04 COMMON 1 INJ#1/#4 BATT. A14 PTC HEATER SW PTC HEATER CONT SW(For EU)

A05 COMMON 1 INJ#2/#3 BATT. A15 THR THROTTLE SOLENOID VALVE

(For Thailand model)

A06 A16 W Engine Warning Light

A07 EGR- EGR-DC Motor (-) A17 SCV SWIRL CONT VALVE(For EU)

A08 EGR+ EGR-DC Motor (+) A18

A09 A19

A10 SCV+ Suction Control Valve A20

Q001520E

Rail Pressure Sensor

(Pc Sensor)

EXTAir Temperature Sensor

Airflow Sensor

P1


COMMON1A04

TWV1A43

TWV1A42

COMMON1A05

TWV2

TWV2

A24

Injector3 Drive (#4 Cylinder)

A23

TWV3A41

TWV3A40

TWV4A22

TWV4A21

Body Earth

P-GND

C-GND

P-GNDA01

A03

B33

A48PFUEL1

A63A-VCC5

A68PFUEL RTN

A64

A52BOOST

A71BOOST RTN

A-VCC6

A55

A74

A54AMF

A73AMF RTN

EXT-A-TMP

EXT-A-RTNInjector4 Drive (#2 Cylinder)



B

B

B

Br

W-R

B-L

Y-L

Br

G-Br

Gr

Br

R

R

W

B-G

B-G

Y-G

Y-G

L-G

L-G

L-Y

G

G

W-L

L

Y

Q001521E

PTCSW


50/53




A21TW4 Injection 4 Drive (# 2 Cylinder)

A56

A57

A22 A58

A23TWV2 Injection 2 Drive (#3 Cylinder)

A59

A24 A60

A25 PTC HEATER 1 PTC HEATER (For EU) A61

A26 A/C R Air Conditioning Relay A62

A27 C FAN R FAN Relay A63 A-VCC5 Rail Pressure Sensor Source

A28 PTC HEATER 2 PTC HEATER (For EU) A64 A-VCC6 Turbo Pressure Sensor Source (5V)

A29 SCV- Suction Control Valve A65 NE- Crankshaft Position Sensor Ground

A30 A66 G- Cylinder Recognition Sensor Ground

A31 A/C2 SW A/C2 SW (For EU) A67

A32 A68 PFUEL RTN Rail Pressure Sensor Earth

A33 A69 THF RTN Air Temperature Sensor, Fuel Temper-

ature Sensor Earth

A34 A70 THW RTN Coolant Temperature Sensor Earth

A35 A71 BOOST RTN Turbo Pressure Sensor

A36 A72 EGR Lift RTN EGR Position Sensor Earth

A37 Glow R Glow Plug Relay A73 AMF-RTN Airflow Sensor Earth

A38 Glow L Glow Light A74 EXT-A-RTN Air Temperature Sensor Earth

(W/FAS)

A39 A75

A40 TWV3 Injection 3 Drive (#4 Cylinder) A76



A43 TWV1 Injection 1 Drive (#1 Cylinder) A79 THA Air Temperature Sensor

A44 A-VCC3 Crankshaft Position Sensor BATT A80

A45 A-VCC4 Cylinder Recognition Sensor BATT A81 ETCP-S TPS(SUB) (For EU)

A46 NE+ Crankshaft Position Sensor B01 A-VCC 1 Accelerator Position Sensor (Main)

Source

A47 G+ Cylinder Recognition Sensor B02 APS 1 Accelerator Position Sensor (Main)

A48 PFUEL 1 Rail Pressure Sensor (Pc Sensor) B03 APS 1 GND Accelerator Position Sensor (Main)

Earth

A49 PFUEL F/PRESS SNSR (B/UP) (For EU) B04

A50 THF Fuel Temperature Sensor B05 ETCP-M Electronic Throttle Control (Main)

A51 THW Coolant Temperature Sensor B06 CAN1-L CAN L (W/Resister)

A52 BOOST Turbo Pressure Sensor B07

A53 EGR LIFT EGR Position Sensor B08

A54 AMF Airflow Sensor B09 A-VCC 2 Accelerator Position Sensor (Sub)

Source

A55 EXT-A-TMP Air Temperature Sensor (W/AFS) B10 APS 2 Accelerator Position Sensor (Sub)


51/53




B11 APS 2 GND Accelerator Position Sensor (Sub)

Earth

B26 IG-SW Ignition Switch

B12 B27 +

B13 B28

B14 CAN1-H CAN H (W/Resister) B29

B15 B30 PS-SW Power Steering Switch

B16 SPD Vehicle Speed Sensor B31

B17 FPSW F/FILTER PRESS SW (For low

lubricating)

B32

B18 STA-SW Starter Switch B33 C-GND SIG Ground

B19 MT 1ST SW 1st Shift Switch B34

B20 MT REV SW Reverse Shift Switch B35 ETC+ Electronic Throttle Control Motor (+)

B21 B36

B22 B37 ETC- Electronic Throttle Control Motor (-)

B23 B38 +BP Battery

B24 M-REL Control (ECCS) Relay (W/

DIODE)

B39

B25 TACHO Tacho meter B40 BATT. Battery (Back-up, W/Monitor)


52/53



53/53

DENSO INTERNATIONAL THAILAND

Field Technical Service Department

Edited and published by:

369 Moo 3 Teparak Rd. Muang Samutprakarn Thailand

Published : May, 2006

Documents

1362992205L200w-woperationwmanual,wDENSO