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Worltshop Mqnuol
MITSUBISHI
,ft-":
,-, /**-
F
MOTORS
chqssis
SUPPTEMENT
PITJERO PININ'OI
,'
O
Pub. No. CKRE0OEI-A
J
General
PfTJERCI PININ
Engine
Engine Lubrication
WORKSHOP MANUAL
SUPPLEMENT
.
lntake and Exhaust
Engine Electrical
....
Engine and Emission Gontrol . . . .
FOREWORD
This manual outlines changes
in
servicing
procedures related to the chassis including vehicle
inspections, adjustments and improvements in the
newly added models.
Please read this manualcarefully so that it will be of
assistance for your service activities.
Please note that the following service manuals are
also available and should be used in conjunction
with this manual.
Automatic Transmlssion
Propeller Shaft
Front Axle
Rear Axle
Wheel and Tyre
Power Plant Mount
TECHNICAL INFORMATION MANUAL
IKREOOEl
Front Suspension
.
CHASSIS
CKREOOE1
CKRXo0EI CD(CD-ROM)
ELECTRICAL WIRING
EKREOOE1
EKREOOEl-A
BODY REPAIR MANUAL BKREOOE1
BKREOOEl.A
ENGINE GROUP
PWEEgsO2.E
Rear Suspension .
.
WORKSHOP MANUAL
PARTS CATALOGUE
1603F509Dn
All information, illustrations and product descriptions
contained in this manual are current as at the time
of publication. We, however, reserve the right to
make changes at any time without prior notice or
obligation.
I
.tl
MITSUBISHI MOTOR SALES
Europe B.V.
"GDl"
is a trade mark of
Mitsubishi Motors
Corporation.
@
Fuel
Mitsubishi Motors
Gorporation
..
September 2000
., . r.. !..
Service Brakes
Body
Exterior
lnterior and Supplemental
Restraint System (SRS)
Ghassis Electrical . . ..
WARNING REGARDING SERVICING OF SUPPLEMENTAL
RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLE
WARNING!
(1) lmproper service or maintenance of any component of the SRS, or any SRS-related component,
can lead to personal injury or death to service personnel (from inadvertent firing of the air
bag) or to the driver and passenger (from rendering the SRS inoperative).
(2) The SRS components should not be subjected to temperature of 93'C or more. So, remove
the SRS-ECU, driver's and front passenger's air bag modules, clock spring, side impact sensors
and front seat assemblies (side air bag modules) before drying or baking the vehicle after painting.
(3) Service or maintenance of any SRS component or SRS-related component must be performed
only at an authorized MITSUBISHI dealer.
(4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP
528 - Supplemental Restraint System (SRS), before beginning any service or maintenance of
any SRS component or any SRS-related component.
NOTE
Section titles with asterisks (.) in the table of contents in each group indicate operations requidng warnings.
GENERAL
-
00-1
Vehicle ldentification
GROUP
OO
I
GENERAL
VEH ICLE I DENTI FICATION
MODELS
Model code
H67
WMNJCLA
Engine model
Transmission model
Fuel supply system
4G94-DOHC (1,999 mL)
v5M21 <sM/T>
GDI
WMNJCRA
v4AW4 <4Arf>
WMRJCLA
WMRJCRA
H77
v5M21 <siI/T>
WLNJCLA
WLNJCRA
WRNJCTA
V4AW4
< AT[>
WRNJCRA
MODEL CODE
H6TlTMNJCLA
-r-TTTTTTIT
lllllllrl
No.
Items
Contents
1
Development
H6:
123 456789
H7:
YO24OAL
MITSUBISHI PAJERO
PININ Short wleelbase
MITSUBISHI PruERO
PININ Long whedbase
2
Engine type
7:
2,(XX) mL petrolengine
3
Sort
W:
Wagon
4
Body style
5
Transmission type
6
Trim level
7
Specification engine
feature
M:
L:
N:
R:
3-door
S-door
$speed manual
transmission
4-speed automatic
transmission
J:
GL
C:
GDI-DOHC
oo-2
GENERAL
-
Vehicle ldentification
No.
Items
Contents
I
Steering wheel location
L:
R:
Left hand
A:
For Europe
I
Destination
Right hand
CHASSIS NUMBER
*J+r9+Xg + +++qooool*
-r-TITITTI
'l ll I s 6 7I Te
YOil43AL
No.
Items
1
Steering wheel location
Contents
JMP
Left hand drive
JMR
Right hand ddve
2
Body style
0
Strandard roof
3
Transmission type
N
$speed manual transmission
R
4-speed automatic transmission
H6
PATERO PININ Short wheelbase
H7
PAJERO PININ Long wheelbase
4
Development order
5
Engine
7
4G94: 1,999 mL petrol engine
6
Sort
w
Wagon
7
Model year
1
2001
8
Plant
x
IPF
I
Serialnumber
GENERAL
MAJOR SPECIFICATIONS
<3-door model>
-
Major Specifications
00-3
00-4
GENERAL
dimensions
mm
Major Specifications
HoTWMNJCLA I HoTWMNJCRA
Items
Vehicle
-
Overalllength
1
3,735
Overallwidth
2
1,695
Overall height (unladen)
3
1,690/1,7 25.1 11,700*2
Wheelbase
4 2,280
Track-front
5 1,435
Track-rear
6
Ovefiang-front
7 755
Overhang-rear
I 700
I an
Ground clearance
HoTWMRJCLA I HoTWMRJCRA
1,445
(unladen)
Vehicle
weight kg
1,320
Kerb weight
1,300
Max. gross vehicle weight
1,725
Max. axle weight
rating-front
74s
755
Max. axle weight
rating-rear
555
565
Seating capacity
4
Engine
Model No.
4G94
Totaldisplacement mL
1,999
Model No.
V5M21
V4AW4
Type
$speed manual
4-speed automatic
Fuel supply system
Gasoline Dirrect lnjection
Transmission
Fuel system
NOTE:
"1: Vehicles with roof rails
*2: Vehicles with roof spoiler
GENERAL
<S-door model>
-
Major Specifications
00-s
00-6
GENERAL
Overalllength
1
4,035
Overallwidth
2
1,695
Overall height (unladen)
3
1,7 00 I 1,7 35*
Wheelbase
4 2,450
Track-front
5
1,435
Track-rear
6
1,445
Overhang-front
7 755
Overhang-rear
I
I
Ground clearance
(unladen)
Vehicle
weight kg
Major Specifications
HTTWLNJCLA IHTTWLNJCRA
Items
Vehicle
dimensions
mm
-
1
|
1,7
HTTWRNJCLA IHTTWRNJCRA
20'2
8if0
ax)
Keö weight
1,390
Max. gross vehicle weight
1,890
Max. axle weight
770
785
620
625
1,410
rating-front
Max. axle weight
rating-rear
Seating capacity
5
Engine
Model No.
4G94
Totaldisplacement mL
1,999
Model No.
V5M21
V4AW4
Type
$speed manual
4-speed automatic
Fuel supply system
Gasoline Dirrect Injection
Transmission
Fuel system
NOTE:
*1: Vehicles with roof rails
*2: Vehicles with roof spoiler
114-1
ENGINE
CONTENTS
GENERAL
Outline of
Changes
.........
2
.........2
.
.... . 2
SERVTCE SPECIFICAT|ONS .,... 2
SEALANT AND ADHESIVE .
. .. . 2
SPECIAL TOOLS
......... 3
GENERAL INFORMATION
oN-vEHrcLE SERVTCE
.
..
ldle Mixture Check
Compression Pressure Check
Manifold Vacuum Check
......
..... .3
....... ....3
.... 4
.... 10
..... 14
CAMSHAFT AND CAII'ISHAFT OIL SEAL
CYLINDER HEAD
TIMING
BELT
GASKET
3
.........3
114-2
ENGINE <4G9>
-
General/General Information/Service
Specificationsi/Sealant and Adhesive
GENERAL
OUTLINE OF CHANGES
Due to the new addition of the 4G94 engine vehicles, the following service procedures have been established
regarding the sections which ditfer from that of the previous models with the 4G93 engine. The same
procedures as before are applied except for the items shown below.
Change in the CO and HC concentration
Change in compression pressure
Change of the limits in the intake manifold negative pressure
Removal and installation of camshaft and camshaft oil seal
Removal and installation of cylinder head gasket
Change in the protrusion of the auto tensioner rod
.
.
o
o
.
.
GENERAL INFORMAilON
Items
4G94-GDl
Totaldisplacement mL
1,999
Bore x Stroke mm
81.5
Compression ratio
11.0
x
95.8
SERVICE SPECIFICATIONS
Item
Standard value
CO concentration %
0.5 or less
HC concentration ppm
100 or less
Compression pressure kPa
-
1,800
r/min
-
200
Limit
1,320
Intake manifold negative pressure kPa
56
Shank length of cylinder head bolt mm
96.4
4.8
Protrusion of auto tensioner rod mm
-
-
200
5.5
SEALANT AND ADHESIVE
Application location
Specified sealants
Remarks
Beam camshaft cap
MITSUBISHI GENUINE PART MD970389 or
equivalent
Semi-drying
sealant
Cylinder head
Camshatt position sensor support
Camshaft thrust cover
3M Stud Locking 417O or equivalent
ENGINE <4G9>
-
Special Tools/On-vehicte
Service
114-9
SPECIAL TOOLS
Tools
Number
Name
Use
M8990767
Front hub
Camshaft sprocket held
and
flange york holder
4Y.*
KI
MD998719
Crankshaft pulley
holder pin
MD998713
Gamshaft oilseal
Press-fitting camshaft oil seal
installer
@u,
M8991653
Cylinder head bolt
wrench
Removal and installation of cylinder head bolt
ON-VEHICLE SERVICE
IDLE MIXTURE CHECK
Standard value
CO contents: 0.5olo or less
HC contents: 100 ppm or less
COMPRESSION PRESSURE CHECK
Standard value (at engine speed of 2(D r/min):
1,800 kPa
Limit (at engine speed of 2fl1 r/min):
Min. 1,320 kPa
MANIFOLD VACUUM CHECK
Limit: Min. 56 kPa
11
A-4
ENGINE <4G9>
-
Camshaft and Camshaft Oil Seal
CAMSHAFT AND CAMSHAFT OIL SEAL
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operations
o Fuel Overflow Prevention Operation <only for pre-removal>
o Fuel Leak Check <only for post-installation>
o Air Bleeding The High-pressure Fuel Line <only for post-installation>
to GROUP 13JA - Fuel Pump (High-pressure).]
o [Refer
Removal and Installation of Under Cover
o Check and Adiustment of Drive Beh Teneion <only for post-installation>
o Draining and Filling of Engine Coolant
o Removä and Insallation öt lir lntake Hose and Resonance Tank
ENGINE <4G9>
-
Camshaft and Camshaft Oil Seal
114-5
m
'VOM
ATD Part l.,lo. 8121)
@
18
Nle
>E<
Removal eteps
1. Engine cover
2. Power steering oil pressure switch
connector
3. A/C compressor magnetic clutch
connector
4. lgnition failure sensor connector
5. Crank angle sensor connector
6. Front wiring hamess and injector/EGR
wiring hamess combination connector
7. Fuel pressure sensor connector
L
Detonation sensor connector
9. Engine coolant temperature sensor
connector
10. Engine coolant temperature gauge
unit connector
11. lgnition coil connector
12. Camshaft position sensor connector
13. Throttle control servo connector
14. Throtlle position sensor @nnector
15. Purge control solenoid valve
connector
16. Breather hose
17. PCV hose
o lgnition coil
.
Intake manifiold
Timing belt
18. Intake rocker cover
19. intake rocker cover gasket
20. Exhaust rocker cover
21. Exhaust rocker cover gasket
o
114-6
ENGINE <4G9>
Apply engine oil to any
rotating area at the
installation.
-
Camshaft and Camshaft Oil Seal
10-12
fl-rc
- 23 Nm
10-12Nm
br
ZI
26
Nm
12-15Nm
K&
2
36Nm
\
v0^
<A>
>D<
22. Camshaft sprocket
23. ldler pulley
24. Timing belt rear upper cover
25. Camshaft oil seal
o Fuel pump (high-pressure)
(Refer to GROUP 13A.)
26. Camshatt position sensor support
27. Camshatt thrust cover
>C<
>B<
>B<
>A<
28. O-dng
29. Beam camshaft cap
30. Beam camshaft cap gasket
31. lntake camshaft
32. Exhaust camshaft
33. Camshaft position sensing cylinder
34. Rocker arm
35. Lash adjuster
o
ENGINE <4G9>
-
11A-7
Camshaft and Camshaft Oil Seal
LUBRICANT AND SEALANT APPLICATION LOCATIONS
<Beam camshaft cap bottom surface observation>
)_SectionA-A
| I
I
|
l.-1
?=qo
mm
|
.G.?"ps.?"ag?ag?a
Sealant: MITSUBISHI GENUINE PART MD970389 or equivatent
Adhesive:
3M Stud Locking 4170
or equivalent
Engine
oil (lip)
Sealant:
MITSUBISHI GENUINE PART
<Cylinder head top surface observation>
-GöDcöDcöDcöü
Sealant: MITSUBISHI GENUINE PART MD970389 or
114-8
ENGINE <4G9>
-
Camshaft and Camshaft Oil Seal
REMOVAL SERVICE POINT
<A>
M8990767
CAMSHAFT SPROCKET REMOVAL
Caution
To avoid the danger of damage caused by
interference of the valve and the piston, rotate the
crankshaft from No.l cylinder compression top dead
centre to 90' in the forward direction (clockurise).
MD998719
INSTALLATION SERVICE POINTS
>A<
LASH ADJUSTER INSTALLATION
Caution
To use the lash adjuster again, be surc to clean and
check it beforc installation.
(Reüer to Engine Workshop Manual.)
f
Camshaft sprocket side
>B<
1.
2.
EXHAUST CAMSHAFT/INTAKE CAMSHAFT
INSTALLATION
Apply engine oil to the cam and the joumal of the
camshaft.
Install the camshaft to the cylinder head.
Caution
D,o not mistake the intake side for the exhaust
side. There is a screw hole for the camehaft
position sensing cylinder mounting bolt at the
erhaust side of the camshaft.
Exhaust camshaft
BEAM CAMSHAFT CAP INSTALLATION
Set the dowel pin of the camshatt at the position shown
in the illustration.
>C<
1.
ENGINE <4G9>
-
114-9
Camshaft and Camshaft Oit Seal
2.
Tighten the beam camshaft cap mounting bolt to the
specified torque in the order of the numbers shown in
the illustration.
1
Symbol
'42
3
o
o
I
1
a
141
a
21 20
o
2
15 16
Dimensions
mm (Nominal
diameter x
nominallength)
Tightening
8x32
6x35
8x40
8x40
19-23
10-12
19-23
o o
5
a
9
^
o
4
6
O
7
10
o
a
o
I a
4
17 18
o
Number
of unit
16
4
torque Nm
o
>D<
1.
2.
CAMSHAFT OIL SEAL INSTALLATION
Apply engine oil to the circumference of the oil seal
lip.
Press-fit the oil seal as shown in the illustration.
MD998713
>E<
1.
2.
ENGINE COVER INSTALLATION
Tighten the mounting bolt temporarily in the order of the
numbers shown in the illustration so that the engine cover
can be moved by hand.
Tighten the mounting bolt to the specified torque in the
order of the numbers shown in the illustration.
Tightening torque: 3.0 Nm
114-10
ENGINE <4G9>
-
Cylinder Head Gasket
CYLINDER HEAD GASKET
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operations
o
o
o
o
o
o
o
o
o
o
o
o
Removal and Installation of Engine Cover (Refer to P.11A-5.)
Fuel Overflow Prevention Operation <only for pre-removal>
Fuel Leak Check <only for post-installation>
Air Bleeding the High-pressure Fuel Line <only for post-installation>
[Refer to GROUP 13A - Fuel Pump (High-pressure).]
Removal and Installation of Under Cover
Check and Adjustment of Drive Belt Tension <only for post-installation>
Draining and Filling of Engine Coolant
Removäl and Installation öf Timing Belt Rear Upper Cover (Refer to P.11A-6.)
Removal and Installation of Fuel Pump (High-pressure) (Refer to GROUP 134.)
Removal and lnstallation of Exhaust Manifold
Removal and Installation of Water Pipe
Removal and Installation of EGR Valve and Support Assembly
ENGINE
114-11
<4G$ - Cylinder Head Gasket
74 Nm -+ 0 Nm -+ 20 Nm --> +90' -+ +90"
the engine is cold)
,(when
,/,--s
6u
6:>tu
(Ensine oit)
*=t14
Z!
)#
vt
/
,ae
wlt
/'
qa rrir
<A> >c<
<B>
Removal steps
1. Connection of radiator upper hose
2. Connection of heater hose
3. Power steering oil pump
4. Power steering oil pump bracket
\/
)-w
Nm
p
,8
I
)29 Nm
\
4
bF-
>B<
>A<
5. Cylinder head bolt
6. Cylinder head assembly
7. Gylinder head gasket
11A-12
ENGINE <4G9>
-
Cylinder Head Gasket
REMOVAL SERVICE POINTS
<A>
RADIATOR UPPER HOSE REMOVAL
Put mating marks on the radiator upper hose and the
hose clamp for removal.
<B>
POWER STEERING OIL PUMP REMOVAL
Remove the power steering oil pump with the hose
the bracket.
attrached from
NOTE
Tie the removed power steering oil pump and the A/C
compressor with strings to set aside so that they will not
hinder the removal and installation of the engine
assembly.
Intake
side
Exhaust side
Dowel pin
Dowelpin
<C>
1.
CYLINDER HEAD BOLT REMOVAL
Set the dowel pin of the camshaft at the position shown
in the illustration.
epproi. SO.
Use the special tool to loosen the bott in the order of
the numbers shown in the illustration in two to three stages
for
{:
Front of the engine
removal.
ENGINE <4G9>
-
Cytinder Head Gasket
114-13
INSTALLATION SERVICE POINTS
>A<
1.
CYLINDER HEAD GASKET INSTALLATION
Remove gasket attached on the mounting surface of
the gasket.
Gaution
2.
Be careful not to let foreign objects get inside the
engine coolant and the oil line.
Install so that the each hole of the cylinder head is
aligned with each hole of the cylinder head gasket.
>B<
1.
(Engine
oil)fu
CYLINDEH HEAD BOLT INSTALLANON
Check that the neck down length of the cylinder head
bolt is within the limit. lf it is outside the limit value,
replace the bolt with a new one.
Limit (A): 96.4 mm
3.
4.
Face the sagging side of the bored cylinder head bolt
washer towards the direction shown in the illustration
to install to the cylinder head bolt.
Apply a little amount of engine oil to the cylinder
head bolt thread and the washer.
Use the specialtoolto tighten the bolt according to the
following procedu re (plasticity tightening).
(1) Tighten the bolt to 74 Nm in the order of the
numbers shown in the illustration.
(2) Loosen the bolt completely in the reverse order of
the numbers shown in the illustration.
(3) Tighten the bolt to 20 Nm in the order of the
numbers shown in the illustration.
the paint mark on the head of the cylinder
head bolt and the cylinder to tighten to the 90" in
the order of the numbers shown in the illustration.
(5) Tighten to the 90' in the order of the numbers
shown in the illustration so that the paint marks
on the head of the cylinder head bolt and cylinder
head are aligned.
(4) Put
Gaution
1. lf the tightening angle is leee than Slo, ttte
bolt is not sufficiently tightened.
2. lf the tightening angle is byond the limlt,
rl
{:
remove the bolt and start from step
again.
Front of the engine
Step (5)
Paint mark
Paint mark
1
114-14
ENGINE <4G9>
-
Cylinder Head GaskeUTiming Belt
>C<
RADIATOR UPPER HOSE INSTALLATION
1. Insert the radiator upper hose to the convex section
of the water outlet fitting.
2. Align the mating mark on the radiator upper hose with
that of the hose clamp to install.
TIMING BELT
INSTALLATION SERVICE POINT
Timing belt tension adjustment
Standard value (A): 4.8
AolSOO42
-
5.5 mm
ENGINE LUBRICATION
-
General/On-vehicle Service
12-1
GROUP 12
ENGINE LUBRICATION
GENERAL
OUTLINE OF CHANGE
A quality of the engine oil has been
changed.
ON-VEHICLE SERVICE
Specified Engine Oil (ACEA and API clascification):
ACEA 41, 42, A3/AP| SG or higher
NOTES
o
o
o
o
134-1
FUEL
CONTENTS
GASOLTNE DTRECT TNJECTTON
(cDD
.... . 13A
13A-2
GASOLINE DIRECT
INJECTION (GDt)
CONTENTS
.........3
GENERAL
Outline of Changes
.........3
.
.....
SERV|CE SPECTFTCATTONS .....
.....
TROUBLESHOOTING
GENERAL INFORMANON
oN-vEHtcLE SERVICE
.
..
3
5
6
.... l(n
Test
Component Location
Orygen Sensor Chec*
Fuel Pressure
FUEL PUMP (H|GH PRESSURE)
TNJECTOR
THROTTLE BODY
....... 108
..... 112
.. 112
.......... 114
...... 117
......
121
GDI
-
General/General lnformation
134-3
GENERAL
OUTLINE OF CHANGES
Due to the changes shown below, the service procedures regarding the different description from the
previous version have been established.
On-board Diagnostics System has been adopted to expand the diagnostic items and to change diagnosis
code numbering system.
Fuel pressure regulator (high-pressure) incorporate fuel pump (high-pressure) has been adopted.
An orygen sensor (rear) has been added.
A ignition failure sensor has been added.
.
o
o
.
GENERAL INFORMATION
SELF-DIAGNOSIS FUNCTION
Following functions have been added.
The engine-ECU records the engine operating condition when the diagnosis code is set.
This data is called "treeze frame" data.
This data can be read by using the MUT-II, are can then be used in simulation tests for troubleshooting.
.
GENERAL SPECIFICATION
Items
Engine-ECU
Specification
ldentification No.
E2Ti1582
134-4
-
GDI
General lnformation
GASOLINE DIRECT INJECTION SYSTEM DIAGRAM
*1
*2
*3
*4
Orygen
sensor I o
(front)
Oxygen
(rear)
sensor
a
Airflowsensor
Intake air tempera-
o
ture sensor
:t5 Throttle
position
sensor (2nd chan-
*6
*7
*8
*9
*10
*11
l'a
nel)
o
o
O
O
Camshaft position
sensor
Crank angle sensor
Barometric pressure sensor
Engine coolant temperature sensor
Detonation sensor
Fuel pressure sensor
o
O
O
o
o
o
o
a
st channel) o
o
*l2Throttle position
sensor
(1
Power supply
lgnition switch-lG
lgnition switch-ST
Accelerator pedal position
sensor (1st channel)
Accelerator pedal position
switch
Vehicle speed sensor
A/C switch
:a';"1
+
o
a
o
o
control
o
solenoid valve
a
a
pressure switch
Altemator FR signal
Stop lamp suritch
Small lamp switch
Brake vacuum sgnsor
Fuel pump relay
Injector driver relay
Throttle
control
servo relay
A/G relay
o
lgnition coil
Fan controller
Engine waming
O
GDI ECO indicator
o
lamp
Diagnosis ouput
Altemator G termF
O
o
Injector open circuit check
signal
Throttle valve controller
A/C thermo sensor
nal
Throttle
controller
Orygen
valve
s€nsor
heater
*4 Throttle valve
Power supply
lgnition switch-lG
o
Engine-ECU
control servo
Accelerator pedal position
sensor (2nd channel)
Engine-ECU
*4
Intake airtemporatrre sensor
*5
Throttle position sensor (2nd channel)
*12 Thotüe position sansor (lst channel)
*4
>t3 Air flow sensor
Throttle control servo
*8 Barometric pr€ssur€
sensor
*11 Fuel pressur€ sonsor
*6
Engine control relay
lamp
fluid
ro tuettanr
tt
+l
(stepper motor)
*3 Purge
1
Power steering
(low-pressure)
I
*2
Injector driver
(injecto0
EGR valve
Inhibitor switch <ÄrlT>
From fuel pump
I
*1
Gamshaft
position
pump
(high-pressure)
Canister
*1
lnjec-
*9 Engine coolant
tempsrature sensor
*3 Purge
*10 Detonation sensor
*1
Orygen sensor (front)
*2
/r7 Grank angle
lnjector
driver
oontrol
solenoid valve
Oxygen sensor (rear)
sensor
Y60614',
GDI
-
Service Specifications
SERVICE SPECIFICATIONS
Items
Fuel pressure
Standard value
High-pressure
side
MPa
4-6.9
Low-pressure
side
kPa
Approximately 324
Orygen sensor output voltage (during rewing) V
Orygen sensor heater resistance (at 20"C) Q
0.6
-
1.0
Front
4.5
-
8.0
Rear
11
-18
134-5
134-6
GDI
-
Troubleshooting
TROUBLESHOOTING
DIAGNOSIS FUNCTION
ENGTNE WARNTNG LAMP (CHECK ENGTNE LAMP)
lf an abnormality occurs in any of the following items related
to the GDI system, the engine warning lamp will illuminate
9FU092
or flash. lf the lamp remains illuminated or if the lamp illuminates
while the engine is running, check the diagnosis code output.
However, the warning lamp will illuminate as bulb check for
five seconds whenever the ignition switch is turned to the
ON position.
Engine warning lamp inspection items
Code No.
Diagnosis item
Engine-ECU
P0100
Air flow sensor system
P0105
Barometric pressure sensor system
P0110
Intake air temperature sensor system
P0115
Engine coolant temperature sensor system
P0120*
Throttle position sensor (1st channel) system
P0125
Feedback system
P0130
Orygen sensor (front) system <sensor 1>
P0135
Orygen sensor heater (front) system <sensor 1>
P0136
Orygen sensor (rear) system <sensor 2>
P0141
Oxygen sensor heater (rear) system <sensor 2>
P0170
Abnormal fuel system
P0190*
Abnormalfuel pressure
P0201
No. 1 injector system
P0202
No. 2 injector system
P0203
No. 3 injector system
PO2o4
No. 4 injector system
P0220*
Accelerator pedal position sensor (1st channel) system
PO?25*
Throttle position sensor (2nd channel) system
P0300*
lgnition coil (power transistor) system
P0301
No. 1 cylinder misfire detected
P0302
No. 2 cylinder misfire detected
P0303
No. 3 cylinder misfire detected
P0304
No. 4 cylinder misfire detected
GDI
-
Troubleshooting
Code No.
Diagnosis item
P0335
Crank angle sensor system
P0340
Camshaft position sensor system
P0403
EGR valve system
P0420
Catalyst malfunction
P0443
Purge control solenoid valve system
Pl200
Injector driver system
P1220*
Electronic-controlled throttle valve system
P1221*
Throttle valve position feedback system
P1223*
Communication line with throttle valve controller
P1224*
Throttle valve control servo motor (motor 1st phase malfunction) system
Pl225*
Accelerator pedal position sensor (2nd channel) system
P1228*
Throttle valve control servo motor (motor 2nd phase malfunction) system
P1515
Brake vacuum sensor system
134-7
NOTE
1. lf the engine warning lamp illuminates because of a malfunction of the engine-EOu, communication
between MUT-tr and the engine-EGU is impossible. In this case, the diagnosis code cannot be read.
2. After the engine-ECU has detected a malfunction, the engine warning lamp illuminates when the engine
is next turned on and the same malfunction is re-detected. However, for items marked with a "*"
in the diagnosis code number column, the engine warning lamp illuminates only on the first detection
of the malfunction.
As for P122O, P1221, P1223, P1224, and P1228, the engine warning lamp flashes. lf maffunctions
3.
are detected at the throttle position sensor (1st channel) and the throttle position sensor (2nd channel)
at the same time, or malfunctions are detected at the accelerator pedal position sensor (1st channel)
and the accelerator pedal position sensor (2nd channel) at the same time, the engine waming lamp
will flash.
After the engine warning lamp illuminates, it will be switched off under the following conditions.
(1) When the engine-EOU monitored the power train malfunction three times* and met set condition
requirements, it detected no malfunction.
In this case, "one time" indicates from engine start to stop.
(2) For misfiring malfunction, when driving conditions (engine speed, engine coolant temperature, etc.)
are similar to those when the malfunction was first recorded.
Sensor 1 indicates the sensor mounted at a position closest to the engine, and sensor 2 indicates
the sensor mounted at the position second closest to the engine.
*:
4.
134-8
GDI
-
Troubleshooting
METHOD OF READING AND ERASING DIAGNOSIS
CODES
Refer to GROUP 00 - How to Use Troubleshooting/lnspection
Service Points.
DIAGNOSIS USING DIAGNOSIS 2 MODE
1. Switch the diagnosis mode of the engine control unit to
DIAGNOSIS 2 mode using the MUT-II.
2. Carry out a road test.
3. Take a reading of the diagncis code and repairthe problem
location.
4. Tum the ignition switch to OFF and then backto ON again.
NOTE
5.
By tuming the ignition switch to OFF, the engine-ECu
will switch the diagnosis mode from DIAGNOSIS 2 mode
to DIAGNOSIS 1 mode.
Erase the diagnosis codes.
NSPECNON USING MUT.N DATA LIST AND
ACTUATOR TESTING
1. Carry out inspection by means of the data list and the
actuator test function. lf there is an abnormality, check
and repair the chassis hamesses and components.
2. After repairing, re-check using the MUT-tr and check that
the abnormal input and output have retumed to normal
as a result of the repairs.
3. Erase the diagnosis code memory.
4. Remove the MUT-II, and then start the engine again and
carry out a road test to confirm that the problem has
disappeared.
GDI
-
134-9
Troubleshooting
FREEZE FRAME DATA
When the engine-EOU detects a malfunction and stores a
diagnosis code, it also stores a current status of the engine.
This function is called "Fteeze frame data." By analyzing
this "treeze frame" data with the MUT-II, an effective
troubleshooting can be performed.
The display items of freeze frame data are shown below.
Display item list
Data item
Unit
Engine coolant temperature sensor
oc
Engine speed
r/min
Vehicle speed
krdtl
Long-term fuel compensation (long-term
fueltrim)
o/o
Short-term fuel compensation (short-term
o/o
fueltrim)
Fuel control condi-
Open loop
OL
Closed loop
CL
Open loop owing to
drive condition
OL.DRV.
Open loop owing to
system malfunction
OL.SYS.
Closed loop based
cL-H02S
tion
on one orygen sen-
sor
Calculation load value
o/o
Diagnosis code during data recording
NOTE
lf malfunctions have been detected in multiple syetems, store
one malfunction only, which has been detected first.
READINESS TEST STATUS
The engine-ECU monitors the following main diagnoeis items,
judges if these items are in good condition or not, and the
stores its history. This history can be read out by using MUT-II.
(lf the ECU has judged a item before, the MUT-tr displays
"Complete.")
In addition, if diagnosis codes are erased or the baüery cable
is disconnected, this history will also be erased (the memory
will be reset).
Catalyst: PO42O
Orygen sensor: P0130
Orygen sensor heater: P0135, P0141
o
.
o
134-10
GDI
-
Troubleshooting
FAIL.SAFE FUNCTION REFERENCE TABLE
When the main sensor malfunctions are detected by the diagnosis function, the vehicle is controlled by
means of the pre-set control logic to maintain safe conditions for driving.
Control contents during malfunction
Malfunctioning item
Air flow sensor
1.
Suspends lean burn operation.
2.
Uses the throttle position sensor signal and engine speed signal (crank angle
sensor signal) to take reading of the basic injector drive time and basic ignition
timing from the preset mapping.
Intake air temperature sensor
Controls as if the intake air temperature is 25"C.
Throttle position sensor (2nd
1.
channel)
2.
Suspends lean bum operation.
Gontrols the throttle opening angle feedback (half as much as the opening
rate in the normal condition) by using signals from the throttle position sensor
(1st channel). However, this controlling system is not applied if the throttle
position sensor (lst channel) and throttle position sensor (2nd channel)
combination ouput voltrage is outside 4 6 V.
Refrains from controlling the throttle opening angle feedback if the throttle
position sensor (1st channel) is also defective.
-
Engine coolant temperature
sensor
Controls as if the engine coolant temperature is 80'C. (Moreover, the confol rystem
is uorking until the ipition su,itch is tumed OFF if the sensor signal rcturns to normal.)
Controls maintiaining the condition before determined as failure.
Fuel will be cut-off 4 seconds after a malfunction is detected. (However, only if
No. 1 cylinder TDC has never been detected after the ignition switch is tumed
Camshaft position sensor
to the ON position)
Vehicle speed sensor
1.
2.
Suspends lean bum operation. However, the control is cancelled as a certain
time passes by with the engine speed of 1,500 r/min or more.
Suspends lean bum operation during the engine idling.
Barometric pressure sensor
Controls as if the barometric pressure is 101 kPa.
Detonation sensor
Fixes the ignition timing as that for standard petrol.
lnjector
1.
2.
Communication
line
with
A/T-ECU
Disable ignition timing retard control (engine and transmission total control) during
shift change.
lgnition coil (incorporating pow-
1.
er transistor)
2.
Fuel pressure sensor
1.
2.
3.
Altemator FR terminal
Accelerator pedal position sensor (2nd channel)
Suspends lean bum operation.
Suspends the exhaust gas recirculation.
Suspends lean bum operation.
Cuts off the fuel supply to cylinders with an abnormal ignition signal.
Gontrols as if the fuel pressure is 5 MPa. (ln case of open/short circuit)
Tums the fuel pump relay off. (ln case of abnomality in high pressure)
Suspends fuel injection. (when the low pressure is detected and the engine
speed is more than 3,000 r/min)
Refrains from controlling to suppress the altemator output
(Operated as a normalaltemator)
to electrical
load.
1.
Suspends lean bum operation.
2.
Controls the throttle valve position by using signals from the accelerator pedal
position sensor (lst channel). (However, the control system is not applicable
if the difierence from the accelerator pedal position sensor (1st channel) output
voltage is 1.0 V or higher.)
Suspends the electronic controlled throttle valve system if accelerator pedal
position sensor (lst channel) is also defective.
GDI
-
Troubleshooting
134-11
Malfunctioning item
Control contents during malfunction
Accelerator pedal position sensor (1st channel)
1.
Suspends lean burn operation.
2.
Controls the throttle valve position by using signals from the accelerator pedal
position sensor (2nd channel). (However, this control is not applicable if the
voltage difference between the accelerator pedal position sensor (1st channel)
and accelerator pedal position sensor (2nd channel) is 1.0 V or higher.)
Also suspends the electronic-controlled throttle valve system when the
accelerator pedal position sensor (2nd channel) is defective.
Throttle position sensor (1st
1.
Suspends lean bum operation.
channel)
2.
Controls throttle opening angle feedback by using signals from throttle position
sensor (2nd channel). (However, the controlling system is not applied when
the throttle position sensor (1st channel) and throttle position sensor (2nd
channel) combination output voltage is outside 4 - 6 V.)
Refrains from controlling the throttle opening angle feedback when throttle
position sensor (2nd channel) is also defective.
Electronic-controlled throttle
1.
valve system
2.
3.
Throttle valve position feed-
1.
back
2.
3.
Communication line between
1.
the throttle valve controller and
the engine-ECU
Suspends the electronic controlled throttle valve system.
Suspends lean bum operation.
Suspends the idle speed feedback control.
Suspends the electronic controlled throttle valve system.
Suspends lean burn operation.
Suspends the engine speed feedback control.
Communication enor between the throttle valve controller and the engine'EGU
o Suspends lean burn operation.
r Cuts the fuel supply when the engine speed reaches 3,0@ r/min or morc.
o Suspends the cruise-control.
Communication error between the throttle valve controller and the engine-EOU
. Suspends lean burn operation.
o Cuts the fuel supply when the engine speed reaches 3,(XX) r/min or more.
o Suspends the cruise-control.
o The throttle valve controller controls the throttle valve opening angle by
using signals from accelerator pedal position sensor (2nd channel).
Throttle control servo motor 1st
phase malfunction
Bans lean burn operation.
Throttle control servo motor
1.
2nd phase malfunction
2.
3.
Misfiring
lf the detected misfiring causes damage to the catalyst, the misfiring cylinderwill be
shut down.
Suspends electronic control throttle valve system.
Bans lean burn operation.
Bans engine speed feed back control.
NOTE
lf the electronic-controlled throttle valve system is suspended, the engine warning lamp will illuminate.
134-12
GDI
-
Troubleshooting
INSPECTION CHART FOR DIAGNOSIS CODES
Code No.
Diagnosis item
Reference page
P0100
Air flow sensor system
134-14
P0105
Barometric pressure sensor system
134-16
P0110
Intake air temperature sensor system
134-18
P0115
Engine coolant temperature sensor system
134-19
P0120*
Throttle position sensor 1 (1st channel) system
134-22
P0125
Feedback system
134-24
P0130
Orygen sensor (front) system <sensor 1>
134-25
P0135
Orygen sensor heater (front) system <sensor 1>
134-27
P0136
Orygen sensor (rear) system <sensor 2>
134-28
P0141
Orygen sensor heater (rear) system <sensor 2>
134-30
P0170
Abnormal fuel system
134-31
P0190*
Abnormal fuel pressure
134-33
P0201
No. 1 injector system
134-34
P0202
No. 2 injector system
134-36
P0203
No. 3 injector system
134-37
P0204
No. 4 injector system
134-38
P0220*
Accelerator pedal position sensor (1st ciannel) system
134-40
P0225*
Throttle position sensor (2nd channel) system
134-43
P0300*
lgnition coil (power transistor) system
134-44
P0301
No. 1 cylinder misfire detected
134-46
P0302
No.2 cylinder misfire detected
134-46
P0303
No. 3 cylinder misfire detected
134-46
P0304
No. 4 cylinder misftre detected
134-46
P0325
Detonation sensor slrstem
134-47
P0335
Crank angle sensor system
134-47
P0340
Camshaft position sensor system
134-59
P0,,[03
EGR valve system
134-50
P0420
Catalyst malfunction
134-51
P0443
Purge controlsolenoid valve q6tem
134-52
P0500
Vehicle speed sensor system
134-53
P1200
Injector driver system
13A-s3
P1220*
Electronic-controlled throttle valve system
134-#
GDI
-
134-13
Troubleshooting
Code No.
Diagnosis item
Reference page
P1221*
Throttle valve position feedback system
134-55
P1223*
Communication line with throttle valve controller
134-56
P1224*
Throttle valve controlservo motor (motor 1st phase malfunction) system
134-57
P1225*
Accelerator pedal position sensor (2nd channel) system
134-58
P1228*
Throttle valve control servo motor (motor 2nd phase malfunction) system
134-60
P1500
Alternator FR terminal system
134€1
P1515
Brake vacuum sensor system
134-62
Pl600
Communication wire with A/T-ECU system
134-64
P1610
lmmobilizer system
134-64
NOTE
1. Do not replace the engine-ECU until a through terminal check reveals there are no shorUopen circuit.
2. Check that the engine-ECu earth circuit is normal before checking for the cause of the problem.
3. After the engine-EOu has detected a malfunction, a diagnosis code is recorded the next time the
4.
engine is started and the same malfunction is re-detected. However, for items marked with I "*",
the diagnosis code is recorded on the first detection of the malfunction.
Sensor 1 indicates the sensor mounted at a position closest to the engine, and sensor 2 indicates
the sensor mounted at the position second closest to the engine.
134-14
GDI
-
Troubleshooting
INSPECTION PROCEDURE CLASSIFIED BY DIAGNOSIS CODE
Code No. P0100 Air flow sensor
system
Check
r Engine speed: 5OO r/min or more
Set Conditions
Probable cause
Range of
r
The sensor output frequency is 3.3 Hz or less for four
llUT-II ltata list
.
Io
I
|
seconds.
I
o
Malfunction of air flow sensor
Open or short circuit in air flow sensor circuit or
loose connector contact
Malfunction of engine-EoU
Transient malfunction
(Refer to GROUP 0O
Points to
Note for Intemittent Maftunctions.)
-
12 Air flow sensor (Refer to
P,134.94, DATA LIST REFERENCE
TABLE.}
Measure at air flou, sensor
connector A-71.
.
Disconnect the connector and
measure at the hamess side.
(1) Voltage between terminal 3 and
earth (lgnition switch: ON)
OK: 4.8 5.2 V
(2) Voltage between terminal 4 and
earth (lgnition switcfr: ON)
OK: System voltage
(3) Resisl,ance between teminal 5
and earth
-
(1) NG
Measure
c-l8.
o
o
o
d
ongins-Ecu oonnec'tor
Measure the vottage at lhe
engine-EOU teminal
lgnition switct: ON
Voltage between teminal 61 and
eanh
o{G
4.8
-
5.2 V
OK:2Oorless
Ch€d( tie harness b€tweon the air
sonsor ard the engine-Ecu.
flw
Ched( ü€ hamess bstwe€n the air
flow sensor and the engine control
rglay, and repair if neqBssary.
Chcck the following omn€ctorr:
A-S, G19
Ched( the hamess between the air
fror sensor and the
engine-EGU.
Check the harness betureen the air
flow sensor and the engine-EOu,
and repair al nocsssary.
GDI
-
Troubleshooting
Measure at air flow sensor
connector A-71.
Use test harness (M8991709) to
connect the connector, and
measure at the pick-up hamess.
lgnition switch: ON
Voltage between terminal 7 and
earth
.
.
.
OK:7-8V
Measure at air flow sensor
connector A-71.
Use test hamess (M8991709) to
connect the connector, and
measure at the pick-up harness.
o
.
.
Selector lever position: P
Voltage between terminal 7 and
Check the hamess between the ail
flow sensor and the engine-EOU.
earth
OK:
Engine: ldling
o-1v
Engine speed: 3,000 r/min
6-9V
Measure the output wave form at
air llow sensor @nnector A-71 (by
using an anallzer).
o Use test hamess (M8991709) to
.
.
connect the connector. and
measure at the pick-up harness.
Engine: ldling
Voltage between terminal 3 and
earth
OK: Waveforms should be displayed on P.134-84- (lnspection Procedure Using
an Analfzer) and nois€
should not be displayed in
the waveform.
Replace the air flow sensor.
Check the following conncctor:
c-l8
Ch6ck the hamesses between the
air flow sensor and the engine-Eou
and between the air flow sensor
and the engine control relay, and
repair if necessary.
NOTE
*:
Refer to the '00 PAJERO PININ Workshop Manual (Pub. No. CKREOOEI).
134-15
134-16
GDI
-
Troubleshooting
Code No. P0105 Barometric pressure sensor system
Probable cause
Range of Check
o Two seconds have passed since the ignition switch is tumed ON or the
engine starting process is completed.
. Baüery voltage: 8 V or more
Set Conditions
. The sensor output voltage is 4.5 V or more lor four secords (equivalent to
114 kPa of barometric pressure)
or
. The sensor ouFut roltage is 0.2 V or less (equivalent to 5':l kPa of
o
o
o
Malfunction of barometric pressure sensor
Open or short circuit in barometric pressure
sensor circuit or loose connector @ntact
Malfunction of engine-ECU
barometric
MUT-II Dab list
25 Baometric pressure sensor
(Refer to P.13A-94, DATA LIST
Tnnsient matfunction
(Rsfer to GROUP OO
-
Points to
Note for Intemittent Maffunctions.)
REFERENCE TABLE.)
Measure at air flow sensor
connector A-71.
.
Disconnect the connector and
measure at the hamess side.
(1) Voltage between terminal 1 and
earth (lgnition switch: ON)
OK:
4.8 - 5.2 V
(2) Resistance between terminal 5
and eadh
(1) NG
Measure at engine-Ecu @nnector
c-18.
.
o
.
Measure the voltage at the
engine-EoU terminal.
lgnition switch: ON
Voltage between t€minal 41 and
eanh
OK:
4.8
-
5.2 V
Check the harn€ss between the ail
flow sensor and the engine-EOU
,and repair if necessary.
OK:2Oorless
Ched< the hamess between the air
flow sensor ancl the engine-EoU.
Gheck the iollowing @nnoctor:
A-36, G19
Ched( thg hamess between the air
flow sensor and the engine.ECU.
o
GDI
Measure at air flow sensor
connector A-71.
-
Troubleshooting
(1) NG
o
Connect connector terminals No.
1, No. 2 and No. 5 only by using
test harness (M8991 709), and
measure at the pick-up hamess.
lgnition switch: ON
(1) Voltage between terminal 1 and
earth
o
OK:
4.8
-
Check the harness between the air
flow sensor and the engine-EcU,
5.2 V
(2) Voltage between terminal 2 and
eatth
Replace the air flow sensor.
OK:
Altitude 0 m: 3.7 - 4.3 V
Altitude 1,200 m:
3.2 - 3.8 V
(3) Voltage between terminal 5 and
earth
OK:
0.5 V or less
Check the following connectors:
A-36, C-18, C-19
Check the harness betwgen the air
flow sensor and the engine-ECU,
and repair if necessary.
Measure at engine-EOu connector
c-18.
o Measure the \oltage at the
.
.
engine-ECU tenninal.
lgnition switc-fr: ON
Voltage between teminal 51 and
earth
OK: Ahitude 0 m: 3.7 4.3 V
Altitude '1,200 m:
3.2 3.8 V
-
-
Check the hamess between the air
flow sensor and the engine-EOU,
and repair if
13A-17
134-18
GDI
-
Troubleshoofing
Code No. P0110 lntake air temperature sensor system
Range
.
ol
Check
Two seconds have passed since the ignition switch is tumed ON or the
engine starting process is completed.
Set Conditions
. The sensor output voltage is 4.6 V or more lor four seconds (equivalent to
-45"C of intake air temperature)
or
o The sensor output roltage is O.2 V or more for tour seconds (equivalent to
125'C of intake air temperature)
IUIUT.II Data IBt
13 Intake air temperature sensor
OK: Roughly the same as ambient temperature.
(RefEr
to GROUP ü)
-
Probable cause
o
.
Open or short circuit in intake air temperature
sensor or loose connector contact
Malfunction of engine-ECU
Pcints to
(Refer to P.134-102t
Chcck following connector: A-71
Measure at air flow sensor
connector A-71.
Disconnect the connector and
.
measure at the hamess side.
(1) Resistance between terminal 5
and earth
OK:2Oorless
(1) NG
Check the following qonnectorr:
A-36, c-19
Ched( th€ hamess between the air
flour seneor and the engine-ECU.
(2) Vdtage between terminal 6 and
earth
(lgnition switch: ON)
4.8 - 5.2 V
OK:
Measure at engine-Ecu @nnector
c-18.
o
.
.
.
Measure the voltage at the
engine-EOU teminal.
Disconnect connector A-71.
lgnition switcfr: ON
Vottage bet|ueen teminal 62 and
eaül
OK:
4.8
-
5.2 V
Check the ham€ss betuoen the air
flour sensor and üte engine-EGU,
and repair il n€c€ssary.
Ched( the hamess betwe€n the air
sensor and lhe €ngine-E0u.
fw
NOTE
Refer to the '00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1).
*:
GDI
-
134-19
Troubleshooting
From the previous page
Measure at air flow sensor
connector A-71.
Use the test hamess
(M8991709) to connect only
terminals 5 and 6. and then
measure at the pick-up harness.
lgnition switch: ON
Voliage between terminal 6 and
earth
OK: Ambient temperature OoC:
3.2 3.8 V
Ambient temperature 20'C:
2.3 2.9 V
Ambient temperature 40oC:
1.5 2.1 V
Ambient temperature 80oC:
.
.
.
0.4 -
1.0
Check the following connectors:
A-36, C-18, C-'t9
Check the hamess between the air
flow sensor and the engine-Eou,
and repair if necessary.
v
Code No. P0115 Engine coolant temperature sensor
system
Probable cauae
Range of Check
o
.
. Engine: Two seconds after the engine has been süarted
Set Conditions
. The sensor output voltage is 4.6 V or more for four seconds
or
(equivalent to
-45"C of engine coolant temperature)
.
The sensor output voltage is 0.1 V or less for four seconds (equivalent to
140'C of engine coolant temperature)
Range of Check
o Engine: After starting
Set Conditions
. The engine coolant temperature has reduced
from over 4O'C lo less than
40"C, and that condition has lasted for five minutes or more.
o
Maltunction ol engine @olant temperdire ccnsor
Open or short circuit in the cngine cocilent
temperature ssnsor ciru.rit or bose €nrEcbt
@ntact
Malfunc'tion of engine-EOU
]
134-20
GDI
MUT-U Data list
21 Engine coolant temperature
-
When the engine is cold,
the temperature is roughly
the same as ambient temperature. lf warm, it is 80
- 120"C.
Replm
Measure at engine coolant
temperature sensor @nnector A€9.
.
.
Troubleshooting
Transient malfunction
(Refer to GROUP 00 Points to
Note for Intermittent Malfunctions.)
sensor
OK:
-
Disoonnect the connector and
meesurc at the hamess side.
Resistance between tsrminals 1
and 2
OK: At 20'C of engine coolant
temperature: 2.1 - 2.7 k{,
At 8O"C of engine coolant
temperature: 0.26 - 0.36
ko
Chcck the following omnGctor:
A€9
Measure at engine coolanl
temperature sensor connec-tor A-69.
.
Disconnect the connector and
measure at the hamess side.
(1) Voltage between terminal 1 ard
earth
(lgnition switch: ON)
4.8 - 5.2 V
(2) Resistance between terminal 2
and earth
OK:
(1) NG
Measure at €ngine-Ecu @nnec-tor
c-18.
o
o
o
r
Measure the voltage at the
engine-EoU terminal.
Disconnect connocrbr A€9.
lgnition switcfi: ON
Voltage between terminal
earth
OK: 4.8 5.2 V
4
and
-
OK:2Oorless
Check lhe hamess wire between
the engine coolant tempsrature
sensor and the engine-Ecu.
Gheck
A{6,
tte lollowing oonncctoE:
C-19
Ghed< the hamess wir€ b€ture€n
the engine coolant temp€rsture
Check the hamees wire betvueen
the engine coolant temperatur€
sensor and the engine-EoU, and
GDI
Measure at engine coolant
temperature sensor connector A-69.
o Use test hamess (M8991658) to
connect the connector. and
measure at the pick-up harness.
o lgnition switch: ON
. Voltage between terminal 1 and
earth
OK: At 0"C of engine
coolant
3.8 V
coolant
2.9 V
coolant
1.9 V
coolant
0.9 V
temperature: 3.2 At 20"C of engine
temperature: 2.3 At 40"C of engine
temperature: 1.3 At 80"C of engine
temperalure: 0.3 *
NOTE
*:
Refer to the '00 PAJERO
-
Troubleshooting
Check the engine coolant
temperature sensor.
(Refer to P.134-102..)
Check the following connestois:
A-36, C-18, C-19
Check the harness wire between
the engine coolant temperature
sensor and the engine-Eou, and
repair if necessary.
PININ Workshop Manual (Pub. No. CKRE00E1).
134-21
l
134-22
GDI
-
Troubleshooting
Code No. P0120 Throttle position sensor (1st channel)
system
Probable cause
The throttle valve controller judges a malfunction, and then transmit the result
to the engine-Ecu.
Range of Check
lgnition switch: ON
Set Conditions
The sensor output voltage is 0.2 V or less.
or
The sensor output roltage is 4.9 V or more.
.
o
.
.
.
or
o
or
.
.
.
Malfunction of throttle position sensor
Open or short circuit in the throttle position
sensor (1st channel) circuit or loose conneclor
oontact
Malfunction of throttle valve controller
Malfunction of engine-EoU
The throttle position s€nsor (1st ctannel) ard thrctüe po8ilion sensor (2nd
channel) combination outprrt voltage is outside 4 6 V.
-
The output rcltage of the throtüe position ssnsor (lst ciannel) is
significantly different (approx. lV) f]om the throtüe vahre oponing angle
(voltage), which the engine-ECU request the thrdtle valve controller.
ilUT-tr Data list
79 Throttle position s€nsor (lst
channel) (Refer to P.134-94,
DATA LIST REFERENCE
TABLE.)
tuple
Check the throttle position sensor.
(Refer to P.134-103-.)
Measure at throttle position sensor
connec'tor A-06.
Disconnect the connec'tor and
mgaliure at the hamess side.
(1) Voltage between terminal and
€arül
o
I
(lgnition switch: ON)
OK: 4.8 - 5.2 V
(2) Resistance between terminal 3
and earth
(1) NG
Measuo at throttle valv€ contrcller
Check thc following @nnrctor:
connec'tor C-48.
C.48
o
MsasuE rottage
o
o
valvc co,rtroller connector
terminals.
lgnitirn swibh: ON
Vciltage betreen terminal
earth
OK: 4.8 5.2 V
d
the thottle
Check the hamess wire betu,een
the throttle position sensor and the
throtüe vdw controller, and repair if
6 and
-
OK:2Oorless
Ch€ct
üc follouing @nnocbr:
C.16
Chd( the hamess wire between
the throtüe position sensor and the
throttle valve controller.
OK
NG
NG
Rcpair
Ctpck the hamess wi]€ between
lh€ throtüe positiofl sensor and üle
thrctüe valve oontroller.
Replace the thmttle \ralve controller.
NOTE
*:
Refer to the '00 PA.JERO PININ Workshop Manual (Pub. No. CKPE00E1)
GDI
-
134-23
Troubleshooting
From the previous page
OK
(1) NG
clnnector A-66.
. Use test hamess (M8991536) to
(3) NG
.
earth
CIK: Accelerator pedal lully
Repair
Check the harness wire between
the throttle position sensor and the
throttle valve controller, and repair if
necessary.
(2) NG
re-
leased: 0.45 - 0.8 V
Accelerator pedal lully depressed: 3.9 - 4.9 V
(3) Voltage between terminal 3 and
Adjust the throttle position sensor.
(Refer to P.13A-92..)
Check the following connestor:
NG
C-rtg
earth
OK:
NG
OK
connect the connector. and
measure at the pick-up harness.
lgnition switch: ON
(1) Voltage between terminal 1 and
earth
OK: 4.8 - 5.2 V
(2) Voltage botween terminal 2 and
Check the following connector:
c-48
0.5 V or less
OK
Check th€ hamess wire between
the throttle position sensor and the
throtüe valve controller, and repair if
OK
necessary.
Measure at throttle valve controller
connector C-48.
o Measure voltage at the throüle
valve controller connector
o
.
NG
Check the hamess wire between
the throttle position sensor and the
throttle valve controller, and repair if
lgnition switch: ON
Voltage between terminal 7 and
earth
Acc8lerator pedal fully released: 0.45 - 0.8 V
Accelerator pedal fully depressed: 3.9 - 4.9 V
NG
OK
terminals.
OK:
Check the following connector:
c-48
necessary.
OK
Check th6 lollowing conngctor:
c-48
NG
OK
Check the trouble synptoms.
NG
Rgplace the throttle valve controller.
NOTE
l:t.
Refer to the '00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
:
*.
13A^-24
GDI
-
Troubleshooting
Code No. P0125 Feedback system
Probable cause
Range of Check
o The engine coolant temperature is approx. 80oC or more.
. During stoichiometric feedback control
o The vehicle is not being decelerated.
Set Conditions
o Orygen sensor (front) output voltage has been higher or lower than 0.5 V
for at least thirty seconds.
@
o Open or short circuit in the oxygen sensor (front)
circuit or loose connector contact
. Mallunction of engine-ECU
Ch€ck $s following qmncclor3:
A-36, C-19
Measure at ox)rgen sEnsor (frofit)
connector A€7.
.
.
Disconnest the connec'tor and
measure at the hamess side.
Flesistance between teminal 2
and earth
Ched( the hamess wire between
the orygen sensor (front) and the
OK:2Oorless
engin6-ECU
(1) NG
Measure at orygen sensor (font)
connector A€7.
o Use the test hamess
(MD998464) to clnnect the
connEctor, and measure at the
pick-up hamess side.
Engine: 2,50O r/min (after
warming up)
(1) Voltage between terminal 2 and
earth
OK: 0.5 V or less
(2) Volt€ge between teminal 4 and
earth
o
OK: 0 V and 0.8 V afternate.
Ch€d(
A-36,
üe iollowing oDnnsstor!:
Gtg
Ch€d( the hamess wi]e b€tureen
the orrygen sensor (front) and the
Ched( the orqgen sonsor (fiont).
(Refer to P.134-112.)
Chcc* thc iollorlng connestor:
c-19
Chedr the hamess wire bebveen
the o!rygen rnsor (fnnt) and üte
and rcpair il
Measure at engine-ECU connector
G19.
.
.
.
Mgasure the vofüage at the
engine-EoU terminal.
Engine: 2,5ü) r/min (after
warming up)
Voltage between teminal 71 and
earth
OK: 0 V and 0.8 V alternate.
Transient malfunclion
(Refer to GROUP 0O - Points to
Note br lntormittent Malfunctions.
Replace
GDI
-
Code No. P0130 Oxygen sensor (front) system
<sensor 1>
Range
of Check
. Three minutes have been passed since the engine has been started.
. The engine coolant temperature is approx. 80"C or more.
o lntake air temperature is 20 - 50'C
. Engine speed is 1,200 r/min or more
. Driving on a level surface at constant speed.
Set Conditions
. The oxygen sensor (front) output voltage is 4.5 V or more when the sensor
output voltage is 0.2 V or less and a voltage of 5 V is applied to the
orygen sensor (front) inside the engine-Eou.
Range
ol Check
o Engine speed is 3,ffD r/min or less
o During driving
. During airlfuel ratio feedback control
Set Conditions
o The orygen sonsor (tront) output frequency is five or less per 12 seconds
on average.
134-2s
Troubleshooting
Probable cause
r
o
.
Malfunction of oxygen sensor (front)
Open or short circuit in the orygen sensor (front)
circuit or loose @nnector contact
Malfunction of engine-EoU
134-26
GDI
Troubleshooting
Check the following connectors:
Measure at orygen sensor (front)
connector A-67.
o
o
-
A-36, C-19
Disconnect the connector and
measure at the hamess side.
Resistance between terminal 2
and earth
Gheck the hamess wire between
the orygen sensor (front) and the
OK:2Qorless
(1) NG
Measure at orygen sensor (front)
connector A-67.
Use the test hamess
(MD998/164) to conn€ct ths
connector, and measure at the
pick-up hamess side.
Engina: 2,500 r/min (after
Ch€d( the
iolliling
qonnectors:
o
A-36, C-19
o
the oxygen sonsor (frcnt) and lhe
Ched( ths ham€ss wire between
urarming up)
(1) VoltEge between terminal 2 and
eaüt
OK: 0.5 V or less
(2) Voltage between terminal 4 and
earth
OK: 0 V and
0.8 V altemate.
Ched( üe oxygen sensor (llont).
(Refer to P.134-112.)
Chd( the hamess wire betrreen
the o:<ygen sensor (frmt) and the
Measure at engine-Ecu @nnector
c-l9.
.
.
.
Measurc the rcltage at the
engine-ECU terminal.
Engine: 2,5ü) r/min (after
uraming up)
Check ths iollowing connector:
c-l9
Chod( the hamess wire between
Voltage between terminal 71 and
earth
OK: 0 V and 0.8 V altemate.
Transisnt rnarfunc*ion
(Refer to GROUP 0O Points to
Note ior Intsrmittent Malfunctions.)
-
Replsce
GDI
-
13A-27
Troubleshooting
Gode No. P0135 Oxygen sensor heater (front) system
<sensor 1>
Probable cause
Range of Check
.
o
o
. The engine c,oolant temperature is approx. 20'C or more.
. The oxygen sensor heater (front) remains on.
. The engine speed is 50 r/min or more.
. Battery voltage is '11 - 16 V.
Set Conditions
o The current, which flows through the oxygen sensor heater (front), is 0.2 A
or less or 3.5 A or more for six seconds.
Measure at oxygen sensor (front)
connector A-67.
Disconnect the connector and
measure at the hamess side.
Resistance between terminals
.
o
and 3
OK:
4.5
-
Replace
1
8.0 O
Ch6ck the following connoctor:
A-67
Measure at orygen sensor (front)
connector A€7.
. Disconnect the connector and
measure at the hamess side.
. lgnition switch: ON
o Voltage between terminal 1 and
earth
Measure at engine-Ecu oonneclor
c-19.
. Measlure the voltiage at the
engine-E0U terminal.
. lgnition switch: ON
. Voltage between teminal 89 and
earth
OK:
Check the following conncctora:
A-36, A.4ilX
Check the hamess wires between
the oxygen sensor (frcnt) and the
engine control relay, and repair it
Check the harness wire between
the oxygen sensor (front) and the
System rollage
Check the hamess wires between
the orygen sensor (front) and the
engine-ECU and between the
orygen sensor (tront) and the
engine control relay.
Transient malfunction
(Refer to GROUP 0O Points to
Note for lntermittent Malfunctions.)
-
Malfunction of orygen sensor heater (front)
Open or short circuit in the orygen sensor heater
(front) circuit or loose connector contact
Malfunc{ion of engine-Eou
134-28
GDI
-
Troubleshooting
Code No. P0136 Oxygen sensor (rear) system
<sensor 2>
Range
of Check
o Three minutes have been passed since the engine has been stiarted.
o The engine coolant temperature is approx. 80oC or more.
. Intake air temperature is 20 - 50'C
. Engine speed is 1,2OO ilmin or more
. Driving on a level surtace at constant sp€ed.
Set Conditions
o The orygen sensor (reao output voltage is 4.5 V or more when the sensor
output \oltage is 0.2 V or less and a vottage of 5 V is applied to the
orygen sensor (rear) inside the engine-ECU.
Range
of Check
. Two seconds have passed dter the engine-EoU d€l€ctgd an opon ciGrit.
o When the orygen sensor (front) is in good condition.
Set Conditions
o When the air/firel rdio is rich, the orygen sensor (fiont) output voltage is
0.5 V or more, the o,rylen sensor (reaO ouFut wltage is less than 0.1 V
and the orygen sensor (rear) output roltage fluctuates within 0.078 V.
Probable cause
o
o
.
Malfunction of oxygen sensor (rear)
Open or short circuit in the orygen sensor (rear)
circuit or loose connector contact
Malfunction of engine-Ecu
GDI
Measure al oxygen sensor (rear)
connector B-11.
o Disconnect the connector and
measure at the harness side.
o Resistance between terminal 2
and earth
OK:2Oorless
Measure at orygen sensor (rear)
connector B-11.
o
.
Use ü|e test harness (M8998464)
to connect the connector, and
m€asure at the pick-up hamess
side.
Engine: 2,500 r/min (after
warming up)
(1) Voltage between terminal 2 and
-
Troubleshooting
Check the following connectors:
A-36, C-19
Check the harness wire between
the oxygen sensor (rear) and the
Check the following connectors:
A-36, C-19
Check the hamess wire between
the orygen sensor (rear) and the
oarth
OK: 0.5 V or less
(2) Voltage between terminal 4 and
earth
OK: 0 V and 0.8 V alternate.
Check the orygen sensor (rear).
(Refer to P.13A-113.)
Chec* the hamess wire between
the orygen sensor (rear) and thE
engine-EoU, and repair if necessary.
Measure at engine-Eou connector
c-l8.
o
r
.
Measure the voltage at the
engine-ECU terminal.
Engine: 2,500 r/min (after
warming up)
Voltage between terminal 53 and
Check the hamess wire between
the orygen sensor (rear) and the
earth
OK: 0 V and 0.8 V altemate.
Check the following @nnectors:
A-36, C-18, C-19
Transient malfunstion
-
(Refer to GROUP 00 Points to
Note for lntermittent Malfunclions.)
134-29
134-30
GDI
-
Troubleshooting
Code No. P0141 Oxygen sensor heater (rear) system
<sensor 2>
Range
: Probable cause
i
of Check
o The engine coolanl temperature is approx. 20oC or more.
o The orygen sensor heater (rear) remains on.
. The engine speed is 50 r/min or more.
o Battery voltage is 11 - 16 V.
Set Conditions
o The current, which flows through the orygen sensor heater (rear), is o.2 A
.
.
.
or less or 3.5 A or more for six seconds.
Rrplrcc
Measure at orygen sensor (rear)
connector B-11.
o
.
Disconnect the connector and
measurc at the hamess side.
Resistanco between terminals
1
and 3
OK:11
-18O
Measure at orygen sensor (rear)
connector B-11.
o
.
.
Disconneat the connector and
measure at the hamess side.
lgnition su,itch: ON
Voltage between terminal 1 and
earth
OK: System voltage
Chock the following @nnoctoE:
A-36,443)(
Ched( ths hamess wi]es bstn€sn
the oxygen sensor (rsar) and the
engins contrd relay, and repair if
neoessary.
Msasure at engine-Ecu connector
c-19.
. Measure the voltage at the
.
o
engine-ECU terminal.
lgnition switch: ON
Voltage between terminal 90 and
earth
OK: S)rstem voltage
Ched( ths hamess wire betuv€en
the orygen sensor (rear) and the
engine-EOU.
Roplac€ the engine-ECU.
Transiont rnatfunction
to GROUP (x) Points to
Note for Intermittent Malfunctions.)
(R۟er
-
Malfunction of orygen sensor heater (rear)
Open or short circuit in the oxygen sensor heater
(rear) circuit or loose @nnector contact
Malfunction
ol
engine-EOU
-
GDI
134-31
Troubleshooting
Gode No. P0170 Abnormal fuel system
Probable cause
Range of Check
Engine: Being leaming the air-tuel ratio
Set Conditions
Ten seconds or more have been passed while the fuel injection amount
compensation value is too low.
.
o
.
o
.
o
o
.
or
o
Ten seconds or more have been passed while the fuel iniection amount
compensation value is too high.
MUT-U Self-Diag Code
ls any diagnosis code other than
Refer
Malfunction of fuel supply system
Malfunction of oxygen sensor (front)
Malfunction ol intake air temperature sensor
Malfunction of barometric pressure sensor
Malfunction of air flow sensor
Malfunction of engine-EOu
to P.13A-12. INSPECTION
CHART FOR DIAGNOSIS CODES.
No. P0170 output?
Check the air intrake from the intake
hose and intake manlfold.
Check the exhaust gas leaks from
the exhaust manifold.
Check the throttle body (around the
throtlle valve), and clean if
necessary. (Reter to P.134-92-.)
Cleaning
MUT-ü Data list
74 Fuel pressure sensor
(Refer to 134-94, DATA UST
Check fuel leakage around üte fuel
pump (high-pressure) line.
REFERENCE TABLE.)
ilUT-II Date list
11 Orygen sensor (front)
12 Air flow sensor
13 lntake air temperature sensor
21 Engine coolant temperature
Refer to lhe Inspection procedure
for the sensor, which is indicated by
the abnormal service data.
(Refer to P.l34-12, INSPECTION
cHARr FOR DIAGNOSTS CODES.)
sensor
25 Barometric pressure sensor
(Refer to 134-94, DATA LIST
REFERENCE TABLE.)
Reference
lf all the seMce data is normal, go
to'OK."
lf any
abnormal seMce is found, go
to "NG."
Check the orygen sonsor (tront)
(Refer
Replace
to P.134-112.)
Check the purge control solenoid
valve (Refer to GROUP 17 -
Replace
Emission Control).
NOTE
*:
Refer to the '00 PAJERO
PININ Workshop Manual (Pub. No. CKRE00E1)
134-32
GDI
-
Troubleshooting
Check the EGR valve (Refer to
GROUP 17 Emission Control.)
-
Chec* the fuel lines for fuel leaks.
Cheok the injectors for clogging or
leaks.
Transient malfuirction
(Refer to GROUP 0O Poants to
Nde for Intemittent Malfunctions.)
-
GDI
-
Code No. P0190 Abnormal fuel pressure
Range
134-33
Troubleshooting
Probable cause
of Check
. lgnition switch: ON
Set Conditions
o The sensor output voltage is 4.8 V or more, or 0.2 V or less for four
.
o
o
Malfunction of of fuel pressure sensor
Open or short circuit in the fuel pressure sensor
circuit or loose connector contact
o
o
Malfunction of high-pressure fuel pump
Clogging of high-pressure fuel lines
.
Air trapped due to poor fuel level
Malfunction of engine-EOU
seconds.
Range
o
of Check
The following conditions are detected temporarily afier the engine has been
started.
(1) Engine speed: '1,000 r/min or more
(2) Fuel pressure: 2 MPa or more
. Engine running
Set Conditions
o The fuel pressure
is 6.9 MPa or more, or 2 MPa or less for four seconds.
This diagnosis code will also be output when air is trapped into the
high-pressure fuel lines (such as poor fuel level). ln that case, the air can be
evacuated by operating the engine for at least 15 seconds at 2,qD r/min. After
the repair, use the MUT-tr to erase the diagnosis code.
MUT-u Deta list
74 Fvel pressure sensor (Refer to
Transient malfunction
(Refer to GROUP 00 Points to
Note for Intermittent Malfunctions.)
-
134.94, DATA LIST
REFERENCE TABLE.)
Measure at fuel pressure sensor
connector A-59.
Disconnect the connector, and
measure at the harness side.
(1) Voltage between terminal 1 and
earth (lgnition switch: ON)
OK: 4.8 5.2 V
(2) Resistance between terminal 3
and earth
.
-
(1) NG
Measure at engine-Eou connector
c-18.
Measure the voltage at the
engine-EoU terminal.
lgnition switch: ON
Voltage between teminal 41 and
.
.
.
earth
OK:
4.8
-
5.2 V
OK:2Qorless
Check the harness wire between the
fuel pressure sensor connector and
th€ engine-Eou.
Check the following connectorlB:
A-36, C-19
Check the hamess wire between the
fuel pressure sensor connector and
the engine-E0U.
Check the hamess YYirc b€trtrBg t
the fuel prcssuro sengor cqrndor
and the engine-Ecu, and opair if
n€oessary.
134-34
GDI
-
Troubleshooting
(1) NG
Measure at fuel pressure sensor
connector A-59.
Use test hamess (M8991658) to
@nnect the connector, and
measure at the pick-up hamess.
Engine: ldling
(1) Voltage between terminal 1 and
earth
.
o
OK:
Ched< the hamess wire b€tween
the fuel prcssure sensor @nngctor
and the engine-EOU, and repair if
naoessary.
4.8 - 5.2 V
(2) Voltage between l€rminal 2 and
eanh
OK: 0.3 - 4.7 V
(3) Voltage betu,een terminal 3 and
Replace th€ fuel pressure sensor.
earth
OK:
0.5 V or less
Chock ths trouble swnptonrs.
NG
Chsck thr blloelng oonnsctor:
c-19
NG
OK
Ch€ck lhe hamess wir€ bottireen
tfi€ fuel ptessure s€nsor oonnec'tor
and lhe engine-EGU, and repair if
neoEssary.
Check t|ie üollowing @nnectorr:
A-36, C-19
Check the hamess wire between
the fud pr€a$rre s€nsor connec'lor
and the enginFECU, and repair if
n€oe684ry.
Measure at engine-EcU connector
c-l9.
.
o
.
Mearilrre the voltage at the
engine-Eou terminal.
Engine: ldling
Voltage between terminal 92 and
earth
OK:
0.3
-
4.7 V
Ghedr ths lollowing @nnGctor:
c-19
Check lhe hamess wire b€tween
the fuel pre&surB sgnsor @nnector
and the engine.EOU, and repair if
neo6ssary.
Code No. P0201 No. 1 injector system
Range
o
r
o
of Ched<
The engine speed is 4,000 r/min or less.
The battery \,oltage is 10 V or more.
The fuel cut operation or the injector operdion (by carrying out the Actuator
Test) is not in progress.
Set Conditions
r The injector driver is not transmitting a injec{or opsn cinrit check signal
for four seconds.
Probable cauae
o
.
.
Malfunction of f.lo. 1 anjector
Open or short cisrit in the l,lo. 1 injector cirqrit
or loose connector contac.t
Malfunction of engine-ECU
GDI
-
134-35
Troubleshooting
MUT-[ Actuator Test
01 No. 1 injector
OK: The idling condition should
Transient malfunction
(Refer to GROUP 0O
Note
change.
Measure at intermediate connector
A-78.
Disconnect the connector and
.
r
measure at the harness side.
Resistance between terminals
and 2
OK: 0.9 - 1.1 O
1
Check the harness wire between
No. 1 injector and the intermediate
oonnector.
Check the hamess wire between
the injector driver and the
intermediate connector.
Check the hamess wire between the
injector driver and the engine-ECU.
Use an analyzer to measure the
signal waveform at engine-Ecu
connectoE C-17 and.C-19.
e
.
Engine: ldling
Vottage between terminal 1 and
earth
OK: A normal waveform should
be displayed as descdbed
on P.134-&4* 0NSPECTION PROCEDURE USrNG AN ANALYZER).
Check the hamess wire between
the No. 1 injector and the
i
ntermediate connector.
Check the harness wire between
No. 1 injector and the intemediate
connector.
Replace the No. 1 injector.
NOTE
*:
Refer to the '00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
lor
-
Points to
Intermittent Malfunctions.)
134-36
GDI
-
Troubleshooting
Code No. P0202 No.2 injector system
Range
o
o
o
Probable cause
of Check
The engine speed is 4,000 r/min or less.
The battery voltage is 10 V or more.
The fuel cut operation or the injector operation (by carrying out the Actuator
Test)
is not in
.
o
.
Mallunction ol No. 2 iniector
Open or short circuit in the No. 2 injector circuit
or l@se @nnector contact
Malfunction of engine-EOU
progress.
Set Conditions
o The injector driver is not transmitting a injector open cirqJit check signal
for lour se@nds.
llUT-tr Actuator Teet
Transient rnalf unction
02 No. 2 injector
OK: The idling condition should
(Refer to GROUP (X) Points to
Note for Intermittent Matfunctbns.)
Measure
A-78
.
.
at intermediate
connecitor
Dis@nnect the conneclor and
measure at the hamess side.
Resistance between teminals 3
and 4
OK: 0.9 - 1.1 n
Ched< the hamess wire between
No. 2 iniec{or and the interm€diate
conn€ctor.
Replace the No.
2
inj€ctor.
Ched< the hamess wire between
the injector driver and the
intermediate connector.
Chec* the hamess wire betu,een the
injector driver and the engine-EcU.
Use an analyzer to measure the
signal waveform
at engine-EOU
@nnectors C-17 and C-19. Engine: lclling
. Voltage between terminal 9 and
earth
OK: A
normal waveform should
be displayed as described
Cl|ect the lollowing connoqtor:
A-e
Check the harness wire between
the No. 2 injec{or and the
internediate @nnec{or.
on P.134€4'(INSPECTION PROCEDURE US.
rNG AN ANALYZER).
Replace the sngine-Eou.
NOTE
*:
Refer to the '00 PAJERO PININ Workshop Manual (Pub. No. CKRE0OE1)
-
GDI
-
134-37
Troubleshooting
Check the harness wire between
No. 2 injector and the intermediate
connector.
Replace the No. 2 injector.
Code No. P0203 No.3 injector system
Range
.
o
o
of Check
The engine speed is 4,000 r/min or less.
The battery voltage is 10 V or more.
The fuel cut operation or the injector operation (by carrying out the Actuator
Test) is not in progress.
Set Conditions
The injector driver is not transmitting
.
for four seconds.
Probable cause
o
.
o
a injector open circuit check signal
I'UT-II Actuator Test
No. 3 injector
ffl
OK: The idling
condition should
Measure at intermediate connector
A-78.
Disconnect the connector and
measure at the hamess side.
Resistance botween terminals 5
and 6
OK: 0.9 1.1 O
o
.
-
Check the hamess wire between
the injector driver and the
intermediate @nnector.
Check the hamess wire between the
injector driver and the engine-ECU.
Check the hamess wire between
No. 3 injector and the intermediate
connector.
Malfunction ot No. 3 injector
Open or short circuit in the No. 3 injeclor
or loose @nnec'tor contact
Malfunction of engine-EOU
cinlt
134-38
GDI
Use an analyzer to measure the
signal waveform at engine-Eou
@nnectors C-17 and C-19.
r Engine: ldling
. Voltage between terminal 24 and
earth
OK: A normal waveform should
be displayed as described
-
Troubleshooting
Chec* the hamsss wire between
the No. 3 iniector and the
intem€diate oonn€ctor.
on P.13A€4'(INSPECTION PROCEDURE US.
ING AN ANALYZER).
Check the hamess wirs betwsen
tlo. 3 injeclor and the intermediate
@nnector.
Replace the No.
3
injector.
NOTE
Refer to the '00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1
Probable cause
Code No. P0204 No. 4 injector system
:
Range of Check
The engine speed is 4,000 r/min or less.
The battery voltage is 10 V or more.
The fuel cut operation or the injector operation (by caryrrq out the Aet abt
Test) is not in progress.
Set Conditions
The injector driver is not transmitting a ini€ctor open cirqrit ched( signal
o
o
o
o
tor four seconds.
.
o
.
Matfunctirn of No. 4 injector
Open or shoil circuit in the l,lo. 4 injector circuit
or loose @nn€dor oontact
Malfurr'tion of engine-ECU
GDI
-
MUT-n Actuator Test
04 No. 4 injector
OK:
134-39
Troubleshooting
Transient maltunction
(Refer to GROUP 00
Points to
Note for Intermittent Malfunctions.)
-
The idling condition should
change.
Measure at intermediate connector
A-78.
Disconnec't the connector and
o
.
measurc at the hamess side.
Resistance between terminals 7
and
I
OK:
O.9
-
1.1 O
Check the hamess wire between
No. 4 injector and the intermediate
oonnector.
Replace the No.
4
injector.
Check the hamess wire between
the injector driver and the
intermediate @nnector.
Check the hamess wire between the
injsctor driver and the engine-EOu.
Use an analyzer to measure the
signal wavelorm at engine-Ecu
connectors C-17 and C-l9.
o Engine: ldling
. Voliage bgtwoen terminal 2 and
earth
OK: A
normal waveform should
be displayed as described
on P.134-84* (INSPEC-
Check the harness wire between
the No. 4 inlecitor and the
intermediate connector.
TION PROCEDURE USrNG AN ANALYZER).
Check the harness wire between
No. 4 injector and the intermediate
c-onnector.
Replace the No.
4
injector.
NOTE
Refer to the '00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
*:
134-40
GDI
-
Troubleshooting
Code No. P0220 Accelerator pedal position sensor (1st
channel) system
Probable cause
Range ol Check
Accelerator pedal position sensor (2nd channel) is normal.
Communication between the engine-EoU and the throttle valve controller is
.
o
.
.
normal.
Set Conditions
. The output r/oltage of accelerator pedal position sensor (lst channel) is 0.2
V or less for one second.
or
o The output voltage of accelerator p€dal posfion sensor (2nd cfiannel) is 2.5
V or less, and that of accelerator pedal position sensor (1st channel) is 4.5
o
.
o
Malfunction of accelerator pedal position sensor
('lst channel)
Open or short circuit in the accelerator pedal
position sensor (1st channel) circuit or loose
@nnector contact
Accelerator pedal position switch seized ON
Malfunction of thldle valve controller
Malfunction of engine-EcU
V or more for one second
or
o The difference between aocelerator p€dal position sensor (lst channel) and
ac@lerator pedal position sensor (znd channel) output roltages is 1.0 V or
more (i.e. the throtüe opening angle cfianges slighüy).
or
a
The output rolüage of accelerator p€dal posilion seflsor (1st channel) is
1.875 V or more for one seeond when th6 accelerator pedal posiüon switcfi
is fumed on.
o
GDI
MUT-II Data list
26 Accelerator pedal position switch
-
134-41
Troubleshooting
Check the accelerator pedal position
switch system. (Refer to P.13A-90,
(Refer to P.13A-94, DATA LIST
Inspection Procedure 28.)
REFERENCE TABLE.)
MUT-II Data list
78 Accelerator pedal position sensor
(1st channel) (Refer to P.13A-94,
DATA LIST REFERENCE
Transient malfunction
(Refer to GROUP 00 - Points to
Note for Intermittent Malfunctions.)
TABLE.)
Chec* Accelerator pedal position
sensor (lst channel) (Refer to
Replace
P.134-1O4-.)
Measure at accelerator pedal
position sensor connector C-46.
. Disconnect the connector and
measure at the hamess side.
(1) Resistance between terminal 1
and earth
OK: 2 f,l or less
(2) Voltage between terminal 2 and
earth
(lgnition switch: ON)
OK: 4.8 5.2 V
(1) NG
Check the hamess wire between
accelerator pedal position sensor
(1st channel) and the engine-EOU.
-
Measure
at engine-Eou @nnector
c-18.
o
.
.
Measure the voltage at the
engine-ECU terminal.
lgnition switch: ON
Voftiage between terminal 42 and
earth
OK: 4.8 5.2 V
-
Chec* the harneao wirg b€tursen
accelerator pedal posilion sonsor
(1st channol) and üt€ enginc-EoU,
and repair ff neessary.
the hamess wire between
accelerator pedal position sensor
(1st channel) and the engine-ECU.
Chec-k
NOTE
*:
Refer to the '00 PAJERO PININ Workshop Manual (pub. No. CKRE00E1)
134-42
GDI
-
Troubleshooting
(1), (2) NG
Measure at accelerator gedal
position sensor @nnector C46.
Connect connector terminals No.
1, No. 2 and No. 3 only by using
test hamess (MB991658), and
measure at the pick-up harness.
lgnition switch: ON
(1) Voltage between terminal 1 and
earth
OK: 0.5 V or less
(2) Vottage between terminal 2 and
earth
OK: 4.8 5.2 V
(3) Voltage between terminal 3 and
earth
OK: Accelerator pedal fully releas€d: 0.9&5 1.135 V
Accelerator pedal fully de-
o
o
-
-
4.1 V or highel
Measure
Ched( the hamess wire between
accslerator p€dal position sensor
(lst channel) and the engine-EoU,
and repair if necessary.
Adiust the accelerator pedal position
sensor. (Refer to P.134-1O4.)
Ch.ck thc bllowing omnsstor:
c-l9
the hamess wire betuveen
accelerator pedal position s€nsor
(1st channsD arul the engine-Ecu,
ChecN<
at engine-Ecu connector
c-19.
o
.
.
Measure the voltage at the
engine-EcU termina.
lgnition switctr: ON
Voltage between terminal 94 and
earth
OK: Accelerator
pedal fully re-
-
leased: 0.935 1.135 V
Accelerator pedal fully depressed: 4.1 V or higher
Ched( the hamess wire between
acc€leralor pedal position s€nsor
(1st channel) and the engine-ECU,
ard rcpair if necessary.
ChGck
c-l9
lhe following @nnsctor:
NOTE
*:
Refer to the '00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
GDI
-
134-43
Troubleshooting
Code No. 0225 Throttle position sensor (2nd channel)
system
Probable cause
The throttle valve controller judges a malfunction, and then transmit the result
.
o
to the engine-Eou
Range of Check
. lgnition switch: ON
. The throftle position sensor ('lst channel) is normal.
Set Conditions
. The sensor output voltage is 0.2 V or less for four seconds.
or
o The sensor output voltiage is 4.85 V or more for four se@nds, and the
.
.
Malfunstion of throttle position sensor (2nd
channel)
Open or short circuit in the throttle position
sensor (2nd channel) circuit or loose connector
contacl
Malfunction of the thrcttle valve controller
Mallunction of the engine-EOU
output voltage of the throttle pGition sensor (1st channel) is 1.2 V or more.
or
.
The throttle position sensor (1st channel) and throttle position sensor (2nd
channel) combination output voltage is outside 4 - 6 V.
MUT-II Data list
14 Throttle position sensor (2nd
Intermittent malf unction
(Refer to GROUP 00 - Points to
Note for lntermittent Malfunctions.)
channel)
OK:
Refer to P.134-94, DATA
LIST REFERENCE TABLE.
Check throttle position sensor (2nd
channel). (Refer to P.13A-102..)
Measure at throttle position sensor
connector A-06.
Disconnect the connector and
measure at the hamess side.
(1) The voltage between terminal 1
and earth
o
(lgnition switch: ON)
OK: 4.8 - 5.2 V
(2) Resistance between terminal 3
and earth
Replace
(1) NG
Measure at throttle valve controller
connector C-48.
o Measure the voltage at the
throttle valve controller connector
r
.
terminals.
lgnition switch: ON
The voltage between terminal 6
and earth
OK:
4.8
-
5.2 V
Check the ham€ss tYiro betureen
the thpttle position sensor and lhe
thrcttle valve contdler, ard repair if
OK:2Oorless
Check the following conn€stor:
c-48
Check the hamess wire between
the throttle position sensor and the
throttle valve controller.
Replace the ürottle valve controller.
Check the following @nn@tor:
c-48
Check the hamess wire between
the throttle position sensor and the
throttle valve controll€r.
Replace the throtüe
NOTE
*:
Refer to the '00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
vdw
cottüoller.
134-44
GDI
-
Troubleshooting
From the previous page
Measure at throttle position sensor
connector A-06.
Use test hamess (M8991536) to
connect the connector, and
measure at the pick-up harness.
lgnition switctr: ON
(1) The voltage b€tween terminal 1
and earth
), (2)
NG
.
o
OK: 4.8 - 5.2 V
(2) The r,oltage between terminal 3
and earth
OK: 0.5 V or less
(3) The voltage between tgminal 4
and earth
OK: Accelerator pedal fully re-
leased: 4.0 - 4.8 V
Accelerator pedal fully de
pressed: 0.1 - 1.1 V
Ched(ü|e hamess wire between
thlotüe poGition sensor (2nd cfiannel)
and the throtde valve contrdler.
Adjust the thrdle position ssnsor.
(Reler to P.134-92'.)
Chock thc following omnoctor:
c-l9
Ch€d( ü€ har€ss wir€ b€tYee€n
thEtüe positirn sensor (2nd
channel) and the engine-EoU, and
lEpair if necEssary.
Measure
c-l9.
r
o
.
at engine-Ecu connector
Measure the voltage at the
engine-EoU teminal.
lgnition switcn: ON
The \oltage between terminal 78
and earth
OK: Accelentor
pedal fully re-
leased: 4.0 - 4.8 V
Accelerator pedal fully depressed: 0.1 - 1.1 V
Ch€ck the hamess wire between
throtüe position s€naor (2nd
cfiannel) and th€ engine-E0U, and
repair if neoessary.
NOTE
*:
Refer to the '00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
Gode No. P0300 lgnition coil (power transistor) system
Range
of Ched<
. Engine speed is apprcx. 50 - 4,ü)O r/min.
. Engine is not cranking.
Set Corditions
. The ignitkrn failure sensor does not send a signal about I
for four seconds.
csrtain cylinder
Probable cause
.
.
o
o
o
Malfunction of the ignition coil
Maffunction of the ignition lailure sensor
Matfunction of spark plug
Open or short cirqrit
the pfimary ignifion
cir@it or looge connector coritacl
Malfunction of engine-EcU
in
o
GDI
MUT-II Actuator Test
01
02
03
04
No.
'l
injector
No. 2 injector
No. 3 injector
No. 4 injector
OK: The idling condition should
-
134-45
Troubleshooting
Check the following connectors:
lgnition coil connectors, which
correspond to defective cylinders
(A-09, A-10, A-11, A-12).
change.
Reference
When the cylinder (defective
cylinder) where idling condition does
not change is detected after
suspending the injector, go to (1)
and inspect the spark plug, the
ignition coil, the connector, and the
harness of the defective cylinder.
(When more than one cylinder are
detected, inspect all of them.)
When all the cylinders are OK, go
Replace
Use an analyzer to measure the signal waveform at engine-EoU connoctor C-17.
Engine: ldling
The voltage between the ignition coil primary signal terminal for a defclive cylilüer
and eerth
OK: A normal waveform should be displayed as clescrib€d on P.13A€4'(lnsp@üon Procedure Using an Anallzer).
o
.
Repair the ignition coil assembly for
Use an analyz:et to measure the
signal waveform at the ignition
lailure sensor connector A-90.
. Use test harness (M8991536) to
@nnect the connector, and
moasure at the pick-up hamess.
. Engine: ldling
o The voltage betwe€n terminal 2
and earth
OK: A normal waveform shoutd
be displayed as described
on P.134-84'(INSPECTION PROCEDURE US.
ING AN ANALYZER).
Reference
When a normal waveform is
displayed, @mpare it with that ot
the ignition coil primary signal at the
engine-EoU t€rminal to determine
the cylinder (defective cylinder) with
a defec'tive cylinder and the spark
plug.
Check the hamess wires between
the ignition failure sensor and the
engine-ECU, and between the
ignition failure sensor and earth.
Repair the ignition failure sensor.
an abnormal waveform.
-rwhen one or more cylinders are
abnormal, go to (1)
-+When all of the cylinders are
abnormal, go to (3)
-+When a nomal waveform is
lntemittent
malfu nction
-
(Refer to GROUP 0O Pointe to
Note for lntemittent Malfunctions.
Check the spark plug and the
ignition coil for a defective cylinder.
(Refer to GROUP 16 - lgnition
NOTE
: ct.
Refer to the '00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
*.
Replac€ th6 engine-Ecu.
134-46
Code
Gode
Code
Code
No.
No.
No.
No.
GDI
No. 1 cylinder misfire
P0302 No.2 cylinder misfire
P0303 No. 3 cylinder misfire
P0304 No. 4 cylinder misfire
P0301
-
Troubleshooting
Probable cause
detected
detected
detected
detected
Range of Check
. The engine speed is Sfl) - 4,500 r/min.
o While the engine is running except deceleration and su&len acceleration.
Set Conditions
o The number of misfires exceeds a predetermined number per äX) engine
.
.
o
.
Malfunction
ol the ignition system
Abnormal compression
Matfunction of injecbr
Maltunction of engine-EcU
rerolutions (Misfire has occun€d in only one cylirder).
or
.
The number of misfires er(ceeds a predetemined numbor per 10O engine
revolutions (Misfire has occuned in only one cylinder).
Measure d ignition coil connec'toc
A-09, A-10, A-11, A-12.
Disconnect the connector and
measurc at the hamess side.
(1) The voltage between terminal 1
and earth
(lgnition switch: ON)
Gheck the followlng connoctora:
A-tn, O72, C-74
o
OK:
Check the ignition failure sensor
(Befer to GROUP 16 lgnition
System.)
Syetem voltage
(2) The voltage between te,minal 3
and earür
(Engine: Cranking)
OK: 0.5 - 4.0 V
(3) The resßtance betwe€n terninal
2 and ea.th
-
Ch€d( the hame8e wir€ botrveen the
ignitbn coil and the ignition iailure
sensor, and bgtween the agnition
switcfi and thg agnition failur€ sensor.
OK:2Oorless
Rspail
Chock th€ hamess wirs betu€en
the ignition coil and the earth, and
repair if neoessary.
NG
Chec* the spalk plugs.
Replace
OK
Check thg compr€ssion pr€ssure.
(Refer to GROUP 114 On-Yehicle
-
Service.)
OK
Check the trouble symptoms.
NG
Replace the engine-Ecu.
Rep.ir
GDI
-
134-47
Troubleshooting
Code No. P0325 Detonation sensor system
Probable cause
Range of Check
Engine: Two seconds after the engine has been started
Set Conditions
o
.
o
o
o
Changes in sensor output voltage (detonation sensor peak voltage per "l/g
crankshaft rotation) in 200 consecutive cycles are 0.08 V or less.
Malfunction of the detonation sensor
Open or short circuit in the detonation sensor
circuit or loose connector contact
Malfunction of engine-ECU
Gheck the following conn€ctor: A-81
Measure at the detonation sensor connector A-81.
Disconnect the connector and measure at the hamess
o
o
Gheck the hamess wire between the detonation sensor and
earth, and repair if necessary.
side.
The resistanc€ between terminal 2 and earth
OK:2Oorless
Gheck lhe following connector: C-19
Check the hamess wire between the detonation sensor and
the engine-EOU.
lntermittent malf unction
(Rofer to GROUP 00
Malfunctions.)
-
Points to l,lote for Intemittent
Code No. P0335 Crank angle sensor system
Probable cause
Range of Check
Engine is cranking
.
.
.
.
Set Conclitions
o Sensor output voltage does not change for 4 se@nds (no pulse signal
input).
Malfunction ol the crank angle seßor.
Open or short circuit in the crank anglg sonsor
circuit or loose connec-tor contact.
Malfunction of engine-ECU
134-48
GDI
-
Refer to P.13A-94. DATA
LIST REFERENCE TABLE
Measure al the crank angle 86nsor
connector A-77.
Disconnect the connestor and
measure at the harness side.
(1) The resistance between tetminal
1 and earth
.
OK:2Oorless
(2) The voltage between tenninal 3
and earth
(lgnition switcfi: ON)
OK: 4.8 - 5.2 V
(3) The wltage between terminal 2
and earth
(lgnition switch: ON)
OK: System \ottage
Troubleshooting
lntermittent malfunction
(Refer to GROUP 00
Points to
Note for Interminent Mallunctions.)
MUT-u Data list
22 C'ank angle sensor
OK:
-
(1) NG
Check the harpss between the
crank angle sensor and earth, and
repair if neoEssary.
Measure at engine.Ecu oonnec{or
c-18.
.
o
o
.
MeasurB the rrottag€ at the
engine.EoU terminal.
Disconnect the connector A-77
lgnition sritcft ON
The r'ottage between terminal 4tl
and eanh.
OK: 4.8 - 5.2 V
Ched( tho hamess wire betweon
the crank angle sensor and the
engine-Eou, and repair if necessary.
Ched< the hamess wirc betweon
the crank angle 8€nsor and the
Ched< the hamess wire between the
crank angle sensor and the engine
Use an analfzer to measure the
output wavefom at the crank angle
sonsor connec'tor A-77.
. Use the test hamess
(M8991658) to connec{ th€
connector, and measure at the
pid(-up hame$s side.
.
.
Chod( üte crank angle sensor rrane.
Engine: ldling
The voltage between terminal 3
and earth
OK: A normal wavelorm should
be displayed as dsscfibed
on P.134-&4' (lnspection
Procedure Using an Analyzer). lts maximum value
should be 4.8 V or more,
and its minimum valu€
should be 0.6 V or less
with no noise in waveform,
Check the following connestonB:
A-36, C-18
Ched( the hamess wires between
tho c{ank angle sensor and the
engine-EOU, crank angle sensor
and the engine control rday, and
the crank angle ssnsor and Earth.
Then, repair if necessary.
Replacc
GDI
-
134-49
Troubleshooting
Gode No. P0340 Camshaft position sensor system
Probable cause
Range of Check
a
o
Mallunction of the camshaft position sensor
Ooen or short circuit in the camshaft Dosition
sensor circuit or loose @nnector contact.
a
Malfunction of engine-ECU
r After the engine was started
Set Conditions
. The sensor output voltage does not change for 4 seconds (no pulse signal
input).
Measure at camshaft position
sensor connector A-66.
I Disconnect the connector and
measure at the harness side.
(1) The voltage between terminal 3
and earth
(lgnition switch: ON)
OK: System voltage
(2) The voltage between terminal 2
and earth
(lgnition switch: ON)
OK: 4.8 - 5.2 V
(3) The resistance between terminal
1 and earth
OK:2Oorless
Check the hamess wir6 between
the camshaft position sensor
conngctor and the engine control
Measure at engine-EOU @nnector
c-l8.
o
.
.
.
Measure the voltage at the
engine-ECU terminal.
Disconnect connec'tor A-66.
lgnition switch: ON
The voltage between terminal 50
and earth
OK:
4.8
-
Check tho hamgss wire betw€€n the
camshaft position sensor @nn€cior
and the engine-EOU, and tepsir if
neoessary.
5.2 V
Check the hamess wire between
th€ intermediate connector and the
engine-ECU.
Check the hamess wire between the
camshaft position sensor @nnector
and earth, and repair if necessary.
Use an analyzer to measure the
output waveform at camshaft
position sensor @nnector A-66.
. Use test harness (M8991709) to
connect the connector, and
measure at the pick-up harness.
.
o
Engine: ldling
The \roltage between terminal 2
and earth
OK: A normal waveform should
be displayed as described
on P.13A-84- (lnspection
Procedure Using an Analyzer), its maximum value
should be 4.8 V or more,
and its minimum value
should be 0.6 V or less
with no noise in wavefornr.
Check the lollowing connectoE:
A-36, C-18
Ch€ck the harness wires between the camshaft position sensor @nnec{or and lhe
engins-Ecu, the camshafi position sensor @nnector and the engine oont]ol relay, and
the camshaft position sensor connector and earth. Then, repair if nsces€ary.
Intermittent malf unction
(Reter to GROUP 00
Points
-
I Replace the
to Note for Intermittent Matfunctions.)
enoine-ECu.
I
NOTE
*:
Refer to the '00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
134-50
GDI
-
Troubleshooting
Gode No. P0403 EGR valve system
Probable cause
Range of Check
. lgnition switch: OFF to ON
o EGR valve is in operation after the engine starting process is complete.
Set Conditions
o Ofi-surge voltage is not generated from the motor coil while the EGR valve
control motor is running.
o
o
.
Measure at EGR valve @nnector
A€0.
Malfunction of the EGR valve
Open or short circuit in the EGR valve circuit or
loose connector contacl
Malfunction of engine-ECU
Replece
. Disconn€ct the connector, and
m€asure at the EGR valve side.
o The resistance between te.minals
land2
o The resistance between lEminals
2andg
o The resisliance between terminals
4and5
o The resistan@ between terminals
5and6
OK:10-20O
Measure at EGR valve connector
A€O.
. Disconnect the connestor and
measurc at the hamEss side.
o lgnition switcür: ON
. Th€ voltage betwe€n teminal 2
and earth
o fie voltage between teminal 5
Chrck ths üollowing connector: A-36
Chsck th€ hamess wire between the
EGR rralw and the engine control
relay, and repair if neoessary.
and eafth
OK: System voltage
Measure at engine-Eou @nnector
c-17.
. Measure the voftage at the
o
o
o
.
Check the üollowing connecto€:
A€2,
C-17
engine-ECU terminal.
The
and
The
and
voltage between terminal 5
earth.
voltage between teminal 6
Check the hamess wire betu,sen the
EGR vdw and the engine-EGU.
earth.
The vottage betureen terminal 32
and earth.
The voUage between terminal 34
and earth.
OK: The voltage change as lollows
for three seconds when the
ignition switch is tumed ON.
(When using a circuit tester)
Repbce the ongine-E0u.
SVandgVansmatos
(When using an analyzer)
1 V or less and slrstem roltage
alternates
Check the üollowing connestors:
A-36, A€2, C-17
Check the hamess wires between
the EGR valve and the engine
contrcl relay,
relay. and between
between the EGR
valve and the enqine-ECU
Inbrmittent malfu nction
(Reter to GROUP 0O Pctnts to
Note for Intermittent Malfunctions.)
-
GDI
-
Code No. P0420 Catalyst malfunction
Range
134-51
Troubleshooting
Probable cause
ol Check
. The engine speed is 3,000 r/min or less.
o During driving
. During airlfuel ratio feedback control
Set Conditions
o The ratio between the orygen sensor (rear) and the oxygen sensor (front)
.
o
.
r
Malfunction of catalyst
Malfunction of the orygen sensor (tront)
Malfunction of the orygen sensor (rear)
Malfunction of engine-EcU
output frequencies reaches 0.8 per 12 seconds on average.
ItUT-tr Data list
Check the orygen sensor (rear) s!ßtem <aensot 2>
(Refer to P.134-28, INSPECTION PROCEDURE FOR
DTAGNOSTTC TROUBLE CODE F0136.)
59 Oxygen sensor (rear)
o Transmission: 2nd gear
o
Drive with wide open throttle
600 1.0ü) mV
OK:
-
MUT-II Data list
11 Orygen sensor (front)
OK: 600 1,000 mV when racing suddenly
Check the orygen sensor (front) system €ensor 1>
(Refer ro P.13A-2s, INSPECTTON PR@EDURE FOR
DIAGNOSTTC TROUBLE CODE P0130.)
MUT-tr Data list
11 Oxygen sensor (front)
Replace the orygen sensor (lront).
-
.
Transmission: 2nd gear
OK:
Changeover between 0 - 400 mV and 600
mV occur 15 times in 10 seconds.
Replace the orygen sensor (rear).
-
1,000
134-52
GDI
-
Troubleshooting
Code No. P0443 Purge controlsolenoid valve system
Probable cause
Range of Check
. lgnition switch: ON
. Baüery voltiage is 10 V or more.
Set Conditions
o The solenoid coil surge voltage (battery voltage + 2 V) is not detected
when the purge control solenoid valve is tumed from on to ofi.
.
.
.
ilUT-U Actuator Test
08 Purge control solenoid vafue
OK:
Operating sound can be
heard and the valve vibrdes.
Measure at the purge control
solenoid valve oonnector A-(}2.
o
o
Malfunction of the purge control solenoid valve
Open or short circuit in the purge control solenoid
valve circuit or loose connector contact
lntermittent malfu ndion
(Refer b GROUP 00 Points to
Ilote for lntermiftent Malfunctbns.)
-
Rsplscc
Disconnect the connector, and
measure at the solenoid valve
side.
The reaistance between
teminals 1 and 2
OK: 28 36 A (at 20"C)
-
Check the lollowing @nnector:
A-92
Measure at the purge control
solenoid valve connector A-02.
o
o
o
Disconnect the connEc{or and
measurc at the hamess side.
lgnition suritch: ON
The voltage between tEminal 2
and earth
OK: System vottage
Ched( tho hamess wire b€tween
lhe pues control solenoid valve and
the engine contrd relay, ard repair
if necessary.
Measure at engine-Ecu connector
c-17.
.
o
.
Mgasure the voltage at the
engine-ECU terminal.
lgnition s,witch: ON
The voltage between terminal 16
ard earth
OK: System \,oltage
Check the üollowing @nnestor!:
A-36, C-17
Ched( the hamess wires between
the purge control solenoid valve and
the engin€ control relay, ard
between lhe purge contol solenoid
valve and the engine-EOU.
Replace the
Check the ham$s wire betwgsn
the purge control solencid valve and
tfie engine-EOU.
Malfunction of engine-ECU
GDI
-
134-53
Troubleshooting
Code No. P0500 Vehicle speed sensor system
Probable cause
Range of Check
Engine: Two seconds after the engine was started
ldle switch: OFF
Engine speed: 2,500 r/min or more
During high engine load
Set Conditions
The sensor output voltage does not change for 4 seconds (no pulse signal
input).
r
.
.
o
.
.
.
.
Does the speedometer operate normally?
Malfunction of the vehicle speed sensor
Open or short circuit in the vehicle speed sensor
circuit or loose connector contact
Malfunction of engine-EOu
Check the vehicle speed sensor
(Refer to GROUP 54 Combination Meter.
-
Use an analyzer to measure the output wavelorm of the
vehicle speed sensor at engine-ECU connector C-19.
r Driving the vehicle
o The voltage between terminal 80 and earth
OK: A nomal waveform should be displayed as described in OSCILLOSCOPE INSPECTTON PROCEDURE, and noise should not be displayed in the
waveform. (Refer to GROUP 23 - Troubleshooting.)
Chcck the following @nnGstora:
B-08, C-19, C-28, C-38 <LHD>, C.41 <RHD>, D-ü2
Check the ham€ss wire between vehicle speed eensor and
the engine-Eou, and repair il necessary.
Check the following connector: C-19
Code No. Pl200 Injector driver system
Probable cause
Range of Check
Engine speed: 4,000 r/mimn or less
Battery voltage: 10 V or more
o
.
o
.
.
. The fuel cut operation and the injector operation (by carrying out the
Actuator test) are not in progress.
. During high engine load
Set Conditions
. Injector open circtjit check signal is not output trom the injector driver.
Malfunction ot th€ injec.tor ddrrer
Open or short circuit, or loose connedor oontrct
Malfunction
ol engine-EoU
Check the following connector: C-l9
Check the hamess wire between the injector driver and the
Use an analyzer to measurc the signal waveform at
engine-EoU connectors C-17, C-19.
o
o
Engine: ldling
The voltage between terminal 96 and eadh, terminal 1
and earth
OK: A normal waveform should be displayed as described on P.134-84- (INSPECTION PROCEDURE
usrNc AN ANALYZER).
lntermittent malf unction
(Refer to GROUP ü) - Points to Note for Intemittent
Malfunctions.)
NOTE
*:
Refer to the '00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
134-54
GDI
-
Troubleshooting
Code No. Pl220 Electronic-controlled throttle valve
system
Probable cause
Range of Check
lgnition switch: ON
Error in communication between the engine-EOu and the throüle valve
ffi
.
.
o
o
controller
Set Conditions
o Output voltage of throttle position sensor (2nd channel) fluctuat€s
significantly (approx. 1 V or more) flom an expected value, based on that
of the accelerator pedal position sensor (2rd channel).
Range of Chec*
o lgnition switch: ON
. Enor in @mmunication between the throttle valve ontoller and the
engine-ECU
Set Gonditions
o The ouFut voltage of the thrctüe position sensor (2nd channel) is
significantly different (approx. 1 V) from the thlottls vdw openang angle
(\roltage), which the engine-EoU requ€st the throttle \ralve contoller.
Ch€ck thc following connectora:
c-19, c-48
OK
Check the hamess wire between the tirottle velve contofler
and the engine-EoU.
OK
Check the trouble symptoms.
NG
Replace the throttle valve controller.
Check the trouble symptoms.
NG
Replace the engine-Eou.
NG
NG
Rcpair
Repair
Malfunction ot the engine-Ecu
Malfunstion ol the throttle valve controller
GDI
-
134-55
Troubleshooting
Code No. P1221 Throttle valve position feedback system
Probable cause
The throttle valve controller judges a malfunction, and then transmit the result
to the engine-Ecu.
Range of Check
. lgnition switch: ON
. Battery voltage: 10 V or more
Set Conditions
. Failure in the motor oosition feedback
(The engine-ECu detects that the current in the motor is excessive and the
opening angle difference between the target value of throttle position sensor
(1st channel) and the actual value of throttle position sensor (1st channet)
is 1.0 V or more)
.
.
.
Malfunction of throttle position sensor (1st
channel)
Open or short circuit in the throttle position
sensor (1st channel) circuit or loose connec{or
contact
Mallunction of the throttle valve controller
MUT-II Self-Diag Gode
ls code No. P0120 set?
R6ler to Code No. P0120, Throtüe po€ilion sensor (lst
channel) system (Refer to P.134-22.)
MUT-II Self-Diag Code
ls Code No. P'1224 set?
Refer to Code No. P1224, Throttle rralve control ssnn m@
(motor 1st phase malfunction) system (Refer to P.134-57.)
MUT-II Self-Diag Code
ls Code No. P1228 set?
Reter to Code No. P1228, Throttle valve control san,o mo0or
(motor 2nd phase malfunction) system (Refer to P.134€O.)
Adjust the throttle posilion sensor. (Refer to P.13A-92..)
Check the throtlle valve control servo. (Reter to P.13A-107-.)
Ghcck the following connestoF: A-05, A-06, C48
Check the hamess wires between the throttle position sensor
and the throttle valve controller, and between the throttle
valve control servo and the throttle valve controller.
Replace the throttle valve controller.
NOTE
:
*,
Et,
Refer to the '00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
134-56
GDI
-
Troubleshooting
Code No. Pl223 Communication line system with the
throttle valve controller
I Probable cause
o
o
.
Range of Check
o lgnition switch: ON
. Baüery voltage: 8 V or more.
o Engine: Not cranking
Set Conditions
o System detects an enor in communication
Short in communication line
Malfunction of engine-ECU
Malfunction of throttle valve controller
line between the engine-Eou
and the thrcttle valve controller, and between the throtüe valve controller
and the engine-EoU.
mUT-n Sdt-Diag Code
ls Code No. P1220 oupuf,
ilo. P1220,
El€ctronic-controlled throtüe valve system
Rotsr to Cods
(Ref€r
io
P13A-A|.)
M€asure at thottle valve controller
conneclor C-48.
. Measure voltage at the throttle
valve contrdler @nnector
.
terminals.
lgnition switcfi: ON
(1) Th€ voltage between terminal 5
arul earth
OK: System voltage
(2) The voltage between terminal 3
Ched( th€ hamess wire botwsen the
thrctüe l'ahre contloller and the engine
contrcl nlay, ard repair if necessary.
and earth
The voltage betw€en terminal 4
and earth
The voltage between terminal 16
and earth
OK:
0.5 V or leqs
Check the hamess wire betw€en
the throttle rralve controller and the
enoine-ECU.
OK
Check the touble symptoms.
NG
Replace the throttle valve controller.
Ched( the trouble symptoms.
NG
Replace the engine-EOU
Ch€d( the hamess wire betureen the
throtüe valrre confoller alld earth, and
repair if n€cessary
GDI
-
134-57
Troubleshooting
Code No. P1224 Throttle valve control servo motor
(Motor 1st phase malfunction) system
Probable cause
Range of Check
o
.
. Throttle valve control servo relay: ON
. System voltage: I V or more.
Set Conditions
. Throttle valve control servo drive circuit is shorted to earth.
o Other power source interferences with throttle valve control servo drive
circuit.
. Throttle valve control servo drive circuit is open circuit.
Check the throttle valve control
servo (Refer to P.13A-107-.)
Replace the throttle body assembly.
Moasure at throttle valve controller
connector C48.
. Measure voltage at the throttlg
valve controller connector
o
o
terminals.
lgnition switch: ON
The voltage between terminal
I and earth
.
Malfunction of the throttle valve control servo
ODen circuit or short-circuited harness wire in
throttle valve control servo system, or poor
connector contact
Malfunction of the throttle valve controller
1,
Check the following oonnGctor: A-05
Check the harness wire between the
throttle valve cgntrol ser\ro and the
throttle valve controller.
(Accelerator pedal: Fully open to
fully closed)
OK: The battery voltage temporarily shows a slight de-
.
crease.
The voltage betwoen terminal
14, 15 and earth
Replace the throttle valve controller.
(Accelerator pedal: Fully closed
to fully open)
OK: The battery voltage shoil a
slight (approximately 2 V)
decrease.
NOTE
*:
Refer to the '00 PAJERO PININ
Workshop Manual (Pub. No. CKRE00E1)
134-58
GDI
-
Troubleshooting
Code No. Pl225 Accelerator pedal position sensor (2nd
channel) system
Probable cause
Range of Check
Accelerator pedal position sensor (2nd channel) is normal.
Communication between the engine-Eou and the throttle valve controller is
.
o
o
o
normal.
Set Conditions
o Output voltage of the accelerator pedal position sensor (2nd channel) is 0.2
V or less for one second
or
o OuFut roltage of the accslerator pedal position sensor (lst channel) as 2.5
V or less, and ouFut voltage of the accalsrator podal position sensor (2nd
channel) is 4.5 V or more for one second.
or
.
.
.
Malfunction ol accelerator pedal position sensor
(2nd channel)
Open or short circuit in accelerator pedal position
sensor (2nd channel) circuit or loose @nnector
contact
Malfunction of the thottle valve contpller
Malfunstion ol engine-ECU
Difierence between the accelerator pedal poeition sensor (1st and 2nd
channels) output rcltages exc€eds 1.0 V (i.e. when th€ throtüe valve
opening angle changes slightly).
iluT-tr Drt! list
lntgmittent malfu rrtion
-
to GROUP (X) Points to
Note lor lntermittent Malturdions.)
77 Accelerator pedal position sensor
(REfer
(2nd channel) (Refer to
P.13A-94, DATA LIST
REFERENCE TABLE.)
Ched( the acceleEtor pedal position
sensor (Refer to P.134-104'.)
Measure at accelerator pedal
position sensor connector C-216.
o Disconnect the @nnector and
measurc at the hamgss side.
(1) The resistiance between terminal
7 and earth
OK:2Oorless
(2) The voltage between teminal 8
and earth
Repllce
(1) NG
Check the hamess wire betw€en
accslorator pedal peition sensor
(znd cfiannel) and ths thrctüe valve
controller.
(lgnition switc+r: ON)
OK: 4.8 - 5.2 V
Replace the
thpttlo valve controller.
Measure Et throtüe vahrc contrcller
connoctor C-48.
Measure volhge at the throtü€
valve contrcller @nnector
o
o
o
terminals.
lgnifrcn switcfr: ON
The voltage b€twBen terminal 6
ard sarlh
OK: 4.8 - 5.2 V
Ch€d( ü|o hamess wire betwe€n
accelerator pedal position sensor
(2nd cfiannol) and the thrclüe valw
controller, and ropair if necossary.
Chrck üo iollwing oonncstor:
c-48
Ched< the hamess wire b€tu,sen
accelerator pedal position ssnsor
(2rd channel) and th€ thrdüe \ralve
cont]oller.
NOTE
Refer to the '00 PAJERO PININ Workshop Manual (Pub. No. CKREOOE1)
':
GDI
Measure at accelerator pedal
position sensor connector C-46.
Use test harness (MB9916SB) to
connect terminals No. 6, No. 7,
No. 8 only, and measure at the
.
pick-up hamess side.
lgnition switch: ON
(1) The voltage between terminal 6
and earth
OK: Accelerator pedal futty released: 0.7 - 1.4 V
Accelerator pedal fully depressed: 4.1 V or higher
(2) The voltage between terminal 7
and earth
OK: 0.5 V or more
(3) The voltage between terminal 8
and earth
OK: 4.8 - 5.2 V
-
Troubleshooting
Adjust the accelerator pedal position
sensor (Refer to P.13A-94).
.
Measure at throttle valve controller
connector C'48.
Measure voltage at the throttle
valve controller connector
terminals.
lgnition switch: ON
The resistance between 20 and
earth
Check the hamess wire between
accelerator pedal position sensor (2nd
channel) and the throttle valve controller,
and repair it necessary.
Check the tollowing connector: C48
Check the hamess wire between
ac@lerator pedal position sensor (2nd
channel) and the throttle valve controller,
and repair if necassary.
Check the following connector: C48
o
.
.
OK:
Check the harness wir€ between
accelerator pedal position sensor (2nd
channel) and the throttle valve controller,
Accelerabr pedal fully rel€ased: 0.7 - 1.4 V
Accelerator pedal fully depressed: 4.1 V or higher
Replace the throttle valve controller.
134-59
134-60
GDI
-
Troubleshooting
Code No. P1228 Throttle valve control servo motor
(Motor 2nd phase malfunction) system
Range
of Check
. Throttle valve control servo relay: ON
. System voltage: 8 V or more
Set Conditions
. Throttle valve control servo drive circuit is shorted to earth.
o Other power souroe interferes with throttle valve control servo drive circuit'
o Throttle valve control servo drive circuit is open+iranit.
, Probable cause
.
o
.
Malfunction ol the throttle valve @ntrol servo
Open circuit or short-circuited hamess wire in
throttle valve control servo system, or poor
connector contact
Malfunction of the throttle valve controller
Chec'k thE throttle valve control
servo (Refer to P.134-107').
Replace the thrdüe body assombly.
Measure at thrctüe valve controller
conn€ctor C-48.
. Measure voltage at the throttle
vafue controller @nnector
Chsck the following conncctor: A{F
Repair
Check the ham€ss wir€ betrvesn the
throttle valv€ control seruo and the
throtüe rralve controller.
Repair
.
o
terminals.
lgnition switch: ON
The voltage between terminal 1,
I
and earth
(Accelerator pedal: Fully open to
tully dosed)
OK: The battery voltage temporarily shows a slight de-
o
crease.
The voltage between terminal
14, 15 and earth
(Accelerator pedal: Fully closed
to fully open)
OK: The batt€ry \lottage show a
slight (approximately 2 V)
Replace the thrctüe r,alve conttoller.
decrease.
@
NOTE
*:
Refer to the '00 PAJERO PININ
Workshop Manual (Pub. No. CKRE00E1)
GDI
-
134-61
Troubleshooting
Code No. Pl500 Alternator FR terminal system
Probable cause
Range of Check
Engine speed: 50 r/min or more
Set Conditions
Input voltage from the altemator FR terminal is system voltage for 20
seconds.
o
a
.
.
Measure
at ifiermediate connector
A-86.
o
o
o
Use test hamess (M8991658) to
connect the connector, and
measure at the pick-up hamess.
lgnition switch: ON
The voltage between terminal 6
and earth
OK:9-10V
Measure at engine-EOU @nnector
c-18.
o
o
.
Measure the voltage at the
engine-ECU terminal.
lgnition switch: ON
The \roltage between teminal 52
and earth
OK:9-10V
Ooen circuit in alternator FR terminal circuit
Malfunction
ol
engine-ECU
Chock thc following conneclor:
c-l8
Check the hamess wire beüreen
the intermediate corineclor and thg
Check the hamess wire between
the intermediate connector and the
Measure at intermediate @nnector
A-86.
o
.
.
o
Use test hamess (M8991658) to
@nnect the c,onnector, and
measure at the pick-up harness.
Engine: ldling (After warming up)
Radiator fan: Not operating
The voltage between terminal 2
and earth
OK: The \oltage drops when
the headlamps are tumed
Check the hamess wire between
the altemator and the intermediate
@nnector.
Replace
on.
Check the harness wire between
the interm€diate @nnector and the
engine-ECU.
Intermittent malf unction
(Refer to GROUP o0
Points to
Note for lntermittent Malfunctions.)
-
134-62
GDI
-
Troubleshooting
Code No. P1515 Brake vacuum sensor system
ilUT-n
DEta
.
ol the brake vacuum sensor
lmproper @nnector contact, open circuit or
short-circuited hamess wire ol the brake vacuum
Malfunction
sensor
Malfunction ot the engine-Eou
lntemittent malfunction (Refer b
GROUP 0O Points b Note lor
intsrmittert Malfu nctions.)
list
-
65 Brake rracuum sgnsor
OK:
Probable cause
o
.
Range of Check
. lgnition switch: ON
Set Conditions
o Sensor output voltage is 4.8 V or more.
or
o Sensor output voltage is 0.2 V or less.
(Referto P.134-94, DATA
LIST REFERENCE TABLE.)
Measure at brake nacuum sensor
connector A-56
o
Disconnect the connector and
measure at the hamess sidg.
(1) The voltage betwe€n terminal 3
and earth
(lgnition switctr: ON)
OK: 4.8 - 5.2 V
(2) Continuity between tErminal 2
(1) NG
Measure Et engane-Ecu connector
c-l8.
.
o
o
MeasuE the wltage at th€
€ngine-EOu termanals.
lgnitfurn switcfr: ON
The rroltage betvYeen teminal 41
and earth
OK: 4.8 - 5.2 V
ard earth
OK:
2O or less
Check the hamess wire bstwsen
the brake vacuum sensor and the
Chck tfic following oonnGctor!:
A-36, C-19
To
fie
next
Ched< the hamess wire between
the brake vacuum sensor and the
engine-EcU.
Chack the
c-l8
iolliling
conncc{or:
Check lhe hamess ürire bstvveen
the brake vacuum sensor and the
engine-Eou, and repair if necessary.
GDI
-
134-63
Troubleshooting
(1) NG
Measure at brake vacuum sensor
connector A-56.
o Use test hamess (M8991348) to
@nnect terminals. and measure at
the pick-up harness side.
Engine: ldling
(1) Thevoltage between 3and eanh
o
OK: 4.8 - 5.2 V
(2) The voltage between 1 and earth
OK: 0.9 - 1.5 V
(3) The continuity between 2 and
Replace the brake vacuum sensor.
earth
OK:2Oorless
Check the trouble symptoms.
NG
Check the following @nnector:
c-l9
OK
Check the hamess wir€ between
the brake vacuum sensor and the
engine-EoU, and repair if necessary.
o
Measure at engine-Ecu @nn€ctor
c-19.
o
.
.
Measure the voltage at the
engine-EOu terminal.
Engine: ldling
The voltage between 74 and
earth
OK:
0.9
-
1.5 V
Chcck the following connsctora:
A-36, C-18, C-19
Check the hamess wire between
the brake vacuum sensor and the
NG
134-64
GDI
-
Cord No. P1600 Communication wire with
system
Troubleshooting
A/T-ECU
Range of Check
o After 60 seconds have passed since the engine have started
Set Conditions
o Torque reduction request signal from A/T-ECU is input continuously
seconds
Probable cause
I
for 1.5
o
|.
|.
Short circuit in ECU communication circuit
Malfunction of the engine-Eou
Malfunction of the A/T-ECU
or more.
Checklhe hamess wire betu,€en the engine'EOu and üte Aff-ECU.
NG
Cord No. P1610lmmobilizer system
. lgnition switch: ON
Set Corditions
. lmproper @mmunication betw€en
NOTE
Prcbable cause
o
o
o
Range of Check
the engine-Eou and the immobilizer-Eou
Open or short circ-uit, or bose connector contacl
Matfunction ot the immobilizer-ECU
Mattunction d the engine.EoU
(1) lf the registered ignition keys are close each other when starting the engine, radio interference may
cause this code to be displayed.
(2) This code may be displayed when registering the key lD code.
Check the following qonnestorr:
1, C-19, C-29, C-62
Check the hemess u,ire between
the immobilizer-EOU and the
Replace the engine-Eou.
GDI
-
134-65
Troubleshooting
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble symptom
lnspection
procedure
Reference page
No.
Communication
with MUT-II is
impossible.
Communication with allsystems is not possible,
1
134-66
Communication with engine-ECU only is not possible.
2
134-66
Engine warning
lamp and
related parts
The engine waming lamp does not illuminate right after the
ignition switch is turned to the ON position.
3
134-67
The engine warning lamp remains illuminating and never goes
4
134-67
No initial combustion (starting impossible)
5
134-78
Initial combustion but no complete combustion
(starting impossible)
6
134-70
Unstable idling (Rough idling, hunting)
7
134-71
ldling speed is high. (lmproper idling speed)
I
134-73
When the engine is cold, it stalls at idling. (Die out)
9
134-74
When the engine is hot, it stalls at idling. (Die out)
10
134-75
The engine stalls when starting the car. (Pass out)
11
1gA-77
The engine stalls when decelerating.
12
134-78
Hesitation, sag or stumble
13
134-79
The feeling of impact or vibration when accelerating
14
134-80
The feeling of impact or vibration when decelerating
15
134-81
Knocking
16
134-81
Dieseling
17
134-81
Too high CO and HC concentration when idling
18
134-82
Low alternator output voltage (approx. 12.3 V)
19
134-8tl
Fans (radiator fan, A/C condenser fan) are inoperative
20
134-84
GDI ECO indicator lamp sys-
GDI ECO indicator lamp does not illuminate.
21
134-85
tem
GDI ECO indicator lamp remains illuminated and does not go off.
22
134-85
out.
Starting
Long time to start (improper starting)
ldling stability
(lmproper idling)
ldling speed is low (lmproper idling speed)
ldling stability
(Engine stalls)
Driving
Poor acceleration
Surge
134-66
GDI
-
Troubleshooting
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS
INSPECTION PROCEDURE
1
Communication with MUT-II is not possible.
(Communication with all systems is not possible.)
Probable cause
The cause is probably a defect in the power supply system (including earth) fol
the diagnosis line.
a
a
a
Gheck tlts iollowing connectoc:
Measure at the diagnostic connector
(16-pin) B-35.
Vohage between 16 and earth
o
OK:
Malfunction of the connector
Malfunction of the hamess wire
Malfunction of MUT-n
c-76. c-77
System vdtage
Check the ham€ss wire bstween lhe
supply and diagnoslic connector
Measure at the diagnostic connector
(lSpin) C-ss.
o Continulty betwesn 4 and earth
o
Continurty between 5 and eafth
OK: Continuity
Check th€ hamess wirc between the
diagnoeth connedor (1epin) and
INSPECTION PROCEDURE 2
MUT-tr communication
A/I-ECU) is impossible.
with
engine-EGU (engine-
.
o
.
One of the following causes may be suspected.
. No power supply to engine-EcU
o Defective earth circuit of engine-ECU
.
.
Defecitive engine-EOU
lmproper communication line belween engine-EOu
Probable cause
atd
Malfunction of engine'Eou povyer supply cirwit
Malfunction of engine-EOU
Op€n circuit between the engine-EcU ard diagnosis
@nnector
MUT-tr
Check tho iollowing conncstota:
c-19, C-28, C-35, C-s3, C-70
Check trouble symptom.
Checkthe hamess wire between engine-EOU and diagnoois con-
NG
n6citor.
OK
Check the engine-Eou power supply and eadh circuit system.
(Refer
to P.13A€6, INSPECTION PROCEDURE 23.)
On vehicles with multi oenter display, if a malfunction cannot be resolved after the procedure above, chec* the multi
center display and replace if necessary. (Refer to GROUP 54 Multi Center display.)
-
GDI
-
134-67
Troubleshooting
INSPECTION PROCEDURE 3
The engine warning lamp does not illuminate right after
the ignition switch is turned to the ON position.
Because there is a burnt-out bulb, the engine-EOU <M/T> or engine-A/T-ECU <A/T>
causes the engine warning lamp to illuminate for five seconds immediately after
the ignition switch is tumed to ON. lf the engine waming lamp does not illuminale
immediately after the ignition switch is turned to ON, one of the malfunctions listed
at right has probably occurred.
MUT-u Data list
16 engine-ECu (engine-A/T-ECU) power supply voltage (Refer
to
P.13A-94.)
Probable cause
o
r
.
.
Bumt-out bulb
Defective warning lamp circuit
Maltunction of the engine-Ecu <M/T>
Malfunction of the engine-A/T-p6g <A/T>
Check the engine-EcU (engine-A/T-ECU) power aupply and eetth
circuit system.
(Refer to P.13A-86, INSPECTION PROCEDURE 23.)
Measure at the engine-Ecu connector C-17.
Disconnect the connector, and measure at the hamess side.
Earth the terminal No. 31.
OK: The engine warning lamp illuminates.
Check the iollowing
connector: C-17
Measure at the combination meter connector C-06.
Disconnect the connector, and measure at the hamess side.
Voltage between 1 and earth (lgnition switch: ON)
OK: System voltage
Check the engine waming lamp pow€r supply
.
o
.
.
if
cirafl üd
ropair
necessary.
Check the following connectors:
c47, C-17, C-28
Check the hamess wire between combination m€ter and englne-
ECU, and repair if neoBssary.
INSPECTION PROCEDURE 4
The engine warning lamp remains illuminating and never
goes out.
Probable cause
In cases such as the above, the cause is probably that the engine-ECU is detecting
o Short-circuit between the engine waming lamp and
a problem in a sensor or ac'tuator, or that one of the malfunctions listed at right
has occurred.
a
engine-ECU
Mallunction of the engine-EOU
llUT-II Self-Diag eode
Are diagnosis codes displayed?
REIEr tO P.13A-12, INSPECTION CHART FOR DIAGNOS]S
coDEs.
Measure at the combination meter connector C-07.
Disconnect the connector, and measure at the harness side.
Disconnect the engine-EGu connector
Continuity between 46 and earth
OK: No continuity
Check the hamess wire between combination meter and enginsECU connector, and repair if necessary.
o
.
o
134-68
GDI
-
Troubleshooting
INSPECTION PROCEDURE 5
No initial combustion (starting impossible)
Probable cause
This is caused by incorrect fuel supply into the combustion chamber, and improper
ignition circuit. Besides that, foreign material may be contaminated in fuel.
a
a
o
Check system voltage while the engine is cranking.
OK: SVormore
Malfunction of the fuel supply system
Malfunction ol the ignition system
Malfunction of the engine-Ecu
Ch€d( the batte.y. (R6fer to GROUP SS
to
-
Battery.)
UUr-II Self-Diag code
Refer
ls a diagnosis code displayed?
coDEs.
MUT-II Data list
16 Slrstem voltage (Refer to P.13A-94.)
Ched( the engine conüol nlay and ignfion switclr-lG system.
(Referto P.l3A€7, tNSpECTtON PROCEDURE 24.)
Does the camshaft otiate when the engine is cranking?
Ched( if the timing belt is boken or clamaged.
lf,UT-II Actuator test
07 Fuel pump (lor pressure) (Refer to P.13A-1m.)
Ched( the fud pump (lor pressure) system.
(Refer to P.13A-91, tNSpECTtON PROCEDURE 29.)
ilUT-ü lrsta ligt
22 Crank angle sensor (Refer to P.13A-94.)
Check üle crank angle sensor slrstem. (Refer to p.13A47, lNSPECTTON PROCEDURE FOR DTAGNOSTS CODE p0335.)
ilUT-tr Data list
21 Engine coolant temperature sensor (Refer to P.13A-94.)
Ched( the engine coolant tempsrature sensor system.
(Reterto P.13A-19, tNSpECTtON PROCEDURE FOR DtAcNO
llUT-II ltata l.st
79 Throttle position sensor (1st cfiannel) (Refer to P.13A-90.)
P.13A-12, INSPECTION CHART FOR DtAcNOStS
srs coDE
P0115.)
Chsd( the thrctüe position sensor (lst ctrannel) system.
(Refer to P.1 3A-2., INSPECTION PROCEDURE FOR DTAGNO-
srs coDE
P0120.)
Inspect engine start ability by cranking the engine while the
accelerator pedal is slightly depressed.
Clean around the throtü€ valve. (Refer to P.13A-92..)
Measure at injector dri\rer conn€ctor A-55.
Disconnect the connec{or, and meaaur€ at the conne€ilor side.
Ched< the injector dri\rer sl|Btem.
.
o
Voltage between each of terminals 12, 21 and €aül
(lgnition switc+r: ON)
OK: System voltage
Ch€ck tuel leakage. (Refer
to P.13A-99'.)
Measure low luel prcssurc between the fuel pump (low pressure)
and tuel pump (high pressure). (Ret€r to P.13A-108.)
Measue at ignition coil conneclotB A-09, A-10, A-11, A-12.
. Connec't the connector.
.
Connect a timing light to the No. 1 teminal of each @nnector
in tum.
(Refer to P.13A€8, INSPECTION PROCEDURE 2S.)
Reprir
Rcpair
ClTk the
ignition coil (incorporating porver transitor) q/stem.
(Refer to P.l3A-44, INSPECTION PROCEDURE FOR DtAcNO-
srs coDE ru300.)
(Engine cranking)
Check ignition timing while the engine is cnnking.
OK: Approx.s'
BTDC
NOTE
*:
Refer to the '00 PAJERO PININ Workshop Manual
Ch€d( thd lh€ qank angle serEor ard timing bdt correr arB properly inslalled.
(Pub. No. CKRE00E1)
GDI
-
Troubleshooting
Check ignition coil spark for each cylinder.
(1) Remove the ignition coil.
(2) Insiall a new spark plug to the removed ignition coil.
(3) Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the iniector, or you are seriously injured.
(4) Earth the spark plug electrode securely.
(5) Check that the spark plug ignites when the engine is cranked.
Check all the following items:
. Spark plug
.
o
Compression pressure
Foreign material (such as water or kereine) entered the fuel
lines
134-69
134-70
GDI
-
Troubleshooting
INSPECTION PROCEDURE 6
Initial combustion takes place, but does not complete I Probable cause
(start impossible), too long time to start (poor start)
I
o
o
o
.
.
.
This may be caused by improper spark plug ignition (poor spark), improper miriture
during engine cranking, improper fuel pressure.
Malfunction
Malfunction
Malfunction
Malfunction
system
Malfunction
of the fuel supply system
of the fuel pressure sensor
of the ignition system
of the electronic-controlled throtüe valve
of the engins-Eou <i/UT>
Matfunctbn of the engine-A/T-ECU <A/T>
Check sllstem voltage while the engine is cranking.
Ched( the battery. (Refer to GROUP 55
MUT-II S€lf-Diag code
ls a diagnosis code displayed?
coDEs.
luluT-II Ac.tuator t3st
07 Fuel pump (low pressure) (Refer to P.13A-100.)
Ched( lh6 fuel pump (lorv pressure) system.
(Refer to P.13A-91, INSPECTION PROCEDURE 29.)
ilUT-n lrata
Check th€ engine cootant temperdure EFtem. (Refer to P.l 3A-1 9,
TNSPECTTON PROCEDURE FOR D|AGNOS|S CODE po115.)
OK: SVormore
lasl
21 Engine coolant temperature sensor (Refer to P.13A-94.)
Refsr
to
18 Cranking signal (Refer to P.13A-94.)
ilUf-U
ltat
l.3t
74 Fuel prBssure sensor (Refer to P.13A-94.)
Battery.)
P.134-12, INSPECION CHART FOR DIAGNOS|S
Ched< the ignition switcfi-ST
ltlUT-II ltata list
-
qptem. <M/T>
(Refer ro P.13A€9, tNSpECTtON PROCEDURE 26.)
Ched( the ignition swikh-ST sFtem and inhibitor switctr sytem.
<Ä,/T> (Ref6r lo P.13A€9, INSPECTION PROCEDURE 27.)
Ched( an abnormal fuel pressure system. (Refer to P.lgA-gg,
TNSPECTTON PROCEDURE FOR DIAGNOS|S CODE F0190.)
Check fuel leakage. (Refer to P.13A-99'.)
ls the engine stalted normally when it is cranked with the accsbra-
tor pedal depressed slighüy?
llUT-II
ha
list
Clean arourd the thrcttle valve. (Refer to P.13A-92'.)
79 Throttle position sensor (1st channel) (Refer to P.13A-94.)
Check lhe throtüe rralve poeition fs€dback system.
(Referto P.13A€5, INSPECTION PROCEDURE FOR DTAGNG
Check ignition timing when the engine is cranked.
Ch€ck thal the crank angle sensor and timirg beft cover at€ poperly instajled.
OK: approx.s'BTDC
sfs coDE P1n1.,
Check ignltion coil spark for eacfi cylinder.
(1) Remove the ignition coil.
(2) Install a new spark plug to the removed ignition coil.
(3) Disconnect the injector intermedbte conneclor.
Caution
Naror touch lte conncctor tcrminrl !s.pprpx. l(Il V ig
applied to thc injcctor, or t/ou are reriously inlurcd.
(4) Earth the sparlt plug elecüode securely.
(5) Check that the spaft plug igniles when the engine is cranked.
Check all the following items:
Spark plug
Compression pressure
Foreign matefial (sucfi as water or kerosine) entercd th€ fu€l
o
o
o
lines
NOTE
*:
Refer to the '00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
GDI
-
134-71
Troubleshooting
INSPECTION PROCEDURE 7
Unstable idling (rough idle,
hunting)
] Probable cause
This malfunction. is probably caused by a faulty ignition system, improper airlfuel |
ratio, a faulty electronic-controlled throttle valve system, improper compression I
pressure, etc. As many causes can be suspected, diagnose from easier items. I
Has the battery been disconnected recently?
.
o
o
Malfunction of the ignition system
Malfunction of the airlfuel rätio control s)rstem
.
.
syslem
lmproper compression pressure
Air sucking into the air intrake system
Malfunction of the electronic-control thrbtfle valve
Warm up the engine, and then let it run at idle tor apprcx. ten
minutes.
MUT-[ Selt-Diag code
ls a diagnosis code displayed?
coDEs.
Does the engine idle speed tluctuates excessively (excessive
Clean around the thrcttle valve. (Reter to P.13A€f.)
REfEr tO P.13A-12, INSPECTION CHART FOR DIAGNOSIS
hunting)?
llUT-II Data list
79 Throttle position sensor (lst channel) (Refer to P.13A-94.)
Check the throttle valve position fe€dback systcm.
(Refer ro P.134-55, TNSPECTTON PROCEDURE FOR D|AGNO.
sfs coDE P122t.l
MUT-tr Data list
26 Accelerator pedal position switch (Refer to P.13A-94.)
Check the accelerator pedal position svtritch sysilem. (Refer to
MUT-tr Data li3t
13 Intake air temperature sensor (Refer to P.13A-94.)
Check the intake air temperature sensor aystem.
(Refer to P.13A-18, TNSPECTTON PROCEDURE FOR DTAGNO
MUT-ü Data list
25 Barometric pressure sensor (Refer to
P.13A-94.)
MUT-II Data list
21 Engine coolant temperature sensor (Refer to
P.13A-94.)
MUT-tr Actuator test
08 Purge conlrol solenoid valve (Refer to
P.13A-100.)
MUT-II Data list
59 Orygen sensor (rear)
o Transmission: 2nd gear <M/T>, L range <4,/T>
o
P.13A-90, TNSPECTTON PROCEDURE 28.)
srs coDE
P0110.)
Check the barometrb pressure sensor systern. (Rcferto P.13A-f6,
TNSPECTTON PROCEDURE FOH DIAGNOSTS CODE P010s.)
Check the engine coolant temperatlre sensor. (Rderto P.13A-1q
TNSPECTTON PROCEDURE FOR DTAGNOSIS CODE P0115.)
Check the grrge conhd sdenoid vahre systdn. (R6ferb P.13A€2,
rNspEcTroN PRooEDURE FOR D|AGNOSTS CODE F044{t.)
Check the orygen sensor (rear) slrstem. (Refer to P.134-28, lNSPECTTON PROCEDURE FOR DTAGNOSF Cq)E p0136.)
Driving with throttle widely open
600 - 1,ffD mV
OK:
MUT-II Data Iist
11 Orygen sensor (front)
OK: 6ü) 1,000 mV when the engine is suddenly raced
-
Check the oryggn sensor (trofit) slrstom. (Refer to P.134-25, lN.
SPECTTON PROCEDURE FOR DTAGNOSTS CODE P0130.)
NOTE
*:
Refer to the '00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
13A.-72
GDI
-
Troubleshooting
MUT-II Data list
11 Orygen sensor (front)
OK: 0 - 400 mV and 600 - 1,000 mV altemates when the
engine is idling (wait lor four minutes after the engine
Measure fuel high-pressure between the fuel pump (high pressure)
and injector. (Refer to P.134-108.)
started).
Ched( that air is sud<ed in the air intiake syS€m.
o Broken intiake manitold gasket
o Damaged varruum hose
Ched( the power steering fluid pressure srvitch system. (Refer
I'UT-II Data li3t
27 Pwtet steedng fluid pressure switch (Refer to P.134-90.)
to P.134-92, INSPECTION PR@EDURE 30.)
tluT-u ltata li3t
28 A/C switch (Refer to P.134-94.)
Check the A/C switch and A/C relay system. (Refer
TNSPECTTON PROCEDURE 31.)
b
P.134-92,
tlUT-II Data llst
Ched( the stop lamp switcfi. (Refer to P.13A-93, INSPECTION
67 Stop lamp switch (Refer to P.134-94.)
PROCEDURE 32.)
l,lUI-II ma l.st
31 Small lamp switcüt (Refer to P.134-94.)
TtoN PR@EDURE 33.)
llUT-II Data list
68 EGR valve (Refer to P.13A-94.)
Checkthe EGRvalve. (Referto P.134-50, INSPECTION PROCEDURE FOB DTAGNOSTS CODE Po4O3.)
Check ignition timing. (Refer to GROUP 11A
Chec*the small larnp svüibfi system. (Reterto P.134-93, INSPEG
- Engine
Miustnent.)
Chsck thal the crank angle ssrisor and timing bglt co\r€r arB pEp€rly installed.
Clean around the throftle valve. (Refer to P.l3A-92'.)
Check ignition coil spark for eaci cylinder.
(1) Remove the ignition coil.
(2) Install a new spark plug to th€ removed ignition coil.
(3) Disconnect the injector int€tmediate oonnec'tor.
Caution
Nwcr touch the connector tcrminal as apprcr. 100 V
applaed
to the injector, or you ar€ $riously inlurcd.
lr
(4) Earth the spark plug electrode securely.
(5) Check that the spaft plug ignltos when the engine is cranked.
Check all the following items in that otder.
(1) Spark plugs
(2) Exhaust gas emission contrcl system
(3) EGR slrstem
(4) Compression prossure
(5) Foreign material (such as water or kercsinc) entered the fuel
line.
(6) Air is sucked in the air intake system,
Damaged intake manifold gasket
Damaged air intake hose
Darnaged vacuum hose
Fautty EGR valve s€at
o
o
.
o
NOTE
*:
Refer to the '00 PAJERO
or EGR gas leal$.
PININ Workshop Manual (Pub. No. CKREOOE1)
GDI
-
134-73
Troubleshooting
INSPECTION PROCEDURE 8
ldle speed is high or low (lmproper idling)
Probable cause
The cause is probably that the intake air amount during idling is too great or too
o
o
Malfunction of the electronic-controlled throttle valve
system
Malfunction of the throttle body
to
P.13A-12, INSPECTION CHART FOR DIAGNOSIS
small.
MUT-[ Self-Diag code
ls a diagnosis code displayed?
(Refer
coDES.)
79 Throttle position sensor (lst channel) (Flefer to P.134-94.)
Check the throttle \ralye position feedbad< system.
(Refer to P.13A-55, INSPECTION PROCEDURE FOH DIAGNG
MUT-[ Actuator test
08 Purge control solenoid valve (Refer to
Check the purge contlol solenc,id valve. (Refer to P.134-52, lNspEcroN PRooEDURE FOR DTAGNOSIS CODE F0443.)
MUT-ü Data list
P.134-10O.)
sls coDE P1221.)
ilUT-u Date list
Ch6ck the accelerator p€dal position $dbfi slFtom.
(Refer to P.13A-90, INSPECTION PR@EDURE 28.)
MUT-II Data lßt
Check the engine coolanttemperature setlsor. (Rsferb P.134-19,
TNSPECTTON PROCEDURE FOR DIAGNOSIS CODE P0115.)
26 Accelerator pedal position switch (Refer to P.134-94.)
2l
Engine coolant temperature sensor (Refer to P.13A-94.)
MUT-II Data list
28 A,/C switch (Refer to P.134-94.)
Check the A/C switci and A/C relay systsm.
MUT-U Data list
67 Stop lamp switch (Refer to P.13A-94.)
Check the stop lamp switch sptem.
(Refer to P.13A-93, INSPECTTON PR@EDURE 32.)
.
.
(Refer
to P.13A-92, INSPECTION PROCEDURE 31.)
Clean around the throttle valve. (Refer to P.134-92-.)
Adjust the throttle position sensor. (Refer to P.13A-92-.)
NOTE
*:
Refer to the '00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
134-74
GDI
-
Troubleshooting
INSPECTION PROCEDURE 9
When the engine is cold, it stalls at idling. (Die out)
Probable cause
The cause is probably an incorrect airlfuel ratio or poor intiake air amount when
the engine is cold.
.
.
Have the battery terminals been disconnected recently?
Mallunction of the electronic-control throtfle valve
system
Malfunction of the throttle body
Wam up the engine, and then let it run at idle lor approx. ten
minutes.
(Refer
IIIUT-U Sclf-Diag code
ls a diagnosis code displayed?
to
coDEs.)
P.13A-12, tNSpECTtON CHART FOR D|AGNOS|S
ls the engine idling conect after the €ngine has bsen warmed up?
Refer to "Unstable idling (rough idle, hunting).
(Refer to P.13A-71, tNSpECTtON PROCEDURE 7.)
llUT-II llata list
Ched< the thrcttle valve positbn to€dback system.
(Referto P.13A-55, INSPECTION PROCEDURE FOR D|AGNO,
22 Crank angle sensor (Refer to P.13A-94.)
Check itlling speed when the engine is cold.
srs coDE
P1221.
MUT-II ha list
26 Accelerator pedal position switcfi (Refer to P.13A-9+.)
Ch€ck thg accelerator position switcü.
(Refer to P.13A-9O, INSPECTION PROCEDURE 28.)
ilUT-n Data list
Ched< the engine coolant temporature sensor. (REfer b P.lgA-1g,
TNSPECTTON PROCEDURE FOR D|AGNOS|S CODE p0115.)
21 Engine coolant temperature sensor (Refer to P.13A-94.)
ilUT-II lteta list
68 EGR valve (Refer to P.13A-94.)
Ched( the EGR valve system. (Refer tio P.13A-50, INSPECTION
PR@EDURE FOR D|AGNOS|S CODE p0403.)
Does the engine stall immsdiately after the accelerator pedal is
released?
Clean around the throttle vahre.
(Refer to P.l3A-91'.)
Measure fuel high pressure betrveen the fud pump (high pressl'e)
and injector. (Reter to P.134-108.)
Check ignilion timing. (Referto GROUP 11A
- Engirn
Adjwünent)
thd the crank angle sensor ard üming
ly installed.
Ch€ck
Check ignition coil spaft lor eaci cylinder.
(1) Remove the ignition coil.
(2) Install a new spark plug to the removed ignition coil.
(3) Disconnect the injector interm€diate conneclor.
Gaution
Nwcr toudr the conncctor terminal es apprcr. lOO V ig
applied to the inicctor, or trou arc aerioudy iniurcd.
(4) Earth the spa* plug electrode securely.
(5) Check that the spaft plug ignites when the engine is cranked.
Check all the following items:
.
.
Spad( plugs
Compression pressure
NOTE
*:
Refer to the '00 PAJERO PININ Workshop Manual (Pub. No. CKREOOEI)
b€fr
cowr arB plop€r-
GDI
INSPECTION PROCEDURE
-
134-75
Troubleshooting
1O
When the engine is hot, it stalls at idling. (Die out)
Probable cause
The cause is probably an improper airlfuel ratio, taulty electronic-controlled throttle
valve system, mmpression pressure. ln addition, if the engine stalls suddenly, another
possible cause might be a poor @nnector contact.
.
r
.
.
o
.
.
Malfunction of the ignition system
Malfunction of air/tuel ratio control system
Malfunction
of
electronic-controlled throttle valve
system
Mallunction ol the throttle body
Poor @nnector oontact
lmproper compression pressure
Air stuck in the air intake system
Have the battery terminals been disconnected recently?
Warm up the engine, and then let it run at idle ior apprcx. ten
minutes.
MUT-I Self-Diag code
ls a diagnosis code displayed?
CODES.
I/|UT-II Data list
Check the throttle valve posifon tosdbacft system.
(Refer to P.13A-55, INSPECTION PROCEDURE FOR DIAGNG
79 Throttle position sensor (1st channel) (Refer to P.134-94.)
ls it easy to reproduce the engine stall?
Refer
to
P.13A-12, INSPECTION CHAHIT FOR DIAGNOSIS
sfs coDE
P1221.1
While carrying out an intetmiüent malfunction simulation t€st. (Re'
fer to GROUP 00 Points to Note for Intemittert Matftrltclion.),
check tor sudden changes in the following signals.
Crank angle sensor signal
Injeclor drive signal
-
.
o
o
.
.
.
Fuel pump (low pressurc) drive sigml
Air flow sensor
Primary ignition signal
Power supply to the engine-EOu
MUT-II Data list
26 Accelerator pedal position switch (Reter to P.134-94.)
Check the accelerator pedal position su,itc{t.
(Refer ro P.13A-$, INSPECTION PROCEDURE 28.)
MUT-II Dsts list
13 lntake air temperature sensor (Refer to P.134-94.)
Check the intake air temperature sensor. (Refer to P.134-18, lNSPECTTON PROCEDURE FOR DTAGNOSIS CODE P0110.)
iluT-tr Data list
25 Barometric pressure sensor (Refer to P.134-94.)
Check the barom€tdc pressure sensor. (Rel6r to P.13A-16, lN'
SPECTTON PROCEDURE FOR DTAGNOSIS CODE P010s.)
MUT-tr Data list
Check the engine coolant temperature seneor. (Refer
b
P.134-19,
21 Engine coolant temperature sensor (Ref€r to P.134-94.)
rNspEcroN PRocEDURE FOR DIAGNGgIS CODE P0115.)
MUT-II Data liet
59 Orygen sensor (rear)
. Transmission: znd gear <M/T>, L range <4,/T>
. Driving with throttle widely open
OK: 600 - 1,000 mV
Check the orygen sensor (rear) system. (REfer to P.134'28, lNSPECTTON PROCEDURE FOR DTAGNOSIS CODE P0136.)
MUT-tr Data list
11 Orygen sensor (front)
OK: 600 1,000 mV when the engine is suddenly raced
Check the orygen sensor (front) system. (Rslor to P.134-25, lN'
spEcroN pRocEDURE FOR DIAGNOSIS CODE PO13O.)
-
MUT-U Data list
11 Oxygen sensor (front)
OK: 0 - 400 mV ancl 600 - l,mo mV altemates when the
engine is idling (wait for lour minutes after the engine
Measure tuel high-pr€ssure betws€n
ü€ fuel pwnp (high prwu]€)
and injector. (Refer to P.134-108.)
NG
started).
Bcpair
Check that air is sucked in the air intake s!6tem.
Broken intake manifold gasket
Damaged vacuum hose
o
o
134-76
GDI
-
Troubleshooting
From the previous page
MUT-II Data last
27 Powet steering fluid pressure switch (Refer to
P.13A-94.)
Check the power steering fluid pressure switch system.
(Refer to P.13A-92, INSPECTION PROCEDURE 90.)
MUT-n Data list
28 NC switch (Refer to P.13A-94.)
Check the A/C switch and A/C relay system.
(Refer to P.13A-92, INSPECTION PROCEDURE 31.)
IIIUT-U ltata liEt
Check the small lamp switch system.
31 Small lamp switch (Refer to P.13A-94.)
(Roter
tlUT-II Data list
to
P.134-93, INSPECTION PROCEDURE gtt.)
34 Air flow sensor reset signal (Refer to P.13A-94.)
Ch€d( the air flou, sensor system. (Refer to P.tgA-14, INSPECTroN PROCEDURE FOR DtAcNOStS CODE p0100.)
tluT-tr Datr list
68 EGR valve (Refer to
Ched(ltle EGR valve. (Referb P.13A-50, |NSPECT|OI{ PROCEDURE FOR DTAGNOS|S CODE PO4o3.)
P.13A-94.)
Does the engine stall immediately after the accelerator podal is
released?
Clean around the throttle valve. (Refer to P.13A-92".)
Check ignition liming. (Refer to GROUP 11A
Check
-
Engine Adjusün€nt.)
thd ths crank angle serEor and timing belt oover arE prcperly installed.
Check ignition coil spark for eacfi cylinder.
(1) Remove the ignition coil.
(2) lnstall a new spad< plug to the remorr€d ignition coil.
(3) Disconnect the injector intermediate @nnector.
Gaution
Newr touch the connoctor tcrminal s3 appror. lm V is
applied to the iniector, or you are rriously lnjured.
(4) Earth the spark plug dectrcde securely.
(5) Check that the spaft plug ignites when tho engine is cranked.
Ch€ck all the lollowing items:
o
o
o
Spa'k plugs
Compression pressure
Foreign material (sucfi as wat€r or kero6in€) enteEd the fu€l
lines
NOTE
*:
Refer to the '00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1)
GDI
INSPECTION PROCEDURE
-
134-77
Troubleshooting
11
The engine stalls when starting the car. (Pass out)
Probable cause
The cause is probably poor ignition due to a malfunctioning spark plug (weak spark),
or an incorrect airlfuel ratio when the accelerator is depressed.
a
Malfunction of the ignition system
o Malfunction of the EGR valve
a Air stuck in the air intake system
MUT-[ Self-Diag code
ls a diagnosis code displayed?
coDEs.)
MUT-II Data list
68 EGR valve (Refer to P.13A-94.)
Check the EGR valve. (Refer to P.13A-50, INSPECTION
DURE FOR DIAGNOS|S CODE P04O3.)
liUT-tr Astuator test
Check the purge contrd sdefloid \ralvg sysEn. (Rderb P.13A-52,
TNSPECTTON PROCEDURE FOR DtAcNOStS CODE p0443.)
08 Purge control solenoid valve (Refer to P.13A-100.)
Check ignition coil spark for each cylinder.
(1) Remove the ignition coil.
(2) Install a new spark plug to the removed ignition coil.
(3) Discunnect the injector intermediate connector.
Caution
Never toueh the connector terminal as appnox. l{Xl V is
applicd to the inlector, or you are seriously injured.
(4) Earth the spark plug electrode securely.
(5) Check that the spark plug ignites when the engine is cranked.
Chsck all the following items:
(1) Spark plug
(2) Gheck if air is stuck in the air intake system.
. Damage intake manifold gasket
o Damaged or disconnected vacuum hose
. Damaged air intake hose
(Refer
to
P.13A-12, INSPECTION CHART FOR DIAGNOSIS
PR@E-
INSPECTION PROCEDURE 12
The engine stalls when decelerating.
Probable cause
The cause is probably an improper airltuel ratio due to a faulty EGR system, or
poor intake air volume due to a laulty electonic-controlled throttle valve system.
o
o
Malfunction of the electronic-controlled throttle valve
sy$em
Malfunction of the EGR valve
Warm up the engine, and then let it run at idle lor appox. ten
Have the battery terminals been disconnected recently?
minutes.
(Refer
to
P.13A-12, INSPECTION CHART FOR DIAGNOSIS
coDEs.)
llUT-II ttata
Ched( the accelerator pedal position switcfi.
(Refer to P.134-90, INSPECTION PROCEDURE 28.)
last
26 Accelerator pedal position switcfi (Refer to P.134-94.)
MUr-II Data li3t
79 Thottle position sensor (1st cfiannel) (Refer to P.134-94.)
applied to the iniector, or you are ecriouely injured.
(4) Eailh the spalk plug elecüode s€ourely.
(Referto P.134-55, INSPECTION PROCEDURE FOR DIAGNG
sfs coDE
P1221.1
Chsck the EGR valve slrstem. (Refer to P.13A-S), INSPECTION
PROCEDURE FOR DTAGNOSTS CODE P0403.)
IIIUT-II t ata list
68 EGR valve (Refer to P.134-94.)
Check ignition coil spark lor each cylinder.
(1) Remove the ignition coil.
(2) Install a new spark plug to the removed ignition ooil.
(3) Disconnect the injector intermediate @nnector.
Caution
Nevcr toucir the connector terminal a8 .ppngx. lm V
Ch€ck the thotüe valve poeition leedback system.
ir
(5) Check that the spark plug ignites when the
Check all the following items:
Spark plug
Clean around the thrutüe valve (Refer to P.134-92'.)
.
o
NOTE
*:
Refer to the '00 PA.JERO PININ Workshop Manual (Pub. No. CKRE00E1)
GDI
-
134-79
Troubleshooting
INSPECTION PROCEDURE 13
Hesitation, sag, stumble, poor acceleration or surge
Probable cause
The cause is probably a malfunction of the ignition system, electronic-controlled
.
r
.
.
.
throttle valve system, compression pressure, etc.
ftlUT-II Selt-Diag ode
ls a diagnosis code displayed?
(Refer
system
lmproper compression pressurc
Air stuck in the air intake system
P.134-12, TNSPECTTON CHART FOR D|AGNOS|S
coDEs.)
Check ignitbn timing. (Referto GROUP 11A
-
Engine Adjustment.)
ttluT-II Data list
MUT-II Data list
to
Check that the crank angle sonsor ard timing belt cover arc pmper-
ly installed.
26 Accelerator pedal position switch (Refer to P.13A-94.)
'13 Intake air temperature sensor (Refer
ro
Mallunction of the ignition system
Malfunction of the air/fuel ratio control system
Maltunction of the electronic-controlled throttle valve
P.13A-94.)
MUT-[ Data lbt
Check the acceleBtor pedal position sf,,itcfi.
(Refer to P.134-90, INSPECTION PROCEDURE 28.)
Check the intake air temperature ssnsor. (Reter to P.13A-18, lNSPECTTON PROCEDURE FOR DTAGNOS|S CODE P0110.)
25 Barometric prsssure sensor (Refer to P.13A-94.
Check the barometric pr€ssure sensor. (fut€r to P.134-'16, lNSPECTTON PROCEDURE FOR DTAGNOSTS CODE P016.)
MUT-II Data list
21 Engine coolant temperature sensor (Refer to P.13A-94.)
Chec* the engine coolant temperaünB sensor. (Refier to P. 1 3A-1 I,
TNSPECTTON PROCEDURE FOR DTAGNOSIS CODE P0115.)
I'UT-II Data list
Check the throttle valve poEition feedback sy8tem.
(Referro P.134-55, TNSPECTTON PROCEDURE FOR DIAGNO
79 Throttle position sensor (1st channel) (Refer to P.13A-94.)
ilUT-tr llata list
59 Orygen sensor (rear)
o Transmission: 2nd gear <M/T>, L range
o
sls coDE
P122't.)
Check the orygen sensor (rea4 system. (R۟ar b P.134-28, lNSPECTTON PROCEDURE FOR DIAGNOSTS CODE P0136.)
<Ä,/T>
Driving with throttle widely open
OK: 6ff)
-
1.üD mV
11 Oxygen sensor (front)
OK:
600
-
SPECTION
1,000 mV when the
s!/stem. (Refer to P.134-25, lNDTAGNOSTS CODE P0130.)
Measure fu€l high-pressurs between fte fuel pump (ltgh pr€ssr'€)
11 Oxygen sensor (front)
OK:
- 400 mV and 600 1,000 mV alternates when the
engine is idling (wait for four minutes after the engine
started).
0
MUT-II Data list
68 EGR valve (Refer to
-
Check that air is sucked in the air intake syEtem.
. Broken intake manifold gasket
. Damaged vacuum hose
o Damaged air intake hoss
Check the EGR valvE. (Refer to P.13A-50, INSPECTION PROCEDURE FOR DTAGNOSTS CODE P0403.)
P.13A-94.)
MUT-II Actuator teat
08 Purge control solenoid valve (Refer to
and injector. (Refer to P.134-108.)
Check the purge control solencid valve. (Refer
P.13A-10O.)
b P.134€4, lN-
SPECT|ON PR@EDUBE FOR DTAGNOS|S CODE P044rl.)
134-80
GDI
-
Troubleshooting
From the previous page
Measure high fuel pressurc between the fuel pump (high pressure)
and iniector. (Refer to P.134-108.)
Check ignition coil spark for each cylinder.
(1) Remove the ignition coil.
(2) Install a new spark plug to the removed ignition cdl.
(3) Disconnect the iniector intermediate @nn€ctor.
Caution
Ncyrr touch the conncstor terminsl as apprc& 100 V
applied to the injector, or you are seriouely injurcd.
(4) Ealth the spark plug elecfods s€qjrely.
it
(5) Check that the spark plug ignites when the engine is cranked.
Ched( all the following items:
Spark plug
EGR system
.
o
o
.
Conrpression pressure
Clogged fuel fi]ter, fuel line
INSPECTION PROCEDURE 14
The feeling of impact when accelerating
Probable cause
The cause is prcbably an ignition leak b€ing generated in line with an increas€
in the spark plug request voltage during acceleration.
o
to
Malfunctian of thg ignfion system
ilUT-U SGlf-Diag coda
ls a diagnosis code displayed?
(Reter
tlUT-II Data list
Chsd( the thrctüe vatue pq$tion feedback q/stem.
(Refer to P.13A-55, INSPECTION PROCEDURE FOR DIAGNO-
79 Throttle position sensor (lst ciannel) (Refer to P.13A-94.)
Check ignition coil spark for eacfi cylinder.
(1) Remove the ignition cclil.
(2) lnstall a new spa* plug to the removed ignition coil.
(3) Disconn€ct the injeclor intemediate connec-tor.
Caution
Never touci the connostot terminsl !9 tpprox. 100 V
P.13A-12, INSPECTION CHART FOR DIAGNOSIS
coDES.)
sfs coDE P121.1
Ch€d( all the tollqving it€ms:
o Spark plug
o lgnition qrrent leak
l!
applisd to the iniector, or you arc seriourly injured.
(4) Earth the spaft plug electode seanrely.
(5) Check that the spaft plug ignites when the engine is crankEtl.
o
GDI
-
134-81
Troubleshooting
INSPECTION PROCEDURE 15
The feeling of impact when decelerating
Probable cause
The cause is probably insufficient intake air due lo a faulty electronic-controlled
o
throttle valve system.
to
Malfunction of the electronic-controlled throttle valve
system
MUT-[ Self-Diag code
ls a diagnosis code displayed?
(Refer
MUT-u Data last
79 Throttle position sensor (lst channel) (Refer to P.13A-94.)
Check the throttle \ralve position feedback system.
(Refer to P.134-55, INSPECTION PROCEDURE FOR DIAGNO-
MUT-II Data list
Check the acceleralor peclal position switcfi systun.
(Refer ro P.13A-90, INSPECTION PROCEDURE 28.)
26 Accelerator pedal position switch (Refer to P.13A-94.)
P.13A-12, INSPECTION CHART FOR DIAGNOSIS
coDEs.)
sls coDE P1221;t
Clean around the throttle valve. (Refer to P.13A-92'.)
NOTE
*:
Refer to the '00 PAJERO PININ Workshop Manual (Pub. No. CKREO0EI)
INSPECTION PROCEDURE 16
Knocking
Probable cauae
The cause is probably inconec{ detonation control or improper heat range of the
spark plugs.
e
o
(Ref,er
to
coDEs.)
Does knocking occurwhen the vehide is driven wih the detonation
sensor disconnec{ed?
(At this time, use the MUT-tr to check whether the ignition timing
is retarded from when the detonation sensor @nnector is con-
Malfunction of the detonation
P.134-12, INSPECTION CHAHT FOR DIAGNOSIS
Check the detonation sensor system. (Refer
TroN PROCEDURE FOR
Gheck all the following items:
o Spark plug
Foreign material (such as water or kerosine) ent€red the fuel
lines
INSPECTION PROCEDURE 17
Run-on (dieseling)
Probable cause
The cause is probably luel leak trom injector(s)
o
Replac€ the injector.
Malfunction
b
P.134-47, INSPEG
DTAGNOSTS CODE P0S25.)
nected.)
o
snsor
lmpoper heat range of the spaft plugg
ol the iniector
134-82
GDI
-
Troubleshooting
INSPECTION PROCEDURE 18
Too high CO and HC concentration when idling
Probable cause
The cause is probably an incorrect air/tuel ratio
a
Malfunction of airlfuel ratio control system
Deterioration of the catialyst
a
(Refer
to
coDEs.)
Check Qnfion timing. (Refer to GROUP 11A
- Engine
Adjr.sünent)
Gheck
P.134-12, INSPECTION CHART FOR DIAGNOSIS
thd the crank angle sensor and timing belt cocr ale proper-
ly installed.
MUT-U lrata list
Engine coolant temperaturc sensor (Refer to P.13A-94.)
Ched< the ongine codant temp€rature sensor. (Refer
llUT-II Data list
Ch€d( the intak€ air tempsrature ssnsor. (Refer to P.13A-18, lN.
SPECTTON PROCEDURE FOR D|AGNOS|S CODE p0110.)
l.st
Check the berometric prgssurc sensor. (Refer to P.13A-16, lNSPECTTON PROCEDURE FOR DIAGNOS|S CODE p0105.)
2'l
13 Intake air tempeEture sensor (Refer to P.13A-94.)
tulUT-II Data
25 Barcmetric pressure sensor (Refer to P.134-94.)
MUT-[ Data list
P. 1
3A-1 9,
Ched< the orygen sensor (rear) system. (Refer to P.13A-28, lNSPECTTON PR@EDURE FOR D|AGNOS|S CODE p0136.)
59 Orygen sensor (rear)
.
.
b
INSPECTTON PROCEDURE FOR D|AGNOS|S CODE p0115.)
Transmission: 2nd gear <i,UT>, L range <4./T>
Driving with thottle widely open
OK: 6fi) 1,(X)0 mV
-
MUT-tr Data list
11 Orygen sensor (front)
OK: 6(X) 1,ü)O mV when the engine iE suddenly raced
Check the oryggn sensor (tront) s!6t€m. (Refer to P.13A-25, lNSPECTTON PR@EDURE FOR DIAGNOSIS CODE F0130.)
IIIUT-II Drta list
11 Orygen sensor (front)
OK: 0 - rOO mV and 6(x)
Replace the oxlrgen sensor (lront).
-
-
1,(nO mV altemates srhen the
engine is idling (urait for four minutes after the engine
started).
Measure fud high-pressure between the fud pump (high pr€ssure)
and inj€ctor. (Refer to P.134-108.)
Check ignition coil spark for each cylinder.
(1) Remove the ignition coil.
(2) lnstall a new spark plug to the removed ignition cclil.
(3) Disconnect the injector int€rmgdiate @nnector.
Caution
Nwer touch the connec'tor termanal .s apprcx. 1ül V is appllcd to tho inicctor, or you arc r€dously injured.
(4) Earth the spaft plug elechode securdy.
(5) Check that the spark plug ignites srfien the engine is crank€d.
Check all the follolMng items:
. Spark plug
o EGR s!6tem
.
o
Compression pressure
Clogged fuel filter or line
GDI
-
134-83
Troubleshooting
MUT-II Data list
Check the EGR valve system. (Refer
68 EGR valve (Refer to P.13A-94.)
to
P.13A-50, code No.
P0403.)
MUT-II Actuator test
08 Purge control solenoid valve (Refer to P.13A-100.)
Check purge control solenoid valve system. (Referto P.13A-52,
TNSPECTTON PROCEDURE FOR D|AGNOSIS CODE p0443.)
INSPECTION PROCEDURE 19
Low alternator output voltage (approx. 12.3 V)
Probable cause
The cause is probably a malfunction of the alternator or one of the problems
listed at right.
o
o
.
MeaEure at the altemator @nnector
A-79.
Connect the connector. (Use the
test hamess M8991519)
o
.
Voltage between 1 (black clip)
and earth
(Engine: ldling)
(Radiator fan: Not operating)
(Headlamp: OFF -+ ON)
(Stop lamp: OFF --r ON)
(Rear defogger switch: OFF -+
oN)
OK:
Voltage increased by
0.2 3.s v.
-
Check the altemator. (Refer to GROUP
16
-
Charging System.)
Measure at the altemator connector
A-79.
Disconnect the connector, and
.
.
.
measure at the hamess side.
Disconnectengine-EoU
connector C-17.
Continuity between 1 and eafih
OK: No continuity
Check the following connss"toru:
A-79, A-86, C-17
Malfunction of the charging s!,stem
Open circuit between the altemator G teminal
and the engine-EoU
Maffunction of the engine-EcU
Ch€ck the harnoss wir€ b€tw€€n
the altemdor and üe engine-EoU,
and repair if necossary.
134-84
GDI
-
Troubleshooting
INSPECTION PROCEDURE 20
Fans (radiator fan, A/G condenser fan) are inoperative.
Probable cause
The engine-EcU sends a duty signal to the fan controller according to engine coolant
temperature, vehicle speed, or A"/C switch load.
The fan controller @ntrols radiator lan and condenser fan speeds, based on this
signal. CIhe closer the terminal vottage @mes to 5 V the higher the fan speed
@
. Malfunction of the fan motor
. Malfunction of the fan controller
I Open or short circuit, or poor connecitor contact
. Malfunction of the engine-ECU
becomes.)
Measure at engine-Ecu connector C-17.
Disconnect the connector, measure at the hamess side.
Voltage between terminal 18 and earth
(lgniüon switctr: ON)
OK: 4.8 5.2 V (Ihe fan runs at high spe€d.)
Eafth t€rminal 18.
(lgnition switch: ON)
OK: The tan sbps.
o
o
o
Check the following @nnectorg: A-29, C-17
NG
Rcpair
-
Ch€d( lhe hamess wirB bstu,€€n the engine-ECU ard fan conüdler.
Gheck the following connestor: C-17
NG
NG
Repair
Repair
Checkthe radiatorlan and condenserfan circuit. (Referb GROUP
llUT-II ltsta list
21 Engine coolant temperature sensor
OK:
After the engine has been warmed up, lhe engine coolant
temperature dudng idling is identical to the MUT-tr rcading.
Ched( fte engine coolant temperature sensor system. (Refer to
P.l34-19, INSPECTION PR@EDURE FOR DIAGNOSIS CODE
011s.)
Replace
GDI
-
134-85
Troubleshooting
INSPECTION PROCEDURE 21
GDI ECO indicator lamp does not illuminate.
Probable cause
lf the GDI ECO indicator lamp does not illuminate after turning switch, the causes
listed in the right column are suspected.
o
.
.
.
Measure at the engine-Ecu connector C-l7.
. Disconnect the connector, and measure at the hamess side.
o Earth terminal 14. (lgnition switch: ON)
OK: The GDI ECO indicator lamp illuminates.
Bumed-oul GDI ECO indicator lamp bulb
Open circuit or short-circuited hamess wire in the
GDI ECO indicator lamp circuit
Malfunction of the engine-ECU
Mallunction of the GDI ECO indicator lamp ECU
Gheck the following connector: C-17
Gheck the following connector: G29, C-55
Check the harness wire between the GDI-ECO Indication lampECU and engine-E0U.
INSPECTION PROCEDURE 22
GDI ECO indicator lamp remains illuminated and does not
Probable cause
lf the GDI ECO indicator lamp does not goofi during high load operation, the causes
listed in the riglrt column are suspected.
o
.
.
go off.
Measure at GDI ECO indicator lamp ECU connector C-55.
Disconnect the connector, and measure at the hamess side.
Disconnect the engine-Ecu connector.
Continuity between terminal 3 and earth
OK: No continuity
.
.
.
Check the relalive circuits of GDI ECO indication lamp.
(Reter to GROUP ilA-Troubleshooting.)
Short cirwit beftieen the GDI ECO indicator lamp
and engine-EOU
Malfunction of the engine-EOU
Maltunction of the GDI ECO indicdor lamp ECU
Check touble hamess wire betrveen the GDI ECO
ECU and engine-EOU, and repair if neeesary
itdic&n bnp-
134-86
GDI
-
Troubleshooting
INSPECTION PROCEDURE 23
Engine-ECU power supply and earth circuit system
Probable cause
The cause is probably a malfunction of the engine-ECU or one of the problems
listed at right.
o
e
.
Measure atthe engineEoU @nnedolE
c-18, G19.
o
(1) NG
Open circuit or short-circuited hamess wire in the
engine-EcU power supply circuit
Open circuit or short-circuited hamess nire in the
engine-EcU earth circuit
Mallunction of the engine-Ecu
Check ths iollowing @nnectorB:
c-72, C-74
Disconnect the connector, and
mealiure at the hamess side.
(1) Voltage between 99 and earth
(lgnition switch: ON)
Ched( the hamess wire between the
engine-EOU and ignition sttitch, and
rspEir if nscessary.
OK:
System voftiage
(2) Voltage between 57 and earth
OK: System voltage
(3) Voltage between 47, 59 and
ea.th (lgnition switc+r: ON)
OK: System voltage (When terminal 57 is shorted to
eatth)
(4) Continuity between zt6, 58 and
earth
OK: Continuity
(5) Voltage between 60 and earth
OK:
System roltage
NG
FSair
Ched( the ignition switch. (Refer to
GROUP s4.)
Ch€ck the hamess wirs between the
erpine-EoU and eqgine cortrol r€lay,
and rcpair il necessary.
Ch€d( the ham€€s wir€ b€tween tfie
erqine.EOU and garlh, and rcpair if
necossary,
Ch€ck the hamess wire between the
engine.EOU arid the baüery and repair
if
Gheck thc lollowing connectora:
Gl8,
C-19
GDI
-
134-87
Troubleshooting
INSPECTION PROCEDURE 24
Engine control relay and ignition switch-lG system
Probable cause
When the ignition switch ON signal is input to the engine-ECU, the
engine-Ecu turns on the engine control relay.
This causes system voltage to be supplied to the engine-Ecu and to the
sensors and actuators.
.
.
o
.
Malfunction of the ignition switch
Malfunc'tion of the engine control relay
Open circuit or short-circuited harness wire of the
engine control relay circuit
Malfunc{ion of the engine-ECU
Check the engine control relay. (Reter
to
P.13A-102-.)
Measure at the engine control relay
connector A-4{lX.
Disconnec{ the cunector, and
measure at the hamess side.
Voltage between 3, 4 and eanh
o
o
OK:
Check the hamess wire betlveen the
battery and the engine control relay,
and repair if necessary.
System wltage
Check üte engine-EOU potiler supply
and earth circuit system.
(Refer
P.13A-86, INSPECTION
PROCEDURE 23.)
to
NOTE
*:
Refer to the '00 PAJERO PININ Wokshop Manual (Pub. No. CKRE00E1)
134-88
GDI
-
Troubleshooting
INSPECTION PROCEDURE 25
Iniector driver relay system
Probable cause
When the ignition switch ON signal is input to the engine-EcU, engine-ECU
turns on the injector driver relay.
This causes system voltage to be supplied to the injector driver.
.
o
.
Check the injector dilver relay. (Refer to P.13A-102'.)
Measure at the injector driver relay connector 4.44X.
Disconnect the connector, and measure at the hamess side.
(1) Voltage between 3 and earth
OK: System voltage
(2) Voltage between 4 and earth (lgnition sntitc'r ON)
OK: System voltage
.
Malfunction of the injector driver relay
lmproper @nnector contact, open circuit or
shon-cirqJited hamess wire
Malfunction ol the engine-EcU
Replace
Ched( the tollowing conncctor: A-36
NG
Repair
Chrc* thr following @nnestorr: C-72, C-71
Bcpair
Ch€ck the hamess wire b€tw€en the iniector <ldver relay ard
the ignit*rn suitcfi, rcpair it necessary.
Chock the iollowing connector: A44X
Measure at the sngine-Eou connec'tor G18.
o
.
Disc,onnect the connector, and measure at the hamess side.
Voltage between 55 and earth
(lgnition switcfr: ON)
OK:
NG
System roltage
Rcpair
Chcck th€ tollowino connector: C-18
NG
Repslr
Ghek ths iollwing conncsto?: A.44X
NG
Measure at the injector dri\rer cünector A-55.
. Connecttheconnector.
o Vohage between 12,21 and earth (lgnition witdr: ON)
Check the injector ddver system.
(Refer to P.13A-53, INSPECTION PROCEDURE FOR
D|AGNOSTS CODE P120O.)
Rcgair
Check the hamess wi]e betwsen the injector driver relay and
the injector ddver, repair if necessary.
NOTE
*:
Refer to the '00 PA.JERO PININ Workshop Manual (Pub. No. CKRE99E1)
GDI
-
134-89
Troubleshooting
INSPECTION PROCEDURE 26
lgnition switch-ST system <M/T>
Probable cause
The ignition switch-ST outputs a HIGH signat to the engine-Ecu white the
engine is cranking.
The engine-EOu uses this signal to carry out functions such as tuel injection
control during starting.
.
.
.
Malfunction of the ignition switch
Open circuit or short-circuited harness wire of the
ignition switch circuit
Malfunction of the engine-EOu
Measure at the engine-ECu connector
c-18.
o
Disconnect the connector, and
measure at the hamess side.
(1) Voltage between 68 and earth
(lgnition switch: START)
OK: SVormore
(2) Continuity between 67 and earth
OK: Continuity
Check the ham€ss wire bEfuren tha
engine-EGU and the ignitbn switch.
Check the harness wire between the
engine-Eou @nnector
(terminal
No.91) and the earth, repair it neces-
sary.
Ched( the ignition swibh. (Refer
GROUP 54.)
INSPECTION PROCEDURE 27
lgnition switch-ST and inhibitor switch system <Aff>
Probable cause
The ignition switch-ST outputs a HIGH signal to the engine-ECU while the
engine is cranking, and the engine-EcU uses this signal to carry out functions
such as fuel injection control during starting.
The inhibitor svitch inputs the position of the selector lever to the engine-Eou.
The engine-EOu uses this signal to carry out idle speed control.
.
o
o
.
Malfunc'tion of the ignition switch
Maltunction of the inhibitor srvitcfr
Open circuit or shod-circnrited hamess wire
between ignition switcfr and inhibitor switch
Malfunction of the engine-EOU
b
134-90
GDI
-
Troubleshooting
Check the inhibitor switch (Refer to
GROUP 23 - On-vehicle Service).
Measure at the inhibitor switch @nnec-
tor B-04.
o
Disconnect the connector, and
Check the following connectors:
c-18, c-24 <LHD>, C-26 <RHD>,
D-O2
measure at the hamess side.
4
(1) Voltage between
(lgnition switch: ON)
OK:
and
connector.
S),stem voltage
(2) Continuity between 1 and earür
OK:
Check the hamess wire bgtur€sn the
engine-Eou and the inhibitor switcfi
eatth
Continuity
4
(3) Voltage between
and earth
(lgnition switc*r: START)
Disconnect the engine-EcU con-
Chech thc lollowing conncclon8:
A€:r,
B-O1
nec{or.
OK:
Choc* the hamess wire betreon the
inhibitor swibh connecior and the starter S teminal, and repair if necessary
System voltage
Check thc following @nnector:
B-04
Chrck ü|c following connoctoE:
c-39, D-02
Check the hamess wire between the
inhibitor switch and the ignition switcfr
@nnecilor.
NG
Check the ignition switcür (Reter to
Repair
GROUP 54.)
INSPECTION PROCEDURE 28
Accelerator pedal position switch system
Probable cause
The accelerator pedal position switcfi detecG that the accelerator
.
.
o
@d
is fully dosed,
and sends a signal to the engine-EOU. The engine-ECU controls idle speed, basod
on this signal.
o
Maladjustment of the accslerator
€ble
Maladjusfnentof the relerator pedal pqtition swibfi
OpEn cirqJit or short€ircuited hgmess wire in the
accelerator pedal position switch system, or pq)r
conn€clor contact
Matfunctirn of the engine-EoU
Checkthe accelerator pedal position swibh. (RElerb P.134-105'.)
R€place the accelerator pedal position sensor assembly.
Measure at accelerator pedal position sensor connector C-46.
Disconnect the connecto( and measure at the hamess side.
Voltage between terminal 4 and earth
(lgnition swhch: ON)
Chcc|( the bllowing connctoru: A-36, C-19
o
o
o
OK:4Vormorc
Continurty between terminal
OK: Continuity
5 and eatth
Ched( the hamess wire betfleen the €ngine-Ecu and accalerdor
pedal position ssnsor.
Check the lollowing connector: C46
NOTE
Refer to the '00 PAJERO PININ Workshop Manual (Pub. No. CKRE99E1)
*:
o
GDI
-
134-91
Troubleshooting
INSPECTION PROCEDURE 29
Fuel pump (low pressure) system
Probable cause
The engine-ECU turns on the fuel pump relay while the engine is cranking or running,
and supplies power source to the fuel pump (low pressure).
o
o
o
e
Malfunction of the fuel pump relay
Malfunction of the fuel pump (low pressure)
Open circuit or short{ircuited hamess wire in the
fuel pump (low pressure) circuit, or poor connecitor
contact
Malfunction ot the engine-EOu
MUT-II Astuator test
07 Fuel pump (Refer to
P.13A-100.)
Check the fuel pump relay. (Refer to
Replace
P.134-102-.)
Measure at fuel pump relay connector
A-41X.
Disconnect the connector, and
o
.
Gheck the lollowing connectora:
c-72. C-74
measure at the harness side.
Voltiage between terminals 3, 4 and
Check the hamEss wim beüre€n the
fuel pump rehy and ignition swftch.
eafth (lgnition switch: ON)
OK:
System voltage
NG
Measure at engine-ECU @nnector
c-17.
. Disconnect the connector, and
measure at the harness side.
. Voltage between terminal 21 and
Check the following conncctor:
A-41X
NG
Repair
earth (lgnition switch: ON)
OK:
Measure
Check the hamoss wlr€ botwosn lhe
fuel pump relay and eng[n€-ECU, and
repair il necessary.
System voltrage
at engine-Ecu
c-'17.
.
.
Disconnect
Gheck the following connector:
connector
the connector,
Bspelr
Ched( the ignitbn sf,,ibh. (R€f6r to
c-17
and
the hamess side.
Short circuit betweon terminal 21
and earth (lgnition switch: ON)
OK: The fuel pump operates (its
measrure at
operation sound
can
be
heard).
Measure at fuel pump (low pressure)
connector D-l7.
o
Disconnect
the connector,
(1) NG
Check the following oonnectorE:
c-24 <LHD>, C-26 <RHD>, D-12
and
measure at the harness side.
(1) Voltage between terminal 5 and
earth (lgnition switch: ON)
Check the harness wire betu,son the
fuel pump relay and fuel pump
OK:
System voltage
(2) Continuity between 4 and earth
OK: Continuity
(lonr
NG
Repair
Ched( the ham€ss wire bdtrsgsn lhe
fuel pump (lo'v pr€ssur6) and earü,
and repair if necessary.
Replace the fuel pump (low pressuß).
NOTE
*:
Refer to the '00 PAJERO PININ Wokshop
Manual (Pub. No. CKRE00E1)
134-92
GDI
-
Troubleshooting
INSPECTION PROCEDURE 30
Power steering fluid pressure switch system
Probable cause
The power steering fluid pressure switch sends a signal to the engine-EoU according
to power steering load.
.
o
Based on this signal, the engine-EcU controls the throttle control servo so that
idle speed increases when the power steering is in operation.
.
Malfunction of the power steering fluid pressure switcfi
Open circuit or short-circuited harness wire in the
power steering fluid pressure switch circuit, or poor
connector contact
Malfunction of the engine-Eou
Check the power steering fluid pressure switch. (Refer to GROUP
374 On-vehicle Service.)
-
Measure at power steering fluid p]sssur€ s,witch conn€ctor A-76.
Disconnect the connector, and measure at the ham€ss side.
Voltage between terminal 1 ard earth
(lgnition switcfi: ON)
OK: S!,stem voltage
o
.
Chcck thc bllowing connsctor: C-18
Chcek the bllowins connoctor: A-76
Check th€ harness wire Hyveon the oqine.ECU and pq,wr stoer-
ing fluid prsssur€ suritch.
INSPECTION PROCEDURE 31
Probable cause
A/C switch and A/C relay system
lf the engine-EcU receives a'A/C on' signal, it operates the thrctüe control se'vo
and A/C oompEssor magnetic dutcft so that idl€ speed inc'reases.
Service the A,/C compressor relay. (Refer to GROUP 55
hicle Service.)
-
OK:0-3V
(A/C sritch: OFD
o
Slrstem voltago
(Ä/C switctt: ON)
Connect teminal 20 to earfi.
(lgnition switch: ON, A/C switch: ON)
OK: A/C oompressor dutch tums on.
Malfunction of the A/C contrcl system
Malfunction of the A/C srnitch
Open cirqJit or shon-cirorited ham€ss wire in the
A/C switch cinUit, or poor connector contact
Malfunc{ion of the engine-EoU
On-ve-
Measure at engine-ECU connec'tots C-17, C-19.
Disconnect the connestor, and measure at the ham€ss side.
Voltage between terminals 20, 8il and earth
(lgnition switch: ON)
.
o
.
o
o
.
Ch€d( üre tollowing connoctoc:
c-17, C-19
GDI
-
134-93
Troubleshooting
INSPECTION PROCEDURE 32
Stop lamp switch system
Probable cause
The engine-EcU determines whether the brake pedal is depressed or not, by means
o
o
.
of the stop lamp switch input signal.
Measure at stop lamp switch connector C{4.
Disconnect the connector, and measure at the harness side.
Voltage between terminal 2 and earth
.
.
Malfunction of the stop lamp switch
Open circuit or shorl+ircuited hamess wire in the
stop lamp circuit, or poor @nnector contact
Malfunction of the engine-Ecu
Check the following connector: C-29
NG
Rcprlr
Check the hamess wire between the battery and stop larnp switsfr.
Measure at engine-Ecu connector C-18.
Disconnect the connector, and measure at the harness side.
Voltage belween terminal 63 and eanh
(lgnition switch: ON)
OK: 0 - 3 V (when the brake pedal is not depressed)
System voltage (when the brake pedal is depressed)
.
.
Check the foffowing conneture: C-o2' C-o4., C-2€
NG
Repair
Check the hamess wire between the engine-EOU erd dop lamp,
Gheck the following connector: C-18
INSPECTION PROCEDURE 33
Small lamp switch system
Probable cause
The engine-EcU determines whether the small lamp switch is on or off.
According to that information, the engine-EcU controls alternator output cunenl
when the vehicle is started.
a
Measure at the engine-Eou connector C-19.
Disconnect the connector, and measure at the harness
o
o
side.
Voltage between 88 and earth
(Lighting switch: ON)
OK: System voltage
Gheck the following connector: C-l9
a
lmproper @nnector contact, open cirtuit or
short-circuited harness wire in the taillamp circuit
Malfunction of the engine-Ecu
Check the taillamp circuit. (Reter
to ELECTRICAL WlRlNG.)
134-94
GDI
-
Troubleshooting
DATA LIST REFERENCE TABLE
Caution
When shifting the select lever to D range, the brakes should be applied so that the vehicle does
not move forvard.
NOTE
*1: Within four minutes after starting the engine
*2: In a new vehicle
[driven approximately 500 km or less], the injector drive time is sometimes 10 %
lonoer than the standard time.
*3: Thiaccelerator pedal position switch normally tums off when the voltage of the accelerator pedal
position sensor (1st channel) is 2(X) - 600 mV higher than the voltage at the idle position. lf the amelerator
pedal position switch turns back on after the accelerator pedal position sensor voltage has risen by
100 mV and the throttle valve has opened, the accelerator pedal position switch and the accelerator
pedal position sensor (1st channel) need to be adjusted.
Item
Check items
Normalcondition
Requirements
No.
lnspection
procedure
Reference
page
No.
11
Orygen sensor
(front)
12
Air flow sensor
Engine:
warm-up
.
.
ldling
Engine coolant
temperature:
80
-
600- 1,000 mV
2,5(D r/min
400 mV or less and
600 1,000 mV
altemates.
ldling
24-
13
lntake air temperature sensor
OFF
Transmission:
Neutral
(A/T: P range)
lgnition switch: ON
134-25
No.
134-14
No.
134-18
-
fiHz
Code
P0100
2,500 r/min
allaccessories:
o
No.
P0130
Sudden racing
95'C
Lamps, electric
cooling fan and
Code
0 mV*1
Racing
70-90H2
Frequenry
creases
in
inre.
sponse to racing.
Intake air temperature: -20'C
-20"c
Intake air tempera-
0"c
ture:0"C
Intake air tempera-
20"c
ture:20oC
Intake air tempera-
40'c
ture:40oC
Intake air tempera-
ture:80'C
800c
Code
P0110
GDI
Item
No.
Check items
-
134-95
Troubleshooting
Requirements
Normalcondition
Inspection
procedure
Reference
page
No.
14
Throttle
tion
posi-
Engine coolant
temperalure:
sensor
(2nd channel)
80 - 95.C
lgnition switch:
ON
(Engine
stopped)
Release the accelerator pedal.
4,000
Depress the accelerator pedal gradually.
Voltage decreases
in response to the
pedal depression.
Depress the accel-
100
erator pedal fully.
16
Power supply
lgnition switch: ON
-
-
4,800
No.
134-43
Procedure
134-86
P0225
1,100 mV
System voltage
voltage
18
Code
No.23
Cranking sig-
nal
Transmission:
(lgnition
switch
-
Neutral
(A/T: P range)
ST)
Engine: Stopped
OFF
Procedure
No.26
<f,r/T>
Engine: Cranking
Procedure
No.27
ON
134-89
<[r/T>
134-89
<4,/T>
<Arf>
21
Engine coolant
temperature
lgnition switch:ON
sensor
22
Crank
Engine coolant
temperature:
r3A-19
P0115
-20"c
angle
sensor
o
.
Engine coolant
temperature: OoC
0"c
Engine coolant
temperature:2O"C
20'c
Engine coolant
temperature: 40oC
40.c
Engine coolant
temperature: 80"C
80"c
Engine: Crank- Compare the engine
speed readings on
the tachometer and
Connected
the MUT-II.
Engine: ldling
Accelerator
pedal position
Engine coolant
temperature:
Drive at 40 km/h
13Ä.47
P0335
1,200
-
1,400 r/min
,100
-
1,300 r/min
Engine coolant
temperature: 20oC
1,000
-
1,200 r/min
Engine coolant
temperature: 40oC
850
- 1,050 r/min
Engine coolant
temperature: 80"C
550
-
-20"c
Engine coolant
1
temperature:0'C
Vehicle speed
sensor
Code No.
Accord
ing
Tachometer:
switch: ON
24
Code No.
-20'c
750 r/min'l
Approximately
Code
40 km/h
P0500
No.
134-53
134-96
Item
GDI
Check items
-
Troubleshooting
Requirements
Normalcondition
No.
Inspection
procedure
Reference
page
No.
25
Barometric
lgnition switch:ON
Altitude: 0 m
Code No.
101 kPa
pressure sensor
26
Accelerator
pedal position
switch
134-16
P0105
lgnition switch: ON
(Depress and release the accelera-
tor pedal
several
times)
Altitude:600 m
95 kPa
Altitude: 1,200 m
88 kPa
Altitude: 1,8ü) m
81 kPa
Release the accelerator pedal.
ON
Depress the accel-
OFF
Procedure
134-90
No.28
erator pedal slightly.
27
Power steering
pressure
switch
fluid
Engine: ldling
Steedng wheelsta-
OFF
taonary
Steering
wheel
Procedure
No.3O
134-92
Procedure
No.31
134-92
Procedure
134-89
ON
tuming
28
A/C switch
Engine: ldling $he
A/C compressor is
running when the
A/C switch is on.)
29
lnhibitor switch
lgnition switch: ON
<4,/T>
A/C switch: OFF
OFF
A/C switch: ON
ON
Selector lever: P or
P,N
No.27
N
Selector lever: D, 2,
LorR
31
Small
lamp
Engine: ldling
37
switch:
OFF
Procedure
Air flow sensor
reset signal
Volumetric efficiency
Engine: After hav-
Ughting switch: ON
ON
Engine is idling
ON
Code No.
ing warmed up
.
o
Engine coolant
temperature:
80 - 95.C
Lamps, electric
P0100
3,(XX) r/min
OFF
Engine is idling
30-
2,500 r/min
10-30%
Engine is suddenly
Volumetric
50 %
cooling fan and
o
38
Crank
sensor
angle
o
o
allaccessories:
OFF
Transmission:
Neutral
(A/T: P range)
raced
Engine: Cranking [reading is possible
134-93
No.3if
OFF
switch
u
Lighting
D,2, L, R
efficiency increases in
response to racing
Engine speeds dis.
on
MUT-II
at 2,000 r/min or lessl
played
Tachometer:Connected
and
tachometer are
identical.
the
134-14
GDI
Item
Check items
-
134-97
Troubleshooting
Requirements
Normalcondition
Inspection
procedure
No.
Reference
page
No.
41
Injector drive
o
time*2
.
Engine coolant
temperature:
80
-
-
0.55 ms*1
ldling
0.35
2,500 r/min
0.4
Sudden racing
Increases
ldling
g
95"C
Lamps, electric
cooling fan and
-
0.6 ms
allaccessories:
o
44
OFF
Transmission:
Neutral
(A/I: P range)
o Engine: After
warm-up
. Set a timing
lgnition
advance
light.
49
A/C relay
After
Engine:
24'BTDC*I
-
134-44
P0300
3s.BTDC
-
2,500 r/min
15
A/C switch: OFF
OFF (compressor
Procedure
No.31
13A-92
Code
No.
134-28
Code No.
Pl515
134-62
sure increases.
OFF
Procedure
134-93
clutch is not oper-
warm-up, idling
Code No.
ating)
59
Orygen sensor
o
(rear)
Transmission:
A/C switch: ON
ON (compressor
clutch is operating)
3,500 r/min
600
2nd gear
.
(A/T:
L
-
1,000 mV
P0136
range)
Drive
throttle
with
widely
open
66
Brake vacuum
.
sensor
.
.
Engine coolant
temperature:
80
-
95.C
Stop the
engine
from idling speed,
and then depress
Lamps, electric
cooling fan and
the brake pedal
allaccessories:
the ignition
OFF
Transmission:
on.
Displayed
pres-
several times with
switch
Neutral
(A/T: P range)
67
Stop
lamp
lgnition switch: ON
switch
Brake pedal: De-
No.32
pressed
Brake pedal: Re-
ON
leased
68
EGR valve
o
o
o
Engine coolant
temperature:
80
ldling
2
- 17 STEP
- gs"c
Lamps, electric
cooling fan and
all accessories:
OFF
Transmission:
Neutral
(A/T: P range)
2,500 r/min
O-9STEP
Code No.
PO40it
134-50
134-98
Item
GDI
Check items
-
Troubleshooting
Normal condition
Requirements
No.
Inspection
procedure
Reference
pa9e
No.
74
Fuel pressure
sensor
o
o
o
Engine coolant
temperature:
80
Engine: ldling
4
-
Code
6.9 MPa
No.
134-33
No.
134-58
No.
134-40
No.
134-22
No.
134-31
No.
134-31
P0190
- 95'C
Lamps, electric
cooling fan and
all accessodes:
OFF
Transmission:
Neutral
(A/T: P range)
77
Accelerator
pedal position
sensor
lgnition switch: ON
Release the accelerator pedal.
Depress the accelerator pedal gradually.
79
Accelerator
pedal position
sensor
(1st channel)'3
Throttle position sensor (1st
channel)
P1225
lncreases
in
rB-
sponse to the peddepression
stroke.
al
4,100 mV or more
Release the acceF
erator pedal.
985
Depress the accelerator pedal gradu-
Increases in response to pedal
ally.
depression stroke.
Depress the accelerator pedalfully.
4,100 mV or more
Engine coolant
temperature:
Release the accelerator pedal.
450
ON
Depress the acceF
erator pedal gradu-
Increases in rcsponse to pedal
ally.
depression stroke.
Depress the accelerator pedal fully.
3,900
No load
450
A/C switch:
OFF + ON
Increases by
100 - 600 mV.
Selector lever:
N -+ D range
0
lgnition switch: ON
80 - 95'C
lgnition switch:
(Engine
Engine:
After
warm-up, idling
82
Code
1,4(X) mV
Depress the accelerator pedal fully.
stopped)
81
-
(2nd
channel)*3
78
700
Engine: Warm, 2,500 r/min without any
Long-term fuel
compensation
load (during closed loop)
Short-term fuel
compensation
load (during closed loop)
Engine: Warm, 2,500 r/min without any
- 1,135 mV
-
-
800 mV
Code
P0220
Code
P0120
-
4,900 mv
1,ü)0 mV
Increases by
- 200 mV.
-10-10%
Code
-25 -25o/o
Code
P0170
P0170
GDI
Item
Check items
-
134-99
Troubleshooting
Normalcondition
Requirements
No.
Inspection
procedure
Reference
page
No.
85
Fuel pressure
sensor
o
.
o
Engine coolant
temperature:
80
-
-
Engine: ldling
4,000
Engine: ldling
15
2,500 r/min
15-35%
2,500 r/min
Closed loop
6,900 kPa
Code
No.P0190
134-33
Code
No.
134-24
No.
134-25
No.
r3A-28
No.
lgA-22
95"C
Lamps, electric
cooling fan and
all accessories:
OFF
Transmission:
Neutral
(A/T: P range)
87
88
Calculation
load value
Fuel control
condition
Engine:Warm
Engine:Warm
When engine
is
suddenly raced
99
Fuel
injection
mode
Engine: After warm
ldling (after
up
minutes
or
-
35
o/o
Open loop
condition
four
-
P0125
drive
Lean compression
more
have passed since
engine start)
A1
Orygen sensor
Engine:
(front)
After warm-up
2,500 r/min
Stoichiometric
metric feedback
Sudden racing after
idle position
Open loop
ldling
OV
Code
-
P0130
v
Sudden racing
0.6
2,500 r/min
0.4 V or less and
0.6 - 1.0 V alter-
1.0
nates
M
Orygen sensor
o
(rear)
r
8A
Throttle position sensor (1st
channel)
(Throttle valve
opening angle)
Transmission:
2nd gear
<M/f>, L range
<A/T>
Drive with
throttle widely
open
3,500 r/min
0.6
I-
-
1.0
v
Code
P0136
Code
Engine coolant
temperature:
erator pedal.
ON
Depress the accelerator pedal gradu-
sponse
ally.
depression stroke.
Depress the accel-
80-100%
80 - 95"C
lgnition switch:
(Engine:
stopped)
Release the accel-
16o/o
P0120
lncrease
in
re-
to pedal
erator pedal fully.
Engine:
Afier
No load
8-18"/"
A/C switch:
OFF + ON
Rises by
warm-up, idling
2-
10oh
134-100
GDI
-
Troubleshooting
ACTUATOR TEST REFERENCE TABLE
Item
No.
Inspection
Drive contents
Inspection contents
Normalcondition
item
Inspection
procedure
Reference
page
No.
01
Injectors
Cut fuel to No.
1
injector
02
Cut fuel to No. 2
injector
03
Cut fuel to No. 3
injector
Cut fuel to No. 4
04
Engine:
After having
warmed up/Engine
is idling
(Cut the fuel supply
to each injector in
tum and check
cylinders which
don't affect idling.)
ldling condition
becomes different
(becomes unsta-
Code No.
ble).
Code No.
08
17
Fuelpump
Fuelpump
(low pressure)
operates and
fuel is recirculated.
Purge
control
solenoid valve
Solenoid valve
turns from OFF to
Basic ignition
timing
Set the engineECU to ignition
134-36
P0202
Code No.
P0203
134-37
Code No.
134-38
P0204
injector
07
134-34
P0201
lgnition switch: ON
Sound of operation is heard.
Procedure
lgnition switch:ON
Sound of operation can be heard
when solenoid
valve is
driven.
Code No.
P0443
134-52
ldling after engine
warm up
5"BTDC
lgnition switch: ON
The fan motor
operates
Procedure
134-84
Throttle valve is
opened slightly.
Code No.
oN.
134-91
No.29
timing adjustment
mode
21
u
Fan controller
Electroniccontrolled
throttle valve
system
Drive the fan motor
Stop the throttle
control servo.
lgnition switch:ON
No.20
P1220
134-54
GDI
-
134-101
Troubleshooting
CHECK AT THE ENGINE-ECU TERMINALS
TERMINAL VOLTAGE CHECK CHART
Engine-ECU Connector Terminal Arrangement
?FU21 19
TerminalNo.
Check item
Check requirements (engine condition)
Normalcondition
1
No. 1 injector
I
No.2 injector
Engine:Warm up, and then depress
the accelerator pedal suddenly from
the idle speed.
Decreases slightly for short
time from I - 13 V
24
No. 3 injector
2
No. 4 injector
3
No. 1 ignition coil
Engine:3,0@ r/min
0.3
13
No.2 ignition coil
12
No. 3 ignition coil
4
No. 4 ignition coil
5
EGR valve (D)
lgnition switch: lmmediately after
tuming ON
5-8V(fluctuatesfor
6
EGR valve (C)
32
EGR valve (B)
34
EGR valve (A)
8
Alternator G terminal
14
GDI ECO indication lamp
.
r
o
o
r
+
ON
Rear defogger switch: OFF
lgnition switch:OFF
+
3.0
v
approx. thrce seconds)
Engine: Warm up, and then idling
Radiator fan: Not operating
Headlamp: OFF -+ ON
Stop lamp: OFF
-
+
Voltage increases by
0.2
-
3.5 V
ON
ON
0-3V(Systemvoltage
after five seconds)
Engine: When the accelerator pedal is
suddenly depressed while the engine
System voltage
is idling
16
Purge control solenoid
valve
o
Engine coolant tempera-
Engine: Stopped
System voltage
ture:
Engine: Start the
engine, and then
increase engine
speed up to 3,500
Voltage decreases
- 95'C
o lgnition
80
switch: ON
r/min.
134-102
GDI
Troubleshooting
TerminalNo.
Check item
Check requirements (engine condition)
Normalcondition
18
Fan controller
Radiator and condenser fans are not
operating.
0-0.3v
Radiator and condenser fans are
operating.
0.7 V or more
20
21
NCrelay
Fuelpump relay
.
.
Engine: ldling
A/C switch: OFF --r ON
(Compressor is operating)
lgnition switch:
Engine waming lamp
lgnition switch: OFF
41
Sensor power supply
lgnition switch: ON
42
Power supply to
accelerator pedal position
sensor (1st channel)
43
Crank angle sensor
44
Engine coolant temperature sensor
moreto0+ 3V
Engine: Stopped
System voltage
Engine: ldling
0-3v
ON
31
System voltage, or cüanges
frommomentarilyGVor
-r
ON
0-3V-+Systemvoltage
(after several seconds)
5.5 V
lgnition switch: ON
4.5 -
Engine: Cranking
0.4
-
4.0
Engine: ldling
1.5
-
2.5 V
3.2
-
3.5 V
4.5
lgnition switch:
Engine coolant
ON
temperature:0"C
Engine coolant
temperature:
5.5 V
v
2.3-2.9V
200c
Engine coolant
temperature:
2.1 V
1.5
-
0.4
- 1.0 v
-
40"c
Engine coolant
temperature:
800c
v
45
Engine ignition signal
Engine: 3,000 r/min
0.3
47
Power supply
lgnition switch: ON
System voltage
Camshaft position sensor
Engine: Granking
0.4
3.0
59
50
0.5 -
Engine: ldling
51
52
Barometric pressure
sensor
Alternator FR terminal
lgnition switch:
v
2.0
v
Altitude:0 m
3.7
-
4.3 V
Altitude: 1,2(X) m
3.2
-
3.8 V
ON
.
.
o
o
.
3.0
Engine: Warm up, and then idling
Radiator fan: Not operating
Headlamp: OFF + ON
Stop lamp: OFF + ON
Rear defogger: OFF + ON
Voltage decreases
GDI
-
TerminalNo.
Check item
Check requirements (engine condition)
53
Oxygen sensor (rear)
.
o
o
54
Power steering fluid
pressure switch
134-103
Troubleshooting
Transmission: 2nd gear
Normalcondition
0.6
Engine speed: 3,500 r/min or more
Driving with the throttle valve widely
open
Engine: Warm
up, and then
idling
-
1.0
v
Steering wheel
stationary
System voltage
Steering wheel
0-3v
turning
55
56
57
Injector driver relay
Throttle valve control
servo relay
Engine control relay
lgnition switch: OFF
0-0.1 v
lgnition switch: ON
lgnition switch: OFF
- 1.0 v
0-0.3v
lgnition switch: ON
0.5
lgnition switch: OFF
0-3v
lgnition switch: ON
System voltage
0.5
-
1.0
v
60
Back-up power source
lgnition switch: OFF
System voltage
61
Air flow sensor
Engine: ldling
2.2-3.2V
Engine:2,500 r/min
62
lntake air temperature
sensor
lgnition switch:
lntake air temper-
ON
ature: OoC
lntake air temper-
3.2
-
3.8 V
2.3-2.9V
ature:20'C
lntake air temper-
1.5-2.1 V
ature:40"C
Intake air temper-
ature:80"C
63
Stop lamp switch
0.4
-
1.0
v
Depress the brake pedal.
System voltage
Release the brake pedal.
0-3v
68
lgnition switch-ST
Engine: Cranking
8 V or more
71
Oxygen sensor (front)
Engine:Warm up, and then hold the
engine speed at 2,500 r/min (Use a
digital voltmeter).
0 er 0.8 V altemates.
74
Brake vacuum sensor
Engine: Stop the engine from idle
speed, tum the ignition switch ON,
and then depress the brake pedal
Voltage increases
severaltimes.
76
Air flow sensor reset
signal
Engine: ldling
0-1v
Engine:3,0(D r/min
6-9V
134-104
GDI
-
Troubleshooting
TerminalNo.
Check item
Check requirements (engine condition)
Normalcondition
78
Throttle position sensor
(2nd channel)
lgnition switch:
Release the
accelerator pedal.
4.0
ON
-
Depress the
accelerator pedal
0.1
- 1.1 V
4.8 V
fully.
79
Accelerator pedal position
switch
lgnition switch:
ON
Release the
accelerator pedal.
0-1v
Depress the
accelerator pedal
4 V or more
fully.
80
Vehicle speed sensor
o
.
83
A/C switch
Engine: ldling
88
89
Smalllamp switch
Orygen sensor heater
lgnition switch: ON
Move the vehicle forward.
0 <-r system voltage
altemates.
A/C switch: OFF
0-3v
A/C switch: ON
(Compressor is
operating)
System voltage
Lighting switch: OFF
0-3v
Lighting switch: ON flaillamp: ON)
System voltage
Engine: ldling
0-3v
Engine:3,500 r/min
System voltage
Engine: ldling
0-3 v
Engine: 3,5(X) r/min
System voltage
0.3 - 4.7 V
(front)
90
Orygen sensor heater
(rear)
92
Fuel pressure sensor
Engine: ldling
94
Accelerator pedal position
sensor (1st channel)
lgnition switch:
ON
Release the acceler-
0.935
ator pedal.
Depress the
accelerator pedal
- 1.135 \r1
4.1 V or mor€*2
fully.
96
Injector open circuit check
signal
97
A/C thermo sensor
99
lgnition switch-lG
NOTE
Engine: Increase engine speed from
idle speed to 4,000 r/min.
o
.
Temperature at sensing portion:
Approx 25'G
lgnition switch: ON
lgnition switch: ON
Check if the difference in output between *1 and *2 is 4 V or more.
Decreases slightly (approx.
0.7 V) from 4.5 V
2.O
-2.9V
System voltage
-
5.0 V.
GDI
-
Troubleshooting
134-105
CHECK CHART FOR RESISTANCE AND CONTINUITY
BETWEEN TERMINALS
1. Turn the ignition switch to OFF.
Disconnect the engine-ECU connector.
Measure the resistance and check for continuity between
the terminals of the engine-ECU harness-side connector
while referring to the check chart.
2.
3.
NOTE
(1) When measuring resistance and checking continuity,
a harness for checking contact pin pressure should
be used instead of inserting a test probe,
(2) Checking need not be carried out in the order given
in the chart.
Caution
lf the terminals that should be checked are mistaken,
or if connector terminals are not correctly shorted
to earth, damage may be caused to the vehicle wirlng,
sensors, engine-EGU and/or ohmmeter.
Be careful to prevent thist
4. lf the ohmmeter shows any deviation from the standard
value, check the corresponding sensor, actuator and
related electrical wiring, and then repair or replace.
5. Atter repair or replacement, recheck with the ohmmeter
to confirm that the repair or replacement has conected
the problem.
134-106
GDI
-
Troubleshooting
Engine-EGU Harness Side Connector Terminal Arrangement
'tFU2l20
TerminalNo.
Check item
Standard value, normal condition (check require
ments)
5-
15
-
20
a
(at
Purge control solenoid valve
30
-
34
a
(at 20"C)
Engine coolant temperature sensor
5.1
47
EGR valve (D)
6-47
EGR valve (C)
32-47
EGR valve (B)
34-47
EGR valve (A)
16-47
M-72
20'C)
- 6.5 kft (when engine coolant temperature
is
2.1
- 2.7 kQ (when engine coolant temp€rature
is
0.9
-
0"c)
20.c)
40.c)
0.26
-
1.3 kO (when engine coolant temperature is
0.361<C) (when engine coolant temperature is
80"c)
46
-
Body earth
- Body earth
62-72
Earth
Continuity (0 A)
lntake air temperature sensor
5.3
58
-
6.7 kO (when intake air temperature is 0"C)
- 3.0 kA (when intake air temperature
1.0 - 1.5 kO (when intake air temperature
2.3
0.30
79-49
Accelerator pedal position switch
-
is
20'C)
is 40"C)
0.42 l<(t (when intake air temperature is 80'C)
Continuity (when the accelerator pedal is released)
No continuity (when the accelerator pedal is slightly
depressed)
89-47
Orygen sensor heater control (front)
4.5
90-47
Orygen sensor heater (rear)
11
-
-
8.0 O (at 20"C)
18 A (at 20"C)
GDI
-
134-107
Troubleshooting
CHECK AT THE THROTTLE VALVE CONTROLLER TERMINALS
TERMINAL VOLTAGE CHECK CHART
Throttle Valve Controller Terminal Arrangement
fitl
7FU2t 27
Terminal
No.
Check items
Requirements
Normal value
1
Throttle valve control servo
(A+)
o
.
Decreases slightly from
system voltage.
I
Throttle valve control servo
(B+)
14
Throttle valve control servo
(A-)
.
I
lgnition switch: ON
Accelerator pedal: Fully opened -+
fully closed
lgnition switch: ON
Accelerator pedal: Fully closed
fully opened
15
+
Decreases sli ghtly (appox.
2 V) from system voltage.
Throttle valve control servo
(B-)
Power supply to throttle
valve control servo
lgnition switch:ON
System voltage
5
Power supply
lgnition switch:ON
System voltage
6
Sensor voltage
lgnition switch:ON
4.5
7
Throttle position sensor (1st
channel)
lgnition switch:
Release the
ON
accelerator pedal.
2
19
Depress the
accelerator pedal
-
0.45
5.5 V
-
0.8 V
V
3.9
-4.9
Release the
accelerator pedal.
0.7
-
Depress the
accelerator pedal
4.1 V or more*l
fully.
20
Accelerator pedal position
sensor (2nd channel)
lgnition switch:
ON
fully.
NOTE:
Check that the voltage difference between *1 and *2 is 4 V or more.
1.4 V*l
134-108
GDI
Fixed SAS
-
On-vehicle Service
ON-VEHICLE SERVICE
Caution
(1) Never attempt to tamper the fixed SAS. The fixed SAS
is precisely adjusted at factory.
(2) Should it be tampered, the full closed position of the
throttle valve will be changed. This causes the
engine-EGU to learn a wrong position of the throttle
valve.
FUEL PRESSURE TEST
High-pressure
MEASUREMENT OF FUEL LOW PRESSURE BETWEEN
FUEL PUirP (LOW PRESSURE) AND FUEL PUMP
(H!GH PRESSURE)
1. Release residual pressure from the fuel pipe line to prevent
fuel gush out.
fuel hose
NOTE
Refer to the '00 PA,JERO PININ Workshop Manual (Pub.
No. CKRE00E1) GROUP 13A On-vehicle Service.
Fuel pump
(high-pressure)
2.
-
Disconnect the high-pressure fuel hose at the fuel pump
(high pressure) side.
Caution
Gover the hose connection with rags to prevent eplash
of fuelthat could be caused by sorne reeidual plessuf€
in the fuel pipe line.
6y
Fuel
pump
(high
pressure)
f
3.
w:ä:r-'
V
MDeesToe
H
- MDee8742
High-pressure
M
\A /"1 / luelho*
r{9/
sFUo?Bz
\
Remove the union joint and bott from the special tool
(adapter hose) and instead attach the special tool (hose
adapter) to the adapter hose.
Install the special tool (for measuring the fuel pressure)
that was set up in step 3.
<When using the fuel pressure gauge set (special tool)>
(1) Install the specialtool (for measuring the fuel pressure)
between the high-pressure fuelhose and the fuelpump
(high pressure).
(2) Install the fuel pressure gauge set (special tool) on
the special tool (for measuring the fuel pressure)
putting the gasket between them.
(3) Connect the lead wire of the fuel pressure gauge set
(special tool) to the power supply (cigarette lighter
socket) and to the MUT-tr.
GDI
-
134-109
On-vehicle Service
<When using the fuel pressure gauge>
(1) lnstall the fuel pressure gauge on the special tool
(for measuring the fuel pressure) putting a suitable
O-ring or gasket between them.
(2) Install the special tool which was set up in step (1)
between the high-pressure fuel hose and the fuel pump
(high pressure).
Fuel pressure gauge
Gn/
V
,.. o+ingorgasket
Fuel pump
V-. MD998709
(high
ffi./'
pressure)
U MD998742
15
%,l,'*a
--ll,B,n;B:ä",'"
@/
\
sFUo?'3
5.
Connect the MUT-tr to the diagnosis connector.
Caution
Turn off the ignition ewitch beforc disconnecting or
connecting the MUT-II.
6.
7.
Turn the ignition switch to ON. (But do not stan the engine.)
Select "ltem No. 07" from the MUT-II Actuator test to ddve
the fuel pump (low pressure) at the fuel tank side. Check
that there are no fuel leaks from any parts.
Finish the actuator test or tum the ignition switch to OFF.
Start the engine and run at idle.
10. Measure fuel pressure while the engine is running at idle.
8.
9.
Standard value: approximately 324 kPa
11. Check to see that fuel pressure at idle does not drop
even after the engine has been raced several times.
12. lf fuel pressure is out of the standard value, troubleshoot
and repair according to the table below.
Symptom
Probable cause
Remedy
r
r
Clogged fuelfilter
Replace fuelfilter
Fuel leaking to retum side due to poor
Replace fuel pressure regulator
(low pressure)
Fuel pressure too low
Fuel pressure drops after racing
fuel pressure regulator (low pressure)
valve seating or settled spring
Low fuel pump (low pressure) delivery
Replace the fuel pump (lort pressure)
pressure
Fuel pressure too high
Binding valve in fuel pressure regulator (low pressure)
Replace fuel pressure regulator
(low pressure)
Clogged fuel retum hose or pipe
Clean or replace hose or pipe
134-110
GDI
-
On-vehicle Service
13. Stop the engine and check change of fuel pressure gauge
reading. Normal if the reading does not drop within 2
minutes. lf it does, observe the rate of drop and
troubleshoot and repair according to the table below.
Symptom
Probable cause
Remedy
Fuel pressure drops gradually after
engine is stopped
Leaky fuel pressure regulator (low
Replace fuel pressure regulator
(low pressure)
Fuel pressure drops sharply
immediately after engine is stopped
Check valve
pressure) valve seat
in fuel pump
(low
Replace the fuel pump (lont pressure)
pressure) is held open
14. Release residual pressure from the fuel pipe line.
NOTE
Refer to the '00 PAJERO PININ Workshop Manual (Pub.
No. CKRE00E1) GROUP 13A On-vehicle Service.
15. Remove the fuel pressure gauge and special tools from the
fuel pump (high pressure).
-
Gaution
Gover the hose connection with rags to pr€vent splash
of fuel that could be caused by some rcsidual pressune
in the fud pipe line.
16. Replace the O-ring at the end of the high-pressure fuel
hose with a new one. Furthermore, apply engine oil to
the new O-ring before replacement.
17. Fit the high-pressure fuel hose to the fuel pump (high
pressure) and tighten the mounting bott to specified torque.
18. Check for any fuel leaks by following the procedure in
step 7.
19. Disconnect the MUT-tr.
IIIEASUREMENT OF FUEL HIGH PRESSURE BETWEEN
FUEL PUMP (H|GH PRESSURE) AND TNJECTORS
NOTE
Measurement of the fuel pressure between the fuel pump
(high pressure) and the injectors should be carried out after
checking that the fuel pressure between the fuel pump (low
pressure) and the fuel pump (high pressure) is normal.
1.
2.
3.
4.
5.
Connect the MUT-II to the diagnosis connector.
Disconnect the injector intermediate harness connector.
Tum the ignition switch to ON.
Select 'ltem No. 74" lrom the MUT-U Data list.
Crank the engine continuously tor 2 seconds or more,
and visually check that there are no fuel leaks from any
parts.
Caution
lf any fuel leaks appear, stop cranking immediately
and repair the source of the leak.
6.
7.
Gheck if the fuel pressure is more than 1 MPa immediately
after 20 seconds have passed since cranking was finished.
lf the fuel pressure is lower than 1 MPa, it means that
there is likely to be a leak in the high-pressure fuel system,
so this system should be checked.
GDI
-
134-111
On-vehicle Service
8. Turn the ignition switch to OFF.
9. Connect the injector intermediate harness
connector.
10. Start the engine and run at idle.
11. Measure fuel pressure while the engine is running at idle.
Standard value: 4
-
6.9 MPa
12. Check to see that fuel pressure at idle does not drop even
after the engine has been raced several times.
13. lf fuel pressure is out of the standard value, troubleshoot
and repair according to the table below.
Symptom
Probable cause
o
o
Fuel leaking to retum side due to poor
Replace the fuel pump (high pres-
fuel pressure regulator valve seating
sure)
Fuel pressure too low
Fuel pressure drops after racing
Remedy
or settled spring in the fuel pump (high
pressure).
Low fuel pump (high
Fuel pressure too high
pressure)
delivery pressure
Replace the fuel pump
(high pressure)
Clogged fuel pressure regulator valve
in the fuel pump (high pressure)
sure)
Clogged fuel retum hose or pipe
Clean or replace hose or pipe
Replace the fuel pump (high pres-
14. Stop the engine and turn the ignition switch to OFF.
15. Disconnect the MUT-[.
134-112
GDI
-
On-vehicle Service
COMPONENT LOCATION
Name
Symbol
Name
Symbol
Fuel pressure sensor
c
Oxygen sensor (front)
B
lgnition failure sensor
A
Orygen sensor (rear)
D
rt
Equipment
side I
connestor / f
2rrffi:f_.
OXYGEN SENSOR CHECK
<Orygen sensor (front)>
1.
Disconnect the orygen sensor connector and connect the
specialtool (test harness) to the connector on the oxygen
sensor side.
Make sure that there is continuity (4.5 - 8.0 O at 20'G)
between terminal 1 (red clip of special tool) and terminal
3 (blue clip of specialtool) on the orygen sensor connector.
3.
lf there is no cpntinuity, replace the orygen sensor.
Warm up the engine until engine coolant is 80'C or higher.
Orygen sensor
(front)
l/iflr-voo--ri4.
GDI
-
134-113
On-vehicle Service
5.
Use a jumper wire to connect terminal 1 (red clip) of the
oxygen sensor connector to the battery (+) terminal and
terminal 3 (blue clip) to the battery (-) terminal.
Gaution
Be very careful when connecting the jumper wire;
incorrect connection can damage the oxygen sensor.
6. Connect a digital voltage meter between terminal2 (black
clip) and terminal 4 (white clip).
7. While repeatedly racing the engine, measure the orygen
sensor output voltage.
Standard value:
Engine
Orygen sensor
Remarks
output voltage
When racing
0.6
the engine
-
1.0 V
lf you make the airlfuel
ratio rich by racirlg the
engine repeatedly, a rrcrmal o4;gen gensor will
output a roltage of 0.6
-
1.0 v.
8.
lf the sensor is defective, replace the orygen
sensor.
NOTE
For removal and installation of the oxygen sensor, refer
to GROUP 15 Exhaust Pipe and Main Muffler.
-
<Orygen sensor (rear)>
Equipment side connestor
1. Disconnect the oxygen sensor connector and connect the
2.
3.
special tool (test harness set) to the connector on the
oxygen sensor side.
Make sure that there is continuity (11 18 O at 20'C)
between terminal 1 (red clip of special tool) and terminal
3 (blue clip of special tool) on the oxygen sensor @nnector.
lf there is no continuity, replace the o)rygen sensor.
-
NOTE
(1) lf the MUT-tr does not display the standard value
although no abnormality is found by the above
mentioned continuity test and hamess check, replace
the orygen sensor (rear).
(2) For removal and installation of the orygen sensor,
refer to GROUP 15
MD998464
lFUOgZg
- Exhaust Pipe and Main Muffler.
134-114
GDI
-
Fuel Pump (High Pressure)
FUEL PUMP (HIGH PRESSURE)
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Engine Cover Removal and Installation (Refer to
GROUP 11A - Camshaft and Camshaft Oil Seal.)
o
o
o
Prevention of Fuel Discharge <before removal only>
Fuel Leak Check <after installation only>
.
o
High-pressure Fuel Line Air Bleeding
<after installation onlp (P.134-116.)
Resonance Tank Removal and Installation
Apply engine oil to all
O-rings during installation.
5.0 Nm
+
<A>
>c<
>c<
>B<
17 Nm
Removalsteps
1. Fuel pump protector
2. Furl retum hose connection
3. Fuel pressure hose connection
4. O-dng
5. Fuel pipe
Back-up ring A
>B< 6.
O-ring
>B< 7.
ring B
>B< L9. Back-up
Fuel pump (high-pressure
>A<10. O-ring
GDI
-
Fuel Pump (High Pressure)
134-115
REMOVAL SERVICE POINT
FUEL PUMP PROTECTOR REMOVAL
Jack up the transmission, and create sutficient clearance
between the engine and the front deck. Then remove the
fuel pump protector.
<A>
INSTALLATION SERVICE POINTS
/\
\t
FUEL PUMP (H|GH-PRESSURE) |NSHLT-AT|ON
Apply clean engine oil to the O-ring and the roller of the
fuel pump (high-pressure).
>A<
\-2
1.
Y.'
2.
/\
1l
\.L
Back-up ring A
(either side)
Insert the fuel pump (high-pressure) into the cylinder head
mounting hole squarely, and finger-tighten the mounting
bolts. The mounting bolts should be tightened securely
at step >B<.
>B<
BACK-UP RING B/O.RING/BACK.UP RING A/FUEL
PIPE INSTALLATION
1. Install the back-up rings and the O-ring as shown in the
illustration.
Caution
(1) Install the back-up ring B facing lts cutaway
surface toward the opposite side of the O-ring
as shown in the illustration.
(2) Confirm the outer diameter of the back-up ring
A. Take care not to install the baclcup ring for
the fuel pressure aensor by mistake. (Outer
diameter of the back-up ring A: 14.8 mm)
2. Apply a small amount of fresh engine oil to the O-ring.
Gaution
Take care not to let any of the engine oll get inside
the fuel pump (high-pressure) or the delivery pipe
assembly.
3. Installthe fuel pipe into the fuel pump (high pressure) and
the delivery pipe ports squarely. Insert the pipe securely,
being carefu! not to twisting it, and then tighten the mounting
bolts to the specified torque.
Tightening torque: 10 13 Nm
-
134-116
GDI
-
Fuel Pump (High Pressure)
4.
5.
Tighten the fuel pump (high-pressure) mounting bolts to
5.0 Nm in the order shown.
Tighten the mounting bolts to 17 Nm in the sequence
shown as second stage. The finaltightening torques should
not vary more than 2.0 Nm.
>C<
1.
O.RING/FUEL PRESSURE HOSE INSTALLATION
Apply a small amount of fresh engine oil to the O-ring.
Caution
Take care not
2.
to let any of the engine oil get inside
the fuel pump (high pressure).
While being careful not to damage the O-ring, tum the
fuel pressure hose to the left and right and connect it
to the fuel pump (high pressure). After connecting, check
that the hose tums smoothly.
lf the hose does not tum smoothly, the cause may be
that the O-ring is getting caught. Disconnect the hose,
check the O-ring for damage and re-connect the hose
to the fuel pump (high pressure) and then re-check.
Tighten the fuel pressure hose mounting botts to the
specified toque.
Tightening torque: 5.0 Nm
AIR-BLEEDING HIGH-PRESSURE FUEL LINE
1. Run the engine at 2@0 r/min for at least 15 seconds
in order to bleed air from the high-pressure fuel line.
2.
NOTE
lf air is trapped in the high-pressure fuel line due to the
removal of fuel pipe, diagnosis code No. P.019O will be
set as abnormal fuel pressure.
Finally confirm diagnosis code by using the MUT-tr. lf
diagnosis code, which indicates defective fuel pressure
sensor system, has been set, erase the code.
o
GDI
-
134-117
Iniector
INJECTOR
REMOVAL AND INSTALLATION
Gaution
1. Disconnect the negative battery cable prior to the service work.
2. The iniector driver may be hot immediately after each operation, and high voltage and current
flows between the injector driver and the injectors while the engine is running. Handle the
injector driver carefully.
Pre-removal and Post{nstallation Operation
Engine Cover Removal and Installation (Refer to
GROUP 11A - Camshaft and Camshaft Oil Seal.)
Prevention of Fuel Discharge <before removal only>
o
o
o
o
Fuel Leak Check <after installation only>
High-pressure Fuel Line Air Bleeding
<after installation only> (P.13A-116.)
Apply engine oil to all
O-rings during installation.
10-13
14
Vi
<A> >E<
>E<
>D<
>D<
Fuel preesure senaor removal steps
't. Fuel pressure sensor connector
2. Flange
3. Fuel pressure sensor
4. O-ring
5. Back-up ring
Injector removalsteps
o
>C<
>C<
>C<
lntake manifold (Refer to GROUP 15.)
6. lnjector connector
7. Fuel pipe
8. Back-up ring A
9. O-ring
10. Back-up ring B
<B>
<B>
11. Injector washer
Inlector holder
Delivery pipe assembly
Insulator
Injector gasket
Injector assembly
17. Corrugated washer
18. Back-up ring A
12.
13.
14.
15.
16.
19. O-ring
20. Back-up ring B
21. lnjector
134-11
I
GDI
-
Injector
REMOVAL SERVICE POINT
FLANGE REMOVAL
lf the fuel pressure sensor is reused, make mating marks
on the sensor and the flange before removal.
<A>
NOTE
The sealing performance and the installation rigidity of the
fuel pressure sensor can be secured by deforming the flange
when the sensor is installed. Therefore, the flange must be
reinstalled on the same side and phase as it is removed.
In addition, if the fuel pressure sensor is replaced, it should
be always replaced together with the flange.
<B> DELIVERY PIPE ASSEMBLYNNJECTOR
ASSEIIBLY REMOVAL
Mating mar*
Remove the delivery pipe assembly with the injector assembly
still attached.
Gaution
Be careful not to drop the injector aseembly when
rcmoving the delivery pipe assembly.
Back-up ring A
(either side)
INSTAL]ÄTION SERVICE POINTS
>A< BACK.UP RING
1.
B/GRING/tsACK-UP RING A
/CORRUGATED WASHER INSTALLATION
Install the back-up rings and the O-ring as shown in the
illustration.
Gaution
Back-up
ring B
Section
(1) lnstall the back-up ring B facing its cutaway
surlace toward the opposite side of the Ouring
as shown in the illustration.
(2) Confirm the outer diameter of the back-up ring
A. Take care not to install the back-up ring for
the fuel preasure sensor by mietake. (Outer
diameter of the back-up ring A: 14.8 mm)
A'A
AYOOTGAU
2.
Apply petroleum jelly to the corrugated washer to prevent
it from falling off, and install it in the direction shown.
Caution
The corrugated washer should always be replaced
with a new part. lf the corrugated washer is rcused,
fuel or gas leak may occur.
>B<
FUEL INJECTOR ASSEM BLY/INJ ECTOR
GAS KET/I NSU LATOR/DELIVERY PI PE
ASSEM BLY/INJECTOR HOLDEMNJECTOR
1.
WASHER INSTALLATION
Apply a small amount of fresh engine oil to the O-ring.
Caution
Take carc not
to let any of the engine oil get inside
the delivery pipe assembly.
GDI
-
134-11 9
Injector
lnsert the injector assembly into the mounting hole on the
delivery pipe squarely. Then check that the fuel injector
turns smoothly.
3. lf the injector does not turn smoothly, the cause may be that
the O-ring is getting caught. Remove the fuel injector, check
the O-ring for damage and re-connect the injector to the
delivery pipe assembly and then re-check.
4. Align the injector assembly mating mark with the delivery
pipe mating mark.
5. lnstall the injector gasket and the insulator to the cylinder
2.
6.
7.
head.
Assemble the delivery pipe and injector assembly to the
cylinder head, then finger-tighten the mounting bolts.
Assemble the injector holder and the injector washer, then
tighten the mounting bolts to the specified torque.
Tightening torque: 20
- 25 Nm
Tighten the delivery pipe and injector assembly mounting
bolts to the specified torque in the order shown.
Tightening torque: 10
-
13 Nm
A-YOOTgAU
Back-up ring A
(either side)
>C<
1.
BACK.UP RING B/O-RING/BACK.UP RING A/FUEL
PIPE INSTALLATION
Install the back-up rings and the O-ring as shown in the
illustration.
Gaution
(1) lnstall the back-up ring B facing its cutaway
surface toward the opposite side of the O-ring
as shown in the illustration.
(2) Confirm the outer diameter of the back-up ring
A. Take care not to install the back-up ring lor
the fuel pressure sensor by mistake. (Outer
diameter of the back-up ring A: 14.8 mm)
Apply a small amount of fresh engine oil to the O-ring.
Caution
Take care not
to let any of the engine oil get inside
the fuel pump (high-pressure) or the delivery pipe
assembly.
3. Installthe fuel pipe into the fuel pump (high pressure) and
the delivery pipe ports squarely. Insert the pipe securely,
being careful not to twisting it, and then tighten the mounting
bolts to the specified torque.
Tightening torque: 10 13 Nm
>D< BACK.UP RING/O.RING INSTALLATION
Assemble the back-up ring and the O-ring as shown.
Caution
Be careful not to confuse thie back-up ring with back-up
ring A for the injector or the fuel plpe. (Back-up rlng outer
diameter: 15.1 mm)
-
O-ring
Back-up ring
(either side)
134-120
GDI
-
Iniector
>E< FUEL PRESSURE
1.
SENSOR/FLANGE
INSTALLATION
Apply a small amount of fresh engine oil to the O-ring.
Caution
Be careful not to allow the engine oil to enter the
delivery pipe.
2.
Make the part number on the fuel pressure sensor face
as shown.
lf the fuel pressure sensor is reused, align the mating
marks to install it to the delivery pipe.
Caution
lf the fuel pressul€ sensor is replaced, always rcplace
it together with the flange.
GDI
-
134-121
Throüle Body
THROTTLE BODY
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
o Engine Coolant Draining and Supplying
o Resonance Tank Removal and Installation
19 Nm
3
leNm&
.w
Removalsteps
1. Throttle position sensor connector
2. Throttle control servo connector
3. Water hose connection
4. Brake booster vacuum hose
connection
>B<
>A<
5. Throttle body stay
6. Throttle body assembly
7. Throttle body gasket
134-122
GDI
-
Throttle Body
INSTALLATION SERVICE POINTS
>A<THROTTLE BODY GASKET INSTALLATION
Install the throttle body gasket with its projection facing
as
shown in the illustration.
>B< TH ROTTLE BODY ASSEM BLY INSTALLATION
lf the throttle body assembly is replaced, initialize
the
electronic-controlled throttle valve system.
lnitialization
Tum on the ignition switch, and tum it to LOCK (OFR position
within one second. Then leave it for at least ten seconds
with the ignition switch in LOCK (OFF) position.
GDI
-
134-123
Throttle Body
DISASSEMBLY AND REASSEMBLY
I
>A<
Dieassembly steps
1. Throttle position sensor
2. Throttle body
REASSEMBLY SERVICE POINT
>A<THROTTLE POSITION SENSOR INSTALLATION
ä\
1.
2.
Y6O 864 J
Measure resistance value between terminal Nos. 1 (sensor
power supply) and 2 (throttle position sensor lst-channel
output) as well as 1 (sensor power supply) and 4 (throttle
position sensor 2nd-channel output).
Throttle posi-
Sensor power
Earth
supply
Position the throttle position sensor on the throttle body
along the dotted line as shown in the illustration.
Rotate the throttle position sensor anticlockwise as shown
in the illustration, and then tighten the screws.
tion
sensor
(2nd channel)
output
Normal condition
Open the throttle valve slowly I Resistance
from the idle position to I smoothly
full-open
Throttle position sensor
(1st channel) output
4.
?F U05 35
position.
value changes
ßsponse to
in
I throttle valve opening angle.
lf the resistance value does not change smoothly, replace
the throttle position sensor.
15-1
INTAKE AND EXHAUST
-
General/Exhaust Pipe and Main Muffter
GROUP 15
INTAKE AND EXHAUST
GENERAL
OUTLINE OF CHANGE
Due to the introduction of the orygen sensor (rear), the following service procedure has been added.
The other service procedures are the same as before.
EXHAUST PIPE AND MAIN MUFFLER
REMOVAL AND INSTALLATION
AYO21
</A>
Removal step
1. Oxygen sensor (rear)
REMOVAL SERVICE POINT
<A>OXYGEN SENSOR (REAR) REMOVAL
Orygen sensor (rear)
IAL
ENGINE ELECTRICAL
-
lgnition System
16-1
GROUP 16
ENGINE ELECTRICAL
IGNITION SYSTEM
GENERAL
OUTLINE OF CHANGES
The 4G93-GD| engine has been replaced with the 4G94-GD| engine. Due to this, the following service
adjustment procedures have been changed. Other procedures are the same as the conventional4G93-GD|
engine.
o
o
An ignition failure sensor has been added.
The spark plug type has been changed.
GENERAL INFORMATION
SPARK PLUG SPECIFICATION
Items
Specifications
NGK
IZFRSB
SERVICE INFORMATION
IGNITION FAILURE SENSOR
Items
4G94-GDl
Resistance O
0.1 or less
ON.VEHICLE SERVICE
IGNITION FAILURE SENSOR CHECK
NOTE
An analog-type circuit tester should be used.
Check that the resistance between terminals 3 and 4 is at
the standard value.
Standard value: 0.1 O or less
T
16-2
ENGINE ELECTRICAL
IGNITION FAILURE SENSOR
REMOVAL AND INSTALLATION
5.0 Nm
Removal steps
1. lgnition failure sensor @nnector
2. lgnition failure sensor
-
lgnition System
17-1
ENGINE AND
EMISSION
CONTROL
T
CONTENTS
GENERAL
Outline of Change
SERVTCE
SPEC|FICAT|ONS
vAcuuM
HosE
Diagram ... .....2
.... ....3
Vacuum Circuit Diagram
Vacuum Hose Piping
EMISSION CONTROL SYSTEM
.......2
.......2
........
.......
2
2
EVAPORATIVE EMISSION CONTROL
........3
.........3
Purge Gontrol System Check
Port
Vacuum
......4
Purge
Check
SYSTEM
Purge Control Solenoid Valve Check
........4
17-2
ENGINE AND EMISSION CONTROL
-
Emission Controt System
EMISSION CONTROL SYSTEM
GENERAL
OUTLINE OF CHANGE
The flow rate of the purge control solenoid valve has been increased and the vacuum line routing has
been changed. Due to these changes, the following service procedures have been established. Other
items are the same as before.
SERVICE SPECIFICATION
Items
Standard value
EGR control solenoid valve coil resistance (at 20 'C) O
30-34
VACUUM HOSE
VACUUM HOSE PIPING DIAGRAM
From fuel pump
(low pressure)
I
I
I
To fuel
tank
tt
Throttle control servo
S"'
Positive
Fuel pump
(high
pressure)
cranl<case
ventilation
(PCV) valve
Purge
control
solenoid valve
(ON: Open)
Orygen sensor (front)
Orygen sensor (rear)
Gatalytic converter
Y60?2AJ
ENGfNE AND EMISSION CONTROL
-
Emission Control
System
17-g
VACUUM CIRCUIT DIAGRAM
chamber
Vacuum hose colour
B: Black
-,,r\r-
i\
n
From air
-a- cleaner
V
EGR control
solenoid
valve (ON:
OPEN)
Y6O21AL
R: Red
EVAPORANVE EMISSION CONTROL
SYSTEM
PURGE CONTROL SYSTEM CHECK
1. Disconnect the vacuum hose (black) from the intake
manifold and connect it to a hand vacuum pump.
2.
3.
Plug the nipple from which the vacuum hose was removed.
When the engine is cold or hot, apply a vacuum of 53
kPa, and check the condition of the vacuum.
When engine is cold
(Engine coolant temperature: 40"C or less)
Engine condition
Normalcondition
At idle
Vacuum is maintained
3,000 r/min
When engine is hot
(Engine coolant temperature: 80oC or higher)
Engine condition
Normalcondition
o
o
At idle
Within
Vacuum is maintained
o
o
Vacuum will leak.
3,000 r/min
Within 3 minutes
4
minutes
afier the engine
has been started
after the
engine
has been started
17-4
ENGINE AND EMISSION CONTROL
-
Emission controt System
PURGE PORT VACUUM CHECK
1. Disconnect the vacuum hose (black) from the
intake
manifold purge vacuum nipple and connect a hand vacuum
pump to the nipple.
Start the engine and check that the vacuum remains fairly
constant after racing the engine.
NOTE
lf vacuum changes, it is possible that the intake manifold
purge port may be clogged and require cleaning.
PURGE CONTROL SOLENOID VALVE CHECK
NOTE
When disconnecting the vacuum hose, always make a mark
so that it can be reconnected at original position.
1. Disconnect the vacuum hose (black stripe, red stripe) from
the solenoid valve.
2. Disconnect the harness connector.
3. Connect a hand vacuum pump to nipple (A) of the solenoid
valve (refer to the illustration at left).
4. Gheck airtightness by applying a vacuum with voltage
applied directly from the battery to the purge control
solenoid valve and without applying voltage.
Battery voltage
Normalcondition
Applied
Vacuum leaks
Not applied
Vacuum maintained
Measure the resistance between the terminals of the
solenoid valve.
Standard value: 30 34 A (at 20"C)
-
AUTOMATIC
TRANSMISSION
CONTENTS
GENERAL
Outline of
Changes
.........2
... .... .z
TROUBLESHOOTING
<A/T>
....2
23-2
AUTOMATIC TRANSMISSION
-
Generat/Troubleshooting <A/T>
GENERAL
OUTLINE OF CHANGES
The following service procedures for items which are different from before have been established to correspond
to the following changes:
The A/T-ECU has been changed.
The shift pattern has been changed.
.
o
TROUBLESHOOTING <A/T>
SHIFT PATTERN
D range (Overdrive switch: ON)
Throttle opening (o/d
+2
100
2{Fs
2+3
1)i
80
l.t'
,/
3*4
{_
l'
I
I
/
20
4
.11/'----
60
40
3<
(
1,000
Output shaft speed r/min 0
Vehicle speed
krüh
2,000
3,(m
4,(x)0
0
5,0m
6,(x)0
150
100
Y0200A[
INSPECTION CHART FOR DIAGNOSIS CODE
Referenoe page
Code
Diagnosis item
13
Accelerator pedal position sensor system
(Throttle opening voltage)
Sensor malfunction/
open circuiUshort circuit
23-3
14
Accelerator pedal position sensor system
(Throttle power supply vottage)
Open
23-3
15
A/T fluid temperature sensor system
Open circuit
2U
16
A/T fluid temperature sensor system
Short circuit
23-4
22
Wide open throttle system
Open circuiUshort circuit
234
29
Inhibitor switch system
Open circuit
23-5
30
Inhibitor switch system
Short circuit
23-s
31
Input shaft speed sensor slrstem
Open circuit
23-6
32
Output shaft speed sensor system
Open circuit
23-6
38
Vehicle speed sensor system
Open circuit
23-7
41
Solenoid valve No. 1 system
Open circuit
2}l8
42
Solenoid valve No. 1 slatem
Short circuit
23-8
ci
rcuit/short
ci
rcuit
AUTOMATIC TRANSMISSION
-
23-3
Troubleshooting <A/T>
Code
Diagnosis item
43
Solenoid valve No. 2 system
Open circuit
23-8
44
Solenoid valve No. 2 system
Short circuit
23-8
47
Solenoid valve No. 3 system
Open circuit
23-8
48
Solenoid valve No. 3 system
Short circuit
2g-8
55
Abnormal communication with engine-EOU
Open circuit
23-9
Reference page
INSPECTION PROCEDURES FOR DIAGNOSIS CODES
Code No. 13, 14 Accelerator pedal position sensor (APS)
lf the APS output voltage (APS opening voltage) is 4.8 V or higher when the engine
is idling, the output voltage is judgsd to be too high and diagnosis code No. 13
is output. ll the APS output voltage (APS opening voltage) is 0.335 V or lower
when the engine is idling, the output voltage is judged to be too low and diagnosis
code No. 13 is output.
lf the APS output voltage (APS power supply voltage) is 3.0 V or tower or if it
is 5.7 V or higher when the engine is idling, the APS is judged to be faulty and
diagnosis cotle No. 14 is output.
Probable cauae
.
o
o
Malfunction of the accelerator pedal pooition sensor
Malfunction ol hamess or connec{or
Malfunc.tion of the A/T-Ecu
*: Refer to '00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1).
Accelerator pedal position sensor check
(Refer to GROUP 13A On-vehicle Service.)'
-
NG
Replaca
Cheek the following connectoB:
<L.H. drive vehicles> C-46, C-25, D-34, D-46
<R.H. drive vehicles> C.46, C-26, D-34, D.46
Hamess check
Between accelerator pedal position sensor and Mr-ECU
o
NG
ncp.ar
I Reptace the
A/r-EctJ.
-l
23-4
AUTOMATIC TRANSMISSION
-
Troubleshooting <A/T>
Code No. 15, 16 A/T fluid temperature sensor system
Probable cause
lf the A/T fluid temperature sensor output is 10oC or less (5.6 kC! or more) even
after running the engine tor 15 minutes or more, it is judged that there is an open
circuit in the A/T fluid temperature sensor and diagnosis code No. 15 is output.
lf the A/T lluid temperature sensor output is 24O'C ot more (10 kO or less), it is
ludged that there is a short circuit in the A/T tluid temperature sensor and diagnosis
code No. 16 is outDut.
o
o
.
Malfunction of the A"/T fluid temperature sensor
Malfunction of hamess or connector
Malfunction of the A/T-ECU
*: Refer to '00 PAJERO PININ Workshop Manual (Pub. No. CKREO0EI).
Gheck the following conncctorr:
B{3, D'{5
Hamess check
Between A/T fluirJ temp€ratur€ sensor and A/T-ECU
o
NG
Code No.22 Wide open throttle switch system
Probable cause
lf the wide open throttle switcfi dose not tum OFF with the acceleralor pedal is
.
.
.
not depressed, there is a short circuit in the wicle open thottle switct and diagnosis
code No. 22 is ouFut.
Matfunction of the wide open thpttle switdr
Malfunction of hamess or connector
Maltunction of the A/T-ECU
*: Refer to '00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1).
Wide open thottle switc{r cteck (Refer to P.2}51).'
Measure at wide open thrctüe switci connector C-58.
Disconnec't th6 connector and measure ۟ the hamess side.
Voltage between terminal 1 and earth
(ignition switch: ON)
OK: System volüage
o
o
NG
Ch€ek the following @nncctors: C-58, D-34, D.46
Hamess check
o
Betureen the wide open throtüe switch and the A/T-ECU
@nnectors, and repair if
NG
AUTOMATIC TRANSMISSION
-
Troubleshooting <A/T>
Code No. 29, 30Inhibitor switch system
Probable cause
lf the inhibitor switch has not sent any signal for 2 seconds while the ignition switch
is on, it is judged that there is an open circuit in the inhibitor switch and diagnosis
a
a
a
code No.29 is set.
lf the inhibitor switch has sent at least two signals simultaneously for 2 seconds
23-5
Malfunction of the inhibitor switch
Malfunc'tion of hamess or
Malfunction of the A/T-ECU
while the ignition switch is on, it is judged that there is an short circuit in the inhibitor
switch and diagnosis code No.30 is set.
*: Refer to '00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1).
ITIUT-II SERVICE DATA
o
37 Inhibitor switch
OK:
The MUT-ll should display a @nect selector lever position.
fnhibitor switch chEck (Refer to P.23-371.'
Measure at inhibitor swltch connector B-04.
. Disconnect the connector and measure at the harness side.
. Voltage between terminal I and earth
(ignition switch: ON)
OK: System rcltage
Check the following @nnestot!: D-02, C-26, C-74, C-78
Check the following @nnectors: B-04, D-46
Hamess check
Between the inhibltor switcfi and ths ignition switoh
.
Chec* the ignition switcfr. (Refer to GROUP 54 - ignition sflitcfi.)'
23-6
AUTOMATIC TRANSMISSION
-
Troubleshooting <A/T>
Code No. 31, 32 Input shaft speed sensor system, output
shaft speed sensor system
Probable cause
lf no output pulse is detec{ed from the input shaft
.
.
.
.
.
.
speed sensor for 120 seconds
or more while driving in 3rd gear at a speed of 60 krn/h or more, there is judged
to be an open circuit in the input shaft speed sensor and diagnosis code No. 31
is output. lf not output pulse is detected from the ouput shaft speed sensor lor
120 seconds or more while driving in 3rd gear at a speed of 60 km/h or more,
there is judged to be an open circuit in the output shaft speed sensor and diagnosis
code No. 32 is output.
Malfunction ol the input shaft speed sensor
Malfunction of the output shaft speed sensor
Malfunction of hamess or connector
Malfunction of the sensor rotor
Malfunction of A/T-ECU
Electrical noise
*: Refer to '00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1).
*:
Refer to the Transmission Workshop Manual
Input shaft speed sensor ched< (Refer to P.2H1).'
Output shaft speed sensor cteck (Refer to P.2H2).-
Replace the hput sfidt speed
sensorild ouFlt shdt speed sensor.
Check the following conn@tors: B-G3, D46
NG
Check the sensor rctor.
Repair
*
NG
Repalr
Hamess check
Betwe€n th€ input shaft speed sensor and the A/I-ECU
Bstw€en the output shatt speed sensor and the A/T-ECU
.
.
Eliminate
NG
Reptir
I Replace ttte
A/r€ctt
-l
a sou.oe of electrical noise.
AUTOMATIC TRANSMISSION
-
Code No. 38 Vehicle speed sensor system
Probable cause
lf no output pulse is detected from the vehicle speed sensor for
or more, there is iudged
to be an open circuit in the vehicle speed sensor and diagnosis code No. 3g is
more continuously while driving at a speed of 60 km/h
'120 seconds or
a
a
a
a
outout.
*: Refer to '00 PAJERO PININ Workshop Manual (Pub. No.
Vehicle speed sensor check
(Refer to GROUP 54
Combination meter.)*
NG
1) NG
.
OK: 4.8 - 5.2 V
Malfunction
Malfunction
Malfunction
Malfunction
of the vehicle speed sensor
of harness or connector
of the A/T-ECU
of the ignition switch
CKRE00E1).
Replace
-
Measure at the vehicle speed sensor connector B-Og.
Disconnect the connector, and measure at the hamess side.
(1) Vohage between 1 and earth (lgnition switch: ON)
OK: System voltage
(2) Voltage between 3 and earth (lgnition switch: ON)
23-7
Troubleshooting <A/T>
NG
Check thc following connecto?s:
<L.H. drive vehicles> D-02, C-38, C-Vz, C-76, C.74
<R.H. drive vehicles> D-ü2, C41, C-76, C-74
NG
NG
Ropair
(3) Continuity between 2 and earth
OK:
Continuity
Hamess check
o
Between the vehide speed sensor and ignilkrn entibtr
@nnector.
NG
Check the lollowing connectors: B-08, D-02, D.46
NG
Rcpdr
Chsck the ignition switch. (Refer to GROUP 34 - lgnitirn
witch.)'
Repair
Check the following connectorr: D{r2, D-46
NG
Rcpeir
Hamess check
Between the A/T-ECU and the vehicle speed sensor.
.
NG
Repair
Harness chgc*
Between the A/I-ECU and the
o
whids sp€€d
8€nsor.
tlG
Rcpair
Harness check
Between the vehide sp€ed sensor and the
repair if necessary.
o
ceü,
end
23-8
AUTOMATIC TRANSMISSION
-
Troubleshooting <A/T>
Code No. 41, 42 Solenoid valve No.l system
lf the resistance value for a solenoid valve No.1 is too large,
is an open circuit in the solenoid valve No.1 and the diagnosis
lf the resistance value for a solenoid valve No.1 is too small,
is a short-circuit in the solenoid valve No.1 and the diagnosis
it is judged that there
code No.41 is output.
it is ludged that there
code No.42 is output.
Probable cause
a
a
a
Malfunction
Malfunction
Malfunction
of solenoid valve No.1
of hamess or connector
ol the A/T-ECU
*: Refer to '00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1).
Solenoid valve No.1 check (Refer to P.2342.)'
Check the lollowing @nnectorr: B-03, D45
Check the ham€ss wire between A/T-ECU and solenoid vahte l,lo.1.
Gode No. 43, 44 Solenoid valve No.2 system
Probable cause
lf the resistance value for a solenoid valve No.2 is too large, it is iudged that there
is an open circuit in thE solenoid vahre No.z and th€ diagnosis code No.'lll is output.
lf the resistance value for a solenoid valve No.2 is too small, it is jt dgpd thEt there
a
Malfunction
of solenoid valve l{o.2
a Malfunction ol hamess or connec'tor
a Maltunction of the A/T-ECU
is a short+ircuit in the solenoid valve No.z and th€ dbgnosis code No.tl4 is output.
*: Refer to '00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1).
Check the following oonnectoi3: B-O3, D-45
Check the hamess wirc between Ä/T-ECU and soletrid van s No.z.
Code No. 47, 48 Solenoid valve No.3 system
lf the resistance value for a solenoid valve No.3 is too large,
is an open circuit in the solenoid valve No.3 ard the diagrosis
lf the resistance value for a solenoid vahre No.3 is too small,
is a short-circuit in ü|e solenoid valve No.3 and the diagnoeis
it is judged that there
code No.47 is output.
it is judged that there
code No.48 is ouFut.
Probable cause
a Matfunc'tion of solenoid valw ilo.3
a MalftJnction of hamess or connec{or
a Maltunction of th€ A/T-ECU
*: Refer to '00 PA"fERO PININ Workshop Manual (Pub. No. CKRE00E1).
Solenoid valve No.3 cheok (Refer
ChGck
lo P.*42.1'
the following clnnectors: B-03,
D-.+5
Check the hamess wire betrveen A/T-ECU and solenoftt vahp
llo.3
o
AUTOMATIC TRANSMISSION
-
23-9
Troubleshooting <A/T>
Code No.55 Abnormal communication with engine-ECU
Probable cause
lf normal communication is not possible for a continuous period of 1 second or
more when the ignition switch is at the ON position and the battery voltage is 10
V or more, diagnosis code No. 55 is output. Diagnosis code No. 55 is also output
if the data being received is abnormal lor a continuous period of 1 second under
the same conditions.
a
o
a
Malfunction of harness or connector
Malfunction of the engine-EoU
Malfunction of the A/T-ECU
MUT-[ Self-Diag code
.
ls the diagnosis code No.61 output?
Ch6ck the üollowing connsctols:
<L.H. vehicle$ C-19, C-25, D-34, D-45
<R.H. vehicles> C-19, C-26, D-34, D-45
Check lhe hamess wire between engine-EOU and A/T-EGU.
INSPECTION CHART FOR TROUBLE SYMPTOMS
*: Refer to '00 PAJERO PININ Workshop Manual (Pub. No. CKREOOEI).
Trouble symptom
lnspection prooedure
Reference page
No.
Communication with the MUT-tr is not possible
1
2$10
Does not move
Does not move forward and reverse
2
23-17',
Does not move forward only
3
2&,18'
Does not reverse only
4
23-1B',
Upshifting does not occur
5
23-19'
Downshifting does not occur
6
*20'
Shifting point abnormality
7
23-20',
Upshifting occurs spontaneously
I
23-21*
lncorrect drive gear position
9
2+21*
Large shocks
10
2&l2*
Slippage (vibration)
11
2+23',
Lockup malfunction
12
224
Abnormal engine braking
13
22+
Overdrive switch system
14
2&11
Stop lamp switch system
15
2+11
Malfunction when
shifting
Electronic circuit
systems
23-10
AUTOMATIC TRANSMISSION
-
Troubleshooting <A/T>
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS
INSPECTION PROCEDURE
1
Communication with the MUT-II is not possible
Probable cause
lf communication with the MUT-II is not possible, the cause is probably a malfunction
in the sef-diagnosis system or the A/T-ECU is not functioning.
.
o
.
.
.
Malfunction
Malfunction
Maltunction
Malfunction
Malfunction
of selfdiagnosis system
of A/T-ECU power circuit
of A/T-ECU earth circuit
of A/T-ECU
of hamess and connector
ls communication with other systems possible using the MUT-U?
Check and repair the selfdiagnosis
s!,stsm with the MUT-II
Measure at A/T-ECU connector D45
. Disconnect the connector and measure at the hamess sids.
o Voltage between teminals 5 and 14 and the earth
(ignition switch: ON)
OK: System voltage
. Continuity between teminal 19 and eailh
Chock the following @nncctora:
<L.H. drive vehicles> D-46, D€4, C-37, G70, C-35
<R.H. ddve vehides> D46, D-34, C-39, C-70, C-35
OK:
NG
Repair
Continuity
Check the following @nnectors:
<LH. drive vehicles> D45, C-24, C-7A, C-74, D-34, C€8, C-72
<R.H. drive vehicles> D-45, C-26, C-78, G74, D-34, C€8, C-72
NG
Rcpair
o
o
Ch€d( and repair the hamess wire bstu een the A/T-EGU
and th6 power supply.
Ched< and repair the hamess wire between the A/T-ECU
and lhe earth.
NG
Repalr
AUTOMATIC TRANSMISSION
-
23-11
Troubleshooting <A/T>
INSPECTION PROCEDURE 14
Overdrive switch system
Probable cause
lf downshifting does not occur when overdrive switch is turned off while
driving
in 4th gear, or if shifting to 4th gear is not possible, the cause is probably a problem
in the overdrive switch system.
.
.
o
.
Mallunction of overdrive switch
Malfunction of harness or connector
Mallunction of A/T-ECU
Malfunction of ignition switch
Refer to '00 PAJERO PININ Workshop Manual (Pub. No. CKRE00E1).
OK
MUT.II SERVICE DATA
.
35
-
OK:
Overdrive switch
MUT-II display and overdrive switch OD/OD-OFF position should match.
Completed
Check the overdrive switch. (Refer to P.23-51.).
Measure at overddve switch connector D-35.
Disconnest the connector and measure at the harness side
Voltage belween terminal 3 and earth
(lgnition switch: ON)
OK: System voltage
.
.
Check the following connectorE: D-35, D-34, D.{6
Check the hamess wire betwesn the ove.driv€
A/T.ECU.
Check the ignition switch. (Refer to GROUP
il - lgnition Switch.f
INSPECTION PROCEDURE 15
Stop lamp switch system
Probable cause
lf large shocK occur during squat contol, the cause is probably a problem with
the stop lamp switch.
a
a
a
Malfunction of stop lamp switdr
Malfunction of hamess or conn€ctor
Mallunction of A/T-ECU
'00 PAJERO PININ Workshop Manual (Pub. No. CKREOOEI).
ilUT-N SERVICE DATA
t
28
-
OK:
Stop lamp switch
ON when the brake pedal is depressed and OFF when
the brake pedal is released
Check the following connectors:
<L.H. drive vehicles> C-(M, C-02, C-29, C-24, D-02, D4S
<R.H. drive vehicles> C-04, C-O2, C-41, D-02, D-45
Check the hamess wire between the stop lamp switch and the
A/T.ECU.
Check the stop lamp switch
(Refer to GROUP 35 Brake Pedal)'
-
$ridt
ancl thg
23-12
AUTOMATIC TRANSMISSION
-
Troubleshooting <A/T>
SERVICE DATA REFERENCE TABLE
Item No. 37 has been changed since the A/T-ECU has been changed. The other SERVICE DATA are
the same as before.
Item
Inspection item
Inspection conditions
lnhibitor switch
lgnition switch: ON
Engine: Stopped
Normalvalue
No.
37
Selector lever position: P
P
Selector lever position: R
R
Selector lever position: N
N
Selector lever position: D
D
Selector lever position: 2
2
Selector lever position: L
L
A/T.ECU TERMINAL VOLTAGE REFERENCE CHART
Terminal
Inspection item
Inspection conditions
Standard value
When in 1st or 2nd gear
System voltage
When in 3rd or 4th gear
OV
When in 2nd or 3rd gear
System voltage
No.
1
2
Solenoid valve No.
1
Solenoid valve No. 2
When in
3
Free-wheeling engage
switch
lst
or 4th gear
OV
Transfer lever position: Other than 4WD
System voltage
Transfer lever position: 4WD
OV
5
Back-up power supply
lgnition switch: OFF
System voltage
6
Solenoid valve No.3
When lockup clutch is operating
System voltage
When lockup clutctr is not operating
0v
11
Communication with input
signals from engine-ECU
Engine: ldling
Selector lever position: D
Oherthan 0 V
13
A/T fluid temperature
sensor
ATF temperature: 120'C
Approx.0.3 V
ATF temperature: 150"C
Approx. 0.15 V
lgnition switch: OFF
OV
lgnition switch: ON
System voltago
Engine: ldling
Selector lever position: D
Oherthan 0 V
14
17
Power supply
Communication with output
signals to engine-ECU
AUTOMATIC TRANSMISSION
-
23-13
Troubleshooting <A/T>
Terminal
No.
Inspection item
Inspection conditions
Standard value
18
Stop lamp switch
Brake pedal: Depressed
System voltage
Brake pedal: Releasec
OV
Engine: ldling
OV
lgnition switch: OFF
OV
lgnition switch: ON
2.5 V
Vehicle: Stopped
Approx. 2.5 V
Vehicle: Driving
CIherthan 2.5 V
Overdrive switch: ON
System voltage
Overdrive switch: OFF
OV
Selector lever position: P
System voltrage
Selector lever position: Other than P
OV
Selector lever position: R
System voltage
Selector lever position: Other than R
OV
Accelerator pedal: Released
4.5
Accelerator pedal: Depressed
Less than 0.4 V
A/C switch: OFF
0v
A/C switch: ON
Syutem voltage
lgnition switch: ON
System voltage
lgnition switch:OFF
0v
Selector lever position: N
System voltage
Selector lever position: Other than N
OV
Selector lever position: D
Syrtem voltage
Selector lever position: Other than D
OV
lgnition switch:ON
Approx. S V
lgnition switch:OFF
0v
19
Earth
20
A/T fluid temperature
sensor earth
21
Diagnostic output terminal
23
Input shaft speed sensor
24
25
26
27
Output shaft speed sensor
Overdrive switch
Inhibitor switch P
Inhibitor switch R
30
Input shaft speed sensor
earth
31
Output shaft speed sensor
earth
33
Wide open throttle switch
34
37
38
39
Dual-pressure switch
N range lamp
lnhibitor switch N
Inhibitor switch D
41
Diagnosis control terminal
42
Accelerator pedal position
sensor (power supply
voltage)
-
5.5 V
23-14
AUTOMATIC TRANSMISSION
-
Troubleshooting <A/T>
Terminal
No.
Inspection item
Inspection conditions
Standard value
43
Accelerator pedal position
sensor (throttle opening
voltage)
Accelerator pedal: Released
Approx. 1 V
Accelerator pedal: Fully depressed
Approx.4 V
Vehicle speed sensor
Vehicle: Slowly moving fonrard
Altemates between
M
0<+Approx. 5 V
47
48
Inhibitor switch 2
Inhibitor switch L
Selector lever position: 2
System voltage
Selector lwer position: Other than 2
OV
Selector lever position: L
System voltage
Selector lever position: Other than L
OV
PROPELLER SHAFT
-
General/Service Specifications
GROUP 25
PROPELLER SHAFT
GENERAL
OUTLINE OF CHANGE
Specifications for 5 door models have been
added.
SERVICE SPECI FICATIONS
Items
Standard value
Propeller shaft runout mm
Front
0.5
Rear
o.4
Length of rear propeller shaft mm
Clearance
groove mm
of snap
ring
Limit
r
790
Front
0
Rear
0.02
-
1.5
0.06
-
0.06
25-1
26-1
FRONT AXLE
-
General/General Information
GROUP 26
FRONTA)(LE
GENERAL
OUTLINE OF CHANGE
.
.
The front differential reduction gear ratio has been changed due to the introduction of 2000-mL engine.
The service procedure has been changed since the wheel bearing has been changed from the previous
oil seal separate type to the integrated type.
Inner oil seal
/.
<abolished> ^
snap nng
Outer oil seal
grated>
<abolished>
AWüI3EAL
.
The solenoid valve for the free-wheeling mechanism has been changed.
Wate
rp
roof t)rpe con nestor
AY0O2.IAL
GENERAL INFORMATION
FRONT DIFFERENTIAL
Item
New
ord
Reduction ratio
4.636*1,4.900'2
4.875
Drive gear
51*1,49,2
39
Drive pinion
11'1, 19.2
I
Number
of teeth
NOTE
*1: M/T,
'2: Afl
FRONT AXLE
-
Hub and Knuckle Assembly
26-2
HUB AND KNUCKLE ASSEMBLY
DISASSEM BLY AND REASSEMBLY
Disassembly steps
>D< o Hub rotation starting torque check
>c< o Wheel bearing axial play check
<A>
>B<
1. Hub
2. Snap ring
<B> >A<
3. Wheelbearing
4. Knuckle
NOTE
The disassembly service points arc the same as
before.
REASSEMBLY SERVICE POINTS
Only the service procedure below has been added. The other
service procedures are the same as before.
>B< SNAP
RING INSTALLATION
The notch in the snap ring should face down.
Caution
The sealing performance between the snap ring and the
bearing seal can be ensured by making the enap rlng
face down. lf the snap ring notches face toward the
different direction, the sealing performance may be
impaired.
27-1
REAR AXLE
-
General/General Information
GROUP 27
REAR A)(LE
GENERAL
OUTLINE OF CHANGE
.
o
The rear differential reduction gear ratio has been changed due to the introduction of 2000-mL engine.
A rear stabilizer bracket has been added to the rear axle housing due to the introduction of the rear
stabilizer bar. Because of this, the service procedure has been added. <S-door models>
GENERAL INFORMATION
REAR DIFFERENTIAL
Item
New
ord
Reduction ratio
4.636'1, 4.9(X)'2
4.875
Drive gear
51*1,49*2
39
Drive pinion
11*1,10'2
I
Number
of teeth
NOTE
*1: M/T
*2: MF
CONSTRUCTION DIAGRAM
AYIXIgOAL
REAR AXLE
-
Axle Assembly<S-door models>
27-2
AXLE ASSEMBLY<s.DOOR MODELS>
REMOVAL AND INSTALLATION
Caution
1. To prevent bushings from breakage, the parts indicated by * should be temporarily tightened,
and then fully tightened with the vehicle on the ground in the unladen condition.
2. Be careful not to strike the pole piece at the tip of the wheel speed sensor against the other
parts when removing and installing the wheel speed sensor.
Pre'removal Operation
r
o
Brake Fluid Draining (Refer
On-vehicle Service.)
Difterential Gear Oil Draining
17
to GROUp g5A
V
-
se*'l*
Post-i nstallation Operation
o
o
o
Brake Fluid Filling and Air Bleeding (Refer to
- On-vehicle Service.)
Parking Brake Lever Stroke Adjustment (Refer to
GROUP 35A
GROUP 36 - On-vehicle SeMce.)
Differential Gear Oil Filling
\v
? \ä
qüW
bl---
:-----
Removalsteps
1. Rear propeller shaft connection
2. Caliper assembly
3. Brake disc
4. Parking brake shoe assembly (Refer
to GROUP 36 - Parking Brake
11. Silencersheet
12.
13.
14.
15.
Drum.)
5. Parking brake cable connection
Bump stopper
Lower spring pad
Lateral rod connection
Rear stabilizer bar connection
(Referto GROUP 34- Rear
stabilizer.)
6. Wheelspeed sensor <Vehicles with
16. Rear brake pipe and hose connection
ABS>
17. Upper arm connection
7. O-ring <Vehicles with ABS>
18. Lower ann connection
8. Spring support <Vehicles without
ABS>
9. Shock absorber connection
10. Coil spring (Refer to GROUP 34
Rear Suspension Assembly.)
12
<D>
-
19. Axle assembly
NOTE
The removalservice points are the same as before.
31-1
WHEEL AND TYRE
-
General/General Information
GROUP 31
WHEELAND TYRE
GENERAL
OUTLINE OF CHANGE
A newly designed aluminium wheel has been added. lts appearance has been improved by attaching
a balance weight on the rim inside surface.
Adhesive tylß balance weigtrt
GENERAL INFORMATION
SPECIFICATIONS
Specification
Items
Wheel
NOTE
*: Optional items
Type
Aluminium type*
Size
16x&l
Amount of wheel offset mm
46
Pitch circle diameter (P.C.D.) mm
114.3
POWER PLANT MOUNT
-
32-1
General/Engine Mounting
GROUP 32
POWER PLANT MOUNT
GENERAL
OUTLINE OF CHANGE
The following service procedures have been added due to the change of the engine mount and transmission
mount.
ENGINE MOUNTING
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Crossmember Removal and lnstallation
I
49
fr{
r
E
g
I
I
\(AlA
Nm
49
4
49Nm I
g
8Y006?Ät-
Removalsteps
1. Engine mount insulator Assembly
(1.H.)
2. Engine mount insulator Assembly
(R.H.)
3. Engine mount bracket (L.H.)
4. Engine mount bracket (R.H.)
32-2
POWER PLANT MOUNT
-
Transmission Mounting
TRANSMISSION MOUNTING
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Jack up the Engine and Transmission Assembly until
there is no weight on the Engine Mount Bncket lns{,rlator.
<it T>
AYdIGSAL
Removalsteps
1. Collar
2. Transmission mount bushing
3. Transmission mount crossmember
Assembly
4. Transmission mount insulator
Assembly
FRONT SUSPENSION
-
General/General Information
334-1
GROUP 33A
FRONT SUSPENSION
GENERAL
OUTLINE OF CHANGE
o
o
The coil spring specifications have been changed. <3-door models>
The coil spring specifications have been added. <S-door models>
GENERAL INFORMATION
COIL SPRING<3-door models>
Items
Wire diameter
x
average diameter X free length mm
New
otd
14x160x365*1
14x160x365
14
x
160 x376*2
14xld)x365
COIL SPRING<5-door models>
Items
Wire diameter
Specifiations
x average diameter X free length mm
NOTE
*1: L.H.D. Vehicles, R.H.D. Vehicles L.H.
*2: R.H.D. Vehicles R.H. side
side
14x160x376*1
14x160x386*2
tI
34-1
REAR SUSPENSION
-
General/General lnformation
GROUP 34
REAR SUSPENSION
GENERAL
OUTLINE OF CHANGE
o
.
o
The coil spring specification has been added. <S-door models>
The service procedures have been added due to the introduction of the rear stabilizer. <S-door models>
The bushing of the upper control arm has been reshaped.
GENERAL INFORMATION
COIL SPRING<S-door models>
Items
Specification
Wire diameter X average diameter
x
free length mm
11x131x305
CONSTRUCTION DIAGRAM
Stabilizer link bracket
Upper control arm
Section A-A
Stabilizer bar
REAR SUSPENSION
-
Service Specification/Special Tool/Stabilizer
Bar
34'2
SERVICE SPECIFICATION
Items
Standard value
Stabilizer link ball joint turning torque Nm
1.7 -3.1
SPECIAL TOOL
Tool
Number
Name
Use
M8990326
Preload socket
Stabilizer link balljoint tuming torque measure
ment
STABILIZER BAR
REMOVAL AND INSTALLATION
Post-installation Operations
Press the dust cover with your finger to check that
there are no cracks or damage in the dust cover.
>A<
>A<
Removal steps
1. Stabilizer link assembly
2. Stabilizer link bracket
3. Stabilizer bracket
4. Bushing
5. Stabilizer bar
34-3
REAR SUSPENSION
-
Stabilizer Bar
INSTALLATION SERVICE POINT
t
STABILIZER BAR/BUSHING/STABILIZER
BRACKET INSTALLATION
Align the identification mark of stabilizer bar with the left end
of the bushing, before tightening the mounting bolts.
>A<
Front of vehicle
,ffi- #
ldentification mark
AYO1IIsAL
INSPECTION
STABILIZER LINK BALL JOINT ruRNNG TORQUE
CHECK
1. After shaking the ball joint stud several times, install the
nut to the stud and use the special tools to measure the
turning torque of the ball joint.
2.
3.
Standard value: 1.7 - 3.1 Nm
When the measured value exoeeds the standard value,
replace the stabilizer link.
When the measured value is lowerthan the standard value,
check that the balljoint tums smoothly without excessive
play. lf so, it is possible to reuse that ball joint.
STABILIZER LINK BALL JOINT DUST COVER CHECK
1. Check the dust cover for cracks or damage by pushing
it with finger.
2. lf the dust cover is cracked or damaged, replace the
stabilizer link.
NOTE
Cracks or damage of the dust cover may cause damage
of the balljoint. When it is damaged during service work,
replace the dust cover.
STABILIZER LINK BALL JOINT DUST COVER
REPLACEMENT
Only when the dust cover is damaged accidentally during
service work, replace the dust cover as follows:
1. Remove the clip ring and the dust cover.
cl2P0ra5
2. Apply multipurpose grease to the inside of the dust cover.
3. Wrap plastic tape around the stabilizer link stud, and then
install the dust oover to the stabilizer link.
4. Secure the dust cover by the clip ring.
5. Check the dust cover for cracks or damage by pushing
it with finger.
358-1
ANTI.SKI D
BRAKING SYSTEM
(ABs)
CONTENTS
GENERAL
Outline of Changes
.
TROUBLESHOOTING
GENERAL INFORMATION
.........
2
........2
.....
oN-vEHrcLE SERVICE
....
....
14
Wheel Speed Sensor Output Voltage Check
14
2
HYDRAULIC UNIT AND AB$ECU . ........ 15
.. .. . 5
I
358-2
ABS <4WD> -
GeneraUGeneral Information
GENERAL
OUTLINE OF CHANGES
.
o
The hydraulic unit (integrated with the ABS-ECU) has been reshaped. In addition, the troubleshooting
has been changed due to the change on the ABS-ECU connector.
The Electronic Brake-force Distribution (EBD) has been adopted. The EBD makes it possible to maintain
the maximum amount of braking force for the rear wheels even when the vehicle's load is unevenly
distributed
GENERAL INFORMATION
EBD CONTROL
In ABS, electronic control method is used whereby
the rear wheel brake hydraulic pressurc dudng braking is regulated by rearwheelcontrolsolenoid valves
in accordance with the vehicle's rate of deceleration
and the front and rear wheel slippage which are
calculated from the signals received from the various
wheel sensors. EBD control is a control system
which provides a high level of control for both vehicle
braking force and vehicle stability. The system has
the following features.
Because the system provides the optimum rear
wheel braking force regardless of the vehicle
.
.
o
laden condition and the condition of the road
surface, the system reduces the required pedal
depression force, particularly when the vehicle
is heavily laden or driving on road surfaces with
high frictional coefficients.
Because the duty placed on the front brakes
has been reduced, the increases in pad temperature can be controlled during front brakes applying to improve the wear resistance characteristics of the pad.
Control valves such as the proportioning valve
are no longer required.
HYDRAULIC UNIT
New
otd
Hydraulic unit
ABS<4WD>
-
35B-3
General Information
ABS.ECU
EBD HYDRAULIC PRESSURE CONTROL
The procedures are the same as that used in PAJERO except for the items shown below.
Item
PAJERO-PININ
PAJERO
EBD control condition
When the difference between the rear
wheel speed and the vehicle speed
When the difference between the
rear wheel speed and the front
exceeds the set value.
wheel speed exceeds the set
value.
<PAJERO-PININ>
Rear wheel
speed sensor
Front wheel
speed sensor
Vehicle
EBD control
Set value of
EBD slip ratio
Set value of
ABSdiprdb
<PAJERO>
Front wheel
Rear wheel
speed sensor
speed sensor
Vehicle
/
value of
EBD slip ratio
Set value of
ABS clip ratio
358-4
ABS<4WD>
-
General Information
FAIL.SAFE FUNCTION
The procedures are the same as that used in PAJERO except for the items shown below.
Item
PAJERO.PININ
PAJERO
Warning lamp during fail-safe opera-
ABS warning lamp
Brake warning lamp
tion
Action during faiFsafe operation
Diagrnsis
oode No.
Item
11
Open circuit or short-circuit in
wheel speed sensor (FR)
't2
ABS control
Open circuit or short-circuit in
wheel speed sensor (FL)
13
Open circuit or short-circuit in
wheel speed sensor (RR)
14
Open circuit or short-circuit in
wheel speed sensor (RL)
15
EBD control
ABS waming lamp
lf faulty wheels include
lf
llluminabd
two rear wheels:
two rear wheels:
Control stopped in all
faulty wheels include
Controlstopped
wheels
Other than the
CIher than the above:
Control sfioppd in faulty
Controlcarried out
above:
wheels
Problem with any one of the
four wheel speed sensors
16
Abnormal drop
or rise in
Controlstopped
Controlstopped
llluminabd
lf faulty wheels include
lf faulty
lllumirnbd
two rear wheels:
two rear wheels:
ABS-ECU power supply voltage
21
Wheel speed sensor
(FR)
system
22
Wheel speed sensor
(FL)
system
23
Wheel speed sensor
24
Wheel speed sensor
(RR)
system
Control stopped in all
wheels include
Controlstopped
wheels
Other than the above:
Other than the above:
Controlcanied out
Control stopped in faulty
wheels
(RL)
system
32
G sensor system
Controlstopped
Controlcanied out
lllumirnFd
33
Stop lamp switch system
Controlstopped
Controlcanied out
llluminabd
41
Solenoid valve (FR) system
System intenupted
System intenupted
llluminated
42
Solenoid valve (FL) system
43
Solenoid valve (RR) s!/stem
44
Solenoid valve (RL) system
51
Valve relay ON problem
Controlstopped
Controlcanied out
llluminabd
52
Valve relay OFF problem
System intenupted
System interrupted
lllumirnted
53
Motor relay OFF problem
Controlstopped
Controlcanied out
lllumirnbd
54
Motor relay ON problem
System intenupted
Controlcanied out
llluminated
55
Motor system
Controlstopped
Controlcanied out
llluminabd
63
ABS-ECU abnormality
System intemrpted
System interrupted
llluminated
NOTE
Contro! stopped: Control is not carried out untilthe ignition switch is turned to the "LOCK' (OFD position.
However, if the problem retums to normal, control is canied out again.
System interrupted: Gontrol is not carried out until the valve relay turns off and the ignition switch is tumed
to the "LOCK' (OFF) position.
358-5
ABS <4WD> - Troubleshooting
TROUBLESHOOTING
INSPECTION CHART FOR DIAGNOSIS CODES
Diagnosis code No.
Inspection item
Reference page
11
Front right wheel speed sensor (Open circuit or short circuit)
358-6
12
Front left wheel speed sensor (Open circuit or short circuit)
358-6
13
Rear right wheel speed sensor (Open circuit or short circuit)
358-6
14
Rear left wheel speed sensor (Open circuit or short circuit)
358-6
15
Wheel speed sensor (Abnormal output signal)
16*
ABS-ECU power supply system (Abnormal voltage drop or rise)
358-7
21
Front right wheel speed sensor
3sB-6
22
Front left wheel speed sensor
358-6
23
Rear right wheel speed sensor
358-6
24
Rear lefi wheel speed sensor
358-6
92
G sensor system
358-7
33
Stop lamp switch system
41
Front right solenoid valve
42
Front left solenoid valve
The diagnosis codes are ouput
when there is no response to the
358-8
drive signals for respective solenoid
valves or the ABS-ECU power
43
Rear right solenoid valve
44
Rear left solenoid valve
51
Valve relay problem (stays on)
52
Valve relay problem (stays off) or ABS-ECU power supply system
supply system is defective.
358-8
problem
53
Motor relay problem (stays off) or ABS-ECU power supply system
problem
54
Motor relay problem (stays on)
55
Motor system (seized pump motor) or ABS-ECU power supply system
problem
63
ABS.ECU
NOTE
*: Tuming the ignition switch to ACC
will erase the diagnosis code No.16.
358-8
358-6
ABS <4WD> - Troubleshooting
INSPECTION PROCEDURE FOR DIAGNOSIS CODES
Code Nos.ll ,12,13 and 14 Wheelspeed sensor
(open circuit or short circuit)
Probable cause
Code Nos.21 ,22,23 and24 Wheel speed sensor
Code Nos. 11, 12, 13 and 14 are output if the ABS-ECU detects an open circuit
or short-circuit in the (+) wire or (-) wire in any one of the four wheel speed sensors.
.
.
o
Maltunction ot wheel speed sensor
Mallunction of wiring hamess or connector
Malfunction of hydraulic unit and ABS-ECU
Code Nos. 21, 2., 23 and 24 arc output in the folloring cases.
When there is no input from any one of the four wheel spe€d ssnsors when
travelling at several km/h or more, even thoJgh open circuit can not be veifisd.
When a chipped or blocked-up ABS totor is detected and it the anti-lock system
operates continuously because a malfunctioning sensor or a waped ABS rotor
is causing sensor output to drop.
.
.
o
.
.
o
of wheel speed sensor
Malfunction ol widng hamess or @nnector
Malfunction of ABS rotor
Too much gap betureen the sensor ard the ABS
Malfunction of hydraulic unit and ABS-ECU
Malfunction of whed beadng
o
.
Malfunc.tion
otor
Wheel speed sensor installation ched(
Measure at the ABS-ECU connector A-58.
Disconnect the connec'tor, and measure at th€ hamess side
o
o
@nnector.
Resistances between 26 and 27,4 and 5, 2 and 1,24
NG
aN
Replace
23
OK:
1.30
-
1.58 K)
Ch€cd( tha iollowing connecloe:
A-58, C-25<LH. ddve vehkJes, G24<R.H. d.ive vehide$, A-24,
A-85, D-24, D-28
Wheel speed sensor output voltage check (Refer to P.35&14.)
NG
Rcpl@
Rsplaca
Wh€el bearing ch€d(
(Referto GROUP 26 and
GROUP 27
SeMce.)
- On-whide
Check the trouble symptom.
Replace the hydraulic unit and ABS-ECU.
Ched< the trcuble symp-
lom.
Rcpair
Ched( th€ hamess wire, and repair if neoessary.
o Between eaci wheel speed s€nsor and ABS-ECU
ABS <4WD> - Troubleshooting
Gode No.16 ABS-ECU power supply system (abnormal
voltage drop or rise)
Probable cause
This code is output if the ABS-ECU power supply voltage drops below or rises
above the rated values.
Furthermore, turning the ignition switch to ACC will erase this code.
.
.
.
35B-7
Malfunction of battery
Malfunction of wiring harness or connector
Malfunction of hydraulic unit and ABS-ECU
Gaution
lf battery voltage drops or rises during inspection, this code will be output as well. lf the voltage
returns to standard value, this code is no longer output.
Before carrying out the following inspection, check the battery level, and refill it if necessary.
.
.
Measure at the ABS-ECU connector A-58.
Disconnect the connector, and measure at the hamess side
connector.
Start the engine. Voltage between 32 and body earth
OK: System voltage
vehicles>, C-02 <R.H. drive vehides>, C-78 <LH. driw t/Bhide$,
C-76 <R.H. drive vehicles>. C-74
Check the following connector: A-58
Check the trouble symptom.
Gheck the trouble symptom.
Check the following conn€ctors: A-58, C-10 <R.H. ddw
Check the hamess wire, and repair il neoessary.
Between ignition switch and ABS-ECU
o
Replace the hydraulic unit and ABS-ECU.
358-8
ABS <4WD>
-
Troubleshooting
Code No.32 G sensor system
Probable cause
This code is output in the following cases.
o G sensor output voltage is less than 0.5 V or more than 4.5 V. (An open or
short circuit is present in the G sensor circuit.)
o
.
.
o
Malfunction of G sensor
Malfunction of wiring hamess or connector
Malfunction of hydraulic unit and ABS-ECU
G sensor output voltage does not change. (G sensor output voltage is abnormal.)
Replace
Measure at the G sensor conneclor D-29.
Disconnect the connector, and measure at the hamsss side
.
.
o
NG
connec'tor.
lgnition switch: ON
Vohage belween 1 and body earth
OK: System \,oltage
Chedr the trouble symp-
Repair
tom.
Ched( the hamess wire, and repair if neoessary.
B€tween ignitirn switch and G sensor
o
Measure at the ABS-ECU connec'tor A-58.
Disconnect the connector, and measure at the hamese sicle
.
.
.
Chec* the üollowlng @nncctotB: A-58, C-25 <L.H.
vehide$, D-29
@nnector.
lgnition switch: ON
Voltage between I and 6
OK: 2.4 - 2.6 V (When labeled surface is faced to \rertical
direction)
Chcok the following connector: A-58
NG
Check the trouble symptom.
ddve
NG
Chec* the trouble symp-
Repeir
tom.
Ched< the hamess wirc, and repair if neoessary.
Betlfle€n G sensor and ABS-ECU
.
Repaat
Replac€ the hydraulic unit and ABS-ECU.
Code Nos.41, 42,
ß
and
4
Solenoid valve
Probable cause
Code No.52 Valve relay problem (stays off)
Code No.53 Motor relay problem (stays off)
Code No.55 Motor system (seized pump motor)
These codes are o{rtpul if there is an open circuit or short{ircuit In the ABS-ECU
porer supply circuit (power zupply ciGrit for solenoid valrre and motor), or lhe intemal
circuit in the hydraulic unit and ABS-ECU is delectve.
Moasure at the ABS-ECU connector A-58.
Dis@nnect the connec-tor, and measure at the hamess side
o
o
a Matfunction of widng hamess or @nnector
o
Malfunction
of hydraulic unit and ABS-ECU
Glreck the lollowing connoctorr: A-58, C-24 <R.H. drive
vehides>
@nnec'tor.
Voltage betveen 34 and body earth, and b€tween 12 and
body earth
OK: System roltage
NG
Check the trouble symptom.
Replace the hydraulic unit and ABS-ECU.
NG
Chd( the tro!üle symtr
tom.
Check lhe hamess wire, and repair if necessary.
Between fusible link No.1 and ABS-ECU
o
ABS <4WD>
-
358-9
Troubleshooting
INSPECTION CHART FOR TROUBLE SYMPTOMS
Trouble symptoms
lnspection procedure
Reference page
No.
Communication between the MUT-II and the whole system
possible.
is
not
1
Communication between the MUT-II and the ABS-ECU is not possible.
2
When the ignition key is turned to'ON" (engine stopped), the ABS waming
lamp does not illuminate.
3
Even after the engine is started, the ABS warning lamp remains
4
35&rl
5
358-12
illuminated.
Faulty ABS operation
358-10
Gaution
1. lf steering movements are made when driving at high speed, or when driving on noad rurfaces
with low frictional resistance, or when passing over bumps, the ABS may operate even though
sudden braking is not being applied. Because of this, when getting information from the customer,
check if the problem occurred while driving under such conditions as these.
2. During ABS operation, the brake pedal may vibrate or may not be able to be depressed. Such
phenomena are due to intermittent changes in hydraulic pressure inside the brake line to prevent
the wheels from locking and is not an abnormality.
35B-10
ABS <4WD> - Troubleshooting
INSPECTION PROCEDURE FOR TROUBLE SYMPTOMS
Inspection Procedure 2
Communication between MUT-II and the ABS-ECU is not
possible.
Probable cause
The cause may be an open circuit in the ABS-ECU power supply circuit or an open
circuit in the diagnosis output circuit.
.
.
o
Measure at the diagncis connec'tor G-35 and the ABS-ECU corr
neclor A-58.
Disconnect the connectors, and measure at the hamess sids
@nnectors.
Continuity between the following terminals
ABS-ECU side Diagnosis connec'tor side
o
o
21 -7
19-1
(}{(:
Continuity
Blown fuse
Malfunction of widng hamess or connector
Malfunction of hydraulic unit and ABS-ECU
Ghect tlrc iolloüing oonn.ctoE: A-58, C-28 <L.H.
ddve
vehicles>, C.40 <R.H. drive vehicles>, C-70, C-35
NG
Ched< the t.ouble symptorn.
Repair
Ched( üt€ hamess wire, and repair if necessary.
Between ABS-ECU and diagnosis @nnecilor
o
Measure at the ABS-ECU connector A-58.
Disconnect the connector, and measure at lhe ham€ss side
.
.
o
@nnector.
Chcck the iollowing @nncctorE: A-58, C40 <R.H. ddve
vehicle$, C-(}2 <R.H. ddve vehides>, C-78 <L.H. drive vehkdes>,
G76 <R.H. drive vehicles>, C-74
lgnition slritch: ON
Voltage between 32 and body earth
OK: S]rstem rcltage
NG
Repalr
Ch€d( the trouble symptom.
Ch6d( the hamess wir€, and repair if neoessary.
Between ignition swihh and ABS-ECU
o
Measure at the ABS-ECU connector A-58.
Disconnect the connec{or, and measurs at the hamess sid€
.
o
@nnec{or.
Continuity between 3il and botly earth, and between 11 and
body earth
OK: Continuity
Check the following connector: A-58
NG
Check the touble symptom.
Replace the hydraulic unit and ABS-ECU.
Repaar
Chcck thG
iollwing connector:
A-58
NG
ABS <4WD> - Troubleshooting
358-11
Inspection Procedure 4
Even after the engine is started, the ABS warning lamp
remains illuminated.
Probable cause
The cause is probably a short-circuit in the ABS waming lamp illumination circuit.
.
.
.
.
Malfunction of combination meter
Malfunction of ABS warning lamp relay
Malfunction of wiring hamess (shod circuit)
Malfunction of hydraulic unit and ABS-ECU
NOTE
This trouble symptom is limited to cases where communication with the MUT-tr is possible (ABS-ECU
power supply is normal) and the diagnosis code is a normal diagnosis code.
Does the ABS waming lamp
sW
illuminated when the combination
Replace the combination meter.
meter connector C-07 is disconnected and the ignition switch
is tumed to ON?
Replace the ABS waming lamp relay.
Does the ABS waming lamp stay illuminated when the ABS waming
lamp relay connector A-57 is disconnected and the ignition switch
Chec* the hame$s wire, and r€pair if neoa8sary.
Between combination meter and ABS uaaming lamp rclay
Measure at the ABS warning lamp relay connector A-S7.
Disconnect the connector, and measure at the hamess side
Check the following connector: A-57
is tumed to ON?
.
.
.
.
NG
connector.
lgnition switch: ON
Voltage between 5 and body earth
OK: System \oltage
Check the trouble symptom.
@rir
Check the hamess wire, and repair if neoossary.
. B€tween ignition switch and ABS uraming lemp r8lay
Measure at the ABS-ECU connector A-58.
lgnition switch: ON
Voltage between 22 and body earth
.
.
Check thG following conncctonB: A-58, A-57
NG
Check the trouble symptom.
Rcpair
Replac€ the hydraulic unit and ABS-ECU.
Chec'k the hamess wire, and
.
cpair if
n€ogssary.
Between ABS waming lamp relay and ABS-ECU
ABS <4WD> - Troubleshooting
358-12
lnspection Procedure
5
Faulty ABS operation
Probable cause
This varies depending on the driving conditions and the road surface conditions,
so problem diagnosis is difiicult. However, if a normal diagnosis code is displayed,
carry out the lollowing inspection.
.
.
.
o
o
o
.
lmproper installation of wheel speed sensor
Malfunction ol wiring harness or connector
Malfunction ol wheel soeed sensor
Malfunction of ABS rotor
Foreign material adhering to wheel speed sensor
Malfunction of wheel bearing
Matfunction of hydraulic unit and ABS-ECU
Wheel speed sensor installation cfiec*
wheel speed sensor ouFut rottage cfied< (Refer to P.358-14.)
Replace the wheel speed sensor.
Wheef bearing check (Refer to GROUP 26 and GROUP 27
On-vehide SeMce.)
-
Check the iollowing connoctors:
A-58, C-25 <L.H. drive vehicle$, C-24 <R.H. drive vehide>,
A-24, A-85, D-24, D-28
Measure at the ABS-ECU connector A-58.
. Disconnect the connector, and measure at th€ ham€s side
.
connector.
Resistances betile€n
n
and
27,4 and 5, 24 aN
8,2 aN
1
OK:
1.30 - 1.58 kO
(The sensor hamess and conneclor should b€ moved while
these inspections are canied out.)
Check the following connector: A-58
Ched< the hamess wir€.
o
Between each ufieel speed sensor and ABS-ECU
358-13
ABS <4WD> - Troubleshooting
CHECK AT ABS.ECU
TERMINAL VOLTAGE CHECK CHART
1. Measure the voltages between the respective terminal
and earth.
2. The terminal layout is shown in the illustration.
TerminalNo.
Check item
Checking requirements
3
Stop lamp switch input
lgnition switch: ON
Normalcondition
Stop lamp switch: ON
System voltage
Stop lamp switch: OFF
1 V or less
6
G sensor earth
Always
OV
I
Input from G sensor
lgnition switch: ON
Vehicle is horizontal
2.4-2.6V
Solenoid valve power
Always
System vottiage
When the MUT-II is connected
OV
When the MUT-II is not connected
Approx. 12 V
When the MUT-tr is connected
Serial communication
with MUT-tr
When the MUT-II is not connected
1 V or less
12
supply
19
Diagnosis changeover
input
21
22
MUT-II
ABS warning lamp
relay transistor output
lgnition switch: ON
When the lamp
is
2 V or less
switched off
When the lamp is illu-
System voltage
minated
32
u
ABS-ECU power
supply
Motor power supply
lgnition switch: ON
System voltage
lgnition switch: START
OV
Always
System voltagp
RESISTANCE AND CONTINUITY BETWEEN
HARNESS.SIDE CONNECTOR TERMINALS
1. Turn the ignition key to the LOCK (OFF) position.
Disconnect the ABS-ECU connector.
Check the resistance and continuity between the terminals
indicated in the table below
The terminal layout is shown in the illustration.
2.
3.
4.
358-14
ABS <4WD>
-
Troubleshooting/On-vehicle Service
ABS-ECU terminal No.
Signal
Normalcondition
1-2
Wheel speed sensor (rear left)
1.30
23-24
Wheel speed sensor (rear right)
4-5
Wheel speed sensor (front left)
26-27
Wheel speed sensor (front right)
'll -
Body earth
Earth
-
Body earth
Earth
33
-
1.58 kO
Continuity
ON.VEHICLE SERVICE
WHEEL SPEED SENSOR OUTPUT VOLTAGE
CHECK
1.
Lift up the vehicle and release the parking brake.
2. Disconnect the ABS-ECU connector.
3. Rotate the wheelto be measured at approximately
112-1
rotation per second, and check the output voltage using a
circuit tester or an oscilloscope.
Wheelspeed
sensol
Front
left
Front
right
Rear left
Rear
right
TerminalNo.
4
26
2
24
5
27
1
23
Output voltage
When measuring with a circuit teter:
42 mV or more
When measuring with an oscilloscope:
120 mV p-p or more
4. The followings are suspected if the output voltage is lower
than the value described above. Check the wheel speed
sensor, and replace if necessary.
Too large clearance between the pole piece of the
wheel speed sensor and ABS rotor
Faulty wheel speed sensor
.
.
ABS <4WD>
-
Hydraulic Unit and ABS-ECU
358-15
HYDRAULIC UNIT AND ABS-ECU
REMOVAL AND INSTALLATION
Pre-removal Operation
o
o
Brake Fluid Draining
Air Cleaner Removäl (Refer
to GROUP
Post{nstallaüon Operation
Brake Fluid Supplying and Brake Line Bleeding
1S.)
o
o
o
(Refer to GROUP 35A - On-vehicle Service.)
Hydraulic Unit Inspection
Air Cleaner Installation (Refer to GROUP 15.)
<L.H. drive vehicles>
w
J
15
Nm
uuu{"
3
A14soo35
YO2EI6AL
358-16
ABS <4WD>
-
Hydraulic Unit and ABS-ECU
<R.H. drive vehicles>
15 Nm
2
6
%j
AYOItTAL
<A>
>A<
<B>
Removalsteps
1. ABS waming lamp relay
2. Hamess connector
3. Brake pipe connection
4. Hydraulic unit and ABS-ECU
unit bracket assembly
are the same as before.
INSTALLATION
>A< BRAKE
POINT
PIPE CONN
Connect the pipes to the
unit assembly as shown
in the illustration.
1. To the front brake (L.H.)
2. To the proportioning valve (Rear brake, R.H.)
3. To the proportioning valve (Rear brake, L.H.)
4. From the master cylinder {Primary)
5. From the master cylinder (Secondary)
6. To the front brake (R.H.)
42-1
BODY
CONTENTS
GENERAL
ouTLtNE OF CHANGES
......2
.
.
.........
2
GLASS
.... 2
ADHESTVE
. .... 2
SPEC|AL TOOL
.. .... 2
QUARTER WINDOW GLASS ....... 3
DOOR
..... 6
WINDOW
SERVTCE
SPEC|F|CAT|ONS ........
6
SEALANT
.......6
SPEC|AL TOOL
....... 6
TROUBLESHOOTING ........7
REAR DOOR ASSEMBLY
....7
FRONT DOOR TRIM AND WATERPROOF
FILM
.....
I
REAR DOOR TRIM AND WATERPROOF
F|LM
.....
I
.
.
FRONT DOOR GLASS
AND REGULATOR
REAR DOOR GLASS
AND REGULATOR
REAR DOOR HANDLE
....12
....
AND I.ATCH .....
13
16
WINDOW GLASS RUNCHANNEL AND
DOOR OPENING WEATHERSTRIP . ..... 18
...
..20
TROUBLESHOOTTNG .......20
suNRooF
suNRooF
.....21
I
42-2
BODY
GeneralMindow glass
GENERAL
OUTLINE OF CHANGES
Due to the introduction of S-door models, the following service procedures have been added. The
other items are the same as before.
o Quarter window glass removal and installation
. Rear door assembly removal and installation
o Front door trim removal and installation
o Rear door trim and waterproof film removal and installation
o Front door glass and regulator installation service points
o Rear door glass and regulator removal and installation
o Rear door handle and latch removal and installation
o Sunroof removal and installation
WINDOW GLASS
ADHESIVE
Items
Specified adhesive
Quarter window glass
3M ATD Part No. 8609 Super Fast Urethane Auto Glass
Sealant or equivalent
SPECIAL TOOLS
Tool
Number
Name
Use
M8990480
Quarter window
glass
glass
Removal and installation of quarter window
BODY
-
42-3
Window Glass
QUARTER WINDOW GLASS
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
o
o
Quarter
Trim,
Lower (R.H.) Removal
Installation (Refer to GRoUP 52A.)
Headlining Removal and Installation
(Refer to GROUPszA.)
and
mm
Section A
-
Section B
A
-
B
nll
B
-
ll,/ -
\\
A
lv
ll--k-
\V-'r
-/
1
w(E4itAL
Section C
-
Section D
C
w0847AL
-
w0845AL
Sectlon E
-
'x1,,,
W0846AL
E
w084.tAL.
Adhesive: 3M" ATD Part No. 8609 Super Fast Urethane Auto Glass Sealant or equivalent
@--
-2N
<A> >A<
>A<
>A<
Removal steps
1. Quarter window glass
2. Dual lock fastener
3. Clip
42-4
BODY
-
Window Glass
REMOVAL SERVICE POINT
<A>QUARTER WINDOW GLASS REMOVAL
1. Apply cloth tape to protect quarter window glass.
2.
Make mating marks on the quarter window glass and body.
Use glass adhesive knife to cut away adhesive.
Keep glass adhesive knife at right angles with body flange
(from inside the vehicle),and put the blade at body flange.
Then cut away adhesive along the body flange.
o
\ \[
\\\
MB9S)480
4.
Use special tool MB990480 to remove the quarter window
glass.
BODY
-
5.
6.
42-5
Window Glass
Use a knife to cut away the remaining adhesive so that the
thickness is within 2 mm around the entire circumference of
the body flange.
Finish the flange surfaces so that they are smooth.
Caution
(1) Use care not to remove more adhesive than
necessary, or the adhesive could weaken.
(2) Be careful also not to damage the paintwork on
the body surface with the knife. lf the paintwork
is damaged, repair the damaged area with repair
paint or anti-rust agent.
7.
8.
When reusing quarter window glass, remove the remaining
adhesive on the quarter window glass completely. Then,
decrease the windshield with isopropyl alcohol.
Decrease the body flange in the same way.
Caution
Before the next job, leave the decreared parts for 3
minutes or more to dry. Also, do not touch any cbaned
surface.
INSTALLATION SERVICE POINT
>A<
1.
CLIP/DUAL LOCK FASTENER/
QUARTER WINDOW GLASS INSTALLANON
Carry out the following procedure to re-install quarter
window glass.
(1) Fit the clip into the body.
(2) Cut away the clip fitting convex
Fitting convex
on
quarter window glass
on the quarter window
glass.
the
NOTE
2.
lf you fail to cut away the convexes, the glass may
be fitted improperly.
Use a unleaded gasoline to degrease the glass and the
vehicle body, which the dual-lock fasteners are adhered
to.
42-6
BODY
-
Window Glass/Door
Install the dual lock fasteners to the body flange in the
specified positions.
4. Install the dual lock fasteners to the windshield in the
positions corresponding to the ones on the body flange
where the dual lock fasteners have been installed.
5. Apply the primer and adhesive.
6. Install the glass in the same manner as for the windshield.
3.
Dual lock fastener
installation positions
Dual lock
tastener
Glass end line
Align the
dual
lock fastener end
and the marking.
Dual lock fastsner
<r:installation
positions
AYO249AL
DOOR
SERVICE SPECIFICATIONS
Standard value
Items
Glass pad and glass
holder installation
position
mm
Between glass holder and glass
rear end
Front
50.0
Rear
Between glass holders
419.0
Front
-
421.0
Rear
Between glass holder and glass
front end
Front
45.0
Rear
53.0
SEALANT
Items
Specified sealant
Remark
Waterproof film
3M" ATD Part
Ribbon sealer
No. 8625 or equivalent
SPECIAL TOOL
Tool
Number
Name
Use
M8990784
Omament remover
Door trim removal
BODY
-
42-7
Door
TROUBLESHOOTING
The power window and central door locking is controlled by ETACS-ECU. For troubleshooting, refer to
GROUP ilB - Troubleshooting.
REAR DOOR ASSEMBLY
REMOVAL AND INSTALLATION
Poet-installation Operation
Door Fit Adjustment
47
t,
A{
6
.d\,
t!8asAl
oqno:t7l
Door assembly removal steps
1. Harness connector
2. Door check connecting bolt
3. Door assembly
4. Door upper hinge
5. Door lower hinge
Striker lemoval steps
6. Striker
7. Striker shim
Door switch removal rteps
8. Door switch cap
9. Door switch
INSPECTION
DOOR SWITCH CONTINUITY CHECK
\rm
Switch
position
t[ffiül
Released (ON)
@
Depressed (OFF)
YO25OAL
Terminalnumber
2
Earth
o
o
42-8
BODY
-
Door
FRONT DOOR TRIM AND WATERPROOF FILM
CLIP AND CLAW POSITIONS
w0855AL
00009375
Sestion A
-
A
tlelta cover,
inner, doortrim
\ll
Door
trim
n
)H*
lLh/
il||\
ll lr
DOOr
panel
NOTE
Glips
<= Claws
f
BODY
-
42-9
Door
REAR DOOR TRIM AND WATERPROOF FILM
REMOVAL AND INSTALLATION
\\'
:\!
Sealant:
ATD Part No. 8625 or equlvalcnt
@-n'
3M*
e4.
,t/'t
Kl
4
.&
<Vehicles with
power windows>
I
AYO248AL
Removal steps
1. Power window switch panel
assembly
<A>
<B> >B<
>B<
>B<
2. Power window switch panel
3. Power window switch
4. Door inside handle cover
5. Clip
6. Escutcheon
7. Regulator handle
>A<
8. Cap
9. Door trim
10. Grip bracket
11. Door grip
12. Door lamp lense
13. Power window switci bracket
14. Waterproof film
42-10
BODY
-
Door
View D
E
e6
View A
Sestion A
-A
s
G'
a
EView B
VlewA
View C
View B
Reard"rj#.:"""trF
Seetion B
-
B
Rear r\
doortrimll*_--
Claw
tr
th\
l/
tT.-
doortrim
cap
WI'EsEAL
Sestion G
-
C
Vlew D
nl
tr
16,
Door lamp
lense
Powerwindow
switch panel
assembly
NOTE
Clips
{= Claws
D
Rear arm restraint covgr
al-+
Rsar
door
trim
f
Sctlon D -
S
craw
BODY
-
Door
42-11
REMOVAL SERVICE POINTS
<A>
DOOR INSIDE HANDLE COVER REMOVAL
1. Insert the special tool between the inside handle upper
part and the inside handle cover, and then disengage
the upper claw of the inside handle.
2. Disengage the lower claw of the inside handle in the same
manner as for the upper claw
3. Remove the door trim.
4. Remove the inside handle cover from the door trim.
<B> CLIP
REMOVAL
Use a cloth to remove the clip as shown in the illustration.
@
6
t8u0392
INSTALLATION SERVICE POINTS
>A<
lJ f\ \n
$)
Specified sealant 3M" ATD Part No. 8625 or equlvalent
Caution
Be sure to apply the sealant below the inner panel water
drain holes so as not to plug them.
>B<
1.
2.
+
Front of
vehicle
WATERPROOF FILM INSTALLANON
Apply the specified sealant to the shown positions of waterproof
film, and then attach the waterproof film.
Brssot2o
REGULATOR HANDLE/ESCUTCHEON/CLIP
INSTALLATION
Install the clip and escutcheon to the regulator handle.
Close the front door window glass fully, and then install
the regulator handle as shown in the illustration.
42-12
BODY
-
Door
FRONT DOOR GLASS AND
REGULATOR
DOOR WINDOW GLASS/GLASS HOLDER/DOOR
GLASS PAD INSTALLATION
1. lnstall the door glass pads and glass holders to the window
2.
glass in the positions shown.
Standard value (A): 50.0 mm
Standard value (B): a19.0 - 421.0 mm
Standard value (C): t15.0 mm
Install the glass to the window regulator assembly.
Gaution
Do not activate the window regulator assemble before
installing the glass as the resetting in the limit switch
is cancelled.
INSPECTION
POWER WINDOW MAIN SWITCH CONTINUITY CHECK
NOTE
Since the power window main switch uses the SWS system, check the continuity with the input signal
check method. Refer to GROUP 548 - Troubleshooting.
BODY
-
42-13
Door
REAR DOOR GLASS AND REGULATOR
REMOVAL AND INSTALLATION
Pre-removal Operation
Door Trim and Waterproof Film Removal (Refer
o
to
P.42-9.)
Post-installation Operation
o
o
Door Window Glass Adjustment
Door Trim and Waterproof Film Installation (Refer
to
P.42-9.)
0rn09377
11
>B<
>B<
>B<
Door window glass removal steps
1. Door window inner weather strip
2. Door belt line moulding assembly
3. Door window glass runchannel
4. Rear center sash
5. Rear lower sash
6. Rear door window glass
7. Glass holder
8. Door glass pad
Power window rcgulalor and motor
assembly rcmoval stepg
9. Power window regulator and motor
assemblv
Power vüindow motor assembly
Power window regulator assembly
12. Stationary window glass
13. Stationary window glass weather
>4<10.
>A<11.
striP
42-14
BODY
-
Door
INSTALLATION SERVICE POINTS
>A<
30o or less
POWER WINDOW MOTOR ASSEMBLY/POWER
WINDOW REGULATOR ASSEMBLY
INSTALLATION
Adjust the power window motor assembly and power window
regulator assembly positions as follows:
1. Connect the power window motor assembly connector
and the power window switch connector to the wiring
hamess of body side.
2. Tum on the power window switch to operate the power
window motor lor 3 seconds in the direction which the
window glass closes.
3. Disconnect the power window motor assembly connector
and the power window switch connector from the wiring
hamess of body side.
4. Assemble the power window motor assembly and the
power window regulator so that the arm and bracket are
positioned as shown in the illustration, and then install
the power window motor assembly.
Gaution
When installing the power window regulator, do not
set
it in the window glass fully-closed position. lf
installing the power window rcgulator in that condition,
the window glass safety mechanism will not functions
correctly.
>B< REAR DOOR WINDOW GLASS/GLASS
1.
Glass pad and
glass holder
2.
HOLDER/DOOR GLASS PAD INSTALLANON
lnstall the door glass pad and glass holder to the window
glass in the position shown.
Standard value (A): 58.0 mm
Install the glass to the window regulator assembly.
Gaution
Do not activate the window regulator assemble beforc
installing the glass as the resetting in the limit switch
is cancelled.
BODY
-
42-15
Door
INSPECTION
POWER WINDOW SUB SWITCH CONTINUITY CHECK
Switch
Terminal No.
position
4
1
6
o
o
UP
o
o
DOWN
wo568AS
POWER WNDOW RELAY CONTINUITY CHECK
Power window relay
Battery
voltage
Not applied
Applied
04zooor
TerminalNo.
1
3
o- --o
-o
@
4
5
o-- ---.o
42-16
BODY
-
Door
REAR DOOR HANDLE AND LATCH
REMOVAL AND INSTALLATION
Post-i nstallation Operation
Pre-removal Operation
Door Trim Removal (Refer to P.42-9.)
o
o
o
Door handle and door latch
assembly removal stepg
1. Door inside handle
o Waterproof film (Refer to P.42-9.)
2. Door outside handle
3. Door latch assembly
Door Inside Handle Play Check
Door Outside Handle Play Check
Door Trim lnstallation (Refer to P.42-9.)
>A<
Door check removal süepa
o Waterproof film (Refer to P.42-9.)
4. Door check
INSTALLATION SERVICE POINTS
>A<
DOOR CHECK INSTALLANON
Install with the following identification marks upward.
Items
ldentiftcation mark
Left door
26L
Right door
26R
BODY
-
42-17
Door
>B<
1.
DOOR INSIDE HANDLE INSTALLATION
lnstall the inside lock cable to the door inside handle as
follows:
(1) lnstall the inner cable end in the inside lock cable
to the clip in the door inside handle.
(2) Turn the inside lock knob to the door lock position.
(3) Install the outer cable end to the door inside handle
securely.
handle
<Left side>
rod
Awo736AL
2.
3.
(4) lnstall the clip to the inner cable.
Install the inside handle rod to the door inside
Install the door inside handle to the door.
INSPECTION
DOOR LOCK ACTUATOR CHECK
Rod position
2
View A
@
<Right side>
View B
@
TerminalNo.
LOCK
UNLOCK
Rod operation
3
+- ---o
o- --o
LOCK to UNLOCK
UNLOCKto LOCK
handle.
42-18
BODY
-
Door
WINDOW GLASS RUNCHANNEL AND DOOR OPENING
WHETHERSTRIP
REMOVAL AND INSTALLATION
<FRONT DOOR>
f
S*tionalview of
clip position
*#h
n
Iu
€:fff33ft|"T"*"
+
+
+
A
=#F
l/v)
E>
+
AYO2'sAL
<A>
Door inner opening rcatherstrip
removal steps
o Scufi plate (Refer to GROUP 52A.)
o Cowl side trim (Referto GROUP 524.)
o Center pillar lower trim (Refer to
GROUP 524.)
1. Door inner opening weatherstrip
Door outer opening weatherstrip
removal
2. Door outer opening weatherctrip
Door window glass runchannel
removal steps
3. Door window glass runchannel
4. Door window glass lower
runclunnel
Door beltline moulding removal
stepe
o Outside rear view mirror
5. Door beltline moulding
BODY
-
42-19
Door
<REAR DOOR>
+
Sectionalview of
clip position
ffi
€
Sectional view of
clip position
A
(v
<A>
1. Door outer opening weatherstrip
Door window glass runchannel
removalsteps
2. Door window glass runchannel
o Door lower sash (Refer to P.42-13.)
3. Door window glass lower
runchannel
Door beltline Inner weathcnrtrlp
removal steps
o Door trim (Refer to P.42-9.)
4. Door beltline inner weatherstdp
Door beltline moulding removal
5. Door beltline moulding
REMOVAL SERVICE POINT
<A>
DOOR OUTER OPENING WEATHERSTRIP
REMOVAL
Make a tool as shown and remove the door opening
weatherstrip.
42-20
BODY
-
Sunroof
SUNROOF
TROUBLESHOOTING
The timer does not operate for 30 seconds after the
ignition switch is turned to LOCK (OFR position. (When
the ignition switch is turned on, the sunroof operates.)
The sunroof-Ecu has a timer function which operales dudng 30 seoonds after the
ignition switcfi is tumed to L@K (OFD position. lf the timer does not operate,
the cause may be a malfunc'tion of the EIACS-ECU, sunrod'EOU or ol the wiring
hamess or @nnector.
Probable cause
.
o
.
Matfunction of wiring hamess or connector
Malfunction ol sunrcof-ECU
Maltunction of the ETACS-ECU
Cany out the troubleshooting rega]ding
the contral door lod<ing system.
ls a
diagnosis code sent
to
the
Carry out the foubleshooting rega]ding
ETACS-ECU?
the EIACS-ECU.
MUI-II input signal check
Chod( the irput signal carwits.
Measure at the sunroof-ECU connector
D{6 and ETACS-ECU connector C€i!.
Disconnect the @nnec{or and
measure at the hamess sid€.
Continuity between 10 (for tX)G) and
21 (for G-83)
OK: Continuity
Check the üollowlng @nnectonB:
o
o
.
.
lgnition switch (lG1)
Front doorswibh (driver's side)
c€3, c-o2, c-43,
D-06
üe hamsss wire between the
ErACS-ECU and the sunrmf-EcU, ard
Ched(
BODY
-
42-21
Sunroof
SUNROOF
REMOVAL AND INSTALLATION
Post-installation Operation
o
o
Sunroof Water Test
Sunroof Fit Adjustment
AVlIüAE
1. Roof lid glass assembly
Sunrool switch removal steps
2. Sunroof switch cover
3. Sunroof switch
Drain hose removal steps
o
o
o
r
<A> >A<
Headlining
Splash shield (Rear drain hose)
Cowl side trim and instrument iower
Panel
Engine-ECU, throttle valve control
relay and throttle valve controller
(Driver's-side drain hose)
4. Drain hose
Sunroof motor assembly rcmoval
<B> >B<
<A> >A<
stepE
o Headlining
5. Sunroof motor assembly
Sunroof aseombly rumovll stcpt
o
Headlining
4. Drain hose
6. Room lamp bracket
7. Sunroof assembly
42-22
BODY
-
Sunroof
REMOVAL SERVICE POINTS
<A>
DRAIN HOSE REMOVAL
Tie a cord to the end of the drain hose, and wind tape around
it so that there is no unevenness. Then pull the drain hose
out from the passenger compartment.
Drain hose
Cord
f
\iz
<B>SUNROOF MOTOR ASSEMBLY REIIOVAL
Caution
Always close the roof lid glass fully before removing the
sunroof motor. lf the fully-closed positions of the roof
lid glass and the sunroof motor are not the same, tüe
sunroof will not operate properly.
NOTE
ffi
lf there is a problem with the sunroof motor so that the roof
lid glass cannot close fully, use an Allen key to tum the gear
section of the sunroof motor to fully close the roof lid glass.
INSTALLATION SERVICE POINTS
>A<
1.
2.
3.
DRAIN HOSE INSTALLANON
Tie the cord that was used during removal to the end
of the drain hose, and wind tape around it so that there
is no unevenness.
Pull the cord to pull through the drain hose
Install the grommet, and then position the drain hose so
that it protrudes from the grommet as shown in the
illustration.
BODY
-
Sunroof
42-23
>B<
SUNROOF MOTOR ASSEMBLY INSTALLATION
lf the fully-closed position of the sunroof motor assembly is
incorrect, set the sunroof motor to the fully-closed position
by the following procedure, and then install the sunroof motor.
1. Remove the sunroof motor assembly with the connector
still connected.
2. Set the roof lid glass to the fully-closed position.
3. Continue to push the sunroof close switch untilthe sunroof
motor stops turning. Then install the sunroof motor
assembly.
NOTE
Sunroof-ECU will initialize when the sunroof motor stops.
42-24
BODY
-
Sunroof
DISASSEMBLY AND REASSEMBLY
letoocS
YITOCAE
ürc07623
Disassembly stepg
1. Roof lid glass assembly
2. Weatherstrip
3. Sunroof motor
4. Roof wind deflector panel
5. Roof drip channel
6. Panel stopper
7. Sunshade assembly
8. Guide rail stopper
9. Cable guide casing
10.
11.
12.
13.
14.
15.
Side deflector
Drive cable assembly
Seal
Seal
Clamp
Guide rail sub assembly
EXTERIOR
-
General/Rear bumper
51-1
GROUP 51
EXTERIOR
GENERAL
OUTLINE OF CHANGES
a
o
o
O
o
Due to the introduction of S-door models, the rear bumper service procedure has been added.
Due to the introduction of S-door models, the service pröcedures foi the roof drip moulding and the
side protector moulding have been added.
P.u" tg.the change on the front deck garnish, the service procedure has been changed.
The side protector moulding for S-door models has a "Pininiarina' mark and "Pininfariäa- Ogo mark.
Due to this, the service procedure has been established.
Due to the change on the GDI mark, the seruice procedure has been changed.
REAR BUMPER
DISASSEMBLY AND REASSEMBLY
View A
Location of rcar bumper pad)
^.'-$
Disassembly eteps
Rear combination lamp assembly and
rear combination lamp assemblv
bracket <R.H. drive vefiicles>
Rear fog assembly and rear fog
assembly bracket <L.H. drive
vehicles>
1. Rear bumper face side bracket
2. Rear bumper pad
3. Rear bumper cover
4. Rear bumper face
51-2
EXTERIOR
-
Moulding
MOULDING
REMOVAL AN D INSTALLATION
Section G - C
Windshield
2 <Vehiclee n'ith roof rail>
2 <vehlcles without roof rail>
View E
Adhesit e: double-sided tape [5 mm width and 0.8 mm thickness]
<A>
<B> >A<
Roof drip mouldlng removal steps
o Roof rail assembly
1. Roof drip cover
2. Roof drip moulding
Side protector moulding removal
3. Side protector moulding
NOTE
For the removal and installation service points of the
roof drip moulding and the side protector moulding, refer
to the Basic Manual.
EXTERIOR
-
51-3
Garnish
GARNISH
REMOVAL AND INSTALLATION
-\*
Section B
-
s\
B
Section C
1
lu
-M
-
C
1
u\
NOTE
+:
€:
eYoogaaL
'cla*
Clip positions
Claw positions
Adhesive: double-sided tape [5 mm width and 0.8 mm thicknese]
<A> >A<
Front deck garnish removal steps
e Wiper arm and blade assembly
1. Frönt deck garnish
NOTE
For the removal and installation service points of the
side protector moulding, refer to the Basic Manual.
51-4
EXTERIOR
-
Marks
MARKS
REMOVAL AND INSTALLATION
1. Pininfarina
>A< 2.
>A< Pininfarina
mark
logo mark
INSTALLATION SERVICE POINT
>A<
MARK INSTALLATION
(1) PTNTNFAR|NA MARK,(2) P|N|NFARTNA LOGO MARK
Side protect moulding
EXTERIOR
(3)
-
51-5
Marks
GDr MARK
Window moulding end line
Back door end line
12411 mm
Align the application tape end
with the back door end line.
1.
2.
Clean the mark installation surfaces on the body with
unleaded petrol.
Peel off the backing paper from the reverse side of the
marks, and then attach the marks to the vehicle body
so that they fit properly into position.
Gaution
When attaching the markr, the surrounding
temperature should be 20 - 38oC and the alr ehould
be completely free from dust
lf the surrounding temperature is lower than 20"C,
the marks and the places on the body where the mar*s
are to be attached should be heated to 20 38"C.
-
NOTES
o
o
o
o
INTERIOR
-
52A-1
General/Trims <S-door models>
GROUP 52A
INTERIOR
GENERAL
OUTLINE OF CHANGE
.
Due to the introduction of S-door models, the service procedures for the trims, the headlining, the
seat and the seat belts have been added. The other items are the same as before.
TRIMS <s.DOOR MODELS>
REMOVAL AND INSTALLATION
tl4 Nm
20
F
19
@r4 (
9
,&
t
q'
AW|FS4 L
44 Nm
1. Front scuff plate
2. Cowl side trim
3. Front door opening trim
4. Assist grip (front)
5. Front pillar trim
6. Rear scuff plate
7. Front seat belt connection
8. Center pillar lower trim
9. Rear door opening trim
10. Front seat belt connection
11. Center pillar upper trim
12. Rear step plate
r
Rear seat (Referto'00 PAJERO PININ
Workshop Manual
<pub.No.
CKRE00E1> Group 52A)
'13. Luggage floor box <Option>
14. Luggage room hook
15. Net hook <Option>
16. Cover
17. Quarter lower trim
18. Hook
19. Back door opening trim
20. Rear pillar trim
21. Rear seat belt connection
22. Quarter pillar upper trim
52A-2
-
INTERIOR
Trims <S-door models>
CLIP AND CLAW POSITIONS
=W
H
NOTE
t
€
: Clip positions
: Claw positions
For door trim, refer to GROUP 42.
Sestion A
-
A
Seetlon B
-
Seetlon C
B
/
I
ll
tt-
Front pillartrim
-^
I-T
-
äl
#., /(
hT=/'5,r#
I
t t
I.lI
Seetion E
-
JJ
A
H
trr-\-H.r,
Section F
-
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INTERIOR
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524-3
Headlining <S-door models>
HEADLINING <s-DOOR MODELS>
REMOVAL AND INSTALLATION
11
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AYOZISAL
Removal steps
1. Assist grip
2. Grip (rear)
3. Sun visor assembly
4. Sun visor holder
5. Front room lamp assembly
6. Sunroof switch
<Vehicles with sunroof>
7. Rear room lamp assembly
o Front pillar trim (Refer to P.52A-1.)
o Center pillar trim (Refer to P.52A-1.)
.
Quarter pillar upper tdm
(Refer to P.52A-1.)
o Rear pillar trim (Refer to P.52A-1.)
8. Trim clip <Vehicles without
sunroof>
9. Clip
10. Sunroof drip moulding
<Vehicles with sunroof>
11. Headlining
52A-4
INTERIOR
-
Seat <S-door models>
SEAT <s.DOOR MODELS>
REAR SEAT
DISASSEMBLY AND REASSEMBLY
*
+
clip position
: Claw position
:
Secffon A
<Back view of rear seat cushion>
-
A
Section B
-
B
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<A>
Disassembly steps
1. Rear seat cushion cover
2. Rear seat cushion pad
3. Headrestraint guide
4. Rear seat back cover
5. Rear seat back panel
6. Rear seat bac* pad
7. Folding knob assembly
8. Reclining adjuster cover
9. Rear seat center hinge
10. Rear seat back frame assembly
REMOVAL SERVICE POINT
<A>
HEADRESTRAINT GUIDE REMOVAL
INTERIOR
-
Seat Belt <S-door models>
524-5
SEAT BELT <s.DOOR MODELS>
FRONT SEAT BELT
REMOVAL AND INSTALLATION
Gaution: SRS
Before removal of the seat belt pre-tensioner, refer to GROUP 528
Seat Belt with Pre-tensioner.
Outer seat belt removalsteps
1. Sash guide cover
2. Outer seat belt connection
o Center pillar lower trim
(Refer to P.52A-1.)
o Center pillar upper trim
(Refer to P.52A-1.)
3. Adjustable seat belt anchor
4. Outer seat belt
- SRS Service Precautions and
lnner seat belt removal
5. Inner seat belt
524-6
INTERIOR
-
Seat Belt <S-door models>
REAR SEAT BELT
REMOVAL AN D INSTALLATION
44 Nm
5
Removalsteps
o Rear seat cushion assembly
(Refer
to P.524-1.)
1. Sash guide cover
2. Outer seat belt connection
.
Luggage floor box <Option>
(Röler-to P.52A-1.)
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Quarter lower trim
(Refer to P.52A-1.)
o Quarter pillar upper trim
(Refer to P.52A-1.)
3. Outer seat belt
4. Rear noise protector
5. Rear center seat belt
6. Inner seat belt
528-1
o
SUPPLEMENTAL
RESTR AINT
SYSTEM (sRs)
o
CONTENTS
GENERAL
Outline of Change
.........
2
........2
SEAT BELT WITH PRE.TENSIONER
SIDE IMPACT
SENSOR
........2
...,.... 3
o
CAUTION
o
o
o
o
o
C_arefullygead and observe the information in the SERVICE PRECAUTIONS (Refer to '00 PATERO plNlN Wortrhop
Manual <Pub.No.CKREOOE1> P.5284.) prior to any service.
For information concerning troubleshooting or maintenance, always observe the procedures in the Troubleshootlng
(Refer to '00 PAJERO PININ Workshop Manual <pub.No.cKREqlEl> p.528-g.) seüion.
lf any SRS components are removed or replaced in connection with any service procedures, be sure to follow thg
procedures in the INDIVIDUAL COMPONENT SERVICE eection (Refer to '00 PAJERO PININ Workshop Manual
<Pub.No.CKRE00El > P.528€0.) for the eomponents involved.
lf you have any questions about the SRS, please contact your local distributor.
52B'-2
SRS
-
General/Seat Belt with Pre-tensioner
GENERAL
OUTLINE OF CHANGE
o
Due to the introduction of S-door models, the removal and installation procedures for seat belt with
pre-tensioner and side impact sensor have been added. The other items are the same as before.
SEAT BELT WITH PRE-TENSIONER
Caution
1. Never attempt to disassemble or repair the
seat belt with pre-tensioner. lf faulty, replace
it.
2. Be extremely careful when handling the seat
belt with pre-tensioner. Do not subiect it to
shocks, drop it, bring it close to strong
magnets or allow contact with water, grcase
or oil. Always replace it with a new part if
any dents, cracks or deformation is found.
3. Do not place anything on top of the seat
belt pre-tensioner.
Do not expose the seat belt
with
pre-tensioner to temperatures over 90"C.
5. After operating the seat belt pre-tensioner,
replace the seat belt pre-tensioner with a
new part.
Gloves and protective goggles should be
worn when handling a pretensioner once
it has been used.
lf disposing of a seat belt with pre-teneioner
which has not yet been used, its
pre-tensioner should be operated first beforc
disposal. (Refer to '(Xl PAJERO PININ
Workshop Manual <Pub. No. GKREOOEI>
4.
P.528-'18.)
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Tum lgnition Key to LOCK (OFD Position
Disconnect the Negative (-) Battery Terminal.
o
.
tl4 Nm
Installation steps
Removal steps
1. Sash guide cover
2. Outer seat belt connection
Center pillar lower trim
.
(Refer
Post-installation inspection
>A< o3. Seat
belt with pre-tensioner
o
Center pillar lower trim
(Refer to P.524-1.)
2. Outer seat belt connection
1. Sash guide cover
o Negative (-) battery cable connectim
to P.524-1.)
3. Seat belt with pre-tensioner
>B< .
Pre-installation inspection
NOTE
The figure shows the seat belt with pre-tensioner
(R.H.).
For service points, refer to Basic Manual.
SRS
-
52B-3
Side lmpact Sensor
SIDE IMPACT SENSOR
Gaution
1. Disconnect the negative (-) battery terminal
and wait for 60 seconds or more before
starting work. Also, the disconnected battery
terminal should be insulated with tape.
(Refer to '00 PAJERO PtNtN Workshop
Manual <Pub. No. CKRE0OE1> P.S2B-4.)
2. Never attempt to disassemble or repair the
side impact sensors. lf faulty, just replace
with new ones.
Do not drop or subject the side impact
sensors to impact or vibration.
lf denting, cracking, deformation, or rust are
found in the side impact sensors, replace
it with new ones. Discard the old ones.
4. After deployment of the air bags, replace
the side impact sensors with new ones.
5. Never use an ohmmeter on or near the side
impact sensors, and use only the special
test equipment described on '00 PATERO
PININ Workshop Manual
<Pub. No. CKRE00E1> P.528-7.
3.
REMOVAL AND INSTALLATION
Pre-removal Operation
Turn lgnition Switch to LOCK (OFR Position.
Disconnect the Negative (-) Battery Terminal.
o
r
Front of Vehicle
€
Removal steps
o
Installation rtepe
front seat belt (Referto GROUP 52A.)
>A<
>B<
1. Side impact sensor
r Pre-installation inspection
1. Side impaa sensor
r Front seat belt (Referto GROT P 52A.)
. Negatave (-) battery cable connection
o
Post-installation inspection
NOTE
The figure shows the side impact sensor (R.H.).
For service points, refer to Basic Manual.
54-1
CHASSIS ELECTRICAL
-
General/Speaker
GROUP 544
CHASSIS ELECTRICAL
GENERAL
OUTLINE OF CHANGE
o Due to the introduction of S-door models, the rear speaker seruice procedure has been changed.
SPEAKER
REMOVAL AND INSTALTATION
<Rear
sPeakeP
S-door modere
Rear speaker removal eteps
1. Quarter trim, lower (Refer to GROUP 52A.)
2. Rear pillartrim (Referto GROUP 524.)
3. Speaker
SWS
-
548-1
General/Troubleshooting
GROUP 548
SMART WtRtNG SYSTEM(SWS)
GENERAL
OUTLINE OF CHANGES
.
Due to the introduction of 5-door models, the troubleshooting for the rear power windows have been
added.
TROUBLESHOOTING
TROUBLE SYMPTOM CHART
Trouble symptom
Power window
Rear power window sub-switches can not operate rear door
windows. (However, power window main switch can operate rear
door windows.)
Inspection
procedure
Reference
page
D-9
ilg-2
54B,-2
SWS
-
Troubleshooting
lnspection Procedure D-9
Power windows: Rear power window sub'switches can
not operate rear door windows. (However, power window
main switch can operate rear door windows.)
Power supply circuit or earth circuit ol the rear power windoil motor, rear power
window motor or rear power window sub-switches may be clefective.
Measure at rear powsr windovv motor
@nnecto6 E-24 and E-18.
.
o
.
Disconnectconneciorand measure
at ham€ss side.
lgnition s,l,itch: ON
Vottage between terminal 1 and
body ea.th
OK: System voltage
Measure at rear power window motor
@nnectors E-24 and E-18.
.
o
o
.
.
Malfunction ol rear power window sub-switches
Malfunction of rear power window motors
Malfunction of wiring hamess or cunector
Check the following connocto|!:
G74, C-39, C41, D-25, D-Og, E-24,
E-l8
Check hamgss wire bets,€en junction
Uod< and rear pourer window motor,
Gheck tfre lollowing @nncclorr:
E-24, E-18, D25, D-09
Disconnect connestor and m@sure
at hamess side.
@ntinulty between teminal 3 and
body earth
OK:
Check harness wire betwsen rear power windoü, nptor and eanh, and repair
Continuity
Measure at rear power window subswitcfi connec'tors E-23 and E-19.
. Disconnect connector ürd measue
at hamess side.
o
Probable cause
it
neoessary.
Check the lollowing conn€ctott:
E-23, E-19, D-25, D-09
Continuity between teminal 4 and
body earth
Ch€d( hamess wire beifleen rear power window subswitrch and earth, and
OK: Cofiinuity
repair if neogssary.
Chsck the following oonnector8:
E-24, E-18, E-23, E-19
&
#
Check the harn€ss wils betyveen rear
porver windorv motor ard rear power
window sub-swibh.
Ched< rear power windqv
suHttitch
d
Replace
Pub. No. CKREooEI-A
ENGTISH
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