Mitsubishi L200 Triton Service Manual
Mitsubishi L200 Triton Service Manual
Mitsubishi L200 Triton Service Manual
SERVICE MANUAL
Common Rail System (HP3)
for MITSUBISHI L200/TRITON
4D56/4M41Engine
OPERATION
June, 2005
Table of Contents
Table of Contents
Operation Section
1. PRODUCT APPLICATION INFORMATION
1.1
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2
2. OUTLINE OF SYSTEM
2.1
2.2
2.3
2.4
Composition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
2.5
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
2.6
2.7
3. SUPPLY PUMP
3.1
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
3.2
3.3
3.4
3.5
4.2
4.3
5. RAIL
5.1
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
6.2
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
7.2
Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
7.3
7.4
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
7.5
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
7.6
QR Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
7.7
Table of Contents
8.2
8.3
8.4
8.5
8.6
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
9.2
9.3
9.4
9.5
Fuel Injection Pressure Control Function (Rail Pressure Control Function) . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
10.2
10.3
Ouline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
11.2
11.3
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
14.2
15.2
Operation Section
Vehicle Name
Engine Model
Specification
ture
MITSUBISHI
Destination (Vol-
ume)
L200
4D56
4WD (AT)
Europe
Dec, 2005
DENSO P/N
Manufacturer P/N
Remarks
Supply pump
SM294000-0331
1460A001
Injector
SM095000-5600
1465A041
Rail
SM095440-0640
1465A034
Engine ECU
MA275800-4364
1860A549
MA275800-4374
1860A550
079800-5960
MR577031
197920-0020
1450A033
179730-0020
MR547077
VN197400-4030
1460A001
1 1
1 2
Operation Section
2. OUTLINE OF SYSTEM
2.1 Common Rail System Characteristics
The common rail system uses a type of accumulation chamber called a rail to store pressurized fuel, and injectors that contain electronically controlled solenoid valves to inject the pressurized fuel into the cylinders. Because the engine ECU controls the injection
system (injection pressure, injection rate, and injection timing), the injection system is independent, and thus unaffected by the engine
speed or load. This ensures a stable injection pressure at all times, particularly in the low engine speed range, and dramatically decreases the amount of black smoke ordinarily emitted by a diesel engine during start-up and acceleration. As a result, exhaust gas emissions are cleaner and reduced, and higher power output is achieved.
Operation Section
System
Pump (Governor)
Pump (Timer)
Pump
Distributor
Pump
Injection
Injection
Quantity
Control
Injection
Timing
Control
Rising
Pressure
Pressure
Control
< NOTE >
*1 : TWV: Two Way Valve
*2 : SCV: Suction Control Valve
2.4 Composition
The common rail system consists primarily of a supply pump, rail, injectors, and engine ECU.
1 3
1 4
Operation Section
2.5 Operation
(1) Supply Pump (HP3)
The supply pump draws fuel from the fuel tank, and pumps the high pressure fuel to the rail. The quantity of fuel discharged from the
supply pump controls the pressure in the rail. The SCV (Suction Control Valve) in the supply pump effects this control in accordance
with commands received from the engine ECU.
(2) Rail
The rail is mounted between the supply pump and the injector, and stores the high-pressure fuel.
Operation Section
1 5
(1) Sensors
Detect the engine and driving conditions, and convert them into electrical signals.
(3) Actuators
Operate in accordance with electrical signals received from the ECU. Injection system control is undertaken by electronically controlling the actuators. The injection quantity and timing are determined by controlling the duration and timing in which current is applied
to the TWV (Two-Way Valve) in the injector. Injection pressure is determined by controlling the SCV (Suction Control Valve) in the
supply pump.
1 6
Operation Section
3. SUPPLY PUMP
3.1 Outline
The supply pump consists primarily of the pump body (eccentric cam, ring cam, and plungers), SCV (Suction Control Valve), fuel
temperature sensor, and feed pump.
The two plungers are positioned vertically on the outer ring cam for compactness.
The engine drives the supply pump at a ratio of 1:1. The supply pump has a built-in feed pump (trochoid type), and draws the fuel
from the fuel tank, sending it to the plunger chamber.
The internal camshaft drives the two plungers, and they pressurize the fuel sent to the plunger chamber and send it to the rail. The
quantity of fuel supplied to the rail is controlled by the SCV, using signals from the engine ECU. The SCV is a normally open type
(the intake valve opened during de-energization).
Operation Section
1 7
1 8
Operation Section
As the drive shaft rotates, the eccentric cam rotates eccentrically, and the ring cam moves up and down while rotating.
The plunger and the suction valve are attached to the ring cam. The feed pump is connected to the rear of the drive shaft.
Operation Section
1 9
1 10
Operation Section
Operation Section
1 11
1 12
Operation Section
(1) SCV Opening Small (Duty ON time long - Refer to the "Relationship Between Actuation
Signal and Current" Diagram.)
When the opening of the SCV is small, the fuel suction area is kept small, which decreases the transferable fuel volume.
(2) SCV Opening Large (Duty ON time short - Refer to the "Relationship Between Actuation
Signal and Current" Diagram.)
When the opening of the SCV is large, the fuel suction area is kept large, which increases the transferable fuel volume.
Operation Section
1 13
(3) Diagram of Relationship Between Actuation Signal and Current (Magneto motive Force)
1 14
Operation Section
5. RAIL
5.1 Outline
Stores pressurized fuel (25 to 180 MPa) that has been delivered from the supply pump and distributes the fuel to each cylinder injector.
A rail pressure sensor and a pressure limiter valve are adopted in the rail.
The rail pressure sensor (Pc sensor) detects fuel pressure in the rail and sends a signal to the engine ECU, and the pressure limiter
controls the excess pressure. This ensures optimum combustion and reduces combustion noise.
Operation Section
1 15
1 16
Operation Section
7.2 Characteristics
A compact, energy-saving solenoid-control type TWV (Two-Way Valve) injector has been adopted.
QR codes displaying various injector characteristics and the ID codes showing these in numeric form (30 alphanumeric figures) are
engraved on the injector head. The common rail system optimizes injection volume control using this information. When an injector
is newly installed in a vehicle, it is necessary to enter the ID codes in the engine ECU using the MITSUBISHI diagnosis tool (MUT
III).
Operation Section
1 17
1 18
Operation Section
7.4 Construction
7.5 Operation
The TWV (Two-Way Valve) solenoid valve opens and closes the outlet orifice to control both the pressure in the control chamber, and
the start and end of injection.
Operation Section
1 19
solenoid valve is pushed downward, effectively closing the outlet orifice. For this reason, the hydraulic pressure that is applied to the
command piston causes the nozzle spring to compress. This closes the nozzle needle, and as a result, fuel is not injected.
(2) Injection
When current is initially applied to the solenoid, the attraction force of the solenoid pulls the solenoid valve up, effectively opening
the outlet orifice and allowing fuel to flow out of the control chamber. After the fuel flows out, the pressure in the control chamber
decreases, pulling the command piston up. This causes the nozzle needle to rise and the injection to start.
The fuel that flows past the outlet orifice flows to the leak pipe and below the command piston. The fuel that flows below the piston
lifts the piston needle upward, which helps improve the nozzle's opening and closing response.
7.6 QR Codes
Conventionally the whole injector Assy was replaced during injector replacement, but QR (Quick Response) codes have been adopted
to improve injector quantity precision.
1 20
Operation Section
QR codes have resulted in a substantial increase in the number of fuel injection quantity correction points, greatly improving precision.
The characteristics of the engine cylinders have been further unified, contributing to improvements in combustion efficiency, reductions in exhaust gas emissions and so on.
Operation Section
1 21
1 22
Operation Section
Operation Section
1 23
1 24
Operation Section
Operation Section
1 25
1 26
Operation Section
(2) Operation
Operation Section
1 27
9.5 Fuel Injection Pressure Control Function (Rail Pressure Control Function)
The fuel injection pressure control function (rail pressure control function) controls the discharge volume of the pump by measuring
the fuel pressure at the rail pressure sensor and feeding it back to the ECU. It effects pressure feedback control so that the discharge
volume matches the optimal (command) value set in accordance with the engine speed and the injection quantity.
1 28
Operation Section
Operation Section
1 29
Injection quantity
Water temperature
Base injection
quantity
Starter ON time
STA/ON
Start
QD0805E
1 30
Operation Section
The target speed varies, depending on the ON/OFF state of the air conditioner and the coolant temperature.
Operation Section
Speed Pulse
Control Diagram
1 31
1 32
Operation Section
Operation Section
1 33
1 34
Operation Section
Operation Section
1 35
1 36
Operation Section
Operation Section
1 37
Diagnostic Item
Diagnostic Classifica-
Number
Malfunctioning Part
tion
Light
ON
(SAE)
P0016
Speed-G
phase
malfunction
tion
Yes
P0072
(+B
short,
No
ground
short, open)
P0073
(+B
short,
No
ground
short, open)
P0088
P0089
Rail
high
abnormality
system abnormality
Yes
Yes
system abnormality
P0093
Fuel leak
Fuel leak
P0102
Fuel piping
short,
Yes
No
ground
short, open)
P0103
short,
No
ground
short, open)
P0106
Yes
abnor- abnormality
mality
P0107
(+B
short,
Yes
ground
short, open)
P0108
(+B
short,
short, open)
Yes
Remarks
Operation Section
1 38
DTC
Diagnostic Item
Diagnostic Classifica-
Number
Malfunctioning Part
tion
Light
ON
(SAE)
P0112
Intake
sensor - low
(+B
short,
Yes
short, open)
P0113
Intake
sensor - high
(+B
short,
Yes
short, open)
P0117
Coolant
sensor - low
(+B
short,
Yes
ground sensor
short, open)
P0118
Coolant
sensor - high
(+B
short,
Yes
ground sensor
short, open)
P0122
Electronic
throttle - low
short,
Yes
ground
short, open)
P0123
(+B
short,
Yes
ground
short, open)
P0182
(+B
short,
Yes
ground
short, open)
P0183
(+B
short,
Yes
ground
short, open)
P0191
characteristic Rail
Yes
abnor- abnormality
mality
P0192
(+B
short,
Yes
ground
short, open)
P0193
(+B
short,
Yes
ground
short, open)
P0201
actuation Injector
Yes
actuation Injector
Yes
actuation Injector
Yes
actuation Injector
Yes
P0203
P0204
Remarks
Operation Section
DTC
Diagnostic Item
Diagnostic Classifica-
Number
Malfunctioning Part
tion
Light
ON
(SAE)
P0219
Engine
Yes
Engine
Yes
Yes
mality
P0234
P0301
injection) 1
P0302
malily
P0303
P0304
P0340
tio
No G pulse input
Yes
sor
Yes
sor
Cylinder
Yes
sor
tion
P0341
Yes
malily
tion
P0336
Yes
malily
injection) 4
P0335
Yes
malily
Yes
sor
abnormality
P0405
short,
No
ground
short, open)
P0406
short,
No
ground
short, open)
P0502
P0513
Vehicle speed
abnormality - low
tion
Network
Yes
Yes
catuin error
P0551
P0603
malfuncion
EEPROM abnormality
Yes
Yes
RAM abnormality
P0605
Engine
ECU
Engine ECU
Engine ECU
Engine ECU
Engine ECU
Engine ECU
Yes
Engine ECU
Yes
flash-
ROM abnormality
P0606
Engine
ECU
Yes
Yes
abnormality (main IC
abnormality)
P0607
Remarks
1 39
Operation Section
1 40
DTC
Diagnostic Item
Diagnostic Classifica-
Number
Malfunctioning Part
tion
Light
Remarks
ON
(SAE)
P0628
P0629
system abnormality
SCV +B short
Supply pump
Yes
Supply pump
Yes
system abnormality
P0630
ECU
write Engine
defect
ECU
(VIN
Yes
rewrite)
P0638
Yes
stuck
P0642
Engine ECU
Engine ECU
Yes
P0643
Engine ECU
Yes
P0652
Engine ECU
Engine ECU
Yes
P0653
Engine ECU
Yes
P1203
Low charge
Engine ECU
Engine ECU
Yes
P1204
Over charge
Engine ECU
Engine ECU
Yes
P1272
Rail
Yes
Supply pump
Yes
mality
P1273
system abnormality
system abnormality
may
be
detected
when
the
vehicle is restarted.
When "P1273" is displayed, the user should
verify whether or not
there is gas in the vehicle.
Do not replace the
pump assy. if it has
been verified that the
vehicle has run out of
gas. Remove the air
from the fuel, and erase
the code using the
MITSUBISHI MUT III
diagnosis tool.
P1274
system abnormality
Supply pump
Yes
Operation Section
DTC
Diagnostic Item
Diagnostic Classifica-
Number
Malfunctioning Part
tion
Light
ON
(SAE)
P1275
P1625
Pump
exchange
Supply pump
Yes
Engine ECU
Engine ECU
Yes
Engine ECU
Yes
Yes
Yes
plug
system abnormality
QR data
abnormality
P1626
P2122
Accelerator
low
(+B
short,
ground sor
short, open)
P2123
Accelerator
high final
(+B
short,
Yes
ground sor
short, open)
P2124
Accelerator
high
(+B
short,
No
ground sor
short, open)
P2127
Accelerator
low
(+B
short,
Yes
ground sor
short, open)
P2138
Accelerator sensor - Open circuit detection Accelerator position senduplicate malfunction (+B
short,
ground sor
short, open)
high
Accelerator sensor - Open circuit detection Accelerator Position Senduplicate malfunction (+B
ACCP
characteristic Sensor
abnormality
Common
system Injector
system
Yes
sor
actuation Injector , Wire harness or
abnormality
Yes
ground sor
abnormality
open circuit
P2147
short,
short, open)
low
P2146
Yes
Yes
Engine ECU
actuation Injector, Wire harness or
ground abnormality
Yes
Engine ECU
short
P2148
P2149
Common
open circuit
P2228
abnormality
system Injector
Engine ECU
actuation
Yes
abnormality
Yes
(+B
short,
Yes
ground
short, open)
P2229
(+B
short,
short, open)
ground
Yes
Remarks
1 41
Operation Section
1 42
DTC
Diagnostic Item
Diagnostic Classifica-
Number
Malfunctioning Part
tion
Light
ON
(SAE)
P2413
EGR valve
No
mality
UD073
Network
Network
No
UD101
Network
No
Network
No
Network
No
Network
No
Network
No
(trans)
UD102
UD109
UD117
UD190
CAN communication
Network
Remarks
Operation Section
1 43
Operation Section
1 44
Pin Symbol
Signal Name
No.
Pin Symbol
Signal Name
A01
P-GND
Power Ground
A11
A02
A12
A/C1 SW
A03
P-GND
Power Ground
A13
A04
COMMON 1
INJ#1/#4 BATT.
A14
A05
COMMON 1
INJ#2/#3 BATT.
A15
A06
A16
A07
EGR-
A17
A08
EGR+
A18
A09
A19
A10
SCV+
A20
Operation Section
1 45
Pin Symbol
Signal Name
No.
Pin Symbol
Signal Name
A56
A57
A58
A59
A60
A21
TW4
A22
A23
TWV2
A24
A25
A61
A26
A/C R
A62
A27
C FAN R
FAN Relay
A63
A-VCC5
A28
A64
A-VCC6
A29
SCV-
A65
NE-
A30
A66
G-
A31
A67
A32
A68
PFUEL RTN
A33
A69
THF RTN
A34
A70
THW RTN
A35
A71
BOOST RTN
A36
A72
A37
Glow R
A73
AMF-RTN
A38
Glow L
Glow Light
A74
EXT-A-RTN
A39
A75
A40
TWV3
A76
A41
TWV3
A77
A42
TWV1
A78
A43
TWV1
A79
THA
A44
A-VCC3
A80
A45
A-VCC4
A81
A46
NE+
B01
A-VCC 1
A47
G+
B02
APS 1
A48
PFUEL 1
B03
APS 1 GND
A49
B04
A50
THF
B05
ETCP-M
A51
THW
B06
CAN1-L
CAN L (W/Resister)
A52
BOOST
B07
A53
EGR LIFT
B08
A54
AMF
Airflow Sensor
B09
A-VCC 2
A55
EXT-A-TMP
B10
APS 2
Operation Section
1 46
Pin Symbol
APS 2 GND
Signal Name
No.
Pin Symbol
Signal Name
IG-SW
Ignition Switch
Earth
B12
B27
B13
B28
B14
CAN1-H
CAN H (W/Resister)
B29
B15
B30
PS-SW
B16
SPD
B31
B17
B32
B18
STA-SW
Starter Switch
B33
C-GND
SIG Ground
B19
MT 1ST SW
B34
B20
MT REV SW
B35
ETC+
B21
B36
B22
B37
ETC-
B23
B38
+BP
Battery
B24
M-REL
BATT.
Control
(ECCS)
Relay
(W/ B39
DIODE)
B25
TACHO
Tacho meter
B40
Published
: June, 2005