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00400554E Common Rail System (HP3) for MITSUBISHI TRITON 4D56/4M41 Engine DENSO INTERNATIONAL THAILAND CO., LTD

Mitsubishi Triton 4d56 4m4

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Page 1: Mitsubishi Triton 4d56 4m4

00400554E

Common Rail System (HP3)for MITSUBISHI TRITON 4D56/4M41 Engine

DENSO INTERNATIONAL THAILAND CO., LTD

Page 2: Mitsubishi Triton 4d56 4m4

© 2005 DENSO CORPORATIONAll Rights Reserved. This book may not be reproducedor copied, in whole or in part, without the writtenpermission of the publisher.

Page 3: Mitsubishi Triton 4d56 4m4

Revision History

Revision HistoryDate Revision Contents

2005.10.25 • Portions of “14.2 Diagnostic Trouble Code Datails" revised. (See P1-37, 38, 39, 40, 41)• "15.1 Engine ECU Externa Wring Diagram”illustration (Applicable Illust. code: Q001257E,

Q001258E) replaced. (See P1-42, 43)• Portions of the "15.2 Engine ECU Connector Diagram” Terminal Connections (1), (2), (3) replaced .

(See P1-43, 44, 45)

Page 4: Mitsubishi Triton 4d56 4m4

Table of Contents

Operation Section

1. PRODUCT APPILCATION INFOR-MATION

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

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

2. OUTLINE OF SYSTEM

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

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

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

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

2.5 Operation .................................................... 1-4

2.6 Fuel System................................................ 1-4

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

3. SUPPLY PUMP

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

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

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

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

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

4. SUPPLY PUMP COMPONENT PARTS

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

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

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

5. RAIL

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

6. RAIL COMPONENTS PARTS

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

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

7. INJECTOR (G2 TYPE)

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

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

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

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

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

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

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

8. OPERATION OF CONTROL SYS-TEM COMPONENTS

8.1 Engine Control System Diagram............... 1-22

8.2 Engine ECU (Electronic Control Unit) ....... 1-22

8.3 Cylinder Recognition Sensor (TDC).......... 1-23

8.4 Turbo Pressure Sensor ............................. 1-23

8.5 Mass Air Flow Sensor ............................... 1-24

8.6 Electronic Control Throttle ........................ 1-25

9. VARIOUS TYPES OF CONTROL

9.1 Outline....................................................... 1-27

9.2 Fuel Injection Rate Control Function......... 1-27

9.3 Fuel Injection Quantity Control Function... 1-27

9.4 Fuel Injection Timing Control Function...... 1-27

9.5 Fuel Injection Pressure Control Function (Rail Pressure Control Function) ............. 1-27

10. FUEL INJECTION QUANTITY CONTROL

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

10.2 Injection Quantity Calculation Method ...... 1-28

10.3 Set Injection Quantities ............................. 1-28

Page 5: Mitsubishi Triton 4d56 4m4

Table of Contents

11. FUEL INJECTION TIMING CON-TROL

11.1 Ouline........................................................ 1-32

11.2 Main and Pilot Injection Timing Control..... 1-32

11.3 Microinjection Quantity Learning Control .. 1-33

12. FUEL INJECTION RATE CON-TROL

12.1 Outline....................................................... 1-35

13. FUEL INJECTION PRESSURE CONTROL

13.1 Fuel Injection Pressure ............................. 1-36

14. DIAGNOSTIC TROUBLE CODES (DTC)

14.1 About the Codes Shown in the Table........ 1-37

14.2 Diagnostic Trouble Code Details............... 1-37

15. EXTERNAL WIRING DIAGRAM

15.1 Engine ECU External Wiring Diagram ...... 1-42

15.2 Engine ECU Connector Diagram.............. 1-43

Page 6: Mitsubishi Triton 4d56 4m4

Operation Section1–1

1. PRODUCT APPILCATION INFORMATION

1.1 Application

1.2 System Components Part Number

Vehicle Manufac-

ture

Vehicle Name Engine Model Specification Destination (Vol-

ume)

Line Off Period

MITSUBISHI TRITON4D56 2WD (MT/AT)

Thailand June, 20054WD (MT)

4M41 4WD (MT/AT)

Parts Name DENSO P/N Manufacturer P/N Remarks

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

SM294000-0341 1460A003 For 4M41 Engine Model

Injector SM095000-5600 1465A041 For 4D56 Engine Model

SM095000-5760 1465A054 For 4M41 Engine Model

Rail SM095440-0640 1465A034 ALL

Engine ECU MA275800-425# 1860A392 For 4D56 Engine Model (4WD)

MA275800-431# 1860A523 For 4D56 Engine Model (2WD MT)

MA275800-432# 1860A524 For 4D56 Engine Model (2WD AT)

MA275800-357# 1860A390 For 4M41 Engine Model (4WD)

Turbo pressure sensor 079800-5960 MR577031 ALL

Cylinder recognition sensor(TDC)

949979-1590 1865A074 For 4M41 Engine Model

Electronic control throttle 197920-0020 1450A033 For 4M41, 4D56 Engine Model (4WD)

Fuel temperature sensor 179730-0020 MR547077 ALL

Mass air flow meter VN197400-4030 1460A001 ALL

Page 7: Mitsubishi Triton 4d56 4m4

Operation Section1–2

2. OUTLINE OF SYSTEM

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

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

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

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

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

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

2.2 Features of Injection Control

(1) Injection Pressure Control

• Enables high-pressure injection even at low engine speeds.

• Optimizes control to minimize particulate matter and NOx emissions.

(2) Injection Timing Control

• Enables finely tuned optimized control in accordance with driving conditions.

(3) Injection Rate Control

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

Q001223E

Common Rail System

Injection Pressure Control Injection Timing Control Injection Rate Control

Optimization, High Pressurization

Common RailSystem

Conventional Pump

Conventional Pump

Speed SpeedInjection Pressure

Optimization

Common RailSystem

Pa

rtic

ula

te

NO

x

Inje

ctio

n T

imin

g

Speed

Injection Quantity Control

Cylinder Injection Quantity Correction

Pre-Injection

Main Injection

Crankshaft AngleInje

ctio

n R

ate

Inje

ctio

n P

ressu

re

1 3 4 2

Page 8: Mitsubishi Triton 4d56 4m4

Operation Section1–3

2.3 Comparison to the Conventional System

< NOTE >*1 : TWV: Two Way Valve*2 : SCV: Suction Control Valve

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

In-line, VE Pump Common Rail System

System

InjectionQuantityControl

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

InjectionTimingControl

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

RisingPressure

Pump Engine ECU, Supply Pump

Distributor Pump Engine ECU, Rail

InjectionPressureControl

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

Q001224E

High-pressure Pipe

Momentary

High Pressure

NozzleGovernor

Timer

In-line Pump

VE Pump Q001225E

Rail

Usually High Pressure

Supply Pump

Injector

Feed Pump SCV (Suction Control Valve)

Delivery Valve

Fuel Tank

Page 9: Mitsubishi Triton 4d56 4m4

Operation Section1–4

2.5 Operation

(1) Supply Pump (HP3)

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

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

with commands received from the engine ECU.

(2) Rail

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

(3) Injector (G2 type)

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

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

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

(4) Engine ECU

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

well as the EGR (exhaust gas recirculation).

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

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

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

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

Fuel Temperature

Accelerator OpeningTurbo Pressure,Atmospheric Air Pressure

Intake Airflow Rate

Rail PressureSensor

Rail

Engine ECU

Fuel Temperature Sensor

Supply PumpFuel Tank

Injector

PressureLimiter

SCV(SuctionControl Valve)

Intake Air Temperature

Coolant Temperature

Crankshaft position

Cylinder Recognition Position

Q001226E

Engine Speed

Page 10: Mitsubishi Triton 4d56 4m4

Operation Section1–5

(1) Sensors

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

(2) Engine ECU

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

optimal conditions.

(3) Actuators

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

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

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

supply pump.

Q001227E

Crankshaft Position Sensor (NE)

Accelerator Position Sensor

Engine Speed

Cylider Recognition Sensor (TDC)

CylinderRecognition

Load

Injector

Supply Pump (SCV)

•Injection Quantity Control•Injection Timing Control

•Fuel Pressure Control

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

Sensor Actuator

EngineECU

Page 11: Mitsubishi Triton 4d56 4m4

Operation Section1–6

3. SUPPLY PUMP

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

temperature sensor, and feed pump.

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

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

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

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

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

(the intake valve opened during de-energization).

Q001265E

InjectorRail

Discharge Valve

Regulating Valve

Feed Pump

Intake

Fuel Inlet

Fuel Overflow

Fuel Tank

Camshaft

Intake pressureFeed pressure

High pressure

Return pressure

Return

Fuel Filter (with Priming Pump)

Filter

Suction Valve

Plunger

Return Spring

SCV

Page 12: Mitsubishi Triton 4d56 4m4

Operation Section1–7

3.2 Exterior View Diagram4D56 Engine Model

4M41 Engine Model

3.3 Supply Pump Internal Fuel FlowThe fuel that is drawn from the fuel tank passes through the route in the supply pump as illustrated, and is fed into the rail.

Q001253E

From Fuel Tank

Overflow to Fuel Tank

To Rail

Fuel Temperature Sensor

SCV

Q001228E

From

Fuel Tank

Overflow to Fuel Tank

To RailFuel

TemperatureSensor

SCV

Page 13: Mitsubishi Triton 4d56 4m4

Operation Section1–8

3.4 Construction of Supply PumpThe eccentric cam is attached to the drive shaft. The eccentric cam is connected to the ring cam.

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

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

Supply pump interior

Regulating valve

Feed pump

Overflow

Fuel tank

SCV (Suction Control Valve)

Intake valve

Discharge valve

Pumping portion (plunger)

Rail

QD0705E

QD0706E

Cam Shaft

Eccentric Cam Ring Cam

Q001233E

Ring Cam

Eccentric Cam

Cam Shaft

Plunger

Page 14: Mitsubishi Triton 4d56 4m4

Operation Section1–9

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

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

rail.

Q001234E

Plunger A

Ring Cam

Plunger B

Feed Pump

Page 15: Mitsubishi Triton 4d56 4m4

Operation Section1–10

Q001235E

SCV

Plunger A: Finish Compression

Plunger B: Finish Intake

Plunger A: Finish Intake

Plunger B: Finish Compression

Plunger A: Begin IntakePlunger

B: Begin Compression

Plunger A: Begin Compression

Plunger B: Begin Intake

Suction Valve

Plunger A

Plunger B

Discharge Valve

Eccentric Cam

Ring Cam

Page 16: Mitsubishi Triton 4d56 4m4

Operation Section1–11

4. SUPPLY PUMP COMPONENT PARTS

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

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

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

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

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

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

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

pump decreases.

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

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

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

intake and full quantity discharge = normally open)

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

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

plungers.

QD0708E

Outer Rotor

FromFuel Tank

Intake Port

ToPump Chamber

Discharge

Port

Quantity Decrease

Quantity Increase

Quantity Decrease(Fuel Discharge)

Quantity Increase(Fuel Intake)

Inner Rotor

Q001113E

Valve body

Needle valve

Return Spring

Page 17: Mitsubishi Triton 4d56 4m4

Operation Section1–12

(1) SCV Opening Small (Duty ON time long - Refer to the "Relationship Between ActuationSignal 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 ActuationSignal and Current" Diagram.)

• When the opening of the SCV is large, the fuel suction area is kept large, which increases the transferable fuel volume.

Q001114E

Feed Pump

Needle valve Small Opening

Q001115E

Feed Pump

Needle valve Large Opening

Page 18: Mitsubishi Triton 4d56 4m4

Operation Section1–13

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

4.3 Fuel Temperature SensorDetects the fuel temperature and sends a corresponding signal to the engine ECU. Based on this information, the engine ECU calcu-

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

Q001116E

Average Current Difference

Small Suction Volume Large Suction Volume

ActuationVoltage

Current

ON

OFF

Q001237E

<Reference: Temperature-resistance Characteristics>

RESISTANCE(°C) (k )TEMPERATURE

- 30 (25.40)

(9.16)

(1.66)

(1.15)

(0.811)

(0.584)

(0.428)

(0.240)

(0.1836)

(0.1108)

(5.74)

(3.70)

15.40 + 1.29- 1.20

+ 0.14- 0.132.45

0.318 ± 0.008

0.1417 ± 0.0018

- 20

- 10

10

20

30

40

50

60

70

80

90

100

110

120

0

Page 19: Mitsubishi Triton 4d56 4m4

Operation Section1–14

5. RAIL

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

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

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

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

Q001236E

Pressure SensorPressure Limiter

Page 20: Mitsubishi Triton 4d56 4m4

Operation Section1–15

6. RAIL COMPONENTS PARTS

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

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

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

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

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

pressure limiter is returned to the fuel tank.

Q001238E

Vout/Vc

A-VCC A-GNDPEUFL

Vc = 5V

(Mpa)Popt

2001601002000

0.20.264

0.712

0.84

0.52

Q001239E

Valve Open

Valve Close50 MPa (509.5 kg/cm2)

221 MPa (2254 kg/cm2)

From rail

To fuel tank

Page 21: Mitsubishi Triton 4d56 4m4

Operation Section1–16

7. INJECTOR (G2 TYPE)

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

condition, in accordance with commands received from the ECU.

7.2 CharacteristicsA 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).

Page 22: Mitsubishi Triton 4d56 4m4

Operation Section1–17

7.3 Exterior View Diagram

Q001244E

<4M41 Engine Model><4D56 Engine Model>

Page 23: Mitsubishi Triton 4d56 4m4

Operation Section1–18

7.4 Construction

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

the start and end of injection.

(1) Non injection

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

Q001240E

QR Codes

30 Alphanumeric Figures

Pressurized Fuel (from Rail)

Seat

Leak Passage

Multiple Hole Filter

Pressurized Fuel

Command Piston

Nozzle Spring

Pressure Pin

Nozzle Needle

Control Chamber

Page 24: Mitsubishi Triton 4d56 4m4

Operation Section1–19

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.

(3) End of Injection

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

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

the injection to stop.

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

to improve injector quantity precision.

Q001241E

Injection Rate

Control Chamber Pressure

Control Chamber Pressure

Control Chamber Pressure

Solenoid

TWV

Outlet Orifice

Inlet Orifice

Command Piston

NozzleInjection Rate Injection Rate

Non-Injection Injection End of Injection

Rail

Actuating Current

Actuating Current

Actuating Current

To Fuel TankLeak Passage

TWV

Page 25: Mitsubishi Triton 4d56 4m4

Operation Section1–20

4D56 Engine Model

4M41 Engine Model

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

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

tions in exhaust gas emissions and so on.

(1) Repair Procedure

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

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

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

Q001243E

ID Codes (30 base 16 characters)Base 16 characters noting fuel injection quantity correction information for market service use

QR Codes ( 9.9mm)

Q001242E

ID Codes (30 base 16 characters)Base 16 characters noting fuel injection quantity correction information for market service use

QR Codes ( 9.9mm)

Q001245E

Inje

ctio

n Q

ua

ntity

Q

180 Mpa

80 Mpa

112 Mpa

135 Mpa

48 Mpa

25 Mpa

Actuating Pluse Width TQ

Inje

ctio

n Q

ua

ntity

Q

180 Mpa

64 Mpa

96 Mpa130 Mpa

48 Mpa

25 Mpa

Actuating Pluse Width TQ

<4D56 Engine Model> <4M41 Engine Model>

Correction

8 Points

Correction

8 Points

Page 26: Mitsubishi Triton 4d56 4m4

Operation Section1–21

Replacing the Injector

Replacing the Engine ECU

7.7 Injector Actuation CircuitIn order to improve injector responsiveness, the actuation voltage has been changed to high voltage, speeding up both solenoid mag-

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

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

Q001133E

"No correction resistance, cannot be detected electrically"

Replaced injector

Engine ECU

* Injector ID code must be registered with the engine ECU

Q001134E

"No correction resistance, cannot be detected electrically"

* Injector ID code must be registered with the engine ECU

Vehicle injectors

Replaced engine ECU

Q001246E

Constant Amperage Circuit

High Voltage Generation Circuit

ECU

Actuating Current

<ECU Direct Actuation>

2WV#3 (No.4 Cylinder)

2WV#4 (No.2 Cylinder)

Injector

Common 1

2WV#1 (No.1 Cylinder)

2WV#2 (No.3 Cylinder)

Page 27: Mitsubishi Triton 4d56 4m4

Operation Section1–22

8. OPERATION OF CONTROL SYSTEM COMPONENTS

8.1 Engine Control System Diagram

8.2 Engine ECU (Electronic Control Unit)This is the command center that controls the fuel injection system and the engine operation in general.

Q001247E

Rail

Rail Pressure Sensor

(Pc Sensor) Pressure limiter

injector

Engine ECU

SCV

(Sucton Control Valve)

Glow Relay

Crankshaft Position Sensor

(NE Sensor)

Cylinder Recognition

Position Sensor

(TDC Sensor)

Turbo PressureSensor

Electronic ControlThrottle

Fuel Tank

Accelerator Position Sensor

Ignition Switch Signal

Starter Signal

Vihicle Speed Signal

Mitsubishi Diagnosis Tool (MUDIII)

Battery Voltage

Other Signals

Air Mass Flow Sensor

(With Intake Air Temperature)

Fuel Temperature

Sensor

Coolant

Temperature

Sensor

Page 28: Mitsubishi Triton 4d56 4m4

Operation Section1–23

8.3 Cylinder Recognition Sensor (TDC)Outputs a cylinder identification signal. The sensor outputs 5 pulses for every two revolutions (720°CA) of the engine.

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

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

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

Q001248E

<Outline Diagram>

Engine ECU

Detection Calculation Actuation

Sensor Actuator

Q001249E

30°CA 180°CA 180°CA

720°CA

180°CA

5V

1V

0V

Pulser

SensorSignal

Vcc

GND

OUT

Q001229E

GND PBVC

Page 29: Mitsubishi Triton 4d56 4m4

Operation Section1–24

(1) Atmospheric Pressure Measurement Conditions

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

• Engine speed = 0rpm

• Starter is ON

• Idle is stable

(2) Turbo Pressure Measurement Conditions

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

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

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

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

Q001231E

VSV Atmosphere

Turbo Pressure Sensor

Intake Manifold

0.5

4.5

3.2

VC = 5 V

266.6

Absolute Pressure

66.6 202.7

500 20001520

PB (V)

kPa (abs)

mmHg (abs)

<Pressure Characteristics>

ECU

Turbo Pressure Sensor

Pressure Sensor Device

Engine ECU

Constant VoltagePower Supply

Microcomputer

Input SignalProcessing Circuit

Vc

PB

GND

Page 30: Mitsubishi Triton 4d56 4m4

Operation Section1–25

8.6 Electronic Control Throttle

(1) Outline

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

the vehicle is turned off.

Q001260E

Engine ECUEFI Main Relay

Airflow MeterPower Supply

VG

+B

EVG

IC

THAE2Intake Air

Voltage Detection

Voltage Detection

Power Supply

Intake Air Temperature Sensor

Heating Element

Air Thermometer

5V

Temperaturesensingelement

E2 THA VG E2 G +B

Heatingelement

Temperaturesensor

Air

Air Flow-VG Characteristic

5

4

3

2

1

0

VG

(V)

1 2 5 10 20 50 100 200

Air Flow (x10-3kg/s)

-200.2

0.3

0.50.7

1

2

3

57

10

20

30

20 40 60 80 °C0

Page 31: Mitsubishi Triton 4d56 4m4

Operation Section1–26

(2) Operation

Q001256E

VTA1

VTA1 M+ M-

IC1

VC

VC

VTA2

VTA2

E2

E2

M+

M-

IC2

M

Valve Fully Opened

(Mechanical)

Valve Fully Opened

(by Control)

Valve Fully Closed

Q001232E

ON

Target Valve Opening

(Percentage)

Throttle valve fully opened

(by control)

Key switch OFF throttle valve shut.

Approx. 0.1 - 0.2 sec.

Engine OFF, valve fully opened

(by control) Valve fully opened

(mechanical)

OFF

100%

Engine Key

0%

Page 32: Mitsubishi Triton 4d56 4m4

Operation Section1–27

9. VARIOUS TYPES OF CONTROL

9.1 OutlineThis system effects fuel injection quantity and injection timing control more appropriately than the mechanical governor and timer

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

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

realize both optimal injection and injection timing.

9.2 Fuel Injection Rate Control FunctionPilot injection control injects a small amount of fuel before the main injection.

9.3 Fuel Injection Quantity Control FunctionThe fuel injection quantity control function replaces the conventional governor function. It controls the fuel injection to an optimal

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

9.4 Fuel Injection Timing Control FunctionThe fuel injection timing control function replaces the conventional timer function. It controls the injection to an optimal timing based

on the engine speed and the injection quantity.

9.5 Fuel Injection Pressure Control Function (Rail Pressure Control Func-tion)

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

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

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

Page 33: Mitsubishi Triton 4d56 4m4

Operation Section1–28

10. FUEL INJECTION QUANTITY CONTROL

10.1 OutlineThis control determines the fuel injection quantity by adding coolant temperature, fuel temperature, intake air temperature, and intake

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

operating conditions and driving conditions.

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

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

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

used as the basis for the final injection quantity.

10.3 Set Injection Quantities

(1) Basic Injection Quantity

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

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

creases.

Q001152E

Engine Speed

Engine Speed

Accelerator Opening

Inje

ctio

n

Qu

an

tity

Inje

ctio

n

Qu

an

tity

Accelerator Opening

Engine Speed

Basic Injection Quantity

Maximum Injection Quantity

Low Quantity

Side Selected

Corrected Final Injection

Quantity

Injector Actuation

Period Calculation

Individual Cylinder Correction Quantity

Turbo Pressure Correction

Atmospheric Pressure Correction

Intake Air Temperature Correction

Speed Correction

Injection Pressure Correction

Page 34: Mitsubishi Triton 4d56 4m4

Operation Section1–29

(2) Maximum Injection Quantity

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

take air pressure.

(3) Starting Injection Quantity

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

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

engine speed.

(4) Idle Speed Control (ISC) System

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

by the engine ECU.

Ba

sic

In

jectio

n Q

ua

ntity

Engine Speed

Accelerator Opening

Q000888E

QB0717E

Engine Speed

Ba

sic

Ma

xim

um

In

jectio

n Q

ua

ntity

Base injectionquantity

Starter ON time

Start

Water temperature

STA/ONQD0805

Inje

ctio

n qu

antit

y

Page 35: Mitsubishi Triton 4d56 4m4

Operation Section1–30

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

(5) Idle Vibration Reduction Control

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

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

and smoother engine operation is achieved.

Q001254E

•Coolant Temperature

•Air Conditioner Load

•Gear Position

Accelerator Opening

Vehicle Speed

Conditions for Start of Control Control Conditions

Target Speed Calculation

Comparison

InjectionQuantityCorrection

SpeedDetection

Air Conditioner S/W

Coolant Temperature

Neutral S/W Ta

rge

t S

pe

ed

C

alc

ula

tio

n

Inje

ctio

nQ

ua

ntity

De

term

ina

tio

n

[Target speed]

800

20

Coolant water temperature (°C)QD1172

En

gin

e s

pe

ed

(rp

m)

A/C ON/OFF

Page 36: Mitsubishi Triton 4d56 4m4

Operation Section1–31

Speed Pulse

Control Diagram

Q001255E

30°CA360°CA

5V

0V

Pulser

Sensor Signal

(Make the t for all the cylinders equal.)

( t1,4_L)A

( t1,4_H)B

( t2,3_L)C

( t2,3_H)D

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

Q001230E

Crankshaft Angle Crankshaft AngleCorrection

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

Page 37: Mitsubishi Triton 4d56 4m4

Operation Section1–32

11. FUEL INJECTION TIMING CONTROL

11.1 OulineFuel injection timing is controlled by varying the timing in which current is applied to the injectors.

11.2 Main and Pilot Injection Timing Control

(1) Main Injection Timing

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

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

(2) Pilot Injection Timing (Pilot Interval)

• Pilot injection timing is controlled by adding a pilot interval to the main injection timing. The pilot interval is calculated based on the

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

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

Top Dead Center (TDC)

Pilot Injection

Main Injection

Interval

QB0723E

Page 38: Mitsubishi Triton 4d56 4m4

Operation Section1–33

(3) Injection Timing Calculation Method

11.3 Microinjection Quantity Learning Control

(1) Outline

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

quantity.)

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

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

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

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

curate microinjection.

(2) Learning Operations

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

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

NE Pulse

Solenoid Valve Control Pulse

Nozzle Needle Lift

0 1Actual TDC

Main InjectionPilot Injection

Pilot Injection Timing Main Injection TimingPilot Interval

Basic InjectionTiming

Corrections

Engine Speed

Injection Quantity

Main InjectionTiming

Atm

osph

eric

Pres

sure

Cor

rect

ion

Cool

ant T

empe

ratu

re C

orre

ctio

n

Inta

ke A

ir Te

mpe

ratu

re C

orre

ctio

n

Inta

ke A

ir Pr

essu

re C

orre

ctio

n

[1] Outline of Timing Control

[2] Injection Timing Calculation Method

QB0724E

Vo

lta

ge

Co

rre

ctio

n

Page 39: Mitsubishi Triton 4d56 4m4

Operation Section1–34

(3) Operational Outline

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

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

mation. The corrected injection quantity is then calculated.

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

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

Q001250E

Manual Learning Operations (as a Diagnostic Tool)

(A)

Number of IG OFF Occurrences

Vehicle Running Distance

Injection Quantity Deterioration Over Time Judgment

No Load Idle Instability Condition

Establishment of

Learning Operations

Q001251E

1st Cylinder

2nd Cylinder

3th Cylinder

4th Cylinder

1st Cylinder

2nd Cylinder

3th Cylinder

4th Cylinder

: ISC Correction Portion

ISC

Correction

Portion

: FCCB Correction Portion

FCCB

Correction

Portion

<Calculated Microinjection Quantity>

<When Performing Microinjection Quantity Learning>

Learning

Value

Page 40: Mitsubishi Triton 4d56 4m4

Operation Section1–35

12. FUEL INJECTION RATE CONTROL

12.1 OutlineWhile the injection rate increases with the adoption of high-pressure fuel injection, the ignition lag, which is the delay from the time

fuel is injected to the beginning of combustion, cannot be shortened to less than a certain value. As a result, the quantity of fuel that

is injected until main ignition occurs increases, resulting in an explosive combustion at the time of main ignition. This increases both

NOx and noise. For this reason, pilot injection is provided to minimize the initial ignition rate, prevent the explosive first-stage com-

bustion, and reduce noise and NOx.

Normal Injection Pilot Injection

Large First-stage Combustion (NOx and Noise)

Small First-stage Combustion

Injection Rate

Heat Release Rate

-20 TDC 20 40

Crankshaft Angle (deg)

-20 TDC 20 40

Crankshaft Angle (deg)QD2362E

Page 41: Mitsubishi Triton 4d56 4m4

Operation Section1–36

13. FUEL INJECTION PRESSURE CONTROL

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

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

Q000632E

Pressure

Pump Speed

Final Injection Quantity

Page 42: Mitsubishi Triton 4d56 4m4

Operation Section1–37

14. DIAGNOSTIC TROUBLE CODES (DTC)

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

Engineers)

14.2 Diagnostic Trouble Code DetailsThe DTC chart below is common to the 4D56/4M41 model. However, DTC number "P1210" is only for use with the 4D56 2WD mod-

el engine.

DTC

Number

(SAE)

Diagnostic Item Diagnostic Classifica-

tion

Malfunctioning Part Light

ON

Remarks

P0016 Speed-G phase gapmalfunction

Pulse system malfunc-tion

Crankshaft position sen-sor, cylinder recognitionsensor

Yes

P0072 Intake manifold tem-perature sensor - low

Open circuit detection(+B short, ground short,open)

Intake temperature sensor No

P0073 Intake manifold tem-perature sensor - high

Open circuit detection(+B short, ground short,open)

Intake temperature sensor No

P0088 Rail high pressureabnormality

Fuel pressure controlsystem abnormality

Injector Yes

P0089 SCV stuck diagnosis Fuel pressure controlsystem abnormality

Supply pump Yes

P0093 Fuel leak Fuel leak Fuel piping Yes

P0102 Airflow sensor - low Open circuit detection(+B short, ground short,open)

Airflow sensor No

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

Airflow sensor No

P0106 Turbo pressure sensorcharacteristic abnor-mality

Sensor characteristicabnormality

Turbo pressure sensor Yes

P0107 Turbo pressure sensor- low

Open circuit detection(+B short, ground short,open)

Turbo pressure sensor Yes

P0108 Turbo pressure sensor- high

Open circuit detection(+B short, ground short,open)

Turbo pressure sensor Yes

Page 43: Mitsubishi Triton 4d56 4m4

Operation Section1–38

P0112 Intake temperaturesensor - low

Open circuit detection(+B short, ground short,open)

Intake temperature sen-sor (AFS)

Yes

P0113 Intake temperaturesensor - high

Open circuit detection(+B short, ground short,open)

Intake temperature sen-sor (AFS)

Yes

P0117 Coolant temperaturesensor - low

Open circuit detection(+B short, ground short,open)

Coolant temperaturesensor

Yes

P0118 Coolant temperaturesensor - high

Open circuit detection(+B short, ground short,open)

Coolant temperaturesensor

Yes

P0122 Electronic controlthrottle - low

Open circuit detection(+B short, ground short,open)

Electronic control throttle Yes

P0123 Intake valve sensor -high

Open circuit detection(+B short, ground short,open)

Electronic control throttle Yes

P0182 Fuel temperature sen-sor - low

Open circuit detection(+B short, ground short,open)

Supply pump Yes

P0183 Fuel temperature sen-sor - high

Open circuit detection(+B short, ground short,open)

Supply pump Yes

P0191 Rail pressure sensorcharacteristic abnor-mality

Sensor characteristicabnormality

Rail Yes

P0192 Rail pressure sensor(time) low

Open circuit detection(+B short, ground short,open)

Rail Yes

P0193 Rail pressure sensor(time) high

Open circuit detection(+B short, ground short,open)

Rail Yes

P0201 TWV 1 (No.1 cylin-der) actuation systemopen circuit

Injector actuationabnormality

Injector Yes

P0202 TWV 4 (No.2 cylin-der) actuation systemopen circui

Injector actuationabnormality

Injector Yes

P0203 TWV 2 (No.3 cylin-der) actuation systemopen circuit

Injector actuationabnormality

Injector Yes

P0204 TWV 3 (No.4 cylin-der) actuation systemopen circuit

Injector actuationabnormality

Injector Yes

DTC

Number

(SAE)

Diagnostic Item Diagnostic Classifica-

tion

Malfunctioning Part Light

ON

Remarks

Page 44: Mitsubishi Triton 4d56 4m4

Operation Section1–39

P0219 Engine overrunabnormality

Engine abnormality Engine Yes

P0234 High boost abnormal-ity diagnosis

Engine abnormality Engine Yes

P0335 No speed pulse input Pulse system malfunc-tion

Crankshaft position sen-sor

Yes

P0336 Abnormal speedpulse number

Pulse system malfunctio Crankshaft position sen-sor

Yes

P0340 No G pulse input Pulse system malfunc-tion

Cylinder recognition sen-sor

Yes

P0341 Cylinder recognitionsensor pulse numberabnormality

Pulse system malfunc-tion

Cylinder recognition sen-sor

Yes

P0405 EGR lift sensor - low Open circuit detection(+B short, ground short,open)

EGR valve No

P0406 EGR lift sensor - high Open circuit detection(+B short, ground short,open)

EGR valve No

P0502 Vehicle speedabnormality - low

Pulse system malfunc-tion

Vehicle speed sensor Yes

P0604 RAM abnormality Engine ECU Engine ECU Yes

P0605 Engine ECU flash-ROM abnormality

Engine ECU Engine ECU Yes

P0606 Engine ECU CPUabnormality (main ICabnormality)

Engine ECU Engine ECU Yes

P0607 Engine ECU abnor-mality (monitoring ICabnormality)

Engine ECU Engine ECU Yes

P0628 SCV actuation sys-tem abnormality

Fuel pressure controlsystem abnormality

Supply pump Yes

P0629 SCV +B short Fuel pressure controlsystem abnormality

Supply pump Yes

P0638 Intake throttle valvestuck

Actuator malfunction Electronic control throttle Yes

P0642 Sensor - voltage 1low

Engine ECU Engine ECU Yes

P0643 Sensor - voltage 1high

Engine ECU Engine ECU Yes

P0652 Sensor - voltage 2low

Engine ECU Engine ECU Yes

P0653 Sensor - voltage 2high

Engine ECU Engine ECU Yes

DTC

Number

(SAE)

Diagnostic Item Diagnostic Classifica-

tion

Malfunctioning Part Light

ON

Remarks

Page 45: Mitsubishi Triton 4d56 4m4

Operation Section1–40

P1203 Low charge Engine ECU Engine ECU Yes

P1204 Over charge Engine ECU Engine ECU Yes

P1210 Throttle valveopening malfunction

Actuator malfunction Throttle valve Yes Only 4D56 Engine2WD

P1272 P/L open valveabnormality

Fuel pressure controlsystem abnormality

Rail Yes

P1273 Single pump abnor-mality diagnosis

Fuel pressure controlsystem abnormality

Supply pump Yes In the event that thevehicle runs out of gas,"P1273" may bedetected when thevehicle is restarted.When "P1273" is dis-played, the user shouldverify whether or notthere is gas in the vehi-cle.Do not replace thepump assy. if it hasbeen verified that thevehicle has run out ofgas. Remove the airfrom the fuel, and erasethe code using theMITSUBISHI MUT IIIdiagnosis tool.

P1274 Pump protective fillplug

Fuel pressure control system abnormality

Supply pump Yes

P1275 Pump exchange fillplug

Fuel pressure control system abnormality

Supply pump Yes

P1625 QR dataabnormality

Engine ECU Engine ECU Yes

P1626 QR data failure towrite to disc malfunc-tion

Engine ECU Engine ECU Yes

P2118 DC motor over cur-rent abnormality

Actuator malfunction Electronic control throttle Yes

P2122 Accelerator sensor-1low

Open circuit detection(+B short, ground short,open)

Accelerator position sen-sor

Yes

P2123 Accelerator sensor-1high final

Open circuit detection(+B short, ground short,open)

Accelerator position sen-sor

Yes

P2124 Accelerator sensor-1high

Open circuit detection(+B short, ground short,open)

Accelerator position sen-sor

No

DTC

Number

(SAE)

Diagnostic Item Diagnostic Classifica-

tion

Malfunctioning Part Light

ON

Remarks

Page 46: Mitsubishi Triton 4d56 4m4

Operation Section1–41

P2127 Accelerator sensor-2low

Open circuit detection(+B short, ground short,open)

Accelerator position sen-sor

Yes

P2138 Accelerator sensor -duplicate malfunc-tion high

Open circuit detection(+B short, ground short,open)

Accelerator position sen-sor

Yes

P2138 Accelerator sensor -duplicate malfunc-tion low

Open circuit detection(+B short, ground short,open)

Accelerator Position Sen-sor

Yes

ACCP characteristicabnormality

Sensor characteristicabnormality

Accelerator Position Sen-sor

Yes

P2146 Common 1 systemopen circuit

Injector actuationabnormality

Injector, Wire harness orEngine ECU

Yes

P2147 COM1 TWV actua-tion system groundshort

Injector actuationabnormality

Injector, Wire harness orEngine ECU

Yes

P2148 COM1 TWV actua-tion system +B short

Injector actuationabnormality

Injector, Wire harness orEngine ECU

Yes

P2149 Common 2 systemopen circuit

Injector actuationabnormality

Injector, Wire harness orEngine ECU

Yes

P2228 Atmospheric pres-sure sensor - low

Open circuit detection(+B short, ground short,open)

Engine ECU Yes

P2229 Atmospheric pres-sure sensor - high

Open circuit detection(+B short, ground short,open)

Engine ECU Yes

P2413 EGR feedback abnor-mality

Actuator malfunction EGR valve No

UD073 CAN bus OFF error Network Network No

UD101 CAN time out flag(trans)

Network Network No

UD109 CAN time out flag(ETACS)

Network Network No

UD190 CAN communication Network Network No

DTC

Number

(SAE)

Diagnostic Item Diagnostic Classifica-

tion

Malfunctioning Part Light

ON

Remarks

Page 47: Mitsubishi Triton 4d56 4m4

Operation Section1–42

15. EXTERNAL WIRING DIAGRAM

15.1 Engine ECU External Wiring DiagramThe wiring diagram below is common to the 4D56/4M41 model.

Q001257E

ThrottleSolenoid Valve

SCV(SuctionControl Valve)

AirConditioningRelay

FAN Relay

Control (ECCS) Relay

P1 P2

BATT

Air Conditioning 2 Switch

Air Conditioning 1 Switch

Glow Light

Glow Pulg RelayBATT

Key ACCI

SOFF

Battery

Starter

MotorEGR

Position

Sensor

EGR

DC Motor

Elecronic

Throttle

Control

Body

Earth

P1

Engine Warning Light

Tacho Meter

Vehicle Speed Sensor

NE+

NE-

A46

A65

A-VCC3

A-VCC4

Crankshaft

Position

Sensor

Cylinder

Recognition

Sensor

A44

A45

BATTB40

A/C2 SWA31

A/C1 SW A12

WA16

GROW LA38

GROW RA37

IG-SWB26

STA-SWB18

EGR LIFT RTNA72

EGR LIFTA53

B05

EGR -A07

EGR +A08

ETC -B37

ETC +B35

ETCP-S

ETCP-M

A81

SPDB16

TACHOB25

+BPB38

+BPB39

M-RELB24

THRA15

C FAN RA27

A/C RA26

CAN1-H

CAN1-L

B14

B06

SCVA17

G+

G-

A47

A66

PS-SW Power Steering Switch

Reverse Shift Switch

1st Shift Switch

Air Temperature Sensor

Fuel Temperature Sensor

Body

Earth

BATT

AcceleratorPosition Sensor

B30

MT REV SW B20

MT 1ST SW B19

A-VCC1 B01

APS1 B02

APS1 GND B03

A-VCC2 B09

APS2 B10

APS2 GND B11

A10

SCV-

SCV(Suction Control Valve)

SCV+

A29

A79

THF

THA

A50

THFRTN A69

Coolant Temperature SensorA51

THWRTN

THW

A70

Page 48: Mitsubishi Triton 4d56 4m4

Operation Section1–43

15.2 Engine ECU Connector DiagramThe connector diagram and terminal below are common to the 4D56/4M41 model.

Terminal Connections (1)

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

A01 P-GND Power Ground A11 — —

A02 — — A12 A/C1 SW Air Conditioning 1 Switch

A03 P-GND Power Ground A13 — —

A04 COMMON 1 INJ#1/#4 BATT. A14 — —

A05 COMMON 1 INJ#2/#3 BATT. A15 THR Throttle Solenoid Valve

A06 — — A16 W EngineWarning Light

A07 EGR- EGR-DC Motor (-) A17 SCV SCV (Suction Control Valve)

A08 EGR+ EGR-DC Motor (+) A18 — —

A09 — — A19 — —

A10 SCV+ SCV (Suction Control Valve) A20 — —

Q001258E

Rail Pressure Sensor

(Pc Sensor)

EXTAir Temperature Sensor

Airflow Sensor

P1

Turbo Pressure Sensor

COMMON1A04

TWV1A43

TWV1A42

COMMON1A05

TWV2

TWV2

A24

Injector3 Drive (#4 Cylinder)

A23

TWV3A41

TWV3A40

TWV4A22

TWV4A21

P-GND

Body Earth

P-GND

C-GND

A01

A03

B33

A48PFUEL1

A49

A63

PFUEL2

A-VCC5

A68PFUEL RTN

A64

A52BOOST

A71BOOST RTN

A-VCC6

A55

A74

A54AMF

A73AMF RTN

EXT-A-TMP

EXT-A-RTNInjector4 Drive (#2 Cylinder)

Injector2 Drive (#3 Cylinder)

Injector1 Drive (#1 Cylinder)

Q001259E

Page 49: Mitsubishi Triton 4d56 4m4

Operation Section1–44

Terminal Connections (2)

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

A21 TWV4 Injection 4 Drive (#2 Cylinder) A57 — —

A22 TWV4 Injection 4 Drive (#2 Cylinder) A58 — —

A23 TWV2 Injection 2 Drive (#3 Cylinder) A59 — —

A24 TWV2 Injection 2 Drive (#3 Cylinder) A60 — —

A25 — — A61 — —

A26 A/C R Air Conditioning Relay A62 — —

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

A28 — — A64 A-VCC6 Turbo Pressure Sensor Source (5V)

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

A30 TEST Test Switch Input A66 G- Cylinder Recognition Sensor Ground

A31 A/C2 SW Air Conditioning 2 Switch A67 — —

A32 — — A68 PFUEL RTN Rail Pressure Sensor Earth

A33 — — A69 THF RTN Air Temperature Sensor, Fuel Temper-ature Sensor Earth

A34 — — A70 THW RTN Coolant Temperature Sensor Earth

A35 — — A71 BOOST RTN Turbo Pressure Sensor

A36 — — A72 EGR LIFTRTS

EGR Position Sensor Earth

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

A38 GLOW L Glow Light A74 EXT-A-RTN Air Temperature Sensor Earth (W/FAS)

A39 — — A75 — —

A40 TWV3 Injection 3 Drive (#4 Cylinder) A76 — —

A41 TWV3 Injection 3 Drive (#4 Cylinder) A77 — —

A42 TWV1 Injection 1 Drive (#1 Cylinder) A78 — —

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

A44 A-VCC3 Crankshaft Position Sensor BATT A80 — —

A45 A-VCC4 Cylinder Recognition Sensor BATT A81 ETCP-S Electoronic Throttle Control (Sub)

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

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

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

A49 PFUEL Rail Pressure Sensor (B/UP) B04 — —

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

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

A52 BOOST Turbo Pressure Sensor B07 — —

A53 EGR LIFT EGR Position Sensor B08 — —

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

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

Page 50: Mitsubishi Triton 4d56 4m4

Operation Section1–45

Terminal Connections (3)

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

B11 APS 2 GND Accelerator Position Sensor (Sub)Earth

B26 IG-SW Ignition Switch

B12 — — B27 — —

B13 — — B28 — —

B14 CAN1-H CAN H (W/Resister) B29 — —

B15 — — B30 PS-SW Power Steering Switch

B16 SPD Vehicle Speed Sensor B31 — —

B17 — — B32 — —

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

B19 MT 1ST SW 1st Shift Switch B34 — —

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

B21 — — B36 — —

B22 — — B37 ETC- Electronic Throttle Control Motor (-)

B23 — — B38 +BP Battery

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

B39 +BP Battery

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

Page 51: Mitsubishi Triton 4d56 4m4

Operation Section1–46

Page 52: Mitsubishi Triton 4d56 4m4

DENSO INTERNATIONAL THAILAND Field Technical Service Department

Edited and published by:

369 Moo 3 Teparak Rd. Muang Samutprakarn Thailand

Published : June 2005

Printed in Thailand