Mitsubishi Montero (2002-2004). Manual - part 556

 

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Mitsubishi Montero (2002-2004). Manual - part 556

 

 

ON-VEHICLE SERVICE

TSB Revision

MULTIPORT FUEL INJECTION (MFI)

13Aa-11

THROTTLE BODY CLEANING

M1131001000246

1. Start the engine and warm it up until the coolant is heated to 

80

°C (176°F) or higher. Stop the engine.

2. Remove the air intake hose from the throttle body.
3. Spray cleaning solvent into the valve through the throttle 

body intake port and leave it for approximately five minutes.

4. Start the engine, rev it several times and then idle it for about 

one minute. If the idling speed becomes unstable (or if the 
engine stalls) due to the bypass passage being plugged, 
slightly open the throttle valve to keep the engine running.

5. If the throttle valve deposits are not removed, repeat steps 3 

and 4.

6. Unplug the bypass passage inlet.
7. Attach the air intake hose.
8. Use scan tool MB991502 to erase any diagnostic trouble 

code.

AK201059 AC

X

EVAPORATIVE 
EMISSION 
VENTILATION 
SOLENOID

AK201275AC

RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)

RIGHT BANK
HEATED OXYGEN
SENSOR (REAR)
CONNECTOR

Y

AK201288

TRANSMISSION 
RANGE SWITCH

AC

Z

AK201308

FUEL SENSOR 
(INCORPORATING 
FUEL TEMPERATURE
SENSOR)

AB

a

FUEL TANK DIFFERENTIAL
PRESSURE SENSOR

ON-VEHICLE SERVICE

TSB Revision

MULTIPORT FUEL INJECTION (MFI)

13Aa-12

ACCELERATOR PEDAL POSITION SENSOR 
ADJUSTMENT

M1131050500016

Required Special Tools:

• MB991658: Test Harness Set

CAUTION

1. The accelerator pedal position sensor should not be 

moved unnecessarily; it has been precisely adjusted by 
the manufacture. If the adjustment is disturbed for any 
reason, readjust as follows.

2. If the adjustment is disturbed for any reason, readjust 

as follows.

1. Remove the accelerator pedal complete.

2. Connect the scan tool MB991502 to the data link connector. 

If the can tool MB991502 is not used, carry out the following 
steps.

(1) Disconnect the accelerator pedal position sensor 

connector, and connect the special tool (test harness: 
MB991658) to that connector. (Be careful not to confuse 
the terminal numbers.)

(2) Connect a digital voltmeter between accelerator pedal 

position sensor connector terminal No. 3 accelerator 
pedal position sensor (main) output and terminal No. 3 
accelerator pedal position sensor (main) earth.

3. Loosen the accelerator pedal position sensor mounting 

bolts, and hold the accelerator pedal position sensor 
temporary.

4. Check that the accelerator pedal arm touches the full-closed 

stopper.

5. Adjust the pedal arm by the adjusting screw so that 

clearance "A" (see the illustration) is 0.5 

− 0.93 mm (0.020 − 

0.037 in).

6. Hold the adjusting screw with the lock nut. 
7. Turn the ignition switch to the ON position. (but do not start 

the engine.)

8. Turn the accelerator pedal position sensor until the output 

from accelerator pedal position sensor (main) satisfies the 
standard value.

Standard value: 0.905 

− 1.165 volts

9. Tighten the accelerator pedal position sensor mounting bolts 

securely.

10.Install the accelerator pedal complete.

1 2 3 4 5 6 7 8

AK201309 AB

Equipment side
connector

ACCELERATOR PEDAL
POSITION SENSOR

ACCELERATOR 
PEDAL

AK201310 AB

ACCELERATOR PEDAL
POSITION SENSOR

MB991658

AK201311

ACCELERATOR 

PEDAL POSITION 

SENSOR

ACCELERATOR 
PEDAL ARM

ADJUSTING
SCREW

FULL-CLOSED
STOPPER

CLEARANCE
"A"

AB

ON-VEHICLE SERVICE

TSB Revision

MULTIPORT FUEL INJECTION (MFI)

13Aa-13

FUEL PRESSURE TEST

M1131001900238

Required Special Tools:

• MB991502: Scan Tool (MUT-II)

• MB991637: Fuel Pressure Gauge Set

• MD998709: Adaptor Hose

• MD998742: Hose Adaptor

1. Release residual pressure from the fuel line to prevent fuel 

spray. (Refer to 

P.13Aa-15

.)

WARNING

To prevent a fire, cover the hose connection with 
shop towels to prevent splashing of fuel that could be 
caused by some residual pressure in the fuel pipe 
line.

2. Disconnect the fuel high-pressure hose at the fuel rail side.
3. Assemble the fuel pressure measurement tools as follows.

<When using the fuel pressure gauge>

1. Remove the union joint and bolt from special tool 

MD998709 (adapter hose) and instead attach special tool 
MD998742 (hose adapter) to the adapter hose.

2. Place a suitable O-ring or gasket on the assembled special 

tools MD998709 and MD998742 and install the fuel pres-
sure gauge.

3. Install the assembled fuel pressure measurement tools 

between the fuel rail and fuel high-pressure hose.

<When using special tool MB991637 (fuel pressure gauge 

set)>

1. Remove the union joint and bolt from special tool 

MD998709 (adapter hose) and instead attach special tool 
MD998742 (hose adapter) to the adapter hose.

2. Install special tool MB991637 (fuel pressure gauge set) into 

assembled special tools MD998709 and MD998742 via a 
gasket.

3. Install the assembled fuel pressure measurement tools 

between the fuel rail and fuel high-pressure hose.

AK201312AB

HIGH-PRESSURE
FUEL HOSE

AKX01457AB

FUEL PRESSURE 
GAUGE

O-RING OR GASKET

MD998709

MD998742

HIGH-PRESSURE
FUEL HOSE

FUEL 
RAIL 

AKX01458

MB991637

O-RING OR GASKET

MD998709

MD998742

HIGH-
PRESSURE
FUEL HOSE

FUEL
RAIL

AB

ON-VEHICLE SERVICE

TSB Revision

MULTIPORT FUEL INJECTION (MFI)

13Aa-14

CAUTION

To prevent damage to scan tool MB991502, always turn the 
ignition switch to the "LOCK" (OFF) position before con-
necting or disconnecting scan tool MB991502.
4. Connect scan tool MB991502 to the data link connector.
5. Use Actuator test 07 to drive the fuel pump. Check that there 

is no fuel leaking from any section when the fuel pump is 
operating.

6. Stop the fuel pump.
7. Start the engine and run at idle.
8. Measure fuel pressure while the engine is running at idle.

Standard value: Approximately 270 kPa (38 psi) at 
curb idle

9. Disconnect the vacuum hose (blue stripe) from the fuel 

pressure regulator and measure the fuel pressure with the 
hose end closed with your finger.

Standard value: 330 

− 350 kPa (47 − 50 psi) at curb idle

10.Check to see that fuel pressure at idle does not drop even 

after the engine has been revved several times.

11.Revving the engine repeatedly, hold the fuel return hose 

lightly with your fingers to feel that fuel pressure is present in 
the return hose.
NOTE: If the fuel flow rate is low, there will be no fuel pres-
sure in the return hose.

12.If any of fuel pressure measured in steps 8 to 11 is out of 

specification, troubleshoot and repair according to the table 
below.

13.Stop the engine and observe fuel pressure gauge reading. It 

is normal if the reading does not drop within two minutes. If it 
does, observe the rate of drop and troubleshoot and repair 
according to the table below. Start, then stop the engine.

(1) Squeeze the fuel return line closed to confirm leak-down 

occurs from defective fuel pressure regulator.

SYMPTOM

PROBABLE CAUSE

REMEDY

• Fuel pressure too low

• Fuel pressure drops after racing

• No fuel pressure in fuel return 

hose

Clogged fuel filter

Replace fuel filter

Fuel leaking to return side due to 
poor fuel regulator valve seating or 
settled spring

Replace fuel pressure regulator

Low fuel pump delivery pressure

Replace fuel pump

Fuel pressure too high

Binding valve in fuel pressure 
regulator

Replace fuel pressure regulator

Clogged fuel return hose or pipe

Clean or replace hose or pipe

Same fuel pressure when vacuum 
hose is connected and when 
disconnected

Damaged vacuum hose or 
clogged nipple

Replace vacuum hose or clean 
nipple

Defective fuel pressure regulator

Replace fuel pressure regulator

ACX01539

16-PIN

MB991502

AC

AK201313AB

NIPPLE

 

 

 

 

 

 

 

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