MITSUBISHI PAJERO 4M41 ENGINE COMMON RAIL
MITSUBISHI PAJERO 4M41 ENGINECOMMON RAIL SYSTEM (CRS)Published : March 2007Second Issue : September 200800400597EA
2008 DENSO CORPORATIONAll rights reserved. This material may not be reproducedor copied, in whole or in part, without the writtenpermission of DENSO Corporation.
Table of ContentsTable of ContentsOperation Section1. PRODUCT APPLICATION INFORMATION1.1Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.2Applicable Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.3System Component Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12. SUPPLY PUMP2.1Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32.2Suction Control Valve (SCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42.3Fuel Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-73. RAIL3.1Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-83.2Rail Pressure Sensor (Pc Sensor). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-93.3Pressure Limiter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-94. INJECTOR (G2 TYPE)4.1Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-104.2Characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-104.3Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-114.4QR Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-125. OPERATION OF CONTROL SYSTEM COMPONENTS5.1Engine Control System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-135.2Engine Electronic Control Unit (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-145.3Camshaft Position Sensor (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-215.4Manifold Absolute Pressure (MAP) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-225.5Mass Air Flow (MAF) Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-235.6Diesel Throttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-246. FUEL INJECTION CONTROL6.1Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-256.2Fuel Injection Quantity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-256.3Other Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-277. OTHER SYSTEMS7.1Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-297.2Diesel Particulate Filter (DPF) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-298. DIAGNOSTIC TROUBLE CODES (DTC)8.1Codes Shown in the Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-308.2DTC Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
Table of Contents
Operation Section1 11. PRODUCT APPLICATION INFORMATION1.1 OutlineThis manual describes the 4M41 engine Common Rail System (CRS) installed in the MITSUBISHI PAJERO, on sale from September 2006. As of September 2008, the 4M41 engine CRS has been changed asper the list below. As such, this manual contains additional information related to the aforementioned changes.Supply pump changeInjector changeDiagnostic Trouble Code (DTC) changes1.2 Applicable VehicleVehicle ManufacturerMITSUBISHIVehicle Name Engine ModelPAJERO4M41SpecificationDestinationLine Off Period4WD (MT/AT)Europe, AustraliaSep, 2006 ** : The engine model has not been changed since September 2006. However, the specifications havechanged as of September 2008.1.3 System Component Part NumbersPart NameSupply pumpInjectorRailDENSOManufacturerPart NamePart NameSM294000-034#1460A003Sept. 2006 to Aug. 2008SM294000-107#1460A040from Sept. 2008SM095000-576#1465A054Sept. 2006 to Aug. rksfrom Sept. 2008Sept. 2006 to Aug. 2008275800-468#1860A699Manualtransmissionvehicles onlySept. 2006 to Aug. es onlyEngine ECU275800-932#1860B029from Sept. 2008275800-933#1860B028from Sept. 2008275800-934#1860B027from Sept. 2008275800-935#1860A261from Sept. 2008275800-936#1860B100from Sept. 2008
Operation Section1 2DENSOManufacturerPart NamePart Name079800-779#1865A035Diesel throttle197920-002#1450A033Fuel temperature sensor179730-002#MR547077Mass air flow (MAF) meter197400-227#1525A016Exhaust gas temperature sensor 1265600-145#1587A013Exhaust gas temperature sensor 2265600-146#1587A014Exhaust gas temperature sensor 3265600-147#1587A015Differential pressure sensor104990-136#1865A087Absolute pressure sensor104990-135#0865A086Part NameManifold absolute pressure (MAP)RemarkssensorTemperature sensor for differentialpressure sensorvehicles -Vacuum Regulating Valve(E-VRV)forTurbo (VGT)VariableGeometryAutomatictransmission
Operation Section1 32. SUPPLY PUMP2.1 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 (trochoidtype). The feed pump draws in fuel from the fuel tank for delivery to the plunger chamber.The internal camshaft drives the two plungers which pressurize the fuel sent to the plunger chamber, andthen send the fuel to the rail. The quantity of fuel supplied to the rail is controlled by the SCV via signalsfrom the engine ECU. The SCV is a normally open type (the intake valve is open during de-energization).The HP3 supply pump was equipped with a compact SCV. However, the SCV was changed to the conventional type as of September 2008.For information on basic HP3 supply pump operation (suction from the fuel tank, fuel delivery to the rail,etc.), refer to the publication entitled, "General Edition Manual: Common Rail System (Doc ID:00400076E)."Exterior View
1 4Operation Section2.2 Suction Control Valve (SCV)The supply pump for the 4M41 engine CRS is equipped with a normally open type SCV. From September2006 to August 2008, a compact SCV was used. However, the SCV was changed to the conventional typeas of September 2008.While both the conventional and compact type SCVs have identical functions, the operation method differs.When the solenoid is not energized, the return spring pushes against the needle valve, completely openingthe fuel passage and supplying fuel to the plungers. (Total quantity suctionedTotal quantity discharged)When the solenoid is energized, the armature pushes the needle valve, which compresses the return springand closes the passage. In contrast, the needle valve in the compact SCV is pulled upon, which compressesthe return spring and closes the fuel passage.The solenoid is actuated by the duty ratio control. Fuel is supplied in an amount corresponding to the opensurface area of the passage, which depends on the duty ratio. Fuel is then discharged by the plungers.Conventional SCV: from September 2008Compact SCV: from September 2006 to August 2008
Operation Section1 5(1) When the SCV energized duration (duty ON time) is shortWhen the SCV energization time is short, the average current flowing through the solenoid is small. As aresult, the needle valve is returned by spring force, creating a large valve opening. Subsequently, the fuelsuction quantity increases.Conventional SCV: from September 2008Compact SCV: from September 2006 to August 2008
1 6Operation Section(2) When the SCV energized duration (duty ON time) is longWhen the energization time is long, the average current flowing to the solenoid is large. As a result, theneedle valve is pressed out (in the compact SCV, the needle valve is pulled), creating a small valve opening. Subsequently, the fuel suction quantity decreases.Conventional SCV: from September 2008Compact SCV: from September 2006 to August 2008
Operation Section1 72.3 Fuel Temperature SensorDetects the fuel temperature and sends a corresponding signal to the engine ECU. Based on this information, the engine ECU calculates the injection volume correction that is appropriate for the fuel temperature.
1 8Operation Section3. RAIL3.1 OutlineThe rail stores pressurized fuel (25 to 180 MPa) that has been delivered from the supply pump and distributes the fuel to each cylinder injector. The rail is equipped with a rail pressure sensor and a pressure limitervalve.The rail pressure sensor (Pc sensor) detects fuel pressure in the rail and sends a signal to the engine ECU;the pressure limiter controls the excess pressure. As a result, both optimum combustion and a combustionnoise reduction are achieved.
Operation Section1 93.2 Rail Pressure Sensor (Pc Sensor)The pressure sensor detects the fuel pressure of the rail, and sends a signal to the engine ECU. The sensoris made from a semiconductor that uses the Piezo resistive effect to detect changes in electrical resistancebased on the pressure applied to the elemental silicon. In comparison to the old model, this sensor is compatible with high pressure.3.3 Pressure LimiterThe pressure limiter releases pressure when the internal rail pressure becomes abnormally high. The pressure limiter opens when internal pressure reaches 221 MPa (2254 kg/cm2), and closes when rail pressurereaches a given set pressure. Fuel released from the pressure limiter is returned to the fuel tank.
1 10Operation Section4. INJECTOR (G2 TYPE)4.1 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.For information on both basic injector operation and handling injectors with QR codes, refer to the publication entitled, "General Edition Manual: Common Rail System (Doc ID: 00400076E)."4.2 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 (30alphanumeric 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 enterthe ID codes in the engine ECU using the MITSUBISHI diagnosis tool (MUT III).Compared to the injectors used up to August 2008, the injectors used from September 2008 have differentnozzle specifications and QR code correction points.
Operation Section4.3 Construction1 11
1 12Operation Section4.4 QR CodesConventionally, the entire injector assembly was replaced during injector replacement. However, the QRcodes currently in use improve injector quantity precision.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.September 2006 to August 2008from September 2008
Operation Section5. OPERATION OF CONTROL SYSTEM COMPONENTS5.1 Engine Control System Diagram1 13
Operation Section1 145.2 Engine Electronic Control Unit (ECU)The engine ECU is the command center that controls the fuel injection system and engine operation in general.
Operation Section(1) External wiring diagram1 15
1 16Operation Section
Operation Section1 17(2) Connector diagramTerminal connectionsNo.Pin SymbolSignal NameA01A02A03TWV4Injector #2A07THF-GNDFuel Temperature Sensor GroundA08DPF-DI-P-GNDDPF Difference Pressure Sensor GroundA09EGRLIFT-GNDEGR Position Sensor GroundA10DPFTMP1-GNDDPF Exhaust Gas Temperature Sensor 1 Ground (Before FCC)A11DPFTMP2-GNDDPF Exhaust Gas Temperature Sensor 2 Ground (Before UCC)A12DPFTMP3-GNDDPF Exhaust Gas Temperature Sensor 3 Ground (After DPF)A13DPF-P-TMP-GNDDPF Temperature Sensor for Difference Pressure Sensor GroundA14EXT-A-TMP-GNDIntake Air Temperature Sensor Ground (W/AFS)A15THW-GNDCoolant Temperature Sensor GroundA16PFUEL-GNDRail Pressure Sensor GroundA18G-Camshaft Position Sensor GroundA19NE-Crankshaft Position Sensor GroundA21TPS-VCCDiesel Throttle Position Sensor SourceA22DPF-DI-P-VCCDPF Difference Pressure Sensor SourceTWV2Injector #3A04A05A06A17A20A23A24A25A26A27A28
Operation Section1 18No.Pin SymbolSignal NameA29A30A31THFFuel Temperature SensorA32DPF-DI-PDPF Difference Pressure SensorA33EGRLIFTEGR Position SensorA34DPFTMP1DPF Exhaust Gas Temperature Sensor 1 (Before FCC)A35DPFTMP2DPF Exhaust Gas Temperature Sensor 2 (Before UCC)A36DPFTMP3DPF Exhaust Gas Temperature Sensor 3 (After DPF)A37DPF-P-TMPDPF Temperature Sensor for Difference Pressure SensorA38EXT-A-TMPIntake Air Temperature Sensor (W/AFS)A39THWCoolant Temperature SensorA40PFUELRail Pressure SensorA42G Camshaft Position SensorA43NE Crankshaft Position SensorA44NE-VCCCrankshaft Position Sensor BatteryA45G-VCCCamshaft Position Sensor BatteryA46PFUEL-VCCRail Pressure Sensor SourceA47EGRLIFT-VCCEGR Position Sensor SourceA48BOOST-VCCMAP Sensor SourceA49COMMON1Injector #2/#3 BatteryTWV3Injector #4A55BOOST-GNDMAP Sensor GroundA56THA-GNDIntake Air Temperature Sensor GroundTPS-GNDDiesel Throttle Position Sensor GroundA61BOOSTMAP SensorA62THAIntake Air Temperature SensorTPSDiesel Throttle Position 7
Operation SectionNo.Pin SymbolSignal NameA68A69A70PTC-REL1PTC Relay 1A73COMMON1Injector #1/#4 BatteryA74TWV1Injector #1PTCPTC SwitchA80AC1A/C 1 SwitchA81MT-REVReverse SwitchA83MT-1ST1st Shift SwitchA84AC2A/C 2 SwitchVGTVGT SolenoidA91AC-RELA/C RelayA92GLOW-RELGlow Plug RelayA93FANC Fan RelaySWIRLSwirl Control ValveB02C-GNDSIG GroundB03P-GNDPower GroundB04P-GNDPower GroundB05 BBatteryB06 BBatteryB07SCV-Suction Control Vaive (-)APS-M-VCCAccelerator Position Sensor Main 4A95A96B01B08B09B101 19
Operation Section1 20No.Pin SymbolSignal NameB11APS-MAccelerator Position Sensor MainB12APS-M-GNDAccelerator Position Sensor Main GroundB15CRUISE-GNDCruise Control Switch GroundB16AMF-GNDMass Air Flow Meter GroundSCV Suction Control Valve ( )B23APS-S-VCCAccelerator Position Sensor Sub SourceB24APS-SAccelerator Position Sensor SubB25APS-S-GNDAccelerator Position Sensor Sub EarthB28CRUISECruise Control Switch (without IG)B29AMFMAF MeterB30SPDVehicle Speed SensorM-RELMain Relay (with Diode)B40BRK-L-SWBrake Lamp SwitchB41BRK-SWBrake Switch (Large Current)B42PSPower Steering SwitchB44ETV-Diesel Throttle DC Motor (-)B45EGR-EGR DC Motor (-)B46BATTBattery (Backup with Monitor)B47IG-SWIgnition 5B36B37B38B39B43B48B49
Operation SectionNo.Pin Symbol1 21Signal NameB50B51CAN-HCAN high (without Resistor)B52CAN-LCAN Lo (without Resistor)B53FPSWFuel Filter Pressure SwitchB54STAStarter SignalB55CLUCH-SWCluch SwitchB57ETV Diesel Throttle DC Motor ( )B58EGR EGR DC Motor ( )B565.3 Camshaft Position Sensor (TDC)The camshaft position sensor outputs cylinder identification signals. The sensor outputs five pulses for every two revolutions (720ºCA) of the engine.
1 22Operation Section5.4 Manifold Absolute Pressure (MAP) SensorThe MAP sensor is a type of semiconductor pressure sensor that utilizes changes in electrical resistancethat occur when the pressure applied to a silicon crystal changes. Since a single sensor is used to measureboth manifold absolute pressure and atmospheric pressure, a VSV is used to alternate between atmospheric and turbo pressure measurement.(1) Atmospheric pressure measurement conditionsThe VSV turns ON for 150 msec to detect the atmospheric pressure when one of the conditions below ismet:Engine speed 0 rpmStarter is onIdle is stable(2) Turbo pressure measurement conditionsThe VSV turns OFF to detect the turbo pressure if the atmospheric pressure measurement conditions arenot met.
Operation Section1 235.5 Mass Air Flow (MAF) MeterThe MAF meter is a plug-in type that allows a portion of the intake air to flow through the detection area.Detection precision has been improved, and the intake air resistance has been reduced by directly measuring the mass and flow rate of the intake air.This MAF meter has a built-in intake air temperature sensor.
1 24Operation Section5.6 Diesel Throttle(1) OutlineThe diesel throttle stops the suctioning of air through interlocking the intake throttle with the key switch inorder to reduce engine vibration when the vehicle is not running.(2) Operation
Operation Section1 256. FUEL INJECTION CONTROL6.1 OutlineThe following explains the types of control used in the PAJERO system. For details on each type of control,refer to the publication entitled, "General Edition Manual: Common Rail System (Doc ID: 00400076E)."(1) Fuel injection rate control functionPilot injection control injects a small amount of fuel before the main injection.(2) Fuel injection quantity control functionThe fuel injection quantity control function replaces the conventional governor function. Fuel injectionquantity control adjusts the fuel injection to the optimal injection quantity based on the engine speed andaccelerator position signals.(3) Fuel injection timing control functionThe fuel injection timing control function replaces the conventional timer function. It controls the injectionto an optimal timing based on the engine speed and the injection quantity.(4) Fuel injection pressure control function (rail pressure control function)The fuel injection pressure control function (rail pressure control function) controls the discharge volumeof the pump by measuring the fuel pressure at the rail pressure sensor and feeding it back to the ECU. Iteffects pressure feedback control so that the discharge volume matches the optimal (command) valueset in accordance with the engine speed and the injection qua
MITSUBISHI PAJERO 4M41 4WD (MT/AT) Europe, Australia Sep, 2006* Part Name DENSO Part Name Manufacturer Part Name Remarks Supply pump SM294000-034# 1460A003 Sept. 2006 to Aug. 2008 SM294000-107# 1460A040 from Sept. 2008 Sept. 2006 to Aug. 2008 Injector from Sept. 2008 SM095000-576# 1465A0
Mitsubishi RCN-K-E Mitsubishi RCN-KIT3-E Mitsubishi RCN-T-36W-E Mitsubishi RCN-TC-24W-ER Mitsubishi RKN502A-241D Mitsubishi RKN502A241F Mitsubishi RKS502A503 Mitsubishi RKW502A001 Mitsubishi RKW502A200 Mitsubishi RKW502A200A/B Mitsubishi RKX502A001B Mitsubishi RKX502A001C Mitsubishi RKX502A001G Mitsubishi RKX502A001P Mitsubishi RMA502A001 .
This manual describes the 4M41 engine Common Rail System (CRS) installed in the MITSUBISHI PAJE-RO, on sale from September 2006. As of September 2008, the 4M41 engine CRS has been changed as per the list below. As such, this manual contains additional information related to the aforementioned chang-es. Supply pump change Injector change
The Mitsubishi Pajero Owners Club The Mitsubishi Pajero, Shogun, Montero, Challenger, Raider and EVO 4x4 Owner's Club FAQ Search Watched Topics Memberlist Usergroups Profile You have no new messages Log out [ SimonB ] Calendar Club Shop Chat (0) Classified Ads POCUK Home POCUK Forums POC.pl Yellow Diamond Clubs Diesel pump top leak fix The Mitsubishi Pajero Owners Club Forum Index .
OWNER’S MANUAL PAJERO PAJERO - ENGLISH - OBKE10E1 PAJERO - ENGLISH - OBKE10E1. Foreword E09200103011 Thank you for selecting a PAJERO as your new vehicle. This owner’s manual will add to your understanding and full enjoyment of the many fine features of this vehicle. . 12.Rear differential lock switch* p. 4-28 13.Transfer shift lever p. 4 .
mitsubishi catalogue date: 2017/08/11 seq. photo oem_no description 9 1005a207 mitsubishi 4d56 cyl head gasket 10 1025a091 mitsubishi 4d56 l200 2.5 crdi 16 valv rocker arm with screw 11 md723202 mitsubishi 4d68t/mitsubishi l200 gl gls e . w repair kit for b/master cylinder 120 mr305377 mitsubishi pajero l200/l300 (4g54) speed
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Pajero Angaben zu Verbrauch, CO 2-Emission und Effi zienzklassen fi nden Sie auf der Prospektrückseite. Der kann mehr einstecken, als Sie bisher wussten. Das Pajero Zubehör. Damit Sie Ihren Pajero perfekt an Ihre Bedürf
2.1 ASTM Standards: 2 E 178 Practice for Dealing with Outlying Observations E 867 Terminology Relating to Vehicle-Pavement Systems E 1364 Test Method for Measuring Road Roughness by Static Level Method F 457 Test Method for Speed and Distance Calibration of a Fifth Wheel Equipped with Either Analog or Digital Instrumentation 3. Terminology 3.1 Definitions: 3.1.1 aliasing—in the context of .
