Valid: 03-12-17 Replaces: 03-04-02 ADDITIONAL SUPPLEMENT FOR MITSUBISHI L200 2,5D - 02 VALID FOR CARS WITH STT EMTEC SYSTEM General description Design drawings and Part lists. 60-01 Specification.. 60-02 Installation Before installation. 60-03 Mounting instructions Exhaust system 60-04 Electronics, ECU.. 60-05 Air cleaner system.. 60-06 Handling & Service System function control. 60-07 Fault diagnosis. 60-08 Installation/Quality sheet 60-09 102195 Inst.Man. L200-02eng STT Emtec AB Phone: +46 60 64 10 40 Kontorsvägen 9 Fax: +46 60 64 10 45 SE 852 29 Sundsvall www.sttemtec.com Sweden
DESCRIPTION 60-01 (1/3) VGT = (Variable Geometry Turbine) = Turbo charger with a variable size of the turbine housing. ECU (Electronic Control Unit) Safety features: - The system has a built in temperature compensation that reduces the power output in case the engine temperature should exceed normal values.
Air Cleaner System General Description 60-01 (2/3) L 200 2,5 DIESEL 02 (STT Emtec-conversion) Pos. Quant. STT Art.No. 1 1 410-74-0001.0 2 2 480-00-0653.0 4 1 410-74-0002.0 6 1 101088 7 1 101138 8 1 480-00-0232.0 9 1 480-00-0014.0
General Description 60-01 (3/3) Exhaust system L 200 2,5 DIESEL (STT Emtec-Conversion) Exhaust system complete Installation kit (pos 8 and 9) Pos. Quant. STT Art. No. Pos. Quant. STT Art. No. 1 1 100625 17 Original part 2 1 100626 18 3 1 Original part. 19 4 1 100627 20 5 1 101132 21 6 1 101127 7 1 101211 8 3 407-38-0001.0 9 2 418-00-0038.0 10 Original part 11 12 13 14 15 16
GENERAL DESCRIPTION 60-02 Specification Specification Engine type Engine Mitsubishi 4D56 4 cyl. swirl chamber Bore x Stroke (mm) 91,1 x 95 Number of cylinders 4 in line Cubic capacity (cc) 2477 Compression ratio 21:1 Max. power kw/ (HP) at 3950 v/min 101 (137) Max torque Oil cooling system Oil type Camshaft system Air cleaner type 290 Nm @ 2200-2800 rpm Air/Oil Thermostat control 5W/40 Synthetic, SOHC Dry paper filter Turbocharger type Mitsubishi VGT (49302-5400) Max boost pressure: @ 2500 rpm @ 3750 rpm Intercooler type 1,20-1,35 bar 1,20-1,35 bar Air/Air Exhaust system Absorption system ø 63 Fuel injection system Emission Control System Electronically controlled distributor pump EGR / Oxidation catalyst
DISMOUNTING INSTRUCTIONS 60-03 Before installation 1. Test run for engine condition control. Note idle rpm with warm engine in the Installation/Quality sheet. Page 60-09. 2. Wash the engine and cooler elements. Use compressed air to blow the cooler and remove insects and dirt. (Not new cars). 3. Remove the original exhaust system, from the turbo charger and backwards. 4. Disconnect the batteries. 5. Remove the air filter with hoses. The following original parts are exchanged for STT Emtec parts. Exhaust system. Hoses to and from the air cleaner
Mounting Instructions 60-04 Exhaust system 1. Mount the complete exhaust system including the enclosed supports and mountings. 2. Adjust the exhaust system by turning the pipes and silencer. The system must be properly aligned and not in contact with any part of the body or frame. 3. Tighten the bolts and nuts starting at the motor end.
Mounting Instruction 60-05 (1/2) Electronics, ECU Picture 1 1. Note the ECU serial No. on page 60-09 (Installation/Quality sheet) 2. Remove the side panel and the plastic panel under glove compartment. The plastic panel under the glove compartment is removed by pushing in the center of the three plastic pins that is holding it in position. ( Pict.1). The side panel is removed by loosen the two plastic plugs at the front and then gently bend it to the side and backwards. 3. Fit the ECU (1) on the plastic panel under the glove compartment using the Velcro tapes (2). Place the ECU in a position on the plastic panel were it fits in an empty space under the glove compartment and the harness (3) can reach to its sockets. (Page 60-05 2/2). 4. Connect the harness (3) to the STT Emtec ECU (1) and the std ECU according to the instruction on page 60-05 (2/2). Pos Quant Art. No:. 1 1 100622 2 1 410-00-0092.0 3 1 100623 Picture 2. 1 3
Mounting Instruction 60-05 (2/2) Electronics, ECU 5. Remove connection (A), a 22 pin connector on the standard engine ECU, and connect it in the corresponding socket in the STT Emtec ECU (B). If necessary, take some of the tape off the harness to make the connectors reach their sockets. 6. Connect the 26 pin connector on the STT Emtec harness (3) to the corresponding socket in the STT Emtec ECU (C). Connect the 22 pin connector in the other end of the STT Emtec harness at the now empty socket in the original engine ECU (A).
MOUNTING INSTRUCTIONS 60-06 Air cleaner system 1. Remove the original hose between the air cleaner and turbo charger. 2. Remove the air cleaner. 3. Loosen the front part of the right wing inner fender ( Plastic). Carefully bend it to the side. 4. Drill two holes, 7,0 mm, at the two marked indents located on each side of the air intake hole to the engine compartment. 5. Mount the new air intake duct (1) in the existing hole in the inner fender. Fit it from the outside in and fasten it with the two screws (2). 6. Reinstall the air cleaner together with the rubber hose (4). 7. Mount the plastic inlet pipe (6),together with the rubber sleeve (7), between the turbo charger and air cleaner. Secure it with the hose clamps (8 and 9). 8. Connect the crankcase evacuation hose to the metal pipe on the inlet hose (10).
Mounting Instruction 60-07 System Function Control Control of boost pressure: 1. A MAP sensor is located on the rear bracket to the intercooler. It is connected to the inlet manifold with a hose. (Picture 1). 2. Connect a boost pressure gauge to the hose with a T pipe. ( Picture 2). Note. The hose to the boost pressure gauge must be long enough to reach in to the passanger compartment, (Through the side window). 3. Drive the car and fill in the pressure readings according to the procedure described in the installation/quality sheet on page 60-09. 4. After completed boost pressure control, reconnect the hose to the MAP sensor together with the hose clips that comes with the system. One clip on each end of the hose. (Picture 3). Pict. 1 Pict. 2. Pict. 3. Bild 3.
FAULT DIAGNOSIS 60-08 (1/2) Symptom Low boost pressure High boost pressure High engine temperature Low engine temperature. Blue/black smoke Reason/s Blocked air cleaner filter element. Blocked air intake. Leakage in the intake/intercooler system. Blocked/deformed exhaust system. Turbo charger failure. Engine defect. ECU failure*. (See ECU error code) Leaking/loose hose between the turbo charger and VGN actuator. Turbo charger failure. ECU failure*. (See ECU error code) Low coolant level. Air in the cooling system. Thermostat defect. Cooler blocked on the inside or the outside. Gauge failure. ECU failure*. (See ECU error code) Thermostat defect. Gauge failure. Blocked crankcase breathing. Blocked air cleaner filter element. Blocked air intake. Turbo charger failure. Engine defect. * To locate a possible fault to the STT Emtec ECU or the std. engine ECU, bypass the STT Emtec ECU. Follow the instruction on page 60-05 in reverse. ( Connector A is fitted to the corresponding socket in the std ECU).
FAULT DIAGNOSIS 60-08 (2/2) Symptom Low power Wheezy sound ECU error indication 2 pulses Reason/s Boost pressure too low. Engine defect. ECU failure*. (See ECU error code) Acoustic leak into passanger compartment. Leaking turbo charger system. Leaking exhaust system. Turbo charger failure. Check wiring and connections. Speed sensor defect (original sensor). ECU error indication 3 pulses Check wiring and connections. Water temperature sensor defect. ECU error indication 4 pulses Check wiring and connections. MAP sensor defect. ECU error indication 5 pulses Check wiring and connections. * To locate a possible fault to the STT Emtec ECU or the std. engine ECU, bypass the STT Emtec ECU. Follow the instruction on page 60-05 in reverse. ( Connector A is fitted to the corresponding socket in the std ECU).