Valid: 03-12-15
Replaces: 03-10-14
TECHNICAL HANDBOOK
FOR
MITSUBISHI PAJERO SPORT 2.8
BRAZIL
EQUIPPED WITH
STT EMTEC ENGINE OPTIMISING SYSTEM
________________________________________
GENERAL DESCRIPTION
System overview ..............................................................................1
Parts list .............................................................................................2
MOUNTING INSTRUCTIONS
Electronic control system
Layout, engine compartment......................................................4
Pneumatic layout........................................................................5
Fuel pump and fuel optimizer
Installation.................................................................................7
FAULT DIAGNOSIS.......................................................................8
STT Emtec AB. Kontorsvägen 9. 852 29 Sundsvall. Sweden
www.sttemtec.com Phone: +46 60 64 10 40. Fax: +46 60 64 10 45
SYSTEM OVERVIEW 1
Description:
ECU (Electronic Control Unit).
PWM-valve (Pulse Width Modulated) regulates the pressure in the waste-gate thus controlling
the boost pressure.
On/Off-valve controls the air pressure to the fuel optimizer.
Fuel optimizer regulates the fuel amount from the fuel pump.
MAP-sensor (Manifold Absolute Pressure) measures the boost pressure.
Engine temp. sensor measures the water temperature.
Engine speed sensor measures the speed of the crank shaft.
Safety functions:
• Extra fuel is cut off if the engine temperature exceeds 106˚C. If the engine temperature then
goes down to 104˚C extra fuel is automatically reapplied.
• Should the engine temperatur continue climbing to 108˚C the boost is reduced. If this happens
the temperature must decrease to 104˚C and the ignition has to be turned off to return to
normal conditions.
• Safe mode is activated if the boost pressure exceeds 1,35 bar
• Safe mode is activated if the altitude exceeds 1800 m (800 mbar), to protect the turbo charger
from over speeding.
• The system has a built-in fuel reduction @ 4600 rpm.
• The ECU selects safe settings if the input signals go out of range (i.e. sensor failure).
PARTS LIST 2
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Part Number STT Part No
1 1 101974
2 3 480-00-0665.0
3 1 413-74-0001.0
4 1 480-00-0659.0
5 1 480-00-0209.0
6 1 101983
7 4 480-00-0676.0
8 1 480-00-0669.0
9 1 101985
13 1 414-74-0001.0
11 1 101973
12 2 100870
13 2 480-00-0454.0
14 1 480-00-0821.0
15 1 480-00-0210.0
PARTS LIST 3
13
16
2, 15
11 1
14
3
4
8 12
A 7
17
25
12
12 10
9
6
18
Stt-08-E
Part Number STT Part No Part Number STT Part No
1 1 100979 10 1 101983
2 1 101972 11 1 101991
3 1 100980 12 3 480-00-0676.0
4 1 101988 13 1 101926
5 3 480-00-0665.0 14 1 101928
6 1 101987 15 1 480-00-0821.0
7 2 480-00-0294.0 16 1 410-00-0092.0
8 1 414-74-0004.0 17 1 100900
9 1 101984 18 20 480-00-0024.0
MOUNTING INSTRUCTIONS 4
Electronic control system
Layout, engine compartment
1. Remove the safety valve on the inlet manifold. Use a
hot air gun to loosen it.
2. Mount the plug, with nipple and O-ring, where
the safety valve used to be.
3. Mount the MAP sensor (25) and solenoid valve
(10) on bracket (26) with the screws included.
4. Mount the hoses and clamps on the
PWM valve according to page 5.
5. Lay down the harness (19) as shown in
the picture. Let it follow the main harness
to the fuel pump.
6. Connect the break out connector on the
fuel pump. Make sure that the coulors on
the cables match.
7. Mount the solenoid valve/MAP sensor and
bracket (26) on the firewall using the existing ��������
screw, as shown in the drawing.
8. Remove the glove compartment and the plastic
panel under it.
9. Pull the harness through the existing rubber grommet.
Pos.A. Fasten the ECU behind the plastic panel
using the two Velcro strips. 2, 21, 22
10. Mount and secure the wiring using the 5
enclosed tie wraps.
1
19 13
3
4
14
A 10
24
7
26
25 27, 28, 29
14
12 12
11
6
31
Stt-08-F
MOUNTING INSTRUCTIONS 5
Electronic control system
Pneumatic layout
L= 750
Fit the hoses on the MAP sensor and the so-
lenoid valve. Hose clips shold be fitted on all
connections. These parts are assembled to a
unit before installation in the car.
L= 150
L= 75
L= 95
R Hose to Y-pipe on crankcase ventilation
house. L=420 mm
R
W Hose to wastegate. L=640mm
C Hose to turbo charger. L=620mm
C W
stt-102
MOUNTING INSTRUCTIONS 6
Electronic control system
Pneumatic layout
1. Mount the hose (1) and clamp between the turbo charger and PWM valve (port marked C).
2. Mount the hose (2) and clamp between the PWM valve (port marked R) and T-fitting for
crankcase ventilation.
3. Mount the hose (3) and clamp between the PWM valve port marked (W) and wastegate
actuator.
4. Mount the hose (4), T-joint and clamp the nipple in the inlet manifold plug and the MAP
sensor.
5. Mount the hose (5) and clamp between the hoses (4) T-joint and the axial lower solenoid
valve connection
6. Mount the hose (6) and clamp between the upper radial solenoid valve connection and fuel
optimizer.
6
2
4
5
1
Stt-103
MOUNTING INSTRUCTIONS 7
Fuel pump and fuel optimizer
Installation
Start the calibration with 3 mm of shim
under the fuel optimizer.
Adjust the shimming under the fuel
optimizer until the set values in the table
below are achieved. 0,1 mm of shim
makes a 2,5 mm3/stroke differance.
By adding shim the flow will decrease
and vice versa.
Shim Fuel
optimizer
NOTE! It may be necessary to bend
the cylinder 2 fuel injection pipe a few Figure 1
millimetres to facilitate the mounting.
Tighten the fuel optimizer firmly by
hand. Then tighten an additional 15°
using a 17-mm spanner. See figure 2. 15
When correct shim has been chosen the
final mounting of the fuel optimizer can
begin. Apply a small amount of silicone
to the shim. Repeat the mounting
procedure described above including
the 15º tightening.
Important! Excessive tightening may Figure 2
damage the fuel optimizer.
Stt-10-B
Fuel pump speed (rpm) Alda pressure (bar) F. O. pressure (bar) Set value (mm3/stroke)
750 No No 54,3
1250 0,7 No 80,1
1250 No No 55,2
1250 0,9 0,9 93,4
FAULT DIAGNOSIS 8
Symptom Reason/s
Low boost pressure Blocked air cleaner filter element.
Blocked air intake.
Leakage in the intake/intercooler system.
Blocked/deformed exhaust system.
Turbo charger failure.
Engine defect.
High boost pressure Leaking hose between the turbo charger and PWM
valve or between the PWM valve and wastegate
actuator.
PWM valve blocked from turbo charger to waste gate.
Turbo charger failure.
High engine temperature Low coolant level.
Air in the cooling system.
Thermostat defect.
Cooler blocked on the inside or the outside.
Gauge failure.
Low engine temperature. Thermostat defect.
Gauge failure.
Power loss. Incorrect solenoid valve function.
Leakage between the solenoid valve and the fuel
optimizer.
PWM valve defect.
Leaking hoses.
Blue black smoke Blocked crankcase breathing.
Blocked air cleaner filter element.
Blocked air intake.
Turbo charger failure.
Engine defect.
FAULT DIAGNOSIS 9
Symptom Reason/s
Low power Boost pressure too low.
Hose to the fuel optimizer leaking.
Engine defect.
See ECU Diagnosis.
Wheezy sound Acoustic leak into passanger compartment.
Leaking turbo charger system.
Leaking exhaust system.
Turbo charger failure.
ECU error indication Check wiring and connections.
2 pulses Speed sensor defect (original sensor).
ECU error indication Check wiring and connections.
3 pulses Water temperature sensor defect (original sensor).
ECU error indication Check wiring and connections.
4 pulses MAP sensor defect.
ECU error indication Check wiring and connections.
5 pulses Broken fuse.
