belt MITSUBISHI MONTERO 2000 Service Owner's Manual

ENGINE <4M4> -General Information/Service Specifications11C-2
GENERAL INFORMATION
Items4M41
Total displacement mL3,200
Bore´Stroke mm98.5´105.0
Compression ratio17.0
Camshaft arrangementDOHC
Number of valveIntake8
Exhaust8
Valve timingIntakeOpeningBTDC 13_
ClosingABDC 31_
ExhaustOpeningBBDC 55_
ClosingATDC 17_
Fuel systemDistribution type injection pump
Rocker armRoller type
SERVICE SPECIFICATIONS
ItemsStandard valueLimit
Alternator drive beltVibration frequency Hz122 - 161–
(When inspection)Tension N207 - 363–
Deflection mm 8-11–
Alternator drive beltVibration frequency Hz122 - 136–
(When adjustment)Tension N207 - 259–
Deflection mm 10 - 11–
Alternator drive beltVibration frequency Hz149 - 161–
(When replacement)Tension N311 - 363–
Deflection mm 8-9–
A/C compressor drive beltVibration frequency HzA177 - 191–
(When inspection)B145 - 156–
Tension NC343 - 392–
Deflection mm
C7.5 - 8.5–
A/C compressor drive beltVibration frequency HzA177 - 191–
(When adjustment)B145 - 156–
Tension NC343 - 392–
Deflection mm
C7.5 - 8.5–
A/C compressor drive beltVibration frequency HzA177 - 191–
(When replacement)B145 - 156–
Tension NC490 - 539–
Deflection mm
C6.0 - 6.5–


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V
alv e cle ara nce (a t co ld engin e) m m I
n ta ke va lv e 0
.1 –
E
xh aust va lv e 0
.1 5 –
I
n je ctio n tim in g 4
°B TD C –
I
d le sp eed r/m in 7
50 ±20 –
C
om pre ssio n pre ssu re kP a-r/m in 2
,8 44 -2 40 2
,2 56 -2 40 C
om pre ssio n pre ssu re dif f e re nce of all cylin der kP a – M
axim um 294 S
pecif ie d Seala nts R
em ark s O
il p an co ve r ru bber 3
M AT D Part N o. 8121 or equiv a le nt Q
uic k fix adhesiv e E
ngin e co ve r in su la to r C
onta ct su rfa ce betw een tim in g gear
c a se and cra nkca se asse m bly 3
M AT D Part N o. 8660 or equiv a le nt S
em i- d ry in g
s e ala nt O
il p an M
IT S U BIS H I GEN UIN E PA R T MD970389 or T
im in g gear ca se e
quiv a le nt N
um ber N
am e U
se M
B991502 M
UT-II
s u b-a sse m bly M
B991668 B
elt te nsio n mete r
s e t D
riv e belt te nsio n measu re m ents
( U se wit h M UT-II ) M
B990767 E
ndyo ke hold er C
ra nksh aft pulle y hold in g M
D998754 P
ulle y hold er pin

O
N-V EH IC LE SER VIC E
D RIV E BELT TE N SIO N CHEC K AND
A DJU STM EN T
A LT E R NATO R DRIV E BELT TE N SIO N CHEC K AND
A DJU STM EN T
1 . Check th e driv e belt te nsio n by th e fo llo w in g pro ce dure s.
S ta n dard valu e:
I te m D
urin g
i n sp ectio n D
urin g
a dju stm ent D
urin g
r e pla ce m ent V
ib ra tio n
f r e quency Hz 1
22 -161 1
22 -136 1
49 -161 T
e nsio n N 2
07 -363 2
07 -259 3
11 -363 D
efle ctio n mm
< R efe re nce > 8
.0 -11 .0 1
0.0 -11 .0 8
.0 -9.0 A
lt e rn ato r pulle y w
ww.W ork sh opM an uals .c o .u k
P urc h ased f r o m w ww.W ork sh opM an uals .c o .u k

ENGINE <4M4> -Cylinder Head Gasket11C-27
CYLINDER HEAD GASKET
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
DEngine Coolant Drain and Refill
(Refer to GROUP 14 - On-vehicle Service.)
DEngine Oil Check andRefill
(Refer to GROUP 12 - On-vehicle Service.)

DFuel Line Air-bleeding
(Refer to GROUP 13C - On-vehicle Service.)

DDrive Belt TensionCheck and Adjustment
(Refer to P.11C-5.)DCamshaft Removal and Installation
(Refer to P.11C-20.)
DCooling Fan and Fan Clutch Assembly Removal and
Installation (Refer to GROUP 14.)
DIntake Manifold Removal and Installation
(Refer to GROUP15.)
DTurbocharger Removal and Installation
(Refer to GROUP15.)
DExhaust Manifold Removal and Installation
(Refer to GROUP15.)


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2
GENERAL INFORMATION
Items 4M41
Total displacement mℓ
3,200
Bore x Stroke mm 98.5 x 105.0
Compression ratio 17.0
Camshaft arrangement DOHC
Intake 8Number of valve
Exhaust 8
Opening BTDC 13ºIntake
Closing ABDC 31º
Opening BBDC 55º
Valve timing
Exhaust
Closing ATDC 17º
Fuel system Distribution type injection pump
Rocker arm Roller type
SERVICE SPECIFICATIONS
Items Standard value Limit
Vibration frequentcy Hz 122 – 161 -
Tension N 207 – 363 -
Alternator drive belt
(When inspection)
Deflection mm 8 – 11 -
Vibration frequentcy Hz 122 – 136 -
Tension N 207 – 259 -
Alternator drive belt
(When adjustment)
Deflection mm 10 – 11 -
Vibration frequentcy Hz 149 – 161 -
Tension N 311 – 363 -
Alternator drive belt
(When replacement)
Deflection mm 8 – 9 -
A 177 – 191 -Vibration frequentcy
Hz
B 145 – 156 -
Tension N C 343 – 392 -
A 169 – 189
A/C compressor drive belt
(When inspection)
Deflection mm
C 7.5 – 8.5 -
B 111 – 124
A 177 – 191 -A 285 – 355Vibration frequentcy
Hz
B 145 – 156 -A 7.0 – 8.0
Tension N C 343 – 392 -A 169 – 189
B 111 – 124
A/C compressor drive belt
(When adjustment)
Deflection mm
C 7.5 – 8.5 -
A 285 – 355
A 177 – 191 -A 7.0 – 8.0Vibration frequentcy
Hz
B 145 – 156 -A 207 – 223
Tension N C 490 – 539 -B 135 – 146
A 425 – 500
A/C compressor drive belt
(When replacement)
Deflection mm
C 6.0 – 6.5 -
A 6.0 – 6.5
11C-2ENGINE <4M4> - General Information/Service Specifications



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I
n ta ke v a lv e 0.1 -V
alv e c le ara nce ( a t c o ld e ng in e) m m
Exh aust v a lv e 0.1 5 -I
n je ctio n tim in g 4º
B TD C -I
d le s p ee d r /m in 750 ± 2 0 -C
om pre ssio n p re ssu re k P a-r/m in 2,8 4 4-2 40 2,2 5 6-2 40 C
om pre ssio n p re ssu re d if fe re nce o f a ll c ylin der k P a - Maxim um 2 94 O
il p an c o ve r r u bber E
ng in e c o ve r in su la to r 3
M A TD P art N o. 8 1 21 o r e qu iv a le nt Quic k fix a d hesiv e C
onta ct s u rfa ce b e tw ee n t im in g g ear
c a se a nd c ra nkca se a sse m bly 3
M A TD P art N o. 8 6 60 o r e qu iv a le nt O
il p an T
im in g g ear c a se M
IT S U BIS H I G EN UIN E P AR T M D9703 89 o r
e qu iv a le nt S
em i- d ry in g s e a la nt M
B9915 02 MUT-II
S ub-a sse m bly •
D
riv e b e lt t e nsio n m easu re m ent
• F
uel in fe ctio n tim in g c h eck a nd
a dju stm en t
• I
d le s p ee d c h eck M
B9916 68 Belt te nsio n m ete r
s e t D
riv e b e lt t e nsio n m easu re m ents ( U se w it h
M UT-II) M
B9907 67 Endyo ke h o ld er M
D99 875 4 Pulle y h old er p in C
ra nksh aft p ulle y h old in g

GDI -Troubleshooting 13A-77
Inspection procedure 5
No initial combustion (starting impossible)
Probable cause
This is caused by incorrect fuel supply into the combustion chamber, and improper
ignition circuit. Besides that, foreign material may be contaminated in fuel.DMalfunction of the fuel supply system
DMalfunction of the ignition system
DMalfunction of the engine-ECU
Check system voltage while theengine iscranking.
OK:
8 V or moreNGCheck the battery. (Refer to GROUP 55 - Battery.)
OK
MUT-
IISelf-Diag code
Is a diagnosis code displayed?Ye sRefer to P.13A-15, INSPECTION CHART FOR DIAGNOSIS
CODES.
No
MUT-
IIData list
16 System voltage (Refer to P.13A-105.)NGCheck theengine controlrelay and ignition switch-IG system. (Refer
to P.13A-99, Inspection procedure 26.)
OK
Does the camshaft rotate when theengine is cranking?NoCheck if thetiming belt isbroken ordamaged.
Ye s
MUT-
IIActuator test
07 Fuel pump(low pressure) (Refer to P.13A-110.)NGCheck the fuelpump(low pressure) system. (Refer to P.13A-101,
Inspection procedure 29.)
OK
MUT-
IIData list
22 Crankanglesensor (Refer to P.13A-105.)NGCheck the crankanglesensor system. (Refer to P.13A-56, code
No. P0335.)
OK
MUT-
IIData list
21 Engine coolant temperature sensor (Refer to P.13A-105.)NGCheck theengine coolant temperaturesensor system. (Refer to
P.13A-22, code No. P0115.)
OK
MUT-
IIData list
79 Throttle position sensor (1st channel) (Refer to P.13A-105.)NGCheck the throttle position sensor (1st channel) system. (Refer
to P.13A-25, code No. P0120.)
OK
Inspectenginestart ability by cranking theengine while theaccelera-
tor pedal isslightly depressed.OKClean around the throttle valve. (Refer to P.13A-220.)
NG
Check fuel leakage. (Refer to P.13A-225.)NG
Repair
OK
Measure low fuel pressure between the fuelpump(low pressure)
and fuel pump (highpressure). (Refer to P.13A-222.)NG
Repair
OK
Measure at ignition coil connectors B-101, B-108, B-112, B-113,
B-116, B-119.
DConnect the connector.
DConnect atiming light to theNo.1 terminal of each connector
in turn.
(Engine cranking)
OK:
The timing lightflashes.NGCheck the ignition coil (incorporating power transitor) system. (Refer
to P.13A-53, code No. P0300.)
OK
Check ignitiontiming while the engine iscranking.
OK:
Approx. 5_BTDCNGCheck that the crankanglesensor andtiming beltcover are properly
installed.
OK
To the nextpage
Measure at injector driver connector B-121.
DDisconnect the connector, and measure at the connector side.
DVoltage between each of terminals 4, 12, 21 and earth
(Ignition switch: ON)
OK:
System voltageCheck the injector driver system. (Refer to P.13A-104, Inspection
procedure 34.) NG
OK


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GDI -Troubleshooting 13A-79
Inspection procedure 6
Initial combustion takes place, but does not complete
(start impossible), too long time to start (poor start)
Probable cause
This may be caused by improper sparkplug ignition (poorspark), improper mixture
during enginecranking, improper fuel pressure.DMalfunction of the fuel supply system
DMalfunction of the fuel pressure sensor
DMalfunction of the ignition system
DMalfunction of the electronic-controlled throttle vale
system
DMalfunction of the engine-ECU
Check system voltage while theengine iscranking.
OK:
8 V or moreNGCheck the battery. (Refer to GROUP 55 - Battery.)
OK
MUT-
IISelf-Diag code
Is a diagnosis code displayed?Ye sRefer to P.13A-15, INSPECTION CHART FOR DIAGNOSIS
CODES.
No
MUT-
IIActuator test
07 Fuel pump(low pressure) (Refer to P.13A-110.)NGCheck the fuelpump(low pressure) system. (Refer to P.13A-101,
Inspection procedure 29.)
OK
MUT-
IIData list
21 Engine coolant temperature sensor (Refer to P.13A-105.)NGCheck theengine coolant temperaturesystem. (Refer to P.13A-22,
code No. P0115.)
OK
MUT-
IIData list
18 Cranking signal (Refer to P.13A-105.)NGCheck the ignition switch-ST system. (Refer to P.13A-99, Inspection
procedure 27.)
OK
MUT-
IIData list
74 Fuel pressure sensor (Refer to P.13A-105.)NGCheck an abnormal fuel pressure system. (Refer to P.13A-36, code
No. P0190.)
Check fuel leakage. (Refer to P.13A-225.)NG
Repair
OK
Is the enginestarted normally when it is cranked with the accelerator
pedal depressed slightly?Ye sClean around the throttle valve. (Refer to P.13A-220.)
No
MUT-
IIData list
79 Throttle position sensor (1st channel) (Refer to P.13A-105.)NGCheck the throttle valve position feedback system. (Refer to
P.13A-65, code No. P1221.)
OK
Check ignitiontimingwhen theengine iscranked.
OK:
approx. 5_BTDCNGCheck that the crankanglesensor andtiming beltcover are properly
installed.
OK
To the nextpageOK


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GDI -Troubleshooting 13A-82
OK
Check that air is sucked in the air intake system.
DBroken intake manifold gasket
DDamaged vacuum hose
DDamaged air intake hose
From the previouspage
OK
MUT-
IIData list
27 Power steering fluid pressure switch (Refer to P.13A-105.)NGCheck the power steering fluid pressure switch system. (Refer
to P.13A-102, Inspection procedure 30.)
OK
MUT-
IIData list
28 A/C switch (Refer to P.13A-105.)NGCheck the A/C switch and A/C relay system. (Refer to P.13A-102,
Inspection procedure 31.)
OK
MUT-
IIData list
67 Stoplampswitch (Refer to P.13A-105.)NGCheck the stoplampswitch. (Refer to P.13A-103, Inspection proce-
dure 32.)
OK
MUT-
IIData list
31 Small lampswitch (Refer to P.13A-105.)NGCheck the smalllampswitch system. (Refer to P.13A-104, Inspec-
tion procedure 33.)
OK
MUT-
IIData list
68 EGR valve (Refer to P.13A-105.)NGCheck the EGR valve. (Refer to P.13A-60, code No. P0403.)
OK
NG
Check that the crankanglesensor andtiming beltcover are properly
installed.
OK
Check ignition coil spark for each cylinder.
(1) Remove the ignition coil.
(2) Install a new sparkplug to the removed ignitioncoil.
(3) Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured.
(4) Earth the sparkplug electrodesecurely.
(5) Check that the sparkplug igniteswhen theengine iscranked.NGReplace the ignition coil.
OK
Check trouble symptom.
Check all the following items in that order.
(1) Spark plugs
(2) Exhaust gas emission control system
(3) EGR system
(4) Compression pressure
(5) Foreign material (such as water or kerosine)entered the fuel
line.
(6) Air is sucked in the air intake system, or EGR gas leaks.
DDamaged intake manifoldgasket
DDamaged air intake hose
DDamaged vacuum hose
DFaulty EGR valve seat
OK
MUT-
IIData list
11 Oxygen sensor (front)
OK:
0 - 400 mV and 600 - 1,000 mV alternates when the
engine is idling(wait for four minutes after theengine
started).NG
NG
Repair
Measure fuel high-pressure between the fuel pump (highpressure)
and injector. (Refer to P.13A-224.)
Clean around the throttle valve. (Refer to P.13A-220.)
NG
Check ignition timing. (Refer to GROUP 11A - Engine Adjustment.)


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GDI -Troubleshooting 13A-84
Inspection procedure 9
When the engine is cold, it stalls at idling. (Die out)
Probable cause
The cause is probably an incorrect air/fuel ratio or poor intake airamountwhen the
engine iscold.DMalfunction of the electronic-control throttle valve
system
DMalfunction of the throttle body
Have the battery terminalsbeen disconnectedrecently?Ye sWarm up the engine, and then let it run at idle for approx. ten
minutes.
No
MUT-
IISelf-Diag code
Is a diagnosis code displayed?Ye s(Refer to P.13A-15, INSPECTION CHART FOR DIAGNOSIS
CODES.)
No
Is the engine idlingcorrect after theengine has been warmed up?Ye sRefer to “Unstableidling (rough idle, hunting).”(Refer to P.13A-81,
Inspection procedure 7.)
No
MUT-
IIData list
22 Crankanglesensor (Refer to P.13A-105.)
Checkidlingspeed when theengine iscold.NGCheck the throttle valve position feedback system. (Refer to
P.13A-65, code No. P1221.)
OK
MUT-
IIData list
26 Acceleratorpedal positionswitch (Refer to P.13A-105.)NGCheck the accelerator position switch. (Refer to P.13A-100, Inspec-
tion procedure 28.)
OK
MUT-
IIData list
21 Engine coolant temperature sensor (Refer to P.13A-105.)NGCheck theengine coolant temperaturesensor. (Refer to P.13A-22,
code No. P0115.)
OK
MUT-
IIData list
68 EGR valve (Refer to P.13A-105.)NGCheck the EGR valve system. (Refer to P.13A-60, code No. P0403.)
OK
Does theenginestall immediately after the acceleratorpedal is
released?Ye sClean around the throttle valve. (Refer to P.13A-220.)
No
Measure fuel highpressure between the fuelpump (highpressure)
and injector. (Refer to P.13A-224.)NG
Repair
OK
Check ignition timing. (Refer to GROUP 11A - Engine Adjustment.)NGCheck that the crankanglesensor andtiming beltcover are properly
installed.
OK
Check ignition coil spark for each cylinder.
(1) Remove the ignition coil.
(2) Install a new sparkplug to the removed ignitioncoil.
(3) Disconnect the injector intermediate connector.
Caution
Never touch the connector terminal as approx. 100 V is
applied to the injector, or you are seriously injured.
(4) Earth the sparkplug electrodesecurely.
(5) Check that the sparkplug igniteswhen theengine iscranked.NGReplace the ignition coil.
OK
Check all the following items:
DSpark plugs
DCompression pressure
DEngine oilviscosityNGCheck trouble symptom. OK
Replace the injector.


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