water pump MITSUBISHI MONTERO 2000 Service Repair Manual

ENGINE LUBRICATION -General Information12-2
GENERAL INFORMATION
The lubrication method is a fully force-fed, full-flow
filtration type.An oil cooler with high cooling performance and
which is built into the crankcase has been adopted.
<4M4>
Items6G74D54M4
Oil pump typeTrochoid typeExternal gear typeExternal gear type
Drive methodCrankshaftCrankshaft gearCrankshaft gear
ENGINE OILS
Health Warning
Prolonged and repeated contact with mineral oil
will result in the removal of natural fats from the
skin, leading to dryness, irritation and dermatitis.
In addition, used engine oil contains potentiallyharmful contaminants which may cause skin cancer.
Adequate means of skin protection and washing
facilities must be provided.
Recommended Precautions
The most effective precaution is to adapt working
practices which prevent, as far as practicable, the
risk of skin contact with mineral oils, for example
by using enclosed systems for handling used engine
oil and by degreasing components, where
practicable, before handling them.
Other precautions:
DAvoid prolonged and repeated contact with oils,
particularly used engine oils.
DWear protective clothing, including impervious
gloves where practicable.
DAvoid contaminating clothes, particularly
underpants, with oil.
DDo not put oily rags in pockets, the use of
overalls without pockets will avoid this.
DDo not wear heavily soiled clothing and
oil-impregnated foot-wear. Overalls must be
cleaned regularly and kept separate from
personal clothing.DWhere there is a risk of eye contact, eye
protection should be worn, for example,
chemical goggles or face shields; in addition
an eye wash facility should be provided.
DObtain First Aid treatment immediately for open
cuts and wounds.
DWash regularly with soap and water to ensure
all oil is removed, especially before meals (skin
cleansers and nail brushes will help). After
cleaning, the application of preparations
containing lanolin to replace the natural skin
oils is advised.
DDo not use petrol, kerosine, diesel fuel, gas
oil, thinners or solvents for cleaning skin.
DUse barrier creams, applying them before each
work period, to help the removal of oil from
the skin after work.
DIf skin disorders develop, obtain medical advice
without delay.


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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-171
Inspection procedure 5
No initial combustion (starting impossible)
Probable cause
In cases such as the above, the cause is probably that a sparkplug is
defective, or that the supply of fuel to the combustion chamber is defective.
In addition, foreign materials (water, kerosene, etc.) may be mixed with the fuel.DMalfunction of the fuel supply system
DMalfunction of the ignition system
DMalfunction of the engine-A/T-ECU
NGRepair
OK
MUT-
IIData list
22 Crankanglesensor (Refer to P.13A-198.)NGCheck the crankanglesensor system.
(Refer to P.13A-140, code No.22.)
YES
MUT-
IIActuator Test
07 Fuel pump(low pressure) (Refer to P.13A-203.)NGCheck fuelpump(low pressure) system
(Refer to P.13A-193, Inspection procedure 29.)
OK
Does the camshaft rotate when theengine is cranking?NOCheck if thetiming belt isbroken ordamaged.
NO
MUT-
IIData list
16 Battery voltage (Refer to P.13A-198.)NGCheck theengine controlrelay and ignition switch-IG system
(Refer to P.13A-190, Inspection procedure 25.)
OK
MUT-
IISelf-Diag Code
Is a diagnosis code set?YESRefer to P.13A-130, INSPECTION CHART FOR DIAGNOSIS
CODES
Check battery voltage when cranking.
OK:
8 V or higherNGCheck the battery.
OK
Is starting good if the engine iscranked with the accelerator
pedalslightly depressed?YESDClean the throttle valve area. (Refer to P.13A-220.)
DCheck and adjust the throttle position sensor (Refer to
P.13A-220.)
OK
MUT-
IIData list
79 Throttle position sensor (1st channel) (Refer to P.13A-198.)NGCheck the throttle position sensor (1st channel) system
(Refer to P.13A-158, code No.79.)
OK
MUT-
IIData list
21 Engine coolant temperature sensor (Refer to P.13A-198.)NGCheck theengine coolant temperaturesensor system
(Refer to P.13A-138, code No.21.)
OK
Measure low fuel pressure between the fuelpump(low
pressure) and fuelpump (highpressure) (Refer to P.13A-222.)NGRepair
OK
To the nextpage
NO
Adjust the throttle position sensor (Refer to P.13A-220.)
NG
Measure at injector driver connector B-19
DDisconnect the connector, and measure at the harness
side.
DThe voltage between terminals 4, 12, 21 and earth
(Ignition switch: ON)
OK
Battery voltage
Check fuel leakage (Refer to P.13A-225.)OK
Check the injector driver system.
(Refer to P.13A-196, Inspection procedure 34.) NG


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GDI -Troubleshooting 13A-172
OK
Check the following items in that order.
DCheck the sparkplug
DCheck the compression pressure
DCheck if foreign materials (water, alcohol, etc.) got into
fuel.
OK
Clamp the leads of the ignition coil No.1 terminal with atiming
light pick-up in order. Does thetiming lightflash when the
engine iscranked?NOCheck the ignition coil (built-in power transistor) system (Refer
to P.13A-148, code No.44.)
From the previouspage
OK
Check the trouble symptoms.
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 is
cranked.NGReplace the ignition coil.
YES
Check the ignitiontimingwhen cranking.
OK:
approx. 5_BTDCNGCheck that the crankanglesensor andtiming beltcover are
properly installed.
Replace the injector.NG
Inspection procedure 6
Initial combustion but no complete combustion (starting
impossible), long time to start (hard starting)
Probable cause
In such cases as the above, the cause is probably that the spark plugs are
generating sparks by the spark are weak, or the initial mixture is not appropriate.DMalfunction of fuel supply system
DMalfunction of of fuel pressure control solenoid
valve
DMalfunction of the ignition system
DMalfunction of the electronic-controlled throttle
valve system
DMalfunction of the engine-A/T-ECU
OK
MUT-
IIData list
21 Engine coolant temperature sensor (Refer to P.13A-198.)NGCheck theengine coolant temperaturesensor system (Refer
to P.13A-138, code No.21.)
OK
MUT-
IISelf-Diag Code
Is a diagnosis code set?YESRefer to P.13A-130, INSPECTION CHART FOR DIAGNOSIS
CODES.
Check the battery voltage when cranking.
OK:
8 V or higherNGCheck the battery.
NO
MUT-
IIActuator Test
07 Fuel pump(low pressure) (Refer to P.13A-203.)NGCheck fuelpumpsystem (low-pressure)
(Refer to P.13A-193, Inspection procedure 29.)
OK
To the nextpage


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13B-1
DIESEL FUEL
<4D5>
CONTENTS
GENERAL INFORMATION 2..................
SERVICE SPECIFICATIONS 2.................
SPECIAL TOOL 2............................
ON-VEHICLE SERVICE 2.....................
Fuel Injection Timing Check and Adjustment 2...
Engine Idle Speed Check and Adjustment 2......
Evacuation of Water from Fuel Filter 2..........Evacuation of Air from Fuel Line 3..............
Fuel Filter Cartridge Replacement 3.............
Fuel Injection Pump Check 3...................
Boost Compensator Check 4....................
Injection Nozzle Check and Adjustment 4........INJECTION NOZZLE 6.......................
INJECTION PUMP 10........................


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13C-1
DIESEL FUEL
<4M4>
CONTENTS
GENERAL INFORMATION 2...................
SERVICE SPECIFICATIONS 3.................
SEALANT 3..................................
SPECIAL TOOLS 4...........................
TROUBLESHOOTING 5.......................
ON-VEHICLE SERVICE 42...................
Injection Timing Check and Adjustment 42.........
Idle Speed Check and Adjustment 42.............
Accelerator Pedal Position Sensor (APS)
Adjustment 42.................................
Control Relay Continuity Check 43................
Accelerator Pedal Position Sensor (APS) Check 43.Idle Switch Check 43...........................
Boost Air Temperature Sensor (Intake Air
Temperature Sensor) Check 44..................
Engine Coolant Temperature Sensor Check 44.....
Evacuation of Water from Fuel Filter 45...........
Fuel Filter Cartridge Replacement 45.............
Evacuation of Air from Fuel Line 45...............
Fuel Injection Pump Check 46...................
Intake Air Restriction Equipment Check 48.........
Injection Nozzle Check and Adjustment 49.........
INJECTION NOZZLE 50......................
INJECTION PUMP 56........................
ENGINE-ECU 59............................


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DIESEL FUEL <4M4> -Troubleshooting13C-26
Inspection procedure 5
No initial combustion (unable to start)
Probable cause
Probable causes can be found in troubles with control system, injectionpump,
glow system, and power supply system.DControl system inoperative
DInjection pump inoperative
DGlow system inoperative
DEngine-ECU inoperative
NG
Repair
MUT-
IISelf-Diag code
Is a diagnosis code output?YESInspection chart for diagnosis codes (Refer to P.13C-7.)
NO
Conduct MUT-IIData list check and an actuator test. (Refer
to P.13C-30, 37.)OKCheck the following items in order:
DGlow plug, glowplugrelay
DBattery
DInjection nozzle
DInjection pump
DCompression pressure
DExistence of mixing foreign objects (water, kerosene) with
the fuel
Inspection procedure 6
Starting performance is bad when the engine is cold
(unable to start)
Probable cause
Probable causes can be found in troubles with control system, injectionpump,
fuel system, intake system, and glow system.DControl system inoperative
DInjection pump inoperative
DFuel system inoperative
DIntake system inoperative
DGlow system inoperative
DEngine-ECU inoperative
NG
Repair
MUT-
IISelf-Diag code
Is a diagnosis code output?YESInspection chart for diagnosis codes (Refer to P.13C-7.)
NO
Conduct MUT-IIData list check and an actuator test. (Refer
to P.13C-32, 37)OKInspect the following items in order:
DGlow plug, glowplugrelay
DInjection nozzle, fuel filter
DThrottle body assembly
DExistence of starter switch signal input
DEngine oil
DInjection pump
DExistence of mixing foreign objects (water, kerosene) with
the fuel
Inspection procedure 7
Starting performance is bad regardless of whether the
engine is hot or cold (unable to start)
Probable cause
Probable causes can be found in troubles with control system, injectionpump,
fuel system, and intake system.DControl system inoperative
DInjection pump inoperative
DFuel system inoperative
DIntake system inoperative
DEngine-ECU inoperative
NG
Repair
MUT-
IISelf-Diag code
Is a diagnosis code output?YESInspection chart for diagnosis codes (Refer to P.13C-7.)
NO
Conduct MUT-IIData list check and an actuator test. (Refer
to P.13C-32, 37.)OKInspect the following items in order:
DInjection nozzle, fuel filter
DThrottle body
DCompression pressure
DInjection pump
DExistence of mixing foreign objects (water, kerosene) with
the fuel


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DIESEL FUEL <4M4> -Troubleshooting13C-29
Inspection procedure 13
The engine stalls during idling.
Probable cause
Probable causes can be found in troubles with control system, injectionpump,
intake system, EGR system, and power supply.DControl system inoperative
DInjection pump inoperative
DFuel system inoperative
DEGR system inoperative
DEngine-ECU inoperative
NG
Repair
MUT-
IISelf-Diag code
Is a diagnosis code output?YESInspection chart for diagnosis codes (Refer to P.13C-7.)
NO
Conduct MUT-IIData list check and an actuator test. (Refer
to P.13C-32, 37.)OKInspect the following items in order:
DPower supply system
DThrottle body assembly
DEGR system
DInjection pump
Inspection procedure 14
Lack of output power
Probable cause
Probable causes can be found in troubles with control system, injectionpump,
fuel system, intake system, and EGR system.DControl system inoperative
DInjection pump inoperative
DFuel system inoperative
DIntake system inoperative
DEGR system inoperative
DEngine-ECU inoperative
NG
Repair
MUT-
IISelf-Diag code
Is a diagnosis code output?YESInspection chart for diagnosis codes (Refer to P.13C-7.)
NO
Conduct MUT-IIData list check and an actuator test. (Refer
to P.13C-32, 37.)OKInspect the following items in order:
DInjection nozzle, fuel filter
DThrottle body assembly
DEGR system
DTurbocharger
DCompression pressure
DInjection timing
DInjection pump
DExistence of mixing foreign objects (water, kerosene) with
the fuel
Inspection procedure 15
Occurrence of abnormal knocking
Probable cause
Probable causes can be found in troubles with control system, injectionpump,
fuel system, and EGR system.DControl system inoperative
DInjection pump inoperative
DFuel system inoperative
DEGR system inoperative
DEngine-ECU inoperative
NG
Repair
MUT-
IISelf-Diag code
Is a diagnosis code output?YESInspection chart for diagnosis codes (Refer to P.13C-7.)
NO
Conduct MUT-IIData list check and an actuator test. (Refer
to P.13C-32, 37.)OKInspect the following items in order:
DInjection nozzle
DInjection timing
DEGR system
DInjection pump


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13E-1
DIESEL FUEL
<4D5-STEPIII
>
CONTENTS
GENERAL 2.................................
Outline of Change 2............................
GENERAL INFORMATION 2...................
SERVICE SPECIFICATIONS 4.................
SEALANT 4..................................
SPECIAL TOOLS 5...........................
TROUBLESHOOTING 6.......................
ON-VEHICLE SERVICE 55....................
Injection Nozzle Check and Adjustment 55.........
Injection Timing Check and Adjustment 55.........
Idle Speed Check and Adjustment 55.............
Accelerator Pedal Position Sensor (APS)
Adjustment 56.................................
Control Relay Continuity Check 57................
Accelerator Pedal Position Sensor (APS)
Check 57......................................Idle Switch Check 58............................
Boost Air Temperature Sensor (Intake Air
Temperature Sensor) Check 58..................
Engine Coolant Temperature Sensor Check 59.....
Evacuation of Water from Fuel Filter 59............
Fuel Filter Cartridge Replacement 60..............
Evacuation of Air from Fuel Line 60...............
EGR Valve Position Sensor Check 60.............
Fuel Injection Pump Check 61....................
Throttle Solenoid Valve Check 62.................
Throttle Actuator Check 63......................
Variable Geometry Solenoid Valve Check 63.......
EGR Control Solenoid Valve Check 63............
FUEL INJECTION NOZZLE 64.................
FUEL INJECTION PUMP 64...................
CRANKSHAFT POSITION SENSOR 66.........
ENGINE-ECU 66.............................


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DIESEL FUEL <4D5-stepIII>-Troubleshooting13E-31
INSPECTION PROCEDURE 5
No initial combustion (unable to start)
Probable cause
Probable causes can be found in troubles with control system, injection pump,
glow system, and power supply system.DControl system inoperative
DInjection pump inoperative
DIntake system inoperative
DGlow system inoperative
DEngine-ECU inoperative
NG
Repair
MUT-IISelf-Diag code
Is a diagnosis code output?YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-IIData list check and an actuator test.
(Refer to P.13E-40, 44.)OKCheck the following items in order:
DGlow plug, glow plug relay
DBattery
DInjection nozzle
DThrottle body assembly
DInjection pump
DCompression pressure
DExistence of mixing foreign objects (water, kerosene) with
the fuel
INSPECTION PROCEDURE 6
Starting performance is bad when the engine is cold
(unable to start)
Probable cause
Probable causes can be found in troubles with control system, injection pump,
fuel system, intake system, and glow system.DControl system inoperative
DInjection pump inoperative
DFuel system inoperative
DIntake system inoperative
DGlow system inoperative
DEngine-ECU inoperative
NG
Repair
MUT-IISelf-Diag code
Is a diagnosis code output?YESInspection chart for diagnosis codes (Refer to P.13E-8.)
NO
Conduct MUT-IIData list check and an actuator test.
(Refer to P.13E-40, 44.)OKInspect the following items in order:
DGlow plug, glow plug relay
DInjection nozzle, fuel filter
DThrottle body assembly
DExistence of starter switch signal input
DEngine oil
DInjection pump
DExistence of mixing foreign objects (water, kerosene) with
the fuel


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