Katerina Swanson
The Mitsubishi Pajero is a popular vehicle, but like any car, it has its issues. One of the most common problems is fuel injector pump failure, which can be a costly fix. This guide will take you through the process of removing and replacing the fuel injector pump in your Mitsubishi Pajero, including the tools and steps needed to complete the job successfully. It is important to note that this is not a simple task and may take some time, so it is recommended to set aside a few days and be prepared with the necessary tools and knowledge before beginning the process.
Removing and Replacing the Fuel Injector Pump on a Mitsubishi Pajero
| Characteristics | Values |
|---|---|
| Tools | Socket set of 1/4", 3/8" & 1/2" drive with various extension bars, combination spanners, pliers, a mirror, a torch/inspection lamp, small tie wraps, surgical gloves, penetrating oil, engine degreasant, copper slip, antifreeze, a jug and funnel |
| First Steps | Smear engine oil on the large round o-ring at the front of the pump and on the bolts that pass through the housing |
| Next Steps | Fit the awkward bolt as the third one (fit a couple from the front to take the weight) |
| What to Remove | Remove the bag or whatever was used to cover the hole |
| Flush | Flush the coolant system before refilling |
| Drain Tap | Ensure the drain tap is done up |
| Intercooler Hoses | Temporarily connect the intercooler hoses but have the intercooler sit on the rocker cover so you can see the fuel pump |
| Check For | Check for leaks and make throttle adjustments if you also did the diesel pump top leak fix |
| Pump Degree | Check the pump degree |
| Bolt | Remove the 12mm bolt at the back of the pump in the middle |
| Dial Indicator | Bolt a dial indicator in place of the bolt |
| Bolts | Loosen the three bolts at the front of the body of the pump that hold the pump to the gear housing |
| Rotate | Rotate the pump |
| Gauge | Watch the gauge until it's sitting on the correct degree, nip it up, then remove the gauge |
| Running the Car | Do not run the car until the above steps have been completed |
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What You'll Learn
Fuel injector pump failure
The Mitsubishi Pajero is a popular 4x4 vehicle. However, some owners have reported issues with fuel injector pump failures. This can manifest as the car refusing to start, with no fuel getting to the injectors. In some cases, there may be metal particles in the fuel tank or filter, which can damage the pump and cause bearing issues.
One owner reported that their Pajero refused to start, with no warning signs. A mobile mechanic was unable to fix the issue, and a fuel injection specialist was called, who was able to get the car running, but could not identify the root cause. The owner drove the car for several months without issue, but then experienced the same problem again. This time, the car had to be towed to a local mechanic, who was able to fix the issue. The total cost of repairs was not mentioned.
Another owner reported a similar issue, with their Pajero refusing to start one day, with no fuel reaching the injectors. This owner cracked open the fuel delivery pipe and confirmed that there was no fuel present. The cost of reconditioning the fuel pump was estimated at $4500, and the owner was advised to consult a fuel pump specialist to determine the exact issue.
In some cases, the fuel injector pump failure may be caused by metal particles in the fuel tank or fuel filter, which can damage the pump and cause bearing issues. This can lead to a costly repair, with one owner reporting a $5500 bill for a rebuild.
To avoid potential issues with the fuel injector pump, some owners recommend having the pump reconditioned before any problems arise. This can help extend the life of the pump and potentially avoid more expensive repairs down the line.
When removing the fuel injector pump from a Mitsubishi Pajero, it is important to take certain steps to ensure the job is done safely and correctly. These include:
- Smearing engine oil on the large round o-ring at the front of the pump and on the bolts passing through the housing.
- Ensuring that markings line up correctly.
- Fitting the awkward bolt as the third one to avoid having to undo too much if something goes wrong.
- Remembering to remove any covering used over the hole.
- Flushing the coolant system and refilling it, ensuring the drain tap is secure.
- Temporarily connecting the intercooler hoses, with the intercooler sitting on the rocker cover, to allow for easy inspection of the fuel pump for leaks and adjustments.
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Fuel delivery pipe issues
The Mitsubishi Pajero is known to have some issues with its fuel delivery pipe. One of the common problems is that the fuel tank can get dented, which obstructs the fuel pickup strainer. This can cause the car to not start, as no fuel is getting to the injectors.
To fix this issue, you will need to access the fuel tank by removing the plates under the right-hand middle seat. Once you have access to the tank, scrub and hose off any sand, pebbles, or dirt that may be blocking the fuel return pipes. It is important to dry the area before proceeding.
Another issue with the fuel delivery pipe could be a blocked fuel filter. To check for this, you can use transparent PVC tubing to suck on the pipe. If the tubing becomes blocked with fuel, then the filter is likely blocked. You can try to clear the blockage by blowing through the tubing, and then quickly reconnecting the filter hose before the fuel runs back into the tank.
If you are experiencing issues with the fuel delivery pipe, it is recommended to consult a mechanic or a fuel pump specialist. They will be able to properly diagnose and fix the problem. Additionally, performing a fuel pressure test can help determine if there is an issue with the fuel delivery system.
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Reconditioning the fuel pump
Step 1: Understanding the Issue
Before beginning any work on your Mitsubishi Pajero, it's important to identify the specific problem causing the fuel pump to malfunction. Common issues include contaminated fuel, such as the presence of moisture, rust, dirt, or debris, which can clog the pump or damage its internal components. Additionally, fuel pumps can overheat if the vehicle is frequently driven with low fuel levels.
Step 2: Disassembling the Fuel Pump
To recondition the fuel pump, you will need to carefully disassemble it. This process may vary depending on the specific model of your Mitsubishi Pajero and the type of fuel pump it uses. Refer to model-specific manuals or seek advice from a qualified mechanic if you're unsure. During disassembly, pay close attention to the order in which parts are removed, as this will help during the reassembly process.
Step 3: Cleaning and Inspection
Once the fuel pump is disassembled, clean all the components thoroughly. Use appropriate cleaning solutions and tools to remove any built-up dirt, grease, or debris. After cleaning, carefully inspect each part for any signs of damage, wear, or fatigue. Common wear items include internal seals, the internal diaphragm, and the internal cam lobe. Identify the parts that need to be replaced or repaired.
Step 4: Replacing or Repairing Components
Procure the necessary replacement parts for the fuel pump, ensuring they are compatible with your Mitsubishi Pajero's make and model. Replace any worn or damaged seals, gaskets, diaphragms, or other components. If there are any parts that cannot be easily sourced, explore options for repairing them through specialist services or local mechanics.
Step 5: Reassembling the Fuel Pump
After all the necessary repairs and replacements have been made, carefully reassemble the fuel pump, following the reverse of the disassembly process. Ensure that all components are properly aligned and secured. Refer to manuals or seek advice if needed to ensure a correct and safe reassembly.
Step 6: Testing and Final Adjustments
Once the fuel pump has been reassembled, conduct a thorough test to ensure its optimal performance. This may include a fuel pressure test, checking for leaks, and making any necessary adjustments to the fuel pump's settings. Refer to your vehicle's manual for specific testing procedures and safety precautions.
It is important to note that reconditioning a fuel pump requires a good understanding of automotive mechanics and access to the appropriate tools and replacement parts. If you are unsure or uncomfortable with any part of the process, it is always best to consult a qualified mechanic to ensure the work is done correctly and safely.
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Setting the injector pump
Step 1: Check the Pump Degree
Before installing a new injector pump, it is essential to check the pump degree to ensure it is within the correct specifications. Refer to the manufacturer's instructions or a service manual for the specific degree settings.
Step 2: Install the Injector Pump
Follow the manufacturer's instructions for installing the injector pump. Ensure that all bolts are tightened securely and that any necessary adjustments are made during the installation process.
Step 3: Attach the Dial Indicator
Once the injector pump is fitted, you will need to set it, similar to setting a distributor. Locate the 12mm bolt at the back of the pump and remove it. Attach a dial indicator to this location, as it will be crucial for the next steps.
Step 4: Loosen the Front Bolts
Locate the three bolts at the front of the pump that hold it to the gear housing. Loosen these bolts, but do not remove them completely. By loosening these bolts, you will be able to rotate the pump and make the necessary adjustments.
Step 5: Adjust the Pump to the Correct Degree
With the dial indicator attached and the front bolts loosened, you can now rotate the pump until it aligns with the correct degree setting. Watch the gauge carefully and make adjustments as needed. Once the pump is sitting at the correct degree, tighten the front bolts to secure the pump in place.
Step 6: Final Checks
After setting the injector pump, it is important to perform final checks before starting the engine. Ensure that all bolts are tightened securely and that there are no leaks or other issues. Refer to the manufacturer's guidelines or a mechanic if you have any concerns.
Remember, it is essential to set the injector pump correctly to ensure optimal engine performance and avoid potential issues such as rough running or black smoke, as mentioned by a Mitsubishi owner. Taking your time and following the proper procedures will help ensure a successful injector pump installation and keep your Mitsubishi Pajero running smoothly.
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Tools required for fuel pump removal
To remove the fuel pump from a Mitsubishi Pajero, you will need a range of tools to ensure the job is done properly and safely. Here is a list of the tools required for the fuel pump removal process:
- Socket set of ¼”, 3/8” & ½” drive with various extension bars.
- Combination spanners.
- Nut sizes of 7mm, 8mm, 10mm, 12mm, 14mm, 17mm, 19mm, and 22mm.
- Pliers.
- A mirror and a torch or inspection lamp.
- Small tie wraps.
- Box of surgical gloves.
- Penetrating oil.
- Engine degreaser (include a couple of aerosols).
- Copper slip.
- Antifreeze, a jug, and a funnel.
Additionally, having engine oil to smear on the large round o-ring and bolts at the front of the pump is essential for proper alignment.
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Frequently asked questions
You will need a socket set of 1/4”, 3/8” & 1/2” drive with various extension bars, combination spanners, a mirror and torch/inspection lamp, small tie wraps, surgical gloves, penetrating oil, engine degreasant, copper slip, and antifreeze.
First, smear engine oil on the large round o-ring on the front of the pump and on the bolts that pass through the housing. Fit the awkward bolt as the third one and remove any covering over the hole. Flush the coolant system and refill, ensuring the drain tap is done up. Temporarily connect the intercooler hoses but have the intercooler sit on the rocker cover so you can check for leaks and make adjustments.
You will need to set it, like a distributor. Remove the 12mm bolt at the back of the pump in the middle and bolt a dial indicator in its place. Loosen the three bolts at the front of the body of the pump that hold the pump to the gear housing. The pump will then rotate, and you can watch the gauge until it sits on the correct degree.
There are timing marks on the housing and the pump. You can also use a diagnostic tool and a spill pipe arrangement on No.1 to set the degree.
Yes, you will need to bolt a dial indicator to the back of the pump once fitted to set it to the correct degree.
