Pajero Owners Club of South Africa

I recently removed and refitted my brother's diesel pump so he can have it reconned.

If I was to do it again these are the key notes I would recommend.

- Clean the engine before starting the job.
- disconnect the battery before you start as you have an unfused 12v wire to the starter close by - bracelets burn badly - I learned the hard way with my sister's mini a few years back.
- the intercooler comes out as a whole with the 2x top bolts and 2 radiator located bolts (don't remove all the other ones holding the intercooler to the bracket)
- remember to mark the throttle cable.
- a 12 ring spanner ratchet is a lifesaver for the bolt located behind the aircon belt tensioner pulley - otherwise spray the bracket with penetrating oil and remove the idler for access
- triple mark and triple check the timing - this isn't something that you want to get wrong as it involves removing the whole pump to reset it - I luckily got it right first time round by marking the teeth on the pumps gear and the power steering pump housing surface.
- redo all the coolant pipes and fuel pipes around it while you have access.
- check that the injector pipes are securely tightened at the pump before fitting as they are a PITA to tighten once the pump is in. Alternatively you can fit the pipes separately one by one, but I felt it risked getting dirt in them.
- change the fuel filter at the same time while you have easy access - the water sensor's wiring at the bottom of the filter is EXTREMELY brittle!
- prefill the diesel filter with diesel to save on hand priming.
- make sure you have a fully charged battery when trying to start - if you missed a few things you might have to try a few times.
- if you have small hands with great dexterity it isn't too bad to just remove the bolt at the bottom on the bracket instead of removing the 2x bolts that bolt the bracket onto the block. ( But get it to thread in before you bolt the pump tight ) - in hindsight, I will in future, rather try the 2x bolts against the block.

Other than that, if you work systematically and organised and put all the bolts back in the places where you removed them from it is a fairly easy job to do. For me the worst part was the bolt behind the A/C idler pulley ( 40 minutes to get it back in )

No pics?
No diagrams from the manual?

I didn't take many pics - I used the write-up found as PDF in the library good enough as a write-up. I will post up the pics I did take though.

http://www.pocuk.com/forums/viewtopic.php?t=22531

https://www.pajeroclub.co.za/documentat ... p-leak-fix

Truth be told I almost took no photos at all. I only took photos of the cam markings at TDC but they came out black and then swambo took 2 photos of me.

The old saying comes to mind.....

- "the itch on your face or nose is directly proportioned to the dirt on your hands"

To add to Marius' keynotes, some info on the timing set-up for the 4m40 TD engine:

General precautions

• Disconnect battery earth lead.
• Remove glow plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• Observe tightening torques.
• Do NOT turn crankshaft via camshaft or other sprockets.
• Do NOT turn crankshaft or camshaft with timing chain removed.
• Check diesel injection pump timing after resetting valve timing.

Valve timing procedures

• Ensure crankshaft at TDC on No.1 cylinder.
• Ensure crankshaft pulley timing mark aligned with 0° timing mark on chain cover [1]11928.
• Ensure notch on camshaft points upwards [2]11928.
• If notch not visible, turn crankshaft one more turn.
• Install timing gears as follows:
• Ensure crankshaft gear and intermediate shaft gear timing marks aligned [3].
• Install LH balancer shaft [4].
• Ensure timing marks on intermediate shaft gears and LH balancer shaft gear aligned [5] & [6].
• Ensure RH balancer shaft gear and oil pump gear timing marks aligned [7].
• Install oil pump housing complete with RH balancer shaft.
• Ensure timing marks on oil pump gear and crankshaft gear aligned [8].
• Install injection pump as follows [9]11928:
• Ensure notch on injection pump gear aligned with mark 'T' on flange [10].
• During installation of injection pump: Notch on gear moves in direction of arrow.
• Install timing chain as follows:
  NOTE: Camshaft sprocket bolt has LH thread.
• Ensure crankshaft gear and intermediate shaft gear timing marks aligned [3].
• Align bright coloured chain link with intermediate shaft sprocket mark [11].
• Align camshaft sprocket timing marks with bright links [12].
• Turn cam on tensioner [13]11928and push plunger into tensioner housing. Lock tensioner with hook [14]11928.
• After installation remove hook to release plunger.
• Check timing chain for wear as follows [15]11928:
• Push timing chain tensioner in direction of arrow and measure clearance 'X'.
• Replace the timing chain if the measurement 'X' is 9 mm or less.