1996–1999 Mitsubishi Montero Service Manual (P/N PWEE9409-D)

• Application scope: Covers the Mitsubishi 4M40 diesel engine in Pajero, L200, and Challenger configurations, with separate factory callouts for turbo and non-turbo engines, 1998-on European Pajero hardware, the 2000 Challenger, and 2001 Pajero layouts.
• Major engine repair coverage: Documents cylinder-head removal and installation, camshaft and valve service, lifter-shim adjustment, piston and connecting-rod work, crankshaft and crankcase assembly, flywheel and drive-plate service, and oil-pump disassembly and reassembly.
• Timing-system procedures: Includes timing-chain installation, idler-gear and sprocket-bush service, balance-shaft removal and installation, gear backlash and end-play inspection, match-mark synchronization, and the appended timing-chain clearance bulletin.
• Fuel and turbocharger work: Covers injection-nozzle testing and cleaning, fuel-pump removal and installation, pump-gear alignment, dial-indicator injection-timing checks and adjustment, turbocharger removal, housing disassembly, cartridge inspection, and actuator testing.
• Cooling and lubrication systems: Provides repair procedures for the cooling fan, V-belt, water pump, thermostat, water pipes, oil cooler and filter, oil pan, strainer, oil jets, vacuum pump, intake manifold, and exhaust manifold across the listed vehicle variants.
• Document identity: 141 PDF pages total — 4 title, foreword, and effective-page sheets plus the 137-page 4M40 section. The title issue is PWEE9409-E, July 2001; section 11A carries PWEE9409-D, revised February 2000, with Service Bulletins MSB-99E11-505 and MSB-99E11-506 appended.

Engine Mechanical and Fuel System Documentation

This is the Mitsubishi factory workshop section for the 4M40 engine, not a complete vehicle service manual. Its scope is engine mechanical repair, fuel injection, turbocharging, cooling, lubrication, and the engine-mounted electrical items shown in the contents. It does not substitute for separate transmission, chassis, body, or full vehicle wiring information.

The mechanical chapters follow the factory removal, disassembly, inspection, adjustment, reassembly, and installation format. Cylinder-head coverage includes gasket selection by piston protrusion, rocker-cover sealing, timing-chain tensioner handling, camshaft and cap installation, valve-stem and guide inspection, valve-seat correction and replacement, combustion-jet service, valve-stem seals, and lifter-shim selection for valve-clearance adjustment. Lower-engine repair sections address piston protrusion, piston and cylinder size matching, connecting-rod bearings and bushings, piston rings, crankshaft journals, main-bearing selection, thrust plates, crankcase sealing, front and rear oil seals, flywheel, and automatic-transmission drive plate.

Timing work receives its own detailed section. The manual identifies the timing chain, cam sprocket, idler gear and sprocket assembly, tension lever, oil jet, balance shafts, balance-shaft gears and bushes, idler shafts, and the oil-pump drive. Procedures cover gear backlash and end-play checks, bush removal and press-fit installation, oil-hole alignment, left- and right-hand balance-shaft indexing, chain link and gear match marks, and final rotation checks. The included bulletin adds the factory timing-chain clearance inspection to the original installation page.

Fuel Injection, Turbocharger, Cooling, and Lubrication

Fuel-nozzle service includes nozzle-tester checks for opening pressure, spray pattern, post-injection dribble, and oil tightness, followed by cleaning, shim adjustment, and inspection of the matched needle-valve and nozzle-tip set. Fuel-pump coverage is vehicle-side repair: pump assembly removal and installation, non-turbo versus turbo gear indexing, injection-pipe handling, and dial-indicator timing checks and adjustment. The timing data distinguishes L200, Challenger, and regional Pajero builds, including EFTA, EC, Germany, Hong Kong, South Africa, General Export, and 2001 Pajero turbo engines with or without EGR. It does not contain an internal distributor-pump overhaul chapter.

Turbocharger coverage separates vehicle-specific removal layouts from component service. It documents turbine- and compressor-housing removal, cartridge axial-play and wheel-clearance inspection, snap-ring and coupling orientation, actuator-pressure testing, and pre-lubrication before installation. Cooling and lubrication chapters add dedicated 2001 Pajero views for the fan, water pump, water pipes, glow plugs, and turbo intake manifold, along with the 2001 Australian fuel-pump harness callout. Vacuum-pump diagnosis includes the specified 10-liter tank and gauge test arrangement.

Specifications, Special Tools, and Repair-Sensitive Details

Reference data includes general and service specifications, component-specific torque tables, standard bolt-and-nut tightening tables, sealant locations, inspection limits, bearing and piston selection data, fuel-injection adjustment specifications, and turbocharger and vacuum-pump test criteria. The special-tool pages identify equipment by Mitsubishi or supplier number, including MH063302/MH063300 injection-timing tools, MH062464 fuel-pump gear puller, MH062381 cam-sprocket holder kit, MH062717 balance-shaft bush installer, and 105789-0010 nozzle-cleaning tool.

Visual references include three 4M40 engine sectional views, variant-specific cooling and manifold exploded views, the turbocharger breakdown, the cylinder-head/camshaft/valve assembly, timing-gear and balance-shaft match-mark drawings, and fuel-nozzle spray-pattern illustrations. No full vehicle wiring-diagram chapter is included.

Several cautions matter during repair. The crankshaft must not be turned backward during pump timing because the manual warns that this can damage the timing-chain tensioner. Cylinder-head gasket removal must protect the head, crankcase, and timing-case sealing faces, and gasket class must be rechecked after piston or connecting-rod work. Thermostat and water-pipe O-rings must be kept free of engine oil because it swells them; turbocharger blades and the actuator diaphragm are likewise identified as easily damaged parts. High-pressure nozzle testing, rotating engine components, and heavy cylinder-head or crankcase assemblies require proper shop equipment and strict use of the factory safety notes.