Mitsubishi MOTORS Pajero 2001 Instruction manual

00
11
12
13
14
15
16
17
52
54
General ........................
Engine .........................
Engine Lubrication .............
Fuel ...........................
Engine Cooling ................
Intake and Exhaust .............
Engine Electrical ...............
Engine and Emission Control . . .
Chassis Electrical ..............
EMitsubishi Motors Corporation May 2001
WORKSHOP
MANUAL
SUPPLEMENT
FOREWORD
This manual outlines changes in servicing
procedures related to the chassis including
vehicle inspections and adjustments in the
newly added models. Use the following
manuals in combination with this manual as
required.
TECHNICAL INFORMATION MANUAL
PYJE9002
WORKSHOP MANUAL
ENGINE GROUP PWEE____
(Looseleaf edition)
CHASSIS GROUP PWJE9086(Basic)
PWJE9086-G(Supplement)
PWJE9086-H(Supplement)
PWJE9086-I(Supplement)
ELECTRICAL WIRING PHJE9026(Basic)
PHJE9026-D(Supplement)
PHJE9026-E(Supplement)
PHJE9026-F(Supplement)
PHJE9026-G(Supplement)
PHJE9026-H(Supplement)
PHJE9026-I(Supplement)
PARTS CATALOGUE B60356A2Aj
All information, illustrations and product
descriptions contained in this manual are
current as at the time of publication. We,
however, reserve the right to make changes
at any time without prior notice or obligation.
Interior and Supplemental
Restraint System (SRS) ........

GENERAL - How to Use This Manual/Vehicle Identification 00-1
GROUP 00
GENERAL
HOW TO USE THIS MANUAL
INDICATION OF TIGHTENING TORQUE
Tightening torques (units: N·m) are set to take into account the central value and the allowable tolerance.
The central value is the target value, and the allowable tolerance provides the checking range for tightening
torques. If bolts and nuts are not provided with tightening torques, refer to P.00-5.
VEHICLE IDENTIFICATION
MODELS
<2-DOOR MODELS>
Model code Engine model Transmission model Fuel supply system
V24W NDGL6Y 4D56 (2,477 mL)
with
turbocharger
V5MT1 <5M/T> Injection
GNDGL6Y
w
ith
t
ur
b
oc
h
arger
and inter-cooler
<4-DOOR MODELS>
Model code Engine model Transmission model Fuel supply system
V44W NDGL6Y 4D56 (2,477 mL)
with
turbocharger
V5MT1 <5M/T> Injection
GNDGL6Y
w
ith
t
ur
b
oc
h
arger
and inter-cooler

GENERAL - Vehicle Identification
00-2
CHASSIS NUMBER
The chassis number is stamped on the side wall of the frame
near the right rear wheel.
12 3 4 56789 11
10
No. Items Contents
1 Fixed figure J Asia
2Distribution channel M Japan channel
3Destination B For Europe, left hand drive
4 Body style 0 4 or 2-door with tailgate(back door)
5 Transmission type N 5-speed manual transmission
6Development order V2 PAJERO 2-door models
V4 PAJERO 4-door models
7Engine 44D56: 2,477 mL diesel engine
8 Sort W Station wagon
9Model year 2* 2002
10 Plant J Pajero Manufacturing Co., Ltd. *
11 Serial number - -
NOTE
*: Indicates changes.

GENERAL - Major SpecificationsGENERAL - Major Specifications 00-3
MAJOR SPECIFICATIONS
2-DOOR MODELS
1
84 9
3
6
7
5
2
Items V24W
NDGL6Y GNDGL6Y
Vehicle
di i
Overall length 1 4,075
dimensions
mm
Overall width 2 1,695 1,785
mm
Overall height (unladen) 3 1,835 1,845
Wheelbase 4 2,420
Track-front 5 1,420 1,465
Track-rear 6 1,435 1,480
Ground clearance
(unladen)
7 205 215
Overhang-front 8 675
Overhang-rear 9 980
Vehicle
iht
k
Kerb weight 1,700 1,755
weight kg Max. gross vehicle weight 2,510
Max. axle weight rating-front 1,070
Max. axle weight rating-rear 1,750
Seating capacity 5
Engine Model No. 4D56 Intercooler Turbocharger
g
Total displacement mL 2,477
Transmis-
i
Model No. V5MT1
sion Type 5-speed manual
Fuel system Fuel supply system Injection

GENERAL - Major Specifications
00-4
4-DOOR MODELS
1
84 9
3
6
7
5
2
Items V44W
NDGL6Y GNDGL6Y
Vehicle
di i
Overall length 1 4,655
dimensions
mm
Overall width 2 1,695 1,775
mm
Overall height (unladen) 3 1,890 1,900
Wheelbase 4 2,725
Track-front 5 1,420 1,465
Track-rear 6 1,435 1,480
Ground clearance
(unladen)
7 205 215
Overhang-front 8 650
Overhang-rear 9 1,280
Vehicle
iht
k
Kerb weight 1,875 1,930
weight kg Max. gross vehicle weight 2,750
Max. axle weight rating-front 1,090
Max. axle weight rating-rear 1,780
Seating capacity 7
Engine Model No. 4D56 Intercooler Turbocharger
g
Total displacement mL 2,477
Transmis-
i
Model No. V5MT1
sion Type 5-speed manual
Fuel system Fuel supply system Injection

GENERAL - Standard Part/Tightening-Torque Table 00-5
STANDARD PART/TIGHTENING-TORQUE TABLE
Each torque value in the table is a standard value
for tightening under the following conditions.
(1) Bolts, nuts and washers are all made of steel
and plated with zinc.
(2) The threads and bearing surface of bolts and
nuts are all in dry condition.
The values in the table are not applicable:
(1) If toothed washers are inserted.
(2) If plastic parts are fastened.
(3) If bolts are tightened to plastic or die-cast
inserted nuts.
(4) If self-tapping screws or self-locking nuts are
used.
Standard bolt and nut tightening torque
Thread size Torque N·m
Bolt nominal
diameter (mm)
Pitch (mm) Head mark “4” Head mark “7” Head mark “8”
M5 0.8 2.50.5 5.01.0 6.01.0
M6 1.0 5.01.0 9.02.0 102
M8 1.25 122 224 254
M10 1.25 244 4410 537
M12 1.25 418 8312 9812
M14 1.5 7312 14020 15525
M16 1.5 11020 21030 23535
M18 1.5 16525 30040 34050
M20 1.5 22535 41060 48070
M22 1.5 30040 55585 64595
M24 1.5 39555 735105 855125
Flange bolt and nut tightening torque
Thread size Torque N·m
Bolt nominal
diameter (mm)
Pitch (mm) Head mark “4” Head mark “7” Head mark “8”
M6 1.0 5.01.0 102 122
M8 1.25 132 244 275
M10 1.25 264 499 587
M10 1.5 244 458 5510
M12 1.25 468 9515 10515
M12 1.75 438 8312 9812
NOTE
1. Be sure to use only the specified bolts and nuts, and always tighten them to the specified torques.
2. Bolts marked with indications such as 4T or 7T are reinforced bolts. The larger the number, the
greater the bolt strength.

NOTES

11-1
ENGINE
CONTENTS
ENGINE <4D5-Step III>2.............
GENERAL 2.................................
Outline of Changes 2...........................
GENERAL INFORMATION 2..................
SERVICE SPECIFICATIONS 2.................
SEALANT 3..................................
SPECIAL TOOLS 3...........................
ON-VEHICLE SERVICE 4.....................
Injection Timing Check and Adjustment 4.........
Idle Speed Check 4............................
OIL PAN AND OIL SCREEN 5................
TIMING BELT AND TIMING BELT B 7........
CYLINDER HEAD GASKET 11................

ENGINE <4D5-Step III>-
G
enera
l/G
enera
l
I
n
f
ormat
i
on
/S
erv
i
ce
Specifications
11-2
ENGINE <4D5-Step III>
GENERAL
OUTLINE OF CHANGES
Some service procedures have been revised as the following changes have been made to comply to
the Emission Regulation Step III.
DThe injection timing check and adjustment procedure and the idle speed check procedure have been
changed.
DThe oil pan has a cover in order to reduce noise due to an enhanced engine output.
DA crank angle sensor and crankshaft sensing blade have been added due to the introduction of
an electronic-controlled fuel injection pump. Due to this change, the timing belt front lower cover
has been reshaped.
DThe tightening torque of the cylinder head bolts and the cylinder head gasket have been changed.
GENERAL INFORMATION
Items 4D56
Total displacement mL 2,477
Bore x Stroke mm 91.1 x 95.0
Compression ratio 21
Combustion chamber Vortex chamber type
Camshaft arrangement SOHC
Number of valve Intake 4
Exhaust 4
Valve timing Intake Opening BTDC 20_
Exhaust Closing ABDC 49_
Intake Opening BBDC 55_
Exhaust Closing ATDC 22_
Fuel system Electronically controlled type injection pump
Rocker arm Roller type
Adjusting screw Elephant foot type
SERVICE SPECIFICATIONS
Items Standard value
Timing belt tension mm 4-5
Timing belt B tension mm 4-5
Idle speed r/min 750 ±30

ENGINE <4D5-Step III>-Sealant/Special Tools 11-3
SEALANT
Items Specified sealant Remarks
Oil pan MITSUBISHI GENUINE PART
MD970389 or equivalent
Semi-drying sealant
Semi-circular packing and rocker
cover seal, and cylinder head seal
3M ATD Part No. 8660 or equivalent
SPECIAL TOOLS
Tools Number Name Use
MD998727 Oil pan remover Removal of oil pan
MD998721 Crankshaft pulley
holder
Holding the crankshaft pulley
MD998051 Cylinder head bolt
wrench
Removal and installation of the cylinder head
bolt
MB991614 Angle gauge Tightening of the cylinder head bolts

ENGINE <4D5-Step III>-On-vehicle Service
11-4
ON-VEHICLE SERVICE
INJECTION TIMING CHECK AND
ADJUSTMENT
The cold start device (wax type) has been discontinued as
an electronically controlled injection pump has been used.
The other inspection and adjustment procedures are the same
as before.
IDLE SPEED CHECK
1. Set the vehicle to the pre-inspection condition.
2. Turn the ignition switch to “LOCK” (OFF) position, and
connect the diagnosis connector to the MUT-II.
If the MUT-II is not used, connect a tachometer to the
injection nozzle or the pipe.
3. Start the engine, and let it run at idle.
4. Check the idle speed.
Standard value: 750 ±30 r/min
5. If the idle speed is not within the standard value, refer
to 13C - Troubleshooting to check the electronic controlled
fuel injection system.
NOTE
The idle speed is controlled by the engine-ECU.
Injection nozzle
Tachometer

ENGINE <4D5-Step III>-Oil Pan and Oil Screen 11-5
OIL PAN AND OIL SCREEN
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
DSkid Plate and Under Cover Removal and Installation.
DFront Exhaust Pipe Removal and Installation (Refer
to GROUP 15 - Exhaust Pipe and Muffler.)
DEngine Oil Draining and Supplying.
15
1
9
6
3
5
13
11
10
14
12 ±1N·m
19 ±3N·m
110 ±10 N·m
9.0 ±1.0 N·m
39 ±5N·m
7.0 ±1.0
N·m
35 ±6N·m
(Engine oil)
2
9.0 ±1.0 N·m
8
7
9.0 ±1.0 N·m
12
4
110 ±10 N·m
Sealant:
MITSUBISHI GENUINE Part No.
MD997110 or equivalent
12
4mm
(0.16 in.)
diameter
Hole of boltGroove
Removal steps
1. Vacuum hose connection
2. Bolt
3. Front suspension crossmember
4. Engine oil level gauge and guide
assembly
5. Drain plug
"BA6. Drain plug gasket
7. Alternator vacuum pump oil return
hose connection
8. Oil level sensor connector
9. Oil level sensor
10. Space rubber
11. Bell housing cover
AA""AA. 12. Oil pan
13. Oil pan cover
14. Oil screen
15. Oil screen gasket

ENGINE <4D5-Step III>-Oil Pan and Oil Screen
11-6
REMOVAL SERVICE POINT
AA"OIL PAN REMOVAL
INSTALLATION SERVICE POINTS
"AAOIL PAN INSTALLATION
1. Remove sealant from oil pan and cylinder block mating
surfaces.
2. Degrease the sealant-coated surface and the engine
mating surface.
3. Apply a continuous bead of the specified sealant to the
oil pan mating surface as shown.
Specified sealant:
MITSUBISHI GENUINE PART No. MD970389 or
equivalent
NOTE
The sealant should be applied in a continuous bead
approximately 4 mm in diameter.
4. Assemble oil pan to cylinder block within 15 minutes after
applying the sealant.
Caution
After installing the oil pan, wait at least 1 hour before
starting the engine.
"BADRAIN PLUG GASKET INSTALLATION
Install a new gasket in the direction so that it faces as shown
in the illustration.
MD998727 MD998727
φ4mm
GrooveBolt hole
Drain plug
gasket
Oil pan
side

ENGINE <4D5-Step III>-Timing Belt and Timing B 11-7
TIMING BELT AND TIMING BELT B
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
DIntercooler Removal and Installation
(Refer to GROUP 15.)
DCooling Fan Removal and Installation.
1
6
18
17
16
15
14
13
12
3
4
9
8
7
5
2
11 ±1N·m
(Engine oil)
26 ±3N·m
177 ±9N·m
11 ±1N·m
26 ±3N·m
26 ±3N·m
10
11
9.0 ±1.0 N·m
26 ±3N·m
26 ±3N·m
Removal steps
"CA1. Timing belt front upper cover
2. Tension pulley and tension pulley
bracket assembly
3. Crankshaft pulley (for power steer-
ing and A/C)
AA""DA4. Crankshaft pulley
"CA5. Timing belt front lower cover
AB""BA6. Timing belt
7. Tensioner spacer
8. Tensioner spring
9. Timing belt tensioner
10. Crank angle sensor
11. Crankshaft sensing blade
12. Crankshaft sprocket
13. Flange
AC""AA14. Timing belt B
15. Gasket
16. Tensioner spacer B
17. Tensioner spring B
18. Timing belt tensioner B

ENGINE <4D5-Step III>-Timing Belt and Timing B
11-8
REMOVAL SERVICE POINTS
AA"CRANKSHAFT PULLEY REMOVAL
1. Turn the crankshaft clockwise, align the timing marks
to set No.1 cylinder to TDC of its compression stroke.
Caution
Never turn the crankshaft anticlockwise.
2. Use the special tool to keep crankshaft from turning and
remove the bolts.
AB"TIMING BELT REMOVAL
1. When reinstalling timing belt, mark an arrow at the belt
to show rotation direction.
2. Loosen the tensioner mounting bolt A and B.
3. Push timing belt tensioner to water pump side and tighten
the tensioner mounting bolt A and B. Secure so that
tensioner will not move back.
AC"TIMING BELT B REMOVAL
1. When reinstalling timing belt B, mark an arrow at the
belt to show rotation direction.
2. Loosen the tensioner mounting bolt C and nut D.
3. Push timing belt tensioner to water pump side and tighten
the tensioner mounting bolt C and nut D. Secure so that
tensioner will not move back.
Timing marks
MD998721
Tilt to water pump side
A
B
Water pump
C
D

ENGINE <4D5-Step III>-Timing Belt and Timing Belt BENGINE <4D5-Step III>-Timing Belt and Timing Belt B 11-9
INSTALLATION SERVICE POINTS
"AATIMING BELT B INSTALLATION
1. Align the timing marks of the 3 sprockets.
2. When reusing timing belt B, make sure the arrow mark
is pointing in the same direction as when the belt was
removed.
3. Install timing belt B and make sure there is no deflection
on the tension side.
4. Press the deflection side of timing belt B with the hand
and fully stretch the tensioner side.
5. Make sure that the timing marks are aligned.
6. Loosen the tensioner mounting bolt and nut so that only
the pressure of the spring is applied to timing belt B.
7. Tighten the tensioner mounting bolt C and nut D, tightening
the nut first. If the bolt is tightened first, the tensioner
will move and tension the belt.
Tightening torque: 26 ±3 N·m
8. Press in the direction of the arrow in the figure with the
index finger to check the amount of deflection.
Standard value: 4 - 5 mm
"BATIMING BELT INSTALLATION
1. Align the timing marks of the 3 sprockets.
2. When reusing timing belt, make sure the arrow mark is
pointing in the same direction as when the belt was
removed.
3. Install the timing belt to the crankshaft sprocket, to injection
pump sprocket, to tensioner and to camshaft sprocket
in that order. Being careful not to allow deflection on
the tension side of the timing belt.
Caution
(1) Engage the belt on the various sprockets while
maintaining tension on the belt of tension side.
(2) Align the injection pump sprocket with the timing
mark, hold the sprocket so that is does not turn
and engage the belt.
4. Loosen the tensioner mounting bolts and apply tension
with the spring.
Timing mark
Timing
marks
Tension
side
D
C
Deflection
side
Counterbalance
shaft sprocket
Belt deflection
Crankshaft
sprocket B
Timing marks
Water pump
Tension
side
Tension side

ENGINE <4D5-Step III>-Timing Belt and Timing Belt BENGINE <4D5-Step III>-Timing Belt and Timing Belt B
11-10
5. Turn the crankshaft clockwise and stop at the second
lobe of the camshaft sprocket.
Caution
(1) When turning the crankshaft in item (5), strictly
observe the specified amount of rotation (2 teeth
on the camshaft sprocket) in order to apply a
constant force to the tension side of the belt.
(2) Do not turn the crankshaft counterclockwise.
(3) Do not touch the belt during adjustment.
6. Make sure that the part indicated by arrow A does not
float upward.
7. Tighten the tensioner mounting bolts, starting with the
bolt in the elongated hole. If the lower bolt is tightened
first, belt tension will become too tight.
8. Turn the crankshaft anticlockwise and align the timing
mark. Next, make sure that the timing marks of all
sprockets are aligned.
9. Press on the center of the bolt with an index finger to check
the amount of deflection.
Standard value: 4 - 5 mm
"CATIMING BELT FRONT LOWER COVER/TIMING
BELT FRONT UPPER COVER INSTALLATION
Install the bolts to the timing belt cover at the shown positions.
Name Symbols Size mm (d×l)
Flange bolt A 6×22
B 6×50
C 6×60
d=Nominal diameter
l=Nominal length
"DACRANKSHAFT PULLEY INSTALLATION
Using the special tool to install the crankshaft pulley as same
as removal procedure.
Camshaft sprocket
2 teeth
Tensioner
A
Tensioner
mounting bolt
Tensioner
mounting bolt
Amount of belt
deflection
A
A
A
A
B
A
A
AB
C

ENGINE <4D5-Step III>-Cylinder Head Gasket 11-11
CYLINDER HEAD GASKET
REMOVAL AND INSTALLATION
Pre-removal Operation
DIntake and Exhaust Manifold Removal
(Refer to GROUP 15.)
DTiming Belt Removal (Refer to P.11-4.)
DEngine Coolant Draining.
Post-installation Operation
DTiming Belt Installation (Refer to P.11-4.)
DIntake and Exhaust Manifold Installation
(Refer to GROUP 15.)
DFuel Line Air Bleeding
(Refer to GROUP 13 - On-vehicle Service.)
DEngine Coolant Filling
10 mm 10 mm
Sealant:
3M ATD Part No. 8660 or
equivalent
10
12
11
11
3
2
6
4
7
1
15
14
13
10
5
29 ±2 N·m →+120°
(During cold engine)
5.9 ±1.0 N·m
4.9 ±1.0 N·m
30 ±6N·m
30 ±6
N·m
4.9 ±1.0
N·m
4.9 ±1.0 N·m
30 ±6N·m
22 ±4N·m
22 ±4N·m
24 ±4N·m
8
9
10 ±2N·m
13 ±2N·m
Removal steps
1. Engine coolant temperature switch
connector (for A/C)
2. Engine coolant temperature gauge
unit and sensor connector
3. Glow plug terminal
AA""DA4. Radiator upper hose
AB""CA5. Fuel injection pipe
6. Heater hose or water by-pass hose
connection
7. Fuel hose connection
8. Boost sensor and bracket assembly
9. Vacuum hose and pipe assembly
10. Rocker cover
11. Semi-circular packing
AC"12. Power steering oil pump assembly
13. Power steering oil pump bracket
bolt
AD""BA14. Cylinder head assembly
"AA15. Cylinder head gasket

ENGINE <4D5-Step III>-Cylinder Head Gasket
11-12
REMOVAL SERVICE POINTS
AA"RADIATOR UPPER HOSE DISCONNECTION
After making mating marks on the radiator upper hose and
the hose clamp, disconnect the radiator upper hose.
AB"FUEL INJECTION PIPE REMOVAL
When loosening nuts at both ends of injection pipe, hold
the delivery holder (for pump side) and the injection nozzle
assembly (for nozzle side) with wrench and loosen nut.
Caution
After disconnecting the injection pipe, plug the opening
so that no foreign particles get inside the pump or into
the injection nozzle.
AC"POWER STEERING OIL PUMP REMOVAL
Remove the power steering oil pump from the bracket with
the hose attached.
NOTE
Place the removed power steering oil pump in a place where
it will not be a hindrance when removing and installing the
engine assembly, and tie it with a cord.
AD"CYLINDER HEAD ASSEMBLY REMOVAL
Use the special tool to tighten each bolt 2 - 3 times in the
order shown in the illustration.
Delivery holder
Nut
Front
MD998051

ENGINE <4D5-Step III>-Cylinder Head Gasket 11-13
INSTALLATION SERVICE POINTS
"AACYLINDER HEAD GASKET INSTALLATION
When replacing the cylinder head gasket only, confirm the
gasket identification mark, and then select a replacement
part according to the table below:
Spec Identification mark (size) Parts num-
ber
AD5-774 (fitted thickness 1.45 ±0.04) MD377774
BD5-775 (fitted thickness 1.50 ±0.04) MD377775
CD5-776 (fitted thickness 1.55 ±0.04) MD377776
Caution
The thickness of the original cylinder head gasket is
selected according to the protrusion amount of the piston.
Therefore, if the piston or the connecting rod is replaced,
the protrusion amount may be changed. Always select
a correct gasket by measuring the protrusion amount.
(For details, refer to the Engine Workshop Manual.)
"BACYLINDER HEAD INSTALLATION
1. Select a cylinder head gasket of correct specification.
2. Clean the cylinder head assembly and the cylinder block
mating surfaces with a scraper or a wire brush.
Caution
Do not allow foreign material to enter the engine
coolant or oil passages and the cylinder.
3. Install the cylinder head bolt washer to the cylinder head
bolt so that the washer chamfered side faces as shown.
4. Apply a small amount of engine oil to the cylinder head
bolt thread and the washer.
Identification mark
A
B
C
Cylinder head
bolt washer
Chamfered
side