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Turbocharger FITTING INSTRUCTIONS MITSUBISHI PAJERO EXPRESS TRITON WITH 4D55 & 4D56 MOTOR

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Filed Under (Mitsubishi) by admin on 18-12-2010

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1. Remove exhaust manifolds and inlet manifold thoroughly cleaning old gasket from head. 2. Remove oil plug from rear of cylinder head using a 6 mm Allen headed socket and fit 1/4 BSP oil fitting No. 34 and oil pipe No. 35. 3. Remove oil filter and then whole oil filter casting. Clean old gasket from both surfaces and make a holding jig for aluminium casting so as to be able to drill out the oil return. Drill a 15 mm hole right through to return gallery and tap out to 3/8 BSP. Thoroughly blow clean of metal and fit 3/8 x 16 mm hose fitting No. 42 and oil return hose No. 40. Now refit to block using new gasket No. 39. 4. Fit new manifold gasket No. 7 and Denco Diesel exhaust manifold No. 6. Now fit turbo to manifold making sure to engage oil return fitting. Tighten turbo to manifold using lock nuts .9. (NOTE: Make sure all openings on turbo and motor have been covered to prevent foreign material entering.) 5. Fit oil pipe No. 35 to turbo and tighten fittings. 6. Fit inlet manifold No. 26 to motor and connect to turbo using No. 30 casting and item No. 28 and 29 clamps and hoses. Secure oil pipe with clamp and bolt. 7. Fit heat shield No. 17 to exhaust manifold No. 6 using bolts No. 18. 8. Fit air cleaner to turbo 4D 003 Casting No. 21 or 22 to turbo using items No. 24-25 clamps and hoses and connect to air cleaner using original hoses. 9. Fit exhaust dump pipe No. 43 to turbo using V Clamp No. 16. 10. Connect engine breather pipe to fitting No. 23. 11. Increase Max fuel on fuel injection pump by one sixth of a turn, or 2 segments of the clock inwards. 12. Fit 2 1/4 inch or 55mm exhaust system and straight through muffler (not supplied). 13. Start engine and allow it to idle for 5 minutes whilst checking for air and oil leaks. Set max. boost under load to 50 KPA by adjusting actuator rod. ALL DENCO DIESEL SYSTEMS RUN AT 60 KPA BOOST MAXIMUM AND A MAXIMUM OF 550°C UNDER POWER LOAD UNLESS OTHERWISE STATED. 14. Recheck for leaks.

TOW BAR M-348 FOR MITSUBISHI PAJERO LWB FITTING AND OPERATION MANUAL

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Filed Under (Mitsubishi) by admin on 18-12-2010

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Follow the general directions in order to fit M-348 tow bar properly: 1.Rear bumper removing and cutting is not required. 2.Remove double towing lug from chassis rail (will no longer be used). 3.Remove plastic shield at the right wheel arch. 4.Loosen exhaust silencer. 5.Remove plastic grille under air conditioner. 6.Remove air conditioner. 7.Put (3) to the inside of the right chassis rail and tight loosely using (11) (fitting from the outside of the chassis rail) with (8), (13) and (9) (fitting from the inside of the support) with (15) and (13). 8.Put (4) to the inside of the left chassis rail and follow directions similarly as in point 7. 9.Put (5) and (6) to the right and left chassis rail from the downside and tight loosely using (9) with (15) and (13). Attach (5) and (6) with (3) and (4) using (10) with (7) (fitting from the outside) and (15), (13) and (17) (fitting from the outside). 10.Insert (1) between (3) and (4) and tight loosely using (10) with (15), (13) and (17). 11.Attach (2) to the tow ball holder using (12) with (16), (14) and (18). 12.Tighten all nuts and bolts to the torque staked in the table. 13.Refit all elements that were removed (points 2-5). Obeying this instruction assures correct montage and the tow bar operating in a Mitsubishi Pajero LWB. After assembling of the tow bar M-348 you have to get entry in cars registration book in a quality control station . CAUTION : Check if all bolts and nuts are correctly tightened after 1000km. Keep tow ball clean, grease and cased. All mechanical damages of tow bar excludes its further exploitation . Damaged ball hook cannot be repaired. In case of braking the rules of montage or unproper usage manufacturer do not take responsibility for arised damages . MONTAGE DIAGRAM :

2005-2007 Ford F-Super Duty SPEEDOMETER AND/OR TACHOMETER STUCK OR JUMPING / BOUNCING / ERRATIC

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Filed Under (Ford) by admin on 26-01-2011

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Some 2005-2007 F-Super Duty vehicles may exhibit a speedometer and/or tachometer indicator issue. Symptoms may include intermittent, large inaccuracies, or jumping/bouncing/erratic pointers. ACTION Refer to the Service Procedure. SERVICE PROCEDURE 1. Verify there are no diagnostic trouble codes (DTCs). If there are DTCs present, follow the appropriate procedure in the Workshop Manual to clear the DTC and resolve the concern. 2. Confirm that the axle ratio and tire size are properly configured in the ABS module. 3. For a speedometer related concern, If no DTCs are present, the issue may be with any of the following components: • Cluster • ABS Module • ABS Speed Sensor • Vehicle Wiring • If the symptom is a continuous (non-intermittent) large inaccuracy, ensure that the axle ratio and tire size are properly configured in the ABS module. To identify the cluster as the root cause: 1. Monitor the vehicle speed sensor (VSS) PID in the powertrain control module (PCM), and the speedometer needle position while stopped. 2. If the speedometer displays 5 MPH (8 Km/h) or more, and the VSS PID indicates zero, replace the instrument cluster. 3. With an assistant observing the diagnostic tool, drive the vehicle at 20, 40, and 60 MPH (32, 64, and 97 Km/h) as indicated on the diagnostic tool, and record the value indicated by the speedometer. 4. If the speed indicated on the diagnostic tool versus speedometer readings vary by more than ± 5 MPH, (8 Km/h) replace the instrument cluster. ABS Module Concern To identify if the ABS Module is the root cause, refer to diagnostic procedures in the Workshop Manual. For any customer complaints of jumping/bouncing/erratic speedometers, a wiring concern may exist which is severe enough to interrupt the signal, but not severe enough to totally open/short the circuit.

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2004 Hyundai Sonata Tachometer is erratic and it seems to miss under a light load while driving

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Filed Under (Hyundai) by admin on 20-11-2010

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Tachometer is erratic and it seems to miss under a light load while driving. Has codes P0320. P0300, P0301, P0302, P0303, and P0304. Cleared the codes and P0320 returned. Tests/Procedures: Potential Causes: 1. Check for battery voltage at idle to the ignition failure sensor at terminal 4, Pink/Black wire. 2. Check for battery voltage from the ignition failure sensor to the coils at idle from terminal 3, Tan/Black wire. 3. Bypass the ignition failure sensor by jumping from terminal 4 to terminal 3 and test drive the vehicle to see if the miss still occurs. 4. Scope the signal at the ignition failure sensor at terminal 2, White wire that goes to the instrument cluster for the tach signal. Ignition Failure Sensor

Mitsubishi Shogun/ Mitsubishi Pajero/ Mitsubishi Montero (1991-2000) 2,8D Turbo Valve timing procedures

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Filed Under (Mitsubishi) by admin on 07-06-2010

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Valve timing procedures 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]. Ensure notch on camshaft points upwards [2]. 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] : 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:

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