HOW TO: DIESEL ENGINE SHUT OFF STOP RUN SOLENOID VALVE VE INJECTION PUMP Mitsubishi Pajero 4M40 4D56

THIS will get you STUCK! DIESEL ENGINE SHUT OFF RUN SOLENOID VALVE VE BOSCH INJECTION PUMP. These should last many years, but as it's about the only thing other than no fuel or water pump belt that will get you stranded, I keep an extra onboard...along with the tool to replace it. I bought mine at an auto parts store here in the Philippines, but found a good supply at the link below.
SOLENOID SELLERS: ebay.us/K49177
I may 'get deep in the weeds' or 'waffle on' in these videos, but prefer to provide any relevant detail and let the viewer fast-forward through unneeded parts or details.
MODEL JHAJA'S CHANNEL: / @jhajamorena

[@sapphirepilot]

Warning. Do not work on engines wearing metal watch bands or jewellery. Too much of a chance of injury if you touch 12 volts somewhere. I had an injury (burn) whilst wearing a metal watch band and working on a car.

[@offgridislandfamily]

You're absolutely right and it's when we get too comfortable with our skills that we make a mistake. Thanks for the reminder! I did another video yesterday and literally said, 'Don't do this the way I'm doing it.' LOL CHEERS!

[@harrywillkom1296]

Use crowsfoot wrench with 3/8 drive ratchet this will be a good addition to your tool set for hard to access areas.

[@offgridislandfamily]

Yes. I have a second similar toolbox with extra room in it. Thanks

[@aladdinlaguiwed398]

nice one sir!!!very informative and useful for us newbies....

[@offgridislandfamily]

Thanks bro! Really appreciate that...I watched so many 'How to' videos where they skip the one step, part or detail I needed to see. Decided to make very 'deep in the weeds' videos. ;-)

[@panyalvius1]

Love and respect from pakistan

[@offgridislandfamily]

Thank you very much! Back to you Sir!

[@tonyagudo4515]

Loved this! Having same problem now with my 4m40. I dont have that tool so I guess I'll have to get a mechanic. Hahaha

[@offgridislandfamily]

I can send you one. ;-)

[@panyalvius1]

Gr8 video .. can u make another one showing how to set the rite intake desel for the engine.. mine blows blak smoke when it shifts from first gear to second

[@offgridislandfamily]

Thank you SO MUCH sir! Black smoke on acceleration is actually normal. If you don't have at least some black smoke, then you are probably not getting full power from your engine. Please post a video to my group and get better educated opinions. ;-)

[@jaypearce6199]

Great video, I really need one of those spanner’s 🙈😂

[@offgridislandfamily]

Let me know...I can make another and TEST it before shipping.

[@offgridislandfamily]

@Ignacio Maxim GREAT NEWS! Previously not running or not shutting off?

[@flyingoose305]

Very clever. I want one !

[@offgridislandfamily]

I highly recommend them. ;-)

[@sapphirepilot]

Thanks. Love your style.

[@offgridislandfamily]

WOW! I appreciate that so much. Thank you!

[@neilbotes4746]

Thank you for your video, it helped me quite a bit, just one question? how the hell did you get two hands in that small area behind the pump, I either have one to many left or right hands or needed two left or right hands with broken wrists just to see the shut off valve. 😁

[@offgridislandfamily]

Hehehehe! Well, it's VERY tight, but I loosened one or two of the fuel injector lines and built a custom box wrench.

[@maverickmarinas7372]

i need that tools too on our 4m40 fieldmaster, very nice ,

[@offgridislandfamily]

I can build one for you. ;-) Shipping may be expensive depending where you live.

[@maverickmarinas7372]

How much that is cost for the tools?

[@Jhajamorena]

Be careful! 😉

[@richardgullidge8908]

hi can I ask is it just a 12v feed going to the solenoid or have it got a voltage drop and is it a constant feed as in trying to do away with the pat system ing my 1990s ford transit as the immobilizer is playing up

[@offgridislandfamily]

It's a constant 12v feed, yes. Thanks for watching! ;-)

[@kamfongchou9356]

Hi. I have a 2003 Pajero. Lately my engine stalled whilst driving. Likely no fuel supply. What’s the fault please?

[@offgridislandfamily]

If it happened suddenly, rather than gradually (filter / fuel pump), then it's most certainly THIS fuel shut-off solenoid, which is exactly what this video will show you how to replace. I got stuck twice because of it...once electrically worn out and second time, mechanical failure. So now I keep an extra in the parts box inside the vehicle. They normally last 100,000km, but I've had bad luck with this part.

[@bravo20ghost27]

Another good video bud, thank you. I have the 4D56T on my sport but I'm thinking to put one in my project car. I want it to run on a full mechanical system, no ECU or any other management. Would you recommend the 4M40 over the 4D56 and why? Thanks for the answer in advance. (Maybe you could do a video talking about the differences between the 2, just an idea) 😉

[@offgridislandfamily]

Sorry for the late reply. Missed this post. I would recommend the 4m40 for two reasons at least. 1. Larger engine & more power. 2. Timing chain instead of timing belt. I really don't like timing belts. I also wanted the newest fully mechanical system. One reason is to run vegetable oil as a fuel. Can't do it safely with an ECU if they are too fussy.

[@bravo20ghost27]

@@offgridislandfamily no worries at all, it happens. Yeah I completely understand. I know that I can change it to the mechanical ve pump but I also got myself the legendary om606 for future projects.

[@bravo20ghost27]

@@offgridislandfamily yeah exactly, that's why I'm getting the mechanical pump for the OM606, nice and simple setup. Eletrics for the starter and glow plugs.

[@offgridislandfamily]

@@bravo20ghost27 THAT sounds exactly like something I will want to do. Please keep me posted. I'd really appreciate seeing some progress on that.

[@bravo20ghost27]

@@offgridislandfamily yeah of course, we are currently finishing off my 2021 KTM 690 SMC R build as I intend on sharpening up my bike handling skills. Along with the last bits of our video production equipment. There will be a big reveal video to start of the channel coming soon. We currently have 2 of the Mercedes E300td that those engines come in plus 2 as spares or for maybe a kart build one day.

[@cabalenpinoyfoodadventure7622]

keep vlogging po, stay safe

[@offgridislandfamily]

Thanks for the kind post!

[@rmp8648]

Great Video can you tell me where we can source a new valve for a 4D56 engine. We are in New Zealand.

[@offgridislandfamily]

I think you mean the Shut-Off Solenoid? ebay.us/K49177 I am in the Philippines, so just a local shop, but here is a good link of options. Thanks VERY much for commenting and the feedback!

[@lior.camera]

did you had any leak from the top of the solenoid? after replacing to the new one...

[@offgridislandfamily]

No. No leaks, but for some reason the rubber plunger / valve part keeps getting damaged. As if there is a sharp object inside the seating area. Yes...I looked closely and deeply and couldn't find anything. Ran the engine with the solenoid removed just to attempt flushing out anything inside. Strange...

[@MrFrankstanks]

is this instead of taking the pump off to do the dreaded pump seal on the 2.8td ??

[@offgridislandfamily]

Thanks for commenting, but no. It's just to replace the Shut-Off solenoid and adjust the fuel load screw. I already had the pump recalibrated and resealed at the same time.

[@MrFrankstanks]

@@offgridislandfamily did you change the pump seal yourself, Buddy.

[@offgridislandfamily]

@@MrFrankstanks Nope...I had an injection pump shop reseal and recalibrate the pump, so they did the removal and install on that.

[@Jhajamorena]

Hi

[@anthonyx187]

any idea why my pajero 4d56 does not start at all? i tested my solenoid for power and hear it clicking. it ran perfectly then a few days later 0 sign of starting. no fuel getting to injectors either

[@offgridislandfamily]

So, you have fuel in the tank and when you loosen a fuel like just at the injector and crank th engine, there is no fuel leaking, squirting or dripping at the opening?

[@anthonyx187]

@@offgridislandfamily yes i added more fuel to the tank to be certain and no drips or any signs of fuel coming out of the injector with the line popped off. Thanks for reply

[@offgridislandfamily]

@@anthonyx187 Yeah. Then either you have a fuel blockage (check the flow through the line). You could use a shop vacuum set to exhaust and pressurize the fuel tank with the fuel line open at the engine compartment. If fuel is coming from the tank to the engine compartment, then I hate to tell you, it sound certainly like fuel pump / distributor.

[@anthonyx187]

@@offgridislandfamily will try this, thank you

[@offgridislandfamily]

@@anthonyx187 Just an update. My Pajero wouldn't start. After some trouble shooting, I found out it was the glowplug relay or switch. I touched a jumper cable from the battery to the glowplug rail and it started right up. ;-)

[@the3angelsmessages942]

Where can I buy the solenoid? Link doesn't work

[@offgridislandfamily]

I just bought them at a local parts store. However, the rubber stopper keeps getting damaged every couple months. I don't even bother replacing it now, until I rebuild the injection pump.

[@reytech1786]

Genius ❤

[@offgridislandfamily]

COOL! Thank you!

[@asgharnazautosmoterbaikewa7723]

nice

[@offgridislandfamily]

Thank you!

[@henrybot320]

Hi there, just want to ask what's the actual size of the solenoid to fit a socket wrench? You mentioned 24mm was it the exact size? Thanks in advance. Love your videos and the Paj!!

[@offgridislandfamily]

Yes Sir! 24mm. But a HECK of a spot to work on! HEHEHE! Cheers...I have a new video coming in a couple days for thermostat, engine block cooling tube and silicone hoses. Thanks again

[@henrybot320]

Thanks for the reply 👍

[@offgridislandfamily]

@@henrybot320 No worries. I'm going to have to replace this stupid solenoid a 4th time as of yesterday. Something inside is damaging the rubber plunger so that I can't shut off the engine. Have to pull the intake tube and cut air supply.

[@henrybot320]

@@offgridislandfamily wow! Just got mine started without any help from "Nulon start you bastard "

[@henrybot320]

I broke the camshaft in 3 pieces and damaged 3 valves and the camshaft sprocket 3 months after putting a new cylinder head 😢 😔 😪

[@reytech1786]

I wish I could have that diesel suv in the United States ❤

[@offgridislandfamily]

There are options. You could import your own 4m40 engine and convert. Would be quite simple as the fuel management is all bolt on mechanical. There are also many popular BMW and Mercedes diesel engine options that work amazingly.

[@bp6837]

My shut off valve thread seem to be stuck. The mechanic gave up on it. Any ideas.

[@offgridislandfamily]

You mean you can't remove the valve? If not, then install an old fashioned fuel cut off just before the fuel distributor / pump.

[@jypyz]

Parts number? 2.8td? My Pajero is 2.8 td intercooler and no start. My idea is solenoid valve 🤔

[@offgridislandfamily]

www.ebay.co.uk/itm/322255314050?hash=item4b07e9dc82:g:ze8AAOSwwbdWMfAM

[@offgridislandfamily]

If ZERO signs of life, then very likey. Just make sure your glow plugs are working and fuel is getting to your injection/fuel pump first.

[@Grumleyf]

Hei i got the problem my 4d56 starts bad and runs bad too i guess it's that solenoid any thoughts ?

[@offgridislandfamily]

If it starts and runs, it won't be the solenoid, unless the plunger is damaged and slightly blocking fuel flow when open. Running bad could be anything from worn valve train to your fuel pump / distributor.

[@offgridislandfamily]

If your engine runs, then the electrical part of your solenoid is working. The thing to check on the solenoid would be the rubber plunger that stops fuel supply. If this was damaged (as mine was) then it could allow the engine to 'run' but restrict enough fuel to run correctly at higher RPMS, for example.

[@beauholstein8918]

😂 jewellery and mechanical work dont mix know a few fellow mechanics come unstuck with wedding 💍

[@offgridislandfamily]

Not when the engine's running...that's for sure! Hehehe!

[@beauholstein8918]

Not a good idea to wear a bracelet when doing mechanical work lol

[@offgridislandfamily]

Yeah...you're probably right about that.