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Mitsubishi Pajero: 4M40 2.8L Turbo Diesel Injector Pump Failure (Bosch/Zexel VE Rotary Pump)

4M40 2.8L Turbo Diesel Injector Pump Failure (Bosch/Zexel VE Rotary Pump) is a common engine fault on the Mitsubishi Pajero on the 1993–1999 cars, and we rate it major. Putting it right costs $1,200 to $3,500 at New Zealand independent workshop rates. Below is what goes wrong, the symptoms to notice on a test drive, where to look, and what to ask the seller before you hand over any money. It is one of 39 documented faults on the Mitsubishi Pajero.

Vehicle
Mitsubishi Pajero
Engine
4M40
Years
1993–1999
Fuel
diesel
System
Engine

This page covers the Mitsubishi Pajero as a model. Some faults only affect particular engines or build years — enter a plate below to narrow the list to one car.

All Mitsubishi Pajero faults39 documented faults on this model

What you are looking at

A single common-rail diesel fuel injector photographed against a plain background.Example of the part — not this vehicle

A common-rail diesel injector. Contamination damages the nozzle at the tip.

Panoha · CC BY-SA 3.0 · Wikimedia Commons

What goes wrong

The mechanical Bosch/Zexel VE rotary injection pump on the 4M40 suffers internal wear of the delivery valves and rotor/distributor components above 150,000 km. Pump failures are accelerated by poor-quality diesel, infrequent fuel filter changes, or running the tank near empty. Symptoms include hard cold starting, rough idle, and progressive power loss. New pumps are scarce; rebuilt units vary in quality. A failed pump can also damage injectors if debris is introduced to the fuel circuit.

What you would notice

  • Hard or slow cold starting requiring extended cranking
  • Rough, hunting idle particularly when cold
  • Black or grey exhaust smoke under load
  • Noticeable loss of power at higher engine speeds
  • Diesel knock at idle that worsens over time

How to check it

Where to look. Top centre of engine, driven off the front of the camshaft

  1. Start the engine from cold and observe ease of starting and idle quality.

  2. Rev the engine from idle and watch the exhaust for smoke.

  3. Check fuel filter change intervals in service records.

  4. Ask if the injector pump has been rebuilt or replaced.

  5. If a workshop inspection is possible: A compression test can rule out engine wear as the cause of poor running.

Parts involved: Fuel injector, Turbocharger.

What it costs to put right

$1,200 to $3,500 at New Zealand independent workshop rates. That is for this job on its own, not for the car.

An estimate, in NZD, for the repair as normally carried out. What a specific car costs depends on which part has failed and what it damaged on the way — treat this as the floor for a negotiation, not a quote.

Ask the seller

  • “When was the fuel filter last changed?”
  • “Has the injector pump been rebuilt or replaced?”
  • “Does it start easily on cold mornings without excessive cranking?”

Now check the Mitsubishi Pajero you are actually looking at

Everything above is true of the model, and it is free. What it does not tell you is whether THIS car has been looked after: its odometer history and whether the reading has ever gone backwards, whether there is still money owing on it, whether it has been reported stolen, how many owners it has had and what it is really worth today. That comes from the official records for that plate. Enter the plate for the free details, or get the full history and a market valuation from $13.49.

Not sure what you would be paying for? See what a full KickTyres check includes.

Where this comes from

The failure described above is documented in published sources — owner forums, technical service bulletins, recall notices and workshop write-ups — held in our fault database. The inspection instructions and the cost estimate are KickTyres’ own interpretation of them, and it is a starting point for an inspection rather than a manufacturer statement.

Mitsubishi Pajero buyer questions

Is 4m40 2.8l turbo diesel injector pump failure (bosch/zexel ve rotary pump) serious on a Mitsubishi Pajero?

We rate it major and common on the Mitsubishi Pajero. The mechanical Bosch/Zexel VE rotary injection pump on the 4M40 suffers internal wear of the delivery valves and rotor/distributor components above 150,000 km. Pump failures are accelerated by poor-quality diesel, infrequent fuel filter changes, or running the tank near empty. Symptoms include hard cold starting, rough idle, and progressive power loss. New pumps are scarce; rebuilt units vary in quality. A failed pump can also damage injectors if debris is introduced to the fuel circuit.

How much does it cost to fix on a Mitsubishi Pajero?

$1,200 to $3,500 at New Zealand independent workshop rates. That figure is for this job on its own. A car showing the symptoms on this page is usually worth either walking away from or negotiating down by at least the repair figure.

Which Mitsubishi Pajero years are affected?

Our research records this fault on the 1993–1999 Mitsubishi Pajero. Build dates move around, especially on imported cars, so treat the range as the years to look hardest at rather than a guarantee either way. The official records tell you the exact build and first registration date for the car in front of you.

How do I check for it before I buy?

Start the engine from cold and observe ease of starting and idle quality. Rev the engine from idle and watch the exhaust for smoke. Check fuel filter change intervals in service records. Ask if the injector pump has been rebuilt or replaced. If a workshop inspection is possible: A compression test can rule out engine wear as the cause of poor running. Look here: Top centre of engine, driven off the front of the camshaft