1989 MK1 Pajero now including factory PTO winch goodness

[mat91]

Manged to pick this very nice example up the other day,
Its done just over 300,000km apart from a sloppy gear selection it gets down the road very well
When i bought it, it was already lifted and had the two piece 16" split rims fitted which fit the truck lovely so are staying but do require a refurbish, other than that it was stock even the EGR was still fitted and kinda working, but i cant leave well enough alone, which has saved me some mega expense and work this time read on to find out........


Within 24hours of having the keys i welded the front auto locking hubs up, one was broken for starters and i just hate auto-lockers, they were fun to weld the outer edge was very soft and easily melted where as the inner was pretty solid and took some heat to burn them in


Now to the point where I saved my self lots of expensive and got very lucky
Last night with some free time after work but in work on a ramp I decided to delete the EGR gubbins also remove the viscous fan which was on its way out and costing precious MPG,
EGR was almost blocked anyway


After i had completed that in good time, I decided to check the condition of the timing belts as I had no history of when they where last done,this is when i fount this


This is where i got incredibly lucky, on these engines there is two timing belts the usual crank/cam belt and another smaller belt that sits behind and drives the two balance shafts this one had snapped and just dropped onto the cover instead of rapping into the cam belt and bring unhappy times,
to me it looked like it had been snapped for a long while, as when i removed the belt it left a clean impression on the alloy cover, the dirt/gunk was that thick 2-3mm it took some major scrapping and solvent to remove but i got there in the end,

Quick 40mile round trip to Milner 4x4 giving them £189 of my hard earned cash which let me walk away with a timing belt kit, 3x aux belts yes this has working air-conditioning, a rocker cover gasket, full filter kit, glow plugs plus resister pack, front crankshaft seal, and not pictured a new adjustable drop plate tow bar which is the twin pin version bargain at £189 inc vat which made me very happy

So then i set about fitting all these new goodies like Christmas again
First on was the balance shaft belt, sorry for the picture it came back all blurry and i didnt catch it
Then on with the cam belt, timed up with the two rotation completed


Also fitted the glow plugs

Results which i think is mostly from the EGR and viscous fan removal is, Ive brought down the turbo spool by 400rpm! now 1600rpm, also now the balance shaft is working the engine is much quieter/smoother, torque output has massively increased requiring much less throttle input which should hopefully translate to more MPG and when cold its starts on all four and idles nicely
So I'm very happy with all this work even if it is two/three weeks early

More updates will follow in time

Enjoy

[darrenh]

i do like these early straight vehicles. apologies in advance to anyone reading whos got one, but the 90s versions with all the stick on plastic tutt, bull bars, wheel carriers and two tone paint, round my town they are usually driven by toothless guys in mucky hi vis jackets with 3 staffies bouncing round in the back

[07lilredwagon]

amazingly lucky!...and you just happen to know how to look for these things too....so lets say planned luckiness....

looking good so far!

JP

[mat91]

Second tanks worth of fuel as gone through and including the green-laning day out it netted 25mpg, without a thermostat running very cool ambient was 2 degrees and 4.6 gears so pretty darn good but room for improvement

Well the last couple of days have been interesting, with a few break downs
Had 3 of the 4 brand new glow plugs fail, not sure why as well guess curse word quality, also not sure why i didnt just fit NGK in the first place been 3 days since and there fine
Then the engine started make a odd noise so whipped the rocker cover off to find a cam rocker follower bearing had fail resulting in two trips to Milner 4x4 in one day, also bought a spare inlet+exhaust rocker in case anther fails as you can change these at side of road pretty quickly
Sliding the new rocker on
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Then i finally got round to fitting a new thermostat, along with a coolant flush should gaine me 1-2mpg i hope, also fitted a electric fan just need to wire it up
so the heater has gone from average to hotter than the sun now quarter windows coming in handy now


About a year ago the previous owner had a new starter motor and ring gear fitted where i worked a bonus to buying the truck, over the last couple days it has started not engaging but rolling the truck forward slightly would let it fire it straight up meaning possible ring gear damage, so i pulled the starter out and indeed the ring gear was worn but not bad but still usable,
after some measurements it turned out the starter motor was not throwing out far enough, it was meshing with the ring gear by about 1mm no wonder it wore out the ring gear, so after stripping it down i ended up welding the gear on the starter shaft about 15mm further out gaining 15mm of engagement, result the truck now starts much more positively and no slipping, sorry no picture

also while having the starter in and out i seem to have dislodged a fuel pipe as its now losing fuel pressure when left a few hours so when i get around to fitting the fuel filter ill fit new hoses and clips so one more fault to fix but i can live with it for now

I hope to have a few days with no break downs now as its tested me slightly :roll:

also cleaned it after the day out :wink:

[minininjarob]

That's a very smart looking Pajero indeed - any exterior plans for it?

[mat91]

As today has been a non rain day and i was off work, i got on doing some more jobs to the Pajero cue the music 

First job glow plugs, while ive owned this Pajero the glow plugs have only stayed on for 10 seconds or so when cold, no where near long enough for a indirect diesel cue lots of cranking/smoke when stone cold, i looked into the system and it all seemed to work correctly but i suspect the temp sender may be reading incorrect so the ECU is not sticking them on long enough but i would sooner have it on a switch than throw money at it so i set to removing the ecu of this function, internet points for guessing where the switch came from


Once i got that working i decided it would be nice if the glow plug light worked as its not wired up from the factory, this was more a challenge than i thought it would be, in the end I used a good quality relay for the power feed as the glow plug relays would feed a very slight voltage to the light keeping it lite at all times, i also had to separate the earth from the circuit board on the dash, as when the ignition was on the light would not illuminate unsure why but it was not being beaten
so now it works even if it took alot longer than it should have


and a bit of a hash job on the circuit board separating the earth off, not sure there is a neat way to do this



To run a power feed for the glow plug triggers, i had to remove the battery, lucky i did as it was starting to look a bit crusty, I'm very pleased as apart from a bit of corrosion on the rear chassis leg this is the only bit of corrosion i fount so far


and primed, you will have to use your imagination for the black top coat as i forgot to take a photo



Also converted the factory central locking to remote with the aid of a toad alarm and a £8 door lock solenoid from Maplins, so now the truck is fully alarmed/immobilised on doors,boot and bonnet also has motion,interior etc sensors and a very loud siren, so i can now sleep a bit easier at night although some more security features will be finding there way on very soon

Now i writing it down it doesnt sound like a lot of work but its bloody time consuming running wires and figuring out where items will fit and work best but at least there done now and the truck starts from cold like its been warmed up

thanks for reading

[luckygti]

Love it, really feeling the need for a 4x4 with all this rain and drove one of these round Kenya for a few weeks so know how good they are. Looks good on those wheels too.

[mat91]

Feb 13, 2014 21:30:52 GMT luckygti said:

Love it, really feeling the need for a 4x4 with all this rain and drove one of these round Kenya for a few weeks so know how good they are. Looks good on those wheels too.

Its funny as this year i said i was going to get another truck, i set of a list of specifications i wanted
1:Beam axle front on rear
2:over 100" wheel base
3:Pick up truck with a big bed
4:very cool

So a series 2 landrover 109 meet the bill, then this turned up in work and failed its mot and i just had to have it despite only meeting No4 on my list, I'm glad i did buy it

Feb 9, 2014 0:37:15 GMT minininjarob said:

That's a very smart looking Pajero indeed - any exterior plans for it?

If you mean all the stupid lights and roof rack curse word people stick to 4x4s these days then no, not only do they look horrible they will just get ripped off anyway i like a nice smooth truck,

although i will stick on a snorkel out of nasality, as it was almost coming over the bonnet messing in a river crossing the other day, it did worry me slightly,

there will be winch bumpers but there is some other stuff that will need to be placed before i make those

[bortaf]

That sits really nice
Is the rest of the inlrt clogged like the EGR port ? modern TD are worse than that, ive seen totaly blocked ones at 50K!!
I'm not sure what has happened to glow plugs over the last decade or so?? i never get a new set to last, i use spare OE ones i've removed after testing from breakers and had more life than any new plug i've bought iover the last 15 years or so

[mat91]

The rest of the manifold looked sparkling clean surprisingly, what was there was kinda like a washer of carbon, but very dry unlike modern egr which seem to be very wet and gooey, yesterday i replaced a egr valve on a vauxhall combo due to carbon build up that was just a horrible mess everywhere but then it was a vauxhall

and with glow plugs I'm not sure why i didnt just fit NGK first time round, i guess buying lots of items in one go blinded me and the fact i bought them from a good source, but when i returned them they said they hadnt had a set fail, whether they had fail and people just didnt return them I'm not sure

with mine its been a good while and the NGK ones are still going strong, but then ive never had a set of NGK fail
you have to be carefull with voltages as alot of newer stuff run on 6v VW do this

[mat91]

Spent some more time on the Pajero, started with a drop hitch i bought this at the same time doing the timing belt, only just getting around to fitting it oops


Up next i wanted bin of the rear arb, proper removal would require removing lots more parts which i didnt see the point i am never going to refit the arb, so i decided just to cut it in half, very poor idea but quick


Then i went on to mount the trailer electrics plug, nice and high out of harms way, painted black after the photo


Decided to see what little flex it had, seeing as it still has the front arb and the stock radius arms out rear, not to bad for a IFS truck but not to great either but its a nice photo for the start of the project

[mat91]

Thought id better update this thread as its been a while now

Since my last post,
my back axle started knocking didnt even bother opening it up as its was a tiny 7" or so open diff, so i picked up a mk2 shogun locking axle and slung that under, all it required was swapping the input flanges between old and new so i didnt have to change my prop-shaft, and make some adapters brackets for the rear brakes like so


the same bloke also sold me the matching ratio front diff which are 5:28 flavor and the front shafts all for £100 bargain including the back axle
the front diff required a mix match of mk1 and mk2 drive shafts parts on the n/s and some cutting and welding on the cross-member again noting really major


all in bits, it is very nice having access to a full workshop


I also stripped all the paint/underseal back on the underside and shot it in some lovely white stone guard, that took about 15hrs drive in drive out  :shock:




Some rust repair about the only on the truck



Ive also installed a LR P38 air compressor to run the rear axle, blow up tyres and other good things, ignore the scruffy wiring that was a badge for my glowplugs while i figured out which way i wanted to go with them all sort now



But ive saved the best bit for last and it includes three little letters PTO

Ive manged to source a factory Mitsubishi pajero PTO winch, which is now fitted and functioning minus a rope at the moment








To say I'm over the moon in getting one is a understatement, just need to re-do the mounts as the main load member is rotten, and frankly they could be much
stronger


some cool photos from the last couple on months


dragging the pto winch home

[Colonelk]

such a cool truck. you're doing ace work to it too

[darrenh]

interesting to see the business end of the torsion bars. job i need to do soon on my isuzu

[mat91]

Since its a quite Sunday morning i thought id add another little update

Ive bought some new boots ready for winter and to make life easier off-road 255/85/16 bf goodrich m/t measure just over 33" tall


They did require some slight cutting up front more due the low e.t of my wheels, non out rear nicely





Had to replace a completely worn out uj on my PTO prop-shaft, mitsubishi wanted £63+vat for one, nipped round to Wilsons propshafts £19 inc vat and on the shelf got to love that



and installed a air tank for my OBA system, still need to spend a night on the lathe and make some fittings for it, really is getting tight under the bonnet now

[mat91]

Time for a update I think,
The truck has been running brilliantly, I've fitted a new starter ring gear, rear main oil seal, rear driveshaft seals both ends as they all started festering and had to fit a nsf damper as the rubber bush disintegrated, in my book not bad for a year's motoring, now for some little modifications I've been doing
Picked up the second skid plate to protect the diff cover and steering, it was to cheap to miss only £30 inc p+p


Had to trim the rear arches about 2" for the 33s as they  just caught, there was the starts of some corrosion in there so not to soon really


Sadly with these hand brake calipers this is as much stuff as I can muster at the moment,  tyre also rubs on the top of the arch as well, I'm debating on making a 1" body lift to clear the tyres


Out at Korc I bent the chappy milner4x4 n/s steering idler,  mismatched bushes and used the stock arm as it's much thicker, I also stuck the shaft in double shear really shouldn't bend now




Also had to straighten my gearbox crossmeber after Korc as well haha

[mat91]

Carring on
The other rear arch butchery


The for mentioned damper, it did make a very odd noise rubbing on the driveshaft


Also figured out why my  rear door wouldn't stay open, that shouldn't be two bits haha


Started playing with bumper ideas, I probably ignore this for awhile, till I decide on whether to SAS it


This pajero is really starting to get under my skin now, come the 16th of Jan Ive owned it a year oh dear
I think it's progressed nicely, oh I also got to use my winch in anger boy is it strong and quick especially when driving as well

[mat91]

It also appears i may be a bit harsh on the old ifs, it shoudlnt be bent like this



Or cracked




Ive fitted some defender wing mirrors as the stock ones are rather small and they where worn out and floppy




Had some new pto winch actuation cables made as the old one snapped



Also made and fitted a 1 inch body lift



Also managed to smash my front, recovering a rather stuck and dead landrover




Heres some random photos from the last few weeks







Quiet a bit of water in the engine bay, good snorkel game haha




Slid 6ft sideways into the bloody tree