Fixing my old/new Pajero - pic intensive




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  1. #1
    4ePikanini Guest

    Default Fixing my old/new Pajero - pic intensive

    This index only works if your threads per page is set to 20.

    INDEX

    Threads elsewhere




    Page1
    Strip down
    4x4 dash lights
    Labour Quotes
    Starter clean

    Page2

    Starter service
    Parts inventory for cooling, pulleys, crank bolt, thermostat, thrust bearing etc
    Crank bolt discussion
    Rear bumper rebuild
    Spotlight wiring discussion
    reverse light switch on the gearbox

    Page3

    workshop pictures of rebuilt engine
    first start priming discussion
    big hole lifter
    prelim price breakdown

    Page4

    Workshop pictures of finished engine
    Re-assembly and engine drop into pajero

    Page5

    Final assembly
    Cost breakdown

    Page6

    Running video with sound
    Idle hunting discussion

    Page7

    Pulley squeel
    Trademark stamp
    Left inner CV boot

    Page8
    Left inner CV boot DIY how to.
    Radiator pulled for spout re-alignment
    Radiator drop-in after spout re-alignment - time lapse video
    Old parts pictures
    Collage picture
    Pitman arm replacement picture
    New tyres

    Page9
    pitman arm replacement steps
    My first trail
    A/C fan
    MAF sensor failing and replacement from overseas

    Page10
    Anti-Roll bar bushes
    Last edited by 4ePikanini; 2010/02/03 at 05:31 PM. Reason: Updating index

  2. #2
    4ePikanini Guest

    Default

    ************************************************** *
    ************************************************** *
    ************************************************** *

    I bought a pajero for cheap

    My New Pajero

    Then figured its got a rod knock. More than likely a gudgeon pin

    Rod knock causes

    So the tear down has begun

    Will strip down till just the block and heads are left and then take it out and send it in for a possible bigger bore, head skim and new pistons, bearings and head refresh.

    PICS



    Belts hoses fan and radiator. Radiator got a 3 row recore. Thanks dad




    Cam belt looks pretty good surprisingly


    NOTE TO SELF : Replace ALL water hoses - Only at dealers - Got a quote of R1100 for ALL of them - I think it's 8 hoses






    Got to know where the belts go. haha




    TIMING MARKS


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    And out she comes



    Wonder how long ago the oil was changed and what brand was used?
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    Water passages doesn't look too bad but It did run for a while without antifreeze and badly overheated at some stage as well. The top housing of the radiator was bulging from the pressure


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    Got the fuel rail and intake plenum cleaned up



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    While the engine has been sitting at the rebuilders I tackled the 4x4 dash lights

    I made a DIY about it HERE


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    The engine will be started on tomorrow at the workshop so progress should be updated frequently from this time onwards.

    stripped

    It is not as bad I initially feared but it is clear that the previous owner did no maintenance for over 50k.

    The bores are slightly scored but if you look carefully you can still see the original honing marks after 250k :kewl:

    The crank is slightly scored - due to lack of decent oil and VERY old oil - the workshop reckons it is 60k overdue for a change :8

    Good news is that a bore ( with new pistons ) won't be necessary - just a good re-hone

    I'll let the pictures speak further













    Last edited by 4ePikanini; 2009/10/27 at 02:28 PM.

  3. #3
    4ePajero Guest

    Default

    Seriously neglected engine!
    Got very hot at some stage.

    Should be good as new after the re-build.

  4. #4
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    Marius

    Hats off to you for tackling this project. You are also lucky to have your dad looking over your shoulder. Don't let him interfere TOO much.

    Enjoy and keep us updated.
    Jacques Greyling
    All that is necessary for evil to triumph is for good men to do nothing
    1999 Prado 3.4 V6

  5. #5
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    Marius,

    Take a look at the sleeve on which the thrust bearing slides. It may be worn and would be an easy fix at this stage whilst the engine is out of the vehicle.

    Brandt
    2015 Mahindra Bolero SC 2.5 NEF TCI 4x4 (Ratchet & Clank)
    2007 Mercedes Benz ML500 5.5
    1968 VW Beetle 2276

  6. #6
    4ePajero Guest

    Default

    Quote Originally Posted by hoenner View Post
    Don't let him interfere TOO much.
    No chance of that!
    I only give advice when asked!

  7. #7
    4ePikanini Guest

    Default

    Quote Originally Posted by hoenner View Post
    Marius

    Hats off to you for tackling this project. You are also lucky to have your dad looking over your shoulder. Don't let him interfere TOO much.

    Enjoy and keep us updated.
    He is directly and indirectly 100% responsible for the knowledge that now allows me to tackle unknown territory as he laid good foundations.

    Off the forum we discuss the build in detail passing thoughts to and fro. We agree on most points but when we differ his ideas are better 99% of the time.

    ( After all I can vouch for him swapping his pajero engine 3 times )
    - 2500 diesel mitsu to 4.3 chev V6 (V6 was a wreck that he rebuilt completely and was initially in the kombi first as a mid-engined monster )
    - 4.3 chev V6 to toyota 2.0 TD
    - toyota 2.0 TD to another sub assembly 2.0 TD ( I handed tools with this one - 6pm to 4am and she started on the first crank at 7am - had to wait for gaskets to set )
    - Toyota 2.0 TD to Mitsu 3.2 DiD

  8. #8
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    Looking good guys!
    Could you isolate the knock?
    Was it a gudgeon pin? or big ends?
    SWAMBO
    2009 Suzuki Grand Vitara 3.2i V6 Auto
    Me
    2003 Ford Focus 2.0

    Eurard: For T=2; T=1 but, 1/2T=

  9. #9
    4ePikanini Guest

    Default

    Quote Originally Posted by RedLineR View Post
    Looking good guys!
    Could you isolate the knock?
    Was it a gudgeon pin? or big ends?
    Can't really say for sure as no bearings were spun. The inside looked really bad and the crud on the piston could have been a cause due to pre-ignition but my dad and the workshop suspects it was a big end based on the fact that the one part of the crank ( see right side of pic below ) was badly scored. But knock or not I'm glad it is getting rebuilt as it was badly neglected and overheated pretty badly at some stage in its life. No antifreeze --> badly rusted cap --> failed to release pressure --> bulging radiator top tank --> burst coolant hoses --> overheated



    Next to do
    pay for engine (heads, rebore, pistons and clutch) - still awaiting quote today or tomorrow
    then to do as finances come in ( dealer prices excl vat )
    new engine mountings - R657.14 each
    new TO bearing - R41.65
    clutch cylinder kit - R97-28
    new coolant hoses - approx R1000-00
    ** install engine
    fill with oil and coolant
    diff's oil change
    tranny/transfer oil change
    CV boots
    brake bleed
    clutch bleed
    ** First drive straight to Hi-Q/Tiger wheel
    Tyres
    Shocks
    alignment
    oil pressure/temp gauges
    Loss of coolant alarm
    Voltmeter
    ROAD TRIP!
    Last edited by 4ePikanini; 2009/07/29 at 09:08 AM.

  10. #10
    4ePikanini Guest

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    the quote is in




  11. #11
    4ePikanini Guest

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    I have ordered some parts from the dealer as the machinist says I can have the motor month-end.

    All new coolant hoses except the connections that go to the back heater matrix ( never gets below 10 celsius here )
    Two new tensioner pulleys ( expensive and the quote says they are power steering pump pulleys - I sent a pic to the dealer to make sure they are correct)
    Two new engine mountings
    TO bearing







  12. #12
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    That's all nice and well ... but ... wouldn't it be nicer as a 3.5 or 3.8 by the time you start it
    2005 Saab 9-3 2.0t Arc
    ******************************************
    ex: 2000 Colt Rodeo 2.8 TD 4x4 219 000Kms
    Custom Aluminium Hard Cover, Custom Tool box.
    Madman EMS2 Gauge, monitors EGT, coolant level and voltage.

  13. #13
    4ePikanini Guest

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    Quote Originally Posted by rules View Post
    That's all nice and well ... but ... wouldn't it be nicer as a 3.5 or 3.8 by the time you start it
    It would be nice but seeing as this is my first build ( and my financial constraints ) I want to try and keep it as close to stock as possible - less complications.

  14. #14
    Join Date
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    Default Hats off

    Hats off to you for undertaking this project.You will appresiate the Jaro allot when finished.It is grate to see the younger generation [ no pun ] taking pride in what they are doing and it with there own hands.I am onley about 10 years older but take my hat off to you.Shows big ball bearings !!!

    Toyota Fortuner 4.0L 4X4
    AKA - TUNA

  15. #15
    4ePikanini Guest

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    Quote Originally Posted by Vissie View Post
    Hats off to you for undertaking this project.You will appresiate the Jaro allot when finished.It is grate to see the younger generation [ no pun ] taking pride in what they are doing and it with there own hands.I am onley about 10 years older but take my hat off to you.Shows big ball bearings !!!
    Thanks Vissie.

    There is a sense of pride and satisfaction, when your own hands have laboured on a project, that money can't buy.

  16. #16
    4ePikanini Guest

    Default

    Small progress.

    Engine will be back in two weeks.

    In the meantime I've chased all the wires from the speakers as only the rear right was working.

    All 4 speakers are working now and the wiring ball sorted behind the radio.

  17. #17
    4ePikanini Guest

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    progress

    before


    after

  18. #18
    4ePajero Guest

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    Did you open it to check the

    • brushes
    • bearings/bushes

    ?

  19. #19
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    Pa, keep your nose out of it..........
    LC 78 Troopie 1HD-FTE

  20. #20
    4ePikanini Guest

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    Quote Originally Posted by Henris View Post
    Pa, keep your nose out of it..........
    I'd rather he ( who has put a DiD in a Gen1 ) keeps his nose in it

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