Fixing my old/new Pajero - pic intensive

[4ePikanini]

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INDEX

Threads elsewhere

• Delo 400 testimony in rebuilt engine of my pajero
• MontyMcV from the 4x4wire sends me a replacement MAF sensor
• My 4H vibration issue
• Mitsu V6 lifter tick fix
• Mitsu V6 Crank Bolt info
• Mitsu Starter

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

[4ePikanini]

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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

[4ePajero]

Seriously neglected engine!
Got very hot at some stage.

Should be good as new after the re-build.

[hoenner]

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.

[Koebelwagen]

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

[4ePajero]

Don't let him interfere TOO much.

No chance of that!
I only give advice when asked!

[4ePikanini]

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

[RedLineR]

Looking good guys!
Could you isolate the knock?
Was it a gudgeon pin? or big ends?

[4ePikanini]

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!

[4ePikanini]

the quote is in

[4ePikanini]

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

[rules]

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

[4ePikanini]

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.

[Vissie]

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 !!!

[4ePikanini]

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.

[4ePikanini]

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.

[4ePikanini]

progress

before


after

[4ePajero]

Did you open it to check the

• brushes
• bearings/bushes

?

[Henris]

Pa, keep your nose out of it..........

[4ePikanini]

Pa, keep your nose out of it..........

I'd rather he ( who has put a DiD in a Gen1 ) keeps his nose in it