Adventure Driven Talk

Tech Questions and How-To Articles => Build Threads => Topic started by: PajEvo on January 13, 2018, 06:33:32 PM

Title: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: PajEvo on January 13, 2018, 06:33:32 PM
So I've been looking for about 4 months now for a gen3 Pajero to replace my daily driver pickup. I have several requirements, and some wishes.

Must haves:
-4M41 direct injection diesel 3.2L
-lowish mileage (under 140k kms would be ideal)
-excellent condition (3.5 grade or higher exterior and B or C interior), no rust
-tiptronic trans (no manuals available in JDM land)

Would prefer:
-V68 model, short wheelbase, but if the right V78 LWB came along I might be tempted
-5 speed trans (most of the diesels seem to come with 4 speeds)

Would like:
-front fogs
-rear spoiler
-leather would be nice, if it was an LWB
-blue, navy, or all black, maybe all white if a SWB

Don't really want:
-silver in the LWB (wife already has one)
-white in the LWB (beached whale comes to mind)
-green or red in any size
-the four speed trans without tiptronic
-ZR Model in any size (stripped down inside and out)


Okay, so why do a build thread on a vehicle I don't even have? Let's call it therapeutic. Plus I've begun collecting bits and pieces for it already, so may as well document the build, such as it isn't...?



Title: Re: Build Thread: Pajero V Series Diesel <INSERT MODEL/YEAR HERE>
Post by: PajEvo on January 13, 2018, 06:40:34 PM
Step one for the truck that isn't? Audio. From Japan it will have some sort of gps that doesn't work, or a radio that doesn't work (wrong part of the am and fm band). So why not have that ready to swap in?

Harness complete:



All Mitsu's of this vintage use the single plug style and I'll be damned if I'm hacking the factory harness, so premaking a headunit to OE plug-in adapter only makes sense. And speaking of head units, I'll be using my Android 6.0 unit, from "Joying" that I enjoyed briefly in the pickup. Its a double DIN which *might* require moving the climate control down, if not done already. I've also picked a new launcher for the unit, which is pictured here (running off a portable 12v power source until the truck actually exists)



This is called "Car Launcher AG" and is available in the Play Store for next to nothing. There is a trial version as well, but I ponied up the buck and a quarter and will take my chances. I like its simplicity, and ability to customize. As for the head unit itself, it sounds good, is a stable Android build, and will look nice in a Pajero dash, someday.

Title: Re: 1999 Pajero V68 SWB DiD gen3 (now has a name and face)
Post by: PajEvo on January 30, 2018, 07:36:52 AM
FOUND IT!

After five months of watching and waiting, I now have a rig coming, a 1999 Pajero Super Exceed short wheelbase third generation. It is equipped with a 4M41 direct injection diesel and 5 speed auto. Because of its Super Exceed trim level (very rare in the short diesel), it also has a sunroof, leather, factory navi and backup cam, and all other options available that year, including fogs, spoiler, cruise, auto AC, etc. Lots of plans for this little daily driver, but for now, at least we have found it. Quick sneak peek of the auction pics...



Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: ThePug on January 31, 2018, 01:54:52 PM
Love it!!!!!
Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: PajEvo on February 20, 2018, 12:21:04 PM
Got some more pics of this thing before shipping was booked, but I'm hesitant to upload any at the moment until we get our attachments figured out.  But it looks really good in the detailed pics I asked for. Some deficiencies, but that just gives me something to do. More soon!
Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: PajEvo on March 27, 2018, 06:28:06 AM
So I got over 92 pics all told, before this one shipped. Its now in my garage so I've got some updating to do!

Quick peek at some pics:


Alberta delivery:



She passed inspection with no deficiencies, so I had to go and get her!



Always need to add windshield wash in case they used straight water in the Motherland:


Then I drove her home! More to come!
Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: CharlieN on March 27, 2018, 06:42:12 AM
Sweet
Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: ThePug on March 28, 2018, 06:19:21 AM
Love it!
Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: concealer404 on March 28, 2018, 07:02:31 AM
So how does it drive?  Does it feel noticeably different from the LWB?

My wife misses her Gen3 i think.  This would be a neat way to put her back in one in 5 years.
Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: Crumb on March 28, 2018, 09:04:33 AM
 Is that key fob stock?
Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: MrGalantguy on March 28, 2018, 01:26:24 PM
What a beauty...I bet that thing is fun to drive too!
Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: PajEvo on April 07, 2018, 04:59:40 PM
Is that key fob stock?

Key fob is stock. My wife's was missing when her pajero came so I ordered NOS from the UAE. Mine needs a battery though.
Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: PajEvo on April 07, 2018, 05:03:28 PM
So how does it drive?  Does it feel noticeably different from the LWB?

My wife misses her Gen3 i think.  This would be a neat way to put her back in one in 5 years.

The furthest I've driven it so far was from my importers to the garage, about three hours in the highway. First impressions... zippy. More nimble than the 4 door. More room in the back than the gen 1 or 2 shorties. But I've been on holidays since right after I picked it up. Itching to get home and get working on it... LOL. Soon.

New tires are mounted on wheels and sitting in the garage against the wall ready to bolt up.
Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: PajEvo on April 24, 2018, 07:50:38 PM
Lots of updates coming but wanted to start by saying LOVE THIS THING! Two drives to work now and it is excellent! Worth the wait!
Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: Crumb on April 24, 2018, 08:41:04 PM
Jealous!
Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: MrGalantguy on April 25, 2018, 04:53:42 AM
I showed your SWB Gen 3 to my wife who has a LWD 02 Gen 3 and she smiled and loved it.

I bet this thing is fun to drive.
Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: PajEvo on April 25, 2018, 08:10:26 PM
Thanks guys. Three days in now for the daily drive, so about 400kms or so. Love this thing!

Clunking in the front turned out to be the swaybar endlink. Nut was loose. 5 seconds with a 17mm wrench and it was silenced. Love those kinds of fixes!

Oil leak looks to be the oil pressure switch. Cheap, but a bitch to get to. I'll do it soon though.

Driving it... on the straights it feels very much like its longer sibling, but through corners it feels a little more nimble to me. Braking also feels a little different - you can get an idea of how much less rig is behind you when you clamp on the binders. Turns on a dime, although I find the lwb is no slouch in that department either.

The 5 speed with the 4m41 is pure diesel heaven, to my mind. Not the quietest, but relatively smooth, and plenty of torque. Power delivery on acceleration is muted, but then you look at your tach and realize you haven't gone above 2300 rpm. When you step it down for real, it can actually spool up fairly quickly.

Something about the lines of the shorty accentuates those curves even more than the 4 door, and just enamours me even more with this little rig. Also looks very wide too, since its so short. It really does remind me of the pajevo. The difference is that the bodylines are more organic - built into the shape instead of boxy add-ons. Love both, and of course you know my favorite, but as a DD, this little gen3 is shaping up to be a keeper, so far!
Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: PajEvo on April 26, 2018, 09:12:10 PM
First fuel returns are in. 10.2l/100km or about 23mpg. Not bad for 265-75/16 BFG ATs and no skids on the underside (still watching for oil leaks). Should improve a bit more too, since this sat in Japan for quite a while before I brought it over, from what I can tell.

This got me 620kms, or about 385 miles with still about 6L left in the rank, so pretty good range for a shorty. I think I can improve on these numbers some, but a promising start.

I've also begun work on the filthy exterior. From a few feet away it looks pretty good but up close it is absolutely gross. Every nook and cranny has black stains and in some cases green algae. So far the most effective solution is Spray Nine, which has made short work of the window gaps and inside the doors. This ain't a show truck but years of environmental contamination gives it a neglected appearance which I need to remedy. I may resort to spray nine on the exterior to get rid of the faint stains down the sides.

Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: Wheelybuilt on May 01, 2018, 12:57:11 PM
Looks great! Can't wait to see more
Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: haolepinoy on May 02, 2018, 04:51:30 AM
I can't be the only one...haha.

Paj, what does "clamp on the binders" mean?
Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: PajEvo on May 02, 2018, 06:31:35 AM
It's okay that my reference was lost. Them's the breaks. Or in this case: brakes.
Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: PA_JERO on May 06, 2018, 01:18:58 AM
"The canadian" has struck again! Awesome looking truck dude, you always get the good ones.  Love those tires you put on it also. Hopefully we get the chance to meet up again and I'll see that thing in person, can't wait for that. Good luck with the new wheels Phil.
Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: PajEvo on May 06, 2018, 10:15:47 PM
"The canadian" has struck again! Awesome looking truck dude, you always get the good ones.  Love those tires you put on it also. Hopefully we get the chance to meet up again and I'll see that thing in person, can't wait for that. Good luck with the new wheels Phil.

Thanks Kevin! Appreciate it buddy! We will def meet again - have to!

So I ended up spray-nining the WHOLE TRUCK. Extreme, but damn did it cut through the filth. I rinsed it with water and then immediately went to the car wash and re-washed/rinsed. Looking better already. Still lots of cleaning to do, but way better than it was.

Currently trying to figure out a roofrack. I am right back where I was in terms of not being able to get the RTT out of the garage. I ordered a cheap-ish set of bars from DIRECT 4x4 UK, which attach under the drip rails to the factory attachment points. (I didn't know they were there either!) since my truck didn't come with rails like North American gen3's all seem to. Unfortunately there's quite a bit of room under them. Which puts the RTT at a point where I can't clear my seven foot door. Here's the bars for reference...





I am looking at other options at the moment. Either Rhino rack drill through the roof tracks, or I modify my garage door opening. Or both? I dunno...
Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: PajEvo on May 30, 2018, 04:49:41 PM
So a few comments on roof racks. First off - the DIRECT 4X4 racks? Meh. Wouldn't recommend them. Yes, they use the factory mount, but its a very very small hook, needs compression from the rubber pad it sits on (which is temp dependent), and uses a single allen head cap screw to tighten down each corner. Not much redundancy there. Actually - NONE. So I pulled the pair off the SWB, and mounted all three (three come in the package) on our LWB, to ferry kayaks when towing the trailer. Apparently I didn't compress the rubber pad enough, because my wife called me on her way home from work last night to report a "thumping sound", which ended up being one of the racks popping out of its hook and moving around. I shudder to think how that would have gone with a RTT up there! I re-tightened them last night, forgoing the allen key for a proper allen socket and ratchet. But lightweight boats with strapped backups are as much as this rack will see.



Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: PajEvo on May 30, 2018, 04:57:05 PM
So, that left me with a connundrum. RTT? Kind of requires a roofrack.

Rhino rack makes a trick drip channel rail which retrofits into the channel under the plastic, but since Australia didn't get the gen3 shorty, guess who didn't make a shorty version? I almost bought and modded the LWB channels, but they are pre-drilled, and I wondered what kind of nightmare I'd have trying to get them to fit, after I'd cut them up. Nope, there had to be another way. Soooo... I went cheap. And domestic. Yes, I see the irony.

Junkyard. Ford Windstar. They come from the factory with t-slot rails and crossbars. 40 bucks out the door, once I disentangled them from Henry's clutches.

I began by setting up the rails on the roof, with the crossbars attached to retain a perfect-ish rectangle. Then I marked the bolt holes with a paint pen. This began as 6 holes per side, but then I decided to add a few more, to the tune of 8 per side.  Yes, after measuring about 50 times, I drilled 16 (SIXTEEN) holes in my pristine SWB JDM roof. If you need to leave, here's your chance...

Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: PajEvo on May 30, 2018, 05:07:05 PM
If my sacrilege has not offended you too greatly, allow me to continue:

I was not interested in pulling the headliner. Nor did I want raindrops to pull a Johnny Mathis on me. So I used my nutsert (rivet nut, riv-nut) gun to crush threaded inserts into each of my trucks fresh wounds (preceded of course by paint, and silicone). Then I ran a coarse course of silicone around every hole in the rail's underside, as well as a perimeter bead (FORD used no sealant, simply a plastic gasket, so R&R was pretty straightforward). In fact I used 9/10 of a full tube of silicone, and probably could have done without the 16 holes, but redundancy is never redundant when you're strapping things on your roof.

After this step, I attached the t-slot rails for the final time, adding loc-tite blue to the threads just to ensure I didn't change my mind down the road.

Disclaimer - rhino rack used pop rivets in their attachment materials to attach their rails. One could argue they were in a stronger section of roof, but it did make me feel pretty good about my little screws and nutserts, especially in mass quantities.

Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: PajEvo on June 15, 2018, 01:44:24 PM
This rig came with a lot of oil. Outside the crankcase. All over the side of the block and dripping underneath once I gave it a good highway run. Wasn't really visible with the engine cover on, but when I removed it? OMG! EXXON Veldez...


First thing I did was valve cover gasket and a whole pile of cleaning. It was a disaster in there. Here's a pic midway through the sudsing down...


Here's the VC gasket and other bits...


Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: PajEvo on June 15, 2018, 01:51:11 PM
While I was in there I had a look at the various hoses etc. I made the decision to yank all assoiciated bits of the EGR system. It was starting to coke up everything, and once the EGR is coked, it does more harm than good. This might be controversial, but it's not illegal where I live, and in terms of env impact, when it's non-functioning, or working poorly, I'd argue that it is worse for emissions anyways. In any event...

I used a blanking kit, and was able to pull a lot of things off the engine as a result. Here's the pile:


I also painted the heat shields and added a hose to reconnect up the water lines, since one had a heat exchanger in line as part of EGR setup.


While I was doing the valve cover, I also replaced the upper chain guide. Worth doing for how simple it is to swap. OEM parts of course...


Valve train looked very clean, but this thing only has 113k kms on it, so its what I'd expect. Still, nice to see...


But guess what? After all that, I came back from holidays and there was a giant puddle under the truck. Arrrrgggg...
Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: PajEvo on July 24, 2018, 07:45:04 PM
I am super behind on this thread. I did a few fixes, began a garage expansion project, then had sinus surgery and was confined to spectator status for the month of June. So... where did I leave off?

Ah yes. The oil leak. Even though I had done the leaky valve cover gasket, I was still getting a drip of Rotella wherever I stopped. Not cool. Did some more digging and finally settled on what I figured was the most likely, yet least costly fix. There is an oil pressure switch on the RHS of the block. Same one used by almost every Mitsu made in the 90's and beyond. It appeared to be the spigot I'd been looking to turn off. But there was a catch. Three words: Location, location, location. It was under the manifold, in front of the turbo, behind the oil filter, and right up against a ridge on the block. An absolute nightmare for access. I pulled a whole bunch of stuff one rainy spring afternoon and tried for hours to remove the offending piece (after buying one at a local parts store for 8 bucks). Finally had to give up in frustration and put everything back together, with no progress beyond a few new scars.



A few weeks later and I was back at it. Now I should note that line of sight on this little bugger was pretty much nill unless you stripped down much of the intake system, oil filter, etc etc. I decided to go from the top this time, by feel. I also gave up on the 26mm socket I'd been trying, since I couldn't get any purchase on the switch. The casting ridge on the block wasn't helping either. I went for my inch and 1/16 socket, and ground down much of the socket's sidewall, to make it easier to fit into the tiny space. After about an hour of mucking about, I managed to get the thing moving. It was painstaking, with enough range to get ONE click on the ratchet if i did it right. Finally it started to move, and I wondered briefly if I'd simply buggered the threads, and was facing a bigger problem, but I kept going and eventually the oil pressure switch fully divorced itself from the block. I replaced it with the new piece (loctite on threads) and then began the process of putting it all back together, fingers crossed all the while.





There was some residual oil coming from God knows where, but after a few days, NO MORE LEAKS!! Woohoo! I've now put another 3k kms on this rig, with no more leaking of any kind. I'd call that a win!
Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: PajEvo on July 24, 2018, 08:07:15 PM
So, all leaks fixed - back to the roof!

The Ford crossbars that came from the junkyard with the rails were of no use other than as a way to mount the rails parallel.



 I had some Surco Safari slotted bars hanging around, so I made some brackets, used some t-nuts, and was able to cobble together some very low profile crossbars, strong enough to hold my RTT (reviewed here: https://forum.adventuredrivendesign.com/index.php/topic,266.0.html )





Three bolts per leg, so six bolts per side, plus 8 bolts per side in the rails. Unless the roof is doing some serious flexing, I'm not planning to revisit this again any time soon. Next job was to mount the RTT...



Slightly noisy, but quieter than the rails by themselves. Has had about a liter per 100km effect on fuel econ so far. Fits (just barely) through my seven foot high garage door. All in all I'm very happy with this setup.

Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: PajEvo on August 15, 2018, 04:45:39 PM
So a few updates and things to add that I didn't put in at the time I did them -

Stereo: this came with MMCS, and factory backup cam, as well as a cool display for HVAC that I didn't want to lose when I relocated the heater controls lower and then put in a double DIN (factory controls were part and parcel with factory tape deck/radio). So... I kept the factory radio.



Turns out there was enough room under the double DIN to just squeeze the fm stocker back in there. I put some foam around the corners to avoid rattles, and I had to creatively hack the parts of the harness I needed to run the new radio, while retaining enough of the old to keep the display. Then I covered it all back up again with the new Android headunit. Seamless.





I still want to go back in there and figure out a way to be able to press a few of the buttons - I've got it left on hvac display right now, but wouldn't mind being able to cycle the other info, such as outside temp etc.
Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: PajEvo on August 15, 2018, 04:49:02 PM
Changed cabin air filter (sorry, jdm gen3s came with it.)

Needed to be done badly, apparently.

Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: PajEvo on August 15, 2018, 04:57:31 PM
Not sure how I missed this, but a very important set of pieces was added to my rig.

As you probably know, the gen3 thought it'd be appropriate to show up to the gunfight that is the trail, wearing a knife (AKA PLASTIC underbelly skid). This embarrassing oversight needed correcting, so I went the route of our namesakes, and installed Adventure Driven Design's finest trail armour - front and middle skids! The gen 3 even comes with a rear skid which continues where the mid leaves off. All well and good until an oil change, where you have to get all that hardware out of the way.



Also, they look awesome!



Not installed without difficulty on this, the turbo diesel model, however. THe intercooler hangs down just a little more on this model than anything on the V6 models. Who knew? So I had to straighten the front skid again at it's bend, notch the sides where it wraps, and then rebend  it 20mm further back on the same plane. This, combined with a few washers to space it, allowed the front skid, sized specifically for a V6, to fit the TD-i version too. The mid skid needed no mods, and was a perfect fit the first time.

Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: PajEvo on August 15, 2018, 04:59:50 PM
Swapped the factory chrome grille to an NOS item I found on ebay. It was even colormatched already!

This was purely aesthetics - but maybe it'll help someday 'cause everyone knows "chrome don't get you home"!

Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: MudRaider on August 15, 2018, 05:05:42 PM
That white definitely looks a lot better!
Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: PajEvo on October 03, 2018, 05:19:08 PM
Not an actual concrete update yet, more of an academic one - I have bought an ARB bumper, and it is waiting for me. Ummm. In the United States. In Maine. Little bit of an obstacle I admit, but it is in the custody of our good friend AJ Vega right now, so we'll figure out the logistics of getting it all the way here, somehow.

I bought it (well AJ bought it on my behalf) from a guy in CT who'd purchased it for his Land Rover. Not sure what the breakdown in communications was, but somehow he ended up with an ARB 3434050 to fit a gen3 Montero/Pajero, and no mounting brackets. Supposedly the seller stopped returning his calls. So... he let it go pretty inexpensively compared to what I'd normally have to pay. Through some connections, we managed to find a brand new ARB mounting kit, and so I just have to get all that gear together with my truck.  I do have a pic of it, just to satisfy the naysayers, LOL, but I'm not sure how long the wait will be.

Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: Crumb on October 03, 2018, 08:30:08 PM
Excellent! maybe that's why mine didn't come with a mounting kit either?
Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: PajEvo on October 12, 2018, 05:26:44 PM
Upgraded battery. Group 94R just barely fit in there, so I jammed that sucker in there and then separated my two (factory dual) batteries. This way I can use the main for starting and running, and the old accessory battery (Optima yellow top) for fridge, compressor and jump start duties, if needed.

This was accomplished with a Coast Products 1314 Separator.

The new battery is a Motomaster Eliminator Ultra AGM, a house brand of Canadian Tire, but supposedly manufactured by Exide.

Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: PajEvo on October 12, 2018, 05:33:19 PM
As some of you know, my philosophy is that all vehicles should be blue. Since my rig ended up white, I added some horsepower to bring it closer to the ideal hue. Or, in layman's terms, I added decals. 102 inches per side is so much decal that I may have offset the horsepower with weight and wind resistance, ending up in a dead heat. Oh well, at least I didn't make it slower?

Title: Re: 1999 Pajero Super Exceed SWB DiD (gen3)
Post by: Crumb on October 12, 2018, 09:01:58 PM
 Nice, and they should all be blue.