Adventure Driven Talk

Tech Questions and How-To Articles => ALL MAKES - ALL MODELS - Build Threads => Topic started by: tperkins on January 18, 2019, 11:41:00 AM

Title: tperkins' 1999 Pajero Exceed
Post by: tperkins on January 18, 2019, 11:41:00 AM
Hey Gang,

Be forewarned this won't be much of a build thread. Apart from maintenance, I don't have many big plans for it. Maybe some HD springs in rear, crank the torsions a bit more and some 285/75/16's, rock sliders. This is my daily driver / hunting, fishing, towing ATV vehicle so I like to keep weight down, fuel efficiencies up.

I also own an evo 6, and just recently purchased an evo 5 for a project car. If you're interested you can follow along on those on my instagram: https://www.instagram.com/travisonfire18/?hl=en



I will start at the start!

Prior to this, I had basically always DD'd Tacomas, but the first gens haven't dropped in price in like 8 years, and I just couldn't justify the cost and then being stuck with rotty frames.

Most recent Tacoma, I had it for 6 years, 160,000km (from 120,000 to 280,000), was a great truck.

(https://farm9.staticflickr.com/8845/18627717551_6159920b59_c.jpg)
(https://farm2.staticflickr.com/1558/24740693682_b61437bd7d_c.jpg)

Unfortunately, frame rotted out. I did my best to get Toyota Canada to replace it through the recall, but was unsuccessful. Supposedly the recall was two stages, first stage was an anti corrosive spray, second stage was replacing frame if it still rusted following anti corrosion spray. Now, I got it 6 years prior and when I did the frame had been sprayed, unfortunately I had no records of this and Toyota Canada conveniently keeps their records for only 6 years. Even when the service manager and shop foreman signed off that the frame was sprayed, Toyota Canada wouldn't honour the recall. I don't blame them, as it is quoted as like a 60 hour job plus the cost of the new frame, but if that had happened I would have kept the truck forever.

Anyone who has had a first gen Tacoma likely has encountered the same thing, and I would say monthly someone would try and buy it off me at a car wash or gas station, or at least insist I take their number if it was ever for sale. SO, I called my friend who is a welder / fabricator at a performance shop in BC, told him about the frame and the whole story with Toyota Canada, and he flew up the next week and drove it home. He cut out the rot, welded it up and strengthened it probably stronger than new.

That's when I started looking at trying to import a Toyota Hilux, and after losing three at auctions, on a whim I searched for Pajeros, found this one, thought it looked cool, threw out a bid which was 3-4k less than I was bidding on Hiluxes and won it.

Auction sheet:
(https://farm1.staticflickr.com/856/43230445324_67674d52c6.jpg)
Auction pictures:
(https://farm2.staticflickr.com/1813/43043949775_e3286f8449_c.jpg)
(https://farm1.staticflickr.com/857/43043950095_a89ec3dc8e_c.jpg)
(https://farm2.staticflickr.com/1833/43949218761_c9b4235555_c.jpg)
(https://farm1.staticflickr.com/936/43949218831_7ab9c4de64_c.jpg)

The following week I received pictures from my exporter, of the hundred I uploaded 67 to my old flickr:
https://flic.kr/s/aHsmr7jZu1

(https://farm2.staticflickr.com/1848/30485175358_794d8ec750_c.jpg)
(https://farm2.staticflickr.com/1846/30485175268_62f49c928c_c.jpg)
(https://farm2.staticflickr.com/1852/30485174688_76916fac28_c.jpg)
(https://farm2.staticflickr.com/1855/42544365500_e93db13ecb_c.jpg)
(https://farm2.staticflickr.com/1894/30485169148_73d40a25a9_c.jpg)
(https://farm2.staticflickr.com/1870/29416269087_9967ef16a8_c.jpg)

Next chapter: After it got off the boat.
Title: Re: tperkins' 1999 Pajero Exceed
Post by: tperkins on January 31, 2019, 11:23:13 AM
After a long wait, it finally arrived, but not before some maintenance items:
(https://farm2.staticflickr.com/1977/30252215337_ef78f55be6_c.jpg)

Inland shipping was delayed due to weather, so it got off the truck in Edmonton absolutely filthy. First thing was to go to the car wash.
(https://farm2.staticflickr.com/1902/30252217287_e912b67da5_c.jpg)
(https://farm2.staticflickr.com/1969/45190799941_bd07b00180_c.jpg)

Going over it when it arrived, had some neat stuff:

Rear heater
(https://farm2.staticflickr.com/1940/45377747391_d9a4c051f0_c.jpg)

Sweet package in the glove box from the old owner, including all the shaken inspections to date, spare keys, touch up paint. That was nice to find, vehicle was well cared for:
(https://farm2.staticflickr.com/1929/44280023555_e24aee2c83_c.jpg)
(https://farm2.staticflickr.com/1907/44468901994_436f7e9379_c.jpg)

Fun little things, like this little flashlight:
(https://farm2.staticflickr.com/1918/44280029255_dec1c74d6e_c.jpg)
(https://farm2.staticflickr.com/1927/30252203407_e043ff55de_c.jpg)

Next day I got the daytime running lights wired up and brought it for the OOP inspection, which it failed due to cracked tires,

Luckily Mitsubishi 4x4 club of Calgary had some very nice members, one in Edmonton which leant me a set of tires, so I could pass the OOP, and go hunting.

(https://farm2.staticflickr.com/1945/44463583175_73815a635c_c.jpg)

Borrowed some tires, passed the OOP, put my old tires back on, and went hunting:

(https://farm2.staticflickr.com/1906/43824460130_1ce2c8af36_c.jpg)

I really wasn't worried about the tires that came with it, they had lots of tread left, the cracks were very minor, and I had my friend of mine who has worked at a tire store for 13 years look at them, he also wasn't worried. Before the shop even told me the tires were cracking, they had a new set priced out and ready to send. I think they were just trying to make a buck off me, to be honest.
Title: Re: tperkins' 1999 Pajero Exceed
Post by: PajEvo on February 05, 2019, 05:31:30 PM
Good to see you here Travis. Of course I know the story already, but good to see it all laid out, with updates going forward. WOOHOO! And such a cool truck too!
Title: Re: tperkins' 1999 Pajero Exceed
Post by: ChargerX3 on February 13, 2019, 10:38:23 AM
Nice find! Interested on what it set you back if you dont mind.
Title: Re: tperkins' 1999 Pajero Exceed
Post by: concealer404 on February 13, 2019, 11:47:50 AM
I just noticed this has the 5spd Jatco auto.  How do you like that? 

Any idea from poking around how hard it would be electrically speaking, to swap that trans into a 4spd auto truck?
Title: Re: tperkins' 1999 Pajero Exceed
Post by: tperkins on February 14, 2019, 10:41:15 AM
Good to see you here Travis. Of course I know the story already, but good to see it all laid out, with updates going forward. WOOHOO! And such a cool truck too!

Thanks!

Nice find! Interested on what it set you back if you dont mind.

It was 320,000 yen car price at auction (in Japan). So, you can work that out for imported cost to you if you'd like.

I just noticed this has the 5spd Jatco auto.  How do you like that? 

Any idea from poking around how hard it would be electrically speaking, to swap that trans into a 4spd auto truck?

I couldn't say for certain, but I wouldn't expect it to be too easy. Depends on if you needed extra wires in the trans loom, or you could just plug in the new trans ECU which comes with this box (mine is in a plastic case under the driver's side (RH) foot well), how the trans ECU is tied in with the engine's, etc. I haven't poked around a 4 speed so couldn't tell you how different it looks. Really, this is the only gen 2.5 I have ever seen IRL. Also, the shift levers for the auto trans and t case might be flipped.
Title: Re: tperkins' 1999 Pajero Exceed
Post by: tperkins on February 14, 2019, 11:04:29 AM
After passing the OOP, I ordered some winter tires in preparation for winter! (265/75/16)
(https://farm2.staticflickr.com/1905/31666478338_db881fb577_c.jpg)

First chicken in the Paj
(https://farm2.staticflickr.com/1911/31666478648_3a05ff6680_c.jpg)

Then the snow came!
(https://farm2.staticflickr.com/1942/44827449895_52c1d9a11e_c.jpg)

Activate hover-truck
(https://farm2.staticflickr.com/1956/43923782560_372b9cd79b_c.jpg)

Mounted and studded tires
(https://farm5.staticflickr.com/4842/30801247557_fd9a8d482e_c.jpg)

Factory size / offset for those wondering
(https://farm5.staticflickr.com/4815/45741550991_e338f8c535_c.jpg)

Then I pulled it into friend's shop and removed the monsoon guards. Honestly, this is maybe my favorite thing I have done to the truck. They were God awful to see through, especially hunting. They were always directly mid-vision, frosted up they were even more blurred. You can also see how much I raised the front with the torsions, just to have it sitting more level. On that note, I will be ordering some HD rear coils, and raising the front a little more. I still have lots of space before hitting the bump stops at this point in both directions.
(https://farm5.staticflickr.com/4900/45146723414_62d5463ebe_c.jpg)
Title: Re: tperkins' 1999 Pajero Exceed
Post by: tperkins on February 14, 2019, 11:37:03 AM
Since getting the truck, the coolant was pretty gross and rusty. I flushed it with distilled water and coolant flush a few times, just with draining, filling, and adding the flushing additive and driving around for a couple days. In total, I probably drained the coolant / flushed the rad through 14-15 times.

Around the 10th time, I pulled the thermostat out, and cut the actual internals out, then re-installed and drove around for about an hour with no thermostat, just flushing with distilled water and coolant flush additive. Following that I flushed with distilled water a few more times and filled it up. I was pretty concerned with the coolant that came in it from Japan freezing, as it only tested to -20 c. Should be good now.

(https://farm2.staticflickr.com/1925/45870973581_449ca815a4_c.jpg)
Also replaced the expansion tank, which was gross as well.
(https://farm5.staticflickr.com/4829/44054282810_9e457591d1_c.jpg)

At this point I replaced the front and rear diff fluids with redline gear oil, gl4 in t case, gl5 in diffs iirc, and replaced the trans fluid. The fluid that came out was actually pretty good, so I drained it, filled it with fresh fluid, drove it 1000km, and drained and filled again.
(https://farm5.staticflickr.com/4819/45146725084_7bdaf80c95_c.jpg)
(In this picture I still haven't gotten around to replacing the fuel pump or spark plugs, I was waiting for two little micro filters and o rings for the GDI high pressure fuel system.)

During all the idling, flushing, etc. I used some of this to clean out the h-vac system.
(https://farm5.staticflickr.com/4918/44054282890_076eef2074_c.jpg)

Just for fun, local tire warehouse which supplies zestino tires was having a blow-out sale of their 180TW stock, since they are changing to a 200TW for classing purposes. These are pretty sticky tires, and they were selling them for 75$ a tire, 65$ if you bought 8 or more. So I got two sets for 270$ each. Pajero fits 8 tires easy, could likely have fit 14.
(https://farm5.staticflickr.com/4841/45256391144_7518e02bca_c.jpg)
(https://farm5.staticflickr.com/4901/45931339542_fb2d356bc9_c.jpg)
(https://farm5.staticflickr.com/4876/32109665318_154ca6b4a4_c.jpg)

I also picked up a full sized spare for the Pajero summer tires. Unsure between ko2's and km3's right now. I was sold on the km3's until I found out they no longer have white raised lettering. KM3's would be great a few times a year when I am really in a pickle, KO2's would be more reasonable the rest of the time. Highway driving, etc. I had a set of km2's on my Tacoma that were great in mud, and lasted 110,000km.
(https://farm5.staticflickr.com/4896/32109664498_f177def71e_c.jpg)
(https://farm5.staticflickr.com/4907/45256478714_9608ffacd9_c.jpg)
Title: Re: tperkins' 1999 Pajero Exceed
Post by: concealer404 on February 14, 2019, 12:27:22 PM
Can i buy the monsoon guards from you?  :)
Title: Re: tperkins' 1999 Pajero Exceed
Post by: tperkins on February 14, 2019, 08:04:58 PM
Can i buy the monsoon guards from you?  :)

promised to pajevo already, but he is stuck in Calgary bubble and hasn't picked them up.
Title: Re: tperkins' 1999 Pajero Exceed
Post by: concealer404 on February 15, 2019, 07:58:34 AM
 I know i've asked you this before, but those didn't happen to have a part number on them or anything right? 

Holler if Pajevo can't/doesn't snag them, but no worries, glad someone in the community is getting them either way.  :)
Title: Re: tperkins' 1999 Pajero Exceed
Post by: TOASTY on February 15, 2019, 01:42:52 PM
 Such a bad ass machine.
Title: Re: tperkins' 1999 Pajero Exceed
Post by: tperkins on February 20, 2019, 05:04:21 PM
I know i've asked you this before, but those didn't happen to have a part number on them or anything right? 

Holler if Pajevo can't/doesn't snag them, but no worries, glad someone in the community is getting them either way.  :)

I will double check but I don't remember seeing anything. Seriously, they are terrible for seeing haha. I am not that tall, 6' and they are directly in my vision all the time. I liked how they looked outwardly, but functionally they were horrible.
Title: Re: tperkins' 1999 Pajero Exceed
Post by: tperkins on February 20, 2019, 08:18:23 PM
Since getting vehicle, the driver rear window has never rolled up right.

Ordered a new motor and regulator for same year Montero. Was super wrong, motor was wrong, regulator bolted in but where it bolted to the track was wrong. So, live and learn. Main issue was that the Pajero connector had like 6 wires going to the motor, Montero had 2. I think it has to do with auto up/down feature from driver switch. Anyways, couldn't find the correct motor and regulator together, but upon removal I found the cable had fallen off the track. I went ahead and just ordered a new regulator online and swapped it onto the old motor. For about 4 months I drove around with no door card on there and some vice grips holding the window up.

So, this was nice to see!
(https://farm5.staticflickr.com/4821/45894300124_bc6572f154_c.jpg)
(https://farm5.staticflickr.com/4896/32744167128_ffbbb03e7c_c.jpg)
(https://farm8.staticflickr.com/7924/45894300104_5f176d73b7_c.jpg)

Now, that said! It still doesn't work properly. If you auto up/down from the front it doesn't know where it is. It will go all the way up, decide it is probably crushing someone's arm, then goes down 4". I have looked on the motor for a limiting switch of some sort and found nothing. The montero FSM shows a switch that actually makes contact and you adjust the span. Couldn't find that. In the past I have seen buttons, go up, press and hold, go down press and hold. Viola! Knows its new life. After that failed, I was hoping that if you plugged in the door switch it would learn itself, but that didn't work. I also was hoping using the switches would make it learn. Also didn't work. In the end I just put it back together and it is what it is.

Next thing was to sort out the sound system, which obviously needed some help:
(https://farm8.staticflickr.com/7899/31677374887_2e451c3e86_c.jpg)

Rear was easy
(https://farm5.staticflickr.com/4806/45894299474_d44be6bd10_c.jpg)

Fronts were a little more complicated, just happened that these speakers with external crossovers were on sale, so after humming and hawwing about how to mount it for a while I just mounted them in the door.
(https://farm5.staticflickr.com/4886/32744182958_414c48f748_c.jpg)
(https://farm8.staticflickr.com/7896/32744429288_0fe8b62152_c.jpg)
(https://farm8.staticflickr.com/7864/45704081525_b7899ef361_c.jpg)
(https://farm5.staticflickr.com/4899/32744429228_ea802816ed_c.jpg)
Title: Re: tperkins' 1999 Pajero Exceed
Post by: tperkins on February 25, 2019, 08:59:18 PM
Next was dreaded shifter bushing!

First was Amayama order with things. (yes, that is a new OEM cup holder.. yes, it did break within two months)
(https://farm5.staticflickr.com/4903/45894324014_bdb4d9605a_c.jpg)

Next was to replace the shifter, and those of you here that have done it can see that I removed the wrong thing. I got all 3 nuts off and plop! One stud fell into the top of the transfer case.
(https://farm8.staticflickr.com/7909/31677374877_c39c167168_c.jpg)
Guess which one fell
(https://farm8.staticflickr.com/7833/32744186698_2b02f8082a_c.jpg)
Luckily, it was sitting in this observation window.
(https://farm5.staticflickr.com/4851/45704083745_b9bac943cc_c.jpg)
Since I couldn't get a new gasket in time, I ended up cleaning everything and using black oil resistant RTV.
(https://farm5.staticflickr.com/4807/31677354047_2b139e8460_c.jpg)

Smashed bushing
(https://farm8.staticflickr.com/7820/39653479093_6d7b4a838b_c.jpg)
New bushing
(https://farm8.staticflickr.com/7856/45894322174_f02caf9b72_c.jpg)
I still couldn`t figure out how to get it into 4LLC, until I asked around and found the magic step was to push the shifter down, then frontwards.
(https://farm8.staticflickr.com/7803/46566452332_74907059dc_c.jpg)

Bonus pictures of the rear h-vac control
(https://farm5.staticflickr.com/4892/32744183048_712215ce9a_c.jpg)
(https://farm8.staticflickr.com/7802/32744182108_14be3f2312_c.jpg)
Title: Re: tperkins' 1999 Pajero Exceed
Post by: Shovel on February 25, 2019, 09:16:58 PM

Next was to replace the shifter, and those of you here that have done it can see that I removed the wrong thing. I got all 3 nuts off and plop! One stud fell into the top of the transfer case.


I've posted soooo many times what to remove,  keep hoping I'll "get" everyone before they make this mistake!       But it's not possible to get everyone!   ;D   Glad it was fast to retrieve at least. 
Title: Re: tperkins' 1999 Pajero Exceed
Post by: tperkins on February 26, 2019, 10:41:49 AM

Next was to replace the shifter, and those of you here that have done it can see that I removed the wrong thing. I got all 3 nuts off and plop! One stud fell into the top of the transfer case.


I've posted soooo many times what to remove,  keep hoping I'll "get" everyone before they make this mistake!       But it's not possible to get everyone!   ;D   Glad it was fast to retrieve at least.

It actually like wrecked christmas for me. Met with the whole family for Christmas directly afterwards and had to stress about potentially having to remove my transfer case if I couldn't get it out with a magnet or sitting in the inspection plate. I even thought, weird, that is a silly place to put a stud, but they would have done something so that it won't fall in.. turns out no, and it was actually an upside down bolt suspended from above the abyss lol. I actually noticed one wiggle when I removed it the shifter, so I was in the process of replacing the nuts, which I had the other two secured on there and the moment I tried to grab hold of the last bolt to thread the nut on, that is when it dropped.
Title: Re: tperkins' 1999 Pajero Exceed (with some evo content)
Post by: tperkins on February 26, 2019, 11:36:01 AM
I guess this will basically be the last update and we are caught up for now.

Installed this 400w oil pan heater which sure makes me feel better when I start it in -36, less of a tractor sound. Also, check out this little cup holder.
(https://farm8.staticflickr.com/7903/45895196474_6c54fb315f_c.jpg)

Next was installing a cell signal booster! (Hunting truck, so often I get myself into some pretty remote places). I beleive this bracket is for a new super duty, fits perfectly after a little hole massaging.
(https://farm8.staticflickr.com/7812/46691266302_7b8cccb57a_c.jpg)
(https://farm8.staticflickr.com/7879/46019474644_9c40df4ff3_c.jpg)
(https://farm8.staticflickr.com/7852/46691266172_fe2c010fcb_c.jpg)
(https://farm8.staticflickr.com/7815/46691266712_ba3b38705e_c.jpg)
Ran a separate auxilary plug to the passenger side then mounted the switch to the passenger door kick.
(https://farm5.staticflickr.com/4882/46691268282_5831b093df_c.jpg)
Made use of the cassette tape storage area under passenger seat to mount the boost itself.
(https://farm5.staticflickr.com/4868/46019475034_a86c8a6921_c.jpg)

That's about it for things I have done to the truck. So far I have put 14,000km on it, just changed the oil last week and cleaned the throttle body. So far the GDI has been good. Fuel economy on the highway is better than my Tacoma was, and it weighs an extra 700 lbs. Also puts out 50 more hp than the Tacoma (Mitsubishi claimed 240hp and 263 ft-lbs tq on this engine and also claimed diesel like fuel economy). I am interested to see what fuel economy is like in the summer, as winter fuel economy is always brutal.


Here are some pics!

Out ice fishing
(https://farm8.staticflickr.com/7840/47168363382_8168a5d45b_c.jpg)
(https://farm8.staticflickr.com/7819/46497076694_66e2e400a9_c.jpg)

Out for a rip
(https://farm8.staticflickr.com/7870/45704084125_96145bd60f_c.jpg)

A real issue with this truck is when it sits in the sun, snow melts and freezes the fuel door closed.
(https://farm8.staticflickr.com/7901/47016017642_1d7d8a0a8f_c.jpg)
(https://farm8.staticflickr.com/7896/46344352204_c7260360b6_c.jpg)

Now, when I first got the truck I priced out some American Racing AR23's, with buddies wholesaler discount it was going to work out to about 120$ per wheel (x5) in Canadian schmeckles. Fast forward to yesterday, I assume due to all the winning in America they would now cost me more like 220 goose dollars per wheel (after shipping, import duties, like 170 eagle dollars).
(https://farm8.staticflickr.com/7876/32270855227_7390bb7e31_c.jpg)
(https://farm8.staticflickr.com/7853/32270855267_2691eabdcb_c.jpg)

So, long story short. Due to the necessity of spending money on other projects as opposed to the daily, just ended up with some steelies.
(https://farm8.staticflickr.com/7860/33337491338_8e3ac96285_c.jpg)

Pretty hard to beat 420 legal weed dollars for a set of 5 wheels. They also were having a promotion where they would pay the GST on any orders, so I also ordered a set of medium duty OME springs on a bit of an impulse purchase.

BONUS ROUND:
The new project
(https://farm8.staticflickr.com/7871/47018781861_37ee99a1cb_c.jpg)
Have assembles basically everything I need to assemble, subtract the clutch.
(https://farm8.staticflickr.com/7872/40197688603_aa70e1bec5_c.jpg)
(https://farm8.staticflickr.com/7917/33287359798_43a6164706_c.jpg)
Shiny and chrome
(https://farm8.staticflickr.com/7923/46439237494_e51b8cd161_c.jpg)

Long story with that evo 5: Long story short, young guy picked up this car 4+ years ago. Within a month engine killed itself (not sure why, in the past I have seen waste-gates fail, cars overboost to 28 lbs or whatever no wastegate control gets you, and engines throw a rod out the side of the block). PO decides to buy a fully built motor from the US and install himself.. finds he has no time, brings it to a shop in Edmonton, they have it for over a year and it moves with the same mechanic to 3 different shops. Each one tries their luck at it, after a 5, 7, 8 ECU, followed by a haltech, followed by a link g4 (tuner issues with speed density), they finally get it running. Above wastegate pressure the car gets phantom knock, no one really knows why but his exhaust is super restrictive and he is having crank case pressure issues. Car makes approx 360 whp @ 14 psi. He brings it home, acknowledges issues, brings it to shop in Calgary who works with well known evo tuner. The shop is tasked with giving it a bill of health, addressing issues which might come up. They determine, with a boroscope, that at some point the pistons have made contact with the valves.

Obviously, over this time it has been 4 years, PO is tired of the car, decides to part it out, I messaged him to buy the rolling chassis, granted I bring some of my spare wheels. He sells a bunch of stuff, wheels, turbo and intercooler kit as a whole, ECU, etc. Someone wants to buy the head (as it has cams, ported, etc), when he pulls the head from the car, he finds that there is no valve damage at all, no contact.. so the other shop must have seen the valve clearances and assumed it was contact marks. I actually looked at the engine myself with the head off and also didn't see any evidence of valve-piston contact. At this point, he posts pictures on FB group and an engine builder chimes in that the pistons were orientated backwards this whole time. So the clearances for the exhaust and intake on the pistons were backwards.

In rolls me, I am just going to put it back to stock with this evo 6 engine I picked up, an evo 5 trans I had as a spare, and a spare t case which I have gone through and upgraded the LSD fasteners. I have an evo 7 ECU to go in, and I have a factory 6 wiring harness (spare) sitting here that I can use if the old one has been too molested.

Probably this will raise some questions, I would rather not get into which different shops (3 well known shops in the Edmonton / Calgary scene) dealt with this car as that is not my business, and there are two sides to every story.

My 6 with a 6 engine to go into the 5.
(https://farm8.staticflickr.com/7881/46248415945_43e0113e9d_c.jpg)
Title: Re: tperkins' 1999 Pajero Exceed
Post by: concealer404 on February 26, 2019, 12:37:04 PM
This whole thread i somehow missed this was a gasser.

This is a direct injection 6g74?  o_O
Title: Re: tperkins' 1999 Pajero Exceed
Post by: tperkins on February 26, 2019, 12:55:03 PM
This whole thread i somehow missed this was a gasser.

This is a direct injection 6g74?  o_O

It is indeed
Title: Re: tperkins' 1999 Pajero Exceed
Post by: tperkins on March 01, 2019, 11:16:32 AM
https://www.mitsubishi-motors.com/en/corporate/pressrelease/corporate/detail215.html

Cool press release from back in the day. Mitsubishi reintroduced GDI into automotive engines in 1996. Between 2009 and 2015 the number of GDI engines in new vehicles jumped from 5 to 46% of new vehicles in 2015 were sporting a GDI engine, can't find anything more recent but I would assume still an upward trend.

So far the engine has been good, reliable, its got some decent power. Fuel economy has been pretty varying, interesting to see what its like in summer.

My best fuel up was 8.8L/100 km (26.7 US MPG), that was straight highway driving on a nice day. I have seen quite a few tanks around the 10L/100km (23.5 US MPG), but I would say my average is 12L/100km this winter (19.60 US MPG). Now, I have seen as bad as 16L/100km depending how much I am idling it when it is -40 and driving around the city lol.
Title: Re: tperkins' 1999 Pajero Exceed
Post by: Hooots on March 01, 2019, 01:47:32 PM
good grief.........this thing is so pimp  8)
Title: Re: tperkins' 1999 Pajero Exceed
Post by: tperkins on March 06, 2019, 11:01:49 PM
Wheels showed up!
(https://farm8.staticflickr.com/7891/46391028275_d1c9032ab5_c.jpg)
(https://farm8.staticflickr.com/7879/32364219227_c2becf02f1_c.jpg)
And these little numbers! 
(https://farm8.staticflickr.com/7806/32364219337_522b76265a_c.jpg)
Title: Re: tperkins' 1999 Pajero Exceed
Post by: tperkins on March 07, 2019, 02:37:34 PM
Well I was so excited I went to see how they fit, I would say just about perfect.

(https://farm8.staticflickr.com/7883/47312164011_c0b13457b9_c.jpg)
(https://farm8.staticflickr.com/7853/46588863254_c9e8d9ac7f_c.jpg)
(https://farm8.staticflickr.com/7835/47259820042_b3a30b7840_c.jpg)
(https://farm8.staticflickr.com/7808/47259819892_0fb8900284_c.jpg)
(https://farm8.staticflickr.com/7830/32370385757_65659f48b9_c.jpg)
(https://farm8.staticflickr.com/7852/47312164401_d170885d34_c.jpg)
(should out to city of edmonton for the new surface rust on the frame, for sure Krown or something before next winter)
(https://farm8.staticflickr.com/7899/40347304963_4b8516d3c9_c.jpg)
Title: Re: tperkins' 1999 Pajero Exceed
Post by: tperkins on April 09, 2019, 10:00:13 AM
(https://live.staticflickr.com/7836/40528118603_128377f452_c.jpg)

Will they fit?! 5 33's, 5 16x8 still in boxes, new rear springs, spring compressors, tool kit, tool pouch, a bunch of other random tools, all my stuff for a couple weeks of living.

Yes, of course. Room to spare in the passenger seat. IMAGINE a roof rack.
(https://live.staticflickr.com/7916/46578789695_8430fd24fb_c.jpg)
(https://live.staticflickr.com/7869/46578789785_3ff2ac41cf_c.jpg)
(https://live.staticflickr.com/7925/32552075727_f6775096ac_c.jpg)
(https://live.staticflickr.com/7834/40528118413_716c8ec794_c.jpg)
Yes, I nerded out a little about that.

Truck as it rolled into the shop:
(https://live.staticflickr.com/7863/47441236582_72243202e5_c.jpg)
Seeing as I needed to replace these little plastic bushes on the torsion bars, I re-indexed them while I had that torsion key off.
(https://live.staticflickr.com/7850/33617412688_f78df93a43_c.jpg)
I then replaced the rear springs
(https://live.staticflickr.com/7904/40528116263_2c0ef20347_c.jpg)
These are just Medium Duty OME springs, they're a little thicker so should improve the payload a bit, but still ride nice. After installation and settling, they provided about 3/4" of lift.

You can't really tell, but here, after re-indexing the torsion bars, driving and settling, adjusting, driving, settling, adjusting, I finally ended up with about 1/2" lift in the front over what I had originally, and perfect, I mean perfect, height side to side. If you look at the silver lines you can tell, but it is difficult.
(https://live.staticflickr.com/7926/40528115903_285c5e0150_c.jpg)

Following that, I was deeply offended at the extra amounts of surface rust that showed up over this last winter in Edmonton [read: calcium brine]. So, I might have gone a little overboard with the frame. (Yes, on my DD / hunting truck]. This basically started when swapping over the springs and deciding I might as well paint the spring perches while they're out.

Steps: 1.) Wash the frame big time. Wash everything, I ran water through each hole in the frame until it came out perfectly clear through the drain holes. I even scrubbed with brush.
2.) Hit entire frame with angle grinder + wire wheel to remove any flakey bits of paint or anything. Use wire brush for hard to reach places.
3.) POR15 cleaner / degreaser. Self explanatory, I also worked it in with a sponge and rinsed it off big time.
4.) POR15 Metal Prep. They explain this as a rust neutralizer / etching compound. What you do is spray it on the bits to be painted and keep it wet for a duration of time, keep it MOIST, then rinse it off and let it dry. This leaves the surface with better adhesion and a zinc phosphate coating to improve bonding.
5.) dry, big time dry everything. They say POR15 actually hardens when introduced to water, but I went over the whole thing with an air compressor and gave it heaps of time to sit.
6.) two light coats of por15 classic. Satisfying, but each coat was taking me approximately 2.5 hours to brush on.
7.) two light coats of top coat (chassis black).

In all, this took a couple days, I even woke up one day at 7 AM to do the second coat of POR15, after finishing the first coat at 2AM. The first coat was ready to paint (when dry to touch) after 5 hours. The second coat was ready after 6 hours, same as the third coat. In total, between prepping and painting this was probably 20 hours of work excluding all the drying time.

Following the second coat of POR15 (glossy)
(https://live.staticflickr.com/7801/40528115843_aba98084b2_c.jpg)
(side note, you can see here the 1" body lift from factory for the auto trans units)

Finished product
(https://live.staticflickr.com/7833/46622201575_c0c177ec19_c.jpg)
(https://live.staticflickr.com/7900/46621299345_547f84827b_c.jpg)

To finish it off I am either going to go to a Krown dealer and have them spray inside the frame rails really well right away before any mud or dirt gets in there, then probably krown the whole bottom before winter.
Title: Re: tperkins' 1999 Pajero Exceed
Post by: tperkins on April 09, 2019, 10:34:39 AM
Then I removed the steps and factory flaps (pics later)

Well, after that make work job... I noticed now my paint wasn't up to snuff.
(https://live.staticflickr.com/7815/33660010408_75b03439de_c.jpg)

The white.... man. Fuck the white. So, I started with hand wash bucket style. Then went to a full degreaser my friend had that removes old wax. At that point it was time to clay bar.. I couldn't find iron x, or fallout or magma. Nothing.

To clay bar the silver, no problem. Normal amounts. To clay bar the white took longer than all the silver on the vehicle, which is like 80% of the surface area.

Anyways, following clay bar was meguiars ultimate compound, then meguiars ultimate polish, then I waxed it. A ton of work.. probably in total took 16+ hours. But, it turned out nice.
Test spot on the roof
(https://live.staticflickr.com/7818/33660029938_8378758cd3_c.jpg)

Before:
(https://live.staticflickr.com/7811/46813132094_f56347c160_c.jpg)
After:

Pictures throughout various stages
(https://live.staticflickr.com/7895/33660247698_65d9fc82cd_c.jpg)
(https://live.staticflickr.com/7870/33660959328_e0d703d61e_c.jpg)
(https://live.staticflickr.com/7810/46621298535_528f6fd95b_c.jpg)
(https://live.staticflickr.com/7911/33660029158_d8a2fc9a0c_c.jpg)
(https://live.staticflickr.com/7810/46621298535_528f6fd95b_c.jpg)
(https://live.staticflickr.com/7851/32594338817_9023e70082_c.jpg)

Then I finally got the tires mounted to the truck:
(https://live.staticflickr.com/7846/32594340287_508a4240e8_c.jpg)
(https://live.staticflickr.com/7841/47484992262_d8d00b716a_c.jpg)

Spare tire fits.
(https://live.staticflickr.com/7886/33660031148_608baf3f05_c.jpg)
Three stages of Pajero ownership
(https://live.staticflickr.com/7890/33660959208_19cd499a0f_c.jpg)

(https://live.staticflickr.com/7836/40570710743_5312bfb89e_c.jpg)

Then it went for clear protectant on the rocker panel, bottom of doors, and inside wheel wells:
(https://live.staticflickr.com/7903/47572600041_e8701f1623_c.jpg)

Next up, flaps: (these are 19$ a piece at gregs)
(https://live.staticflickr.com/7864/33695686938_9d2cbb25c9_c.jpg)
Title: Re: tperkins' 1999 Pajero Exceed
Post by: Shovel on April 09, 2019, 12:23:51 PM
I have paint envy!! 
Title: Re: tperkins' 1999 Pajero Exceed
Post by: tperkins on April 15, 2019, 09:37:45 AM
I have paint envy!!

Well, when I went to ceramic coat it, my friend who was going to help me wasn't as happy with it as I was, so he made some touch ups:

(https://live.staticflickr.com/7820/46885522594_80b348b792_c.jpg)
(https://live.staticflickr.com/7870/47556664942_e4e066385a_c.jpg)
Title: Re: tperkins' 1999 Pajero Exceed
Post by: tperkins on June 04, 2019, 07:19:03 PM
All major maintenance is up to date as of this weekend. Timing belt, water pump, tensioner, idler, idle tensioner, cam seals, crank seal, rad hoses, accessory belts and crank bolt / washer replaced.

(https://live.staticflickr.com/65535/47986871832_9acfe69cf1_c.jpg)
(https://live.staticflickr.com/65535/47986920281_27f15857b3_c.jpg)
(https://live.staticflickr.com/65535/47986920121_2f56e6d765_c.jpg)


First issue in 22,000 km, power steering pump started leaking. Ordered a rebuild kit already.
(https://live.staticflickr.com/65535/47986867893_d4992dc365_c.jpg)
Title: Re: tperkins' 1999 Pajero Exceed
Post by: concealer404 on June 05, 2019, 03:14:24 PM
Man, REALLY nice job on the POR15.  :)  I have a bunch of supplies to do the same to mine, but have been waiting on getting a lift installed first so the job is less annoying. 
Title: Re: tperkins' 1999 Pajero Exceed
Post by: tperkins on June 05, 2019, 05:17:15 PM
Man, REALLY nice job on the POR15.  :)  I have a bunch of supplies to do the same to mine, but have been waiting on getting a lift installed first so the job is less annoying.

Thanks! That was a real pain in the butt to do. It probably took like 20 hours of actual work, like I mentioned, but spread over a couple days so there were some weird hours due to re-coating hours.

Title: Re: tperkins' 1999 Pajero Exceed
Post by: tperkins on August 24, 2019, 10:15:22 AM
Remember all that flushing of the rad I did? Well like 11-12 flushes and it was still pretty rusty. Lent the truck to my buddy for the weekend and he hooked it up to the rad cleaning machine at work.

The aftermath is some squeaky clean coolant!
(https://live.staticflickr.com/65535/48353699606_0f66f6788e_c.jpg)

He also hooked it up to the intake service machine to clean up the likely caked up valves.
(https://live.staticflickr.com/65535/48353699821_cf8fae8ab8_c.jpg)
Honestly I have noticed the truck runs smoother and the throttle is more responsive.

With all that done, I would say that the maintenance is entirely up to date!

Please enjoy this picture of how glossy the Sonax is still holding up:
(https://live.staticflickr.com/65535/48353833502_999c8d5a06_c.jpg)
Title: Re: tperkins' 1999 Pajero Exceed
Post by: tperkins on August 24, 2019, 10:24:47 AM
Truck was pretty far north!

(https://live.staticflickr.com/65535/48612819842_80220e7341_c.jpg)
(https://live.staticflickr.com/65535/48612776732_5e5b22c110_c.jpg)
(https://live.staticflickr.com/65535/48612775862_fb1b15e1bd_c.jpg)
(https://live.staticflickr.com/65535/48612333643_d09607dea4_c.jpg)