Picked Up Grand Daddy: Mitsubishi Montero (Pajero MK4) Drives In


Thread Starter #17
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^^ Thank you sharpshooter sahab hows your PS doing long time no updates ?

So in line with my pursuit to restore this to full glory - the item which was a biggest question mark while purchase was the EGR , OBD scans already told me what was the problem pre purchase.
I was hoping a thorough clean up of EGR might solve the problem and temporarily it did, it worked well for a week post clean up, but then egr code appeared again. So i decided in replacing the egr, as the previous egr motor had gone weak and cudnt operate the valves.
I sourced the part from Raj bhai in Delhi and put it in myself. Unfortunately the DC motor is a sealed unit and hard to repair.

With a bad EGR i noticed a coarser sounding engine, once i replaced the new EGR, i removed the battery for 15 mins, so thats one way to reset the ECU and then it goes in to relearning mode - you can do same via the MUT tool too, this was just more easier for me.
Post this the engine was back to the original sound - only thing left is to service all fluids and replace them entirely, will update that in next post. Post this did several OBD scans and found no issues whatsoever.

Some pictures

Old EGR

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New EGR

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Thread Starter #18
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The next item inline was getting the body rubbed thoroughly and then polished and finally 10h coat that i had done on the PS and Isuzu as well, the pics from the opening post already shows the outer effects, to be frank its no match to the PS or Isuzu as far as body shine is concerned but then i have to respect the fact that daddy is 10 years old.
I also got underbody coating done, there was very very minor surface rust at couple of places, so had to sand it before the coat, here are some pictures, Also the silencer was zinc coated - so nothing to bother from here hopefully as far as body and underbody goes :-

Before
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After
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Thread Starter #19
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Next in line was a comprehensive service with all fluids change - the problem with a used car purchase is always the unknown gremlins and what the previous owner might have done,claims to have done vs really done.
So to assuage those fears i decided ill replace all fluids , flush and replace in some cases like engine oil and Coolant.

  • Liquimoly flush was used with existing engine oil and flushed out, Oil was replaced with Shell Synthetic
  • Synthetic oil went in to both front and rear diffs
  • Transfer case was GL5 spec as per Mitsu recommendations
  • ATF fluid and Filter were both replaced - most expensive of the lot as SP3 fluid is 1000Rs a litre nearly and the process requires 9+ litres
  • All underbody checks and torquing were done
  • Diesel, Oil filter, AC and Air filter all are replaced
All on all , i have a fresh baseline from here, pending is coolant flush and brake check - a brake bleeding nipple is broken and i am awaiting that part post which ill replace these two.
Some pictures from the busy day at the workshop


Firstly ATF drain and replace process, this is quite lengthy , as it involves a process of draining oil out of pan as well as front pipes which go through the pump and ATF cooler - this is time consuming but the no.1 most important thing to do
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Old vs New ATF filter
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Two Magnets at the bottom of the ATF drain pan
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Refitted back
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It drank all of that!
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All oils drained
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Shell Liquid Gold goes in
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New Oil and Diesel filters
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Transfer case and Diff oils
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Patient finally getting off the ICU
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Very satisfying for an owner as well as us audience too ,to see all that going on in your car.Old blood drained and brand new put in all the pipes and ducts.Fresh fluids,Fresh energy.
How is the performance now on the road after all this being done?
Any perceived improvements,large or small? Has the engine note softened ? Or its all just the same?
When I do all this on my car, I force my brain to at-least psychologically think that Yes the improvement is there!Like engine is more smooth etc etc.
 
Thread Starter #21
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Absolutely Sir, the vehicle is absolutely smooth now, note softened post ecu relearning, shifts are smooth too - i did a 1200 km run recently and got 12.59 kmpl on a full tank(MID showed 12.3)! Yes from a Montero most people wont believe it. This was a pure highway run speeds not exceeding 100 and kept at a steady 90-95kmph.

Usually with all such a changes you do feel a perceived difference, the only exception i notice is on the isuzu even after a service and when you go from mineral to synth - there is no difference whatsoever.

Screenshot_20190603_175432_com.kajda.fuelio.jpg
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Thread Starter #22
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Some minor items i replaced in a last 2 weeks purchased directly from Japan (Amayama) - surprisingly came within 2 weeks or so

3 of the rear AC vents were wonky probably kids damaged the vents, so replaced them with new ones, thankfully the colors matched, mitsubishi has 2 variants grey and beige and i felt color blind while choosing
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The left side splash guard had fallen off, probably taken a hit somewhere - so replaced that as well
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I wasnt sure of the condition of the MAF sensor, so bought the liquimoly cleaner and cleaned up the MAF sensor
I
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Then bought this to clean seats, i also need a black restorer to restore some bruised edges and conceal the wear - thats next in line
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Nearly 90% of the jobs post purchase are done, whats pending now is :-
  • Brake and Clutch Oil replacement - purchased DOT4 from STP and also bought a brake bleeding valve as the front left is broken. To be done shortly.
  • Coolant flushing and replacement
  • Wheel Alignment
 
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