Pajero Mini 1995 - My first 4x4

[chall3ng3r]

Whatever brand you like and is easily available originally doesn't make a difference as long as grade is right.
I used liqui moly mos2 in mine but shell or any other brand does the job well too at less price
It has roller rocker tappets so using older oils with high ZDDP is not necessary. Take care to not overfill the oil it doesn't take a lot of it, I forgot exact amount. And please use a quality oil filter loads of so called fake Mitsubishi fiters out there for this car leppon is pretty bad too, I used ALCO German filters but they are had to find so try VIC (Japanese) oil filter

And please get coolant as these systems can rust and in a Pajero mini the heater core often leaks if the system is rusted through, though yours is fine just as you say get the thermostat and coolant.

This thread is going to be very beneficial for future owners

You can also join Mitsubishi owners club uk forum if you want to
They have a section on Pajero mini though you'll see a post in that section maybe once a month or two but some useful information is in the threads already there,

A number of these were imported into Ireland so some members post there

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Thanks,

I will keep that in mind. I will post details of change of oil, quantity, brand, grade etc.

As you might have noticed in engine photos I posted, heater core is already bypassed with a U pipe

Once I make the engine in tune, I will open heater core and see if there are any leakes. My guess is some AC wala have bypassed it to "increase" performance of AC.

like he removed clutch cable to fresh air intake in dashboard. And put a permanent stop screw on gate. I already fixed it and now working ok to let fresh air in from vents.

I will check your suggested thread soon, maybe I'll find service manual in English

Pajero Mini 1995 M/T

[arzaam.bhatti]

Thanks,

I will keep that in mind. I will post details of change of oil, quantity, brand, grade etc.

As you might have noticed in engine photos I posted, heater core is already bypassed with a U pipe

Once I make the engine in tune, I will open heater core and see if there are any leakes. My guess is some AC wala have bypassed it to "increase" performance of AC.

like he removed clutch cable to fresh air intake in dashboard. And put a permanent stop screw on gate. I already fixed it and now working ok to let fresh air in from vents.

I will check your suggested thread soon, maybe I'll find service manual in English 

Pajero Mini 1995 M/T

haha, looks like the previous owner liked to drive with fogged up windows or something, but its fun bit by bit youll have it perfect, my heater core was leaking, i noticed it by reducing coolant level and there was no other leak or reaoson for coolant loss and wet carpet on the inside.

I did my best to seach for a english service manual but it was all in vain, coudnt even find a english owners manual, this car was only sold in japan and imported in large quantities to russia thats it, so you wont be able to find it i think, on one website person was claiming to have a translated version of the service manual but that was in newzealand and only in paper back.

[chall3ng3r]

haha, looks like the previous owner liked to drive with fogged up windows or something, but its fun bit by bit youll have it perfect, my heater core was leaking, i noticed it by reducing coolant level and there was no other leak or reaoson for coolant loss and wet carpet on the inside.

I did my best to seach for a english service manual but it was all in vain, coudnt even find a english owners manual, this car was only sold in japan and imported in large quantities to russia thats it, so you wont be able to find it i think, on one website person was claiming to have a translated version of the service manual but that was in newzealand and only in paper back.

I think it's good practice and leaning. I'll know everything about this car, if I decide to keep it longer, it'll be easier for me to troubleshoot

I found couple of service manuals. Both in Russian. But diagrams and other numbered info could be easy to read. For instructions I guess Google Translate app will work which can parse from live camera feed.

I will test this method as I'll be reading about calibration of TPS in manual. I will try to calibrate it myself as I have multimeter and other stuff from elder bro

Currently watching videos for TSP calibrations of different vehicles.

Pajero Mini 1995 M/T

[Proverbial_Slang]

I think it's good practice and leaning. I'll know everything about this car, if I decide to keep it longer, it'll be easier for me to troubleshoot

I found couple of service manuals. Both in Russian. But diagrams and other numbered info could be easy to read. For instructions I guess Google Translate app will work which can parse from live camera feed.

I will test this method as I'll be reading about calibration of TPS in manual. I will try to calibrate it myself as I have multimeter and other stuff from elder bro

Currently watching videos for TSP calibrations of different vehicles.

Pajero Mini 1995 M/T

Excellent! I also learned like this with my old 85 Charade. I was able to get a hold of an English workshop manual which really helped.

Sent using Curiosity's onboard communications sytem.

[KeiWorks12]

I think it's good practice and leaning. I'll know everything about this car, if I decide to keep it longer, it'll be easier for me to troubleshoot

I found couple of service manuals. Both in Russian. But diagrams and other numbered info could be easy to read. For instructions I guess Google Translate app will work which can parse from live camera feed.

I will test this method as I'll be reading about calibration of TPS in manual. I will try to calibrate it myself as I have multimeter and other stuff from elder bro

Currently watching videos for TSP calibrations of different vehicles.

Pajero Mini 1995 M/T

MASHA ALLAH very nice car you bought. I myself is a big fan of this model. Can you tell me for how much you got this car?
do keep updated i have subscribed

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[chall3ng3r]

MASHA ALLAH very nice car you bought. I myself is a big fan of this model. Can you tell me for how much you got this car?
do keep updated i have subscribed

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Thank you

Will PM price I got it for.

I will keep posting updates here as I progress to tune it for better average and troubleshooting I do along.

Pajero Mini 1995 M/T

[chall3ng3r]

Whooops... gear problem

It's stuck in reverse gear. Can't unengage it but clutch works.

I can start with clutch pressed and it goes in reverse, but unable to take car out from reverse gear.

Gear was getting gradually jammed in last couple of weeks, and it was really hard to change gear yesterday. Reached home and put car in reverse and it never came out from it.

I hope it won't be some major issue.

Pajero Mini 1995 M/T

[KeiWorks12]

Whooops... gear problem

It's stuck in reverse gear. Can't unengage it but clutch works.

I can start with clutch pressed and it goes in reverse, but unable to take car out from reverse gear.

Gear was getting gradually jammed in last couple of weeks, and it was really hard to change gear yesterday. Reached home and put car in reverse and it never came out from it.

I hope it won't be some major issue.

Pajero Mini 1995 M/T

Shukar hai ghr pohanch gye. Warna reverse me ghr lani parhti[emoji14]

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[umarxe]

Whooops... gear problem

It's stuck in reverse gear. Can't unengage it but clutch works.

I can start with clutch pressed and it goes in reverse, but unable to take car out from reverse gear.

Gear was getting gradually jammed in last couple of weeks, and it was really hard to change gear yesterday. Reached home and put car in reverse and it never came out from it.

I hope it won't be some major issue.

Pajero Mini 1995 M/T

Is it fixed now? What was the problem? Was it due to the gear oil leakage when it was with previous owner?

[chall3ng3r]

Is it fixed now? What was the problem? Was it due to the gear oil leakage when it was with previous owner?

Yes, Alhamdulillah fixed.

Took it to same mechanic, had to take down gear and fixed by gear specialist, same guy who worked on oil leak issue. He should have inspected it before.

He didn't tell me why it happened, but my guess is previous owner who drove the car without any maintenance. And he told me there's no work in car

Let's see how it goes. I hope it won't happen again, or I will have to go with replacement gear.

Locally driven cars have these issues, one have to be prepared if bought local used car.

Anyway, I know what I'm into, so Insha Allah will make sure it gets in good condition.

Pajero Mini 1995 M/T

[umarxe]

my guess is previous owner who drove the car without any maintenance. And he told me there's no work in car

He actually meant there is no work in car he ever did.
However its part of the game, I mean new owners always have few surprises in first couple of months and even later. I hope it would go fine without some major problem.

[chall3ng3r]

He actually meant there is no work in car he ever did.
However its part of the game, I mean new owners always have few surprises in first couple of months and even later. I hope it would go fine without some major problem.

Haha, yes maybe I didn't catch what he meant [emoji14]

I will now continue my work on it for performance and getting better average.

Pajero Mini 1995 M/T

[chall3ng3r]

I found old thermostat valve in collection of same mechanic, it got 88C rating on it. But its seal have couple of cuts in it. Tested it with boiling water, opens at about 95C.

Installed in car yesterday, and temperature needle is now constantly at the normal position. Digital reading of water temperature is at 80-85C. I think this is perfect range for this car, as mentioned in service manual.

I found new thermostat at Plaza, but guy was asking 3k for it. I was expecting it to be in 500 range.

I guess next time I'm in market, I won't tell for which car its for, just gimme the same reading thermostat.

Pajero Mini 1995 M/T

[chall3ng3r]

So, today in evening I took out throttle body. This is the last thing I wanted to clean for my quest for better fuel economy.

This is what it was like:

That connector in above photo is ISC (idle speed control) motor. I checked it, and unfortunately it's burned. Each coil of motor should give resistance of 33ohm. Only one coil is okay while other are almost short circuit at 3ohm. I checked this with according to service manual instructions.

My elder brother, who is embedded electronics expert, told me there will be damage on ECU as well, if it didn't have any protection fuses.

He was right, do you see brownish color where pen is pointing, thats burn mark, one of the motor driver IC is short. Maybe it's the motor which burned IC.

My brother have newer IC which he can put on ECU with little mods, but I'll need that motor. But I think when everyone throws out 660cc engines of Pajero Mini, these parts should be pretty cheap, right??

So, I am now looking for ECU (computer) for Pajero Mini 660cc. I know many have thrown out 660cc engines, so I hope I can find one in low price and also complete throttle body, with TPS and ISC motor.

I've seen some posts in fan club that in Peshawar, Shoba Bazar, these could be really cheap. Anyone from Peshawar could help me?

Pajero Mini 1995, 660cc Engine
Parts I need:
- ECU
- Throttle body
- Thermostat valve

Does anyone here on PW have old engine laying around?

Pajero Mini 1995 M/T

[chall3ng3r]

Went to shershah and found the throttle body, coils and thermostat valve in good deal. ECU was too expensive at 7k and 5k at two shops, didn't buy it.

This throttle body have different ISC motor design, which is better than previous one. The motor is easily removable, as with old one, only coils of motor were removable.

Today I Installed throttle body, and it was a successful operation, on first try engine was on. ISC / IAC motor is good in new throttle body, checked resistance on all of its coils and it's 42ohm on all of them.

Currently tested with disconnected ISC / IAC motor because there's burnt IC in ECU, and connecting might burn motor again.

Next I installed coils, and on first attempt engine started, Alhamdulillah.

Now I only need ECU in right price. Or if anyone here on PW have damaged ECU from any model of Pajero Mini, I can use that IC from it and repair mine with ease.

I'm gonna wait for few days to see if someone on PW can help me with ECU.

Until then, I'm going to finalize fitting of throttle body and coils, as I just put them to test.

Pajero Mini 1995 M/T

[chall3ng3r]

Alhamdulillah today I have good news. My car Pajero Mini is finally completely running with all sensors and ECU in perfect condition.

Here's how I got it fixed.

The last thing I needed was a healthy ECU or a damaged one so I can take one IC (M5269L) from it. I didn't find good deal for replacement ECU, and couldn't find a damaged one.

The last option was to create a clone IC of original M5269L motor driver. This is exactly what we did [emoji5].

As I posted earlier, my elder brother is expert in embedded electronics. He checked how this driver IC works, and designed this master piece. Shown in above diagram.

This is perfect clone of M5269L, and it can handle upto 20Amps current, original one can handle max 2Amps. The photo also shows SMD parts we used to make it compact enough to just replace in same IC's place.

Here are photos as M5269L IC clone is made in different stages:

First IC complete, ready to test.

Testing phase 1

Testing phase 2, SUCCESS!!! - it was 3:30am in the morning.

Working, exactly as original IC, but now it can handle more current.

M5269L vs DIY replica of it.

Checking if it fits properly in limited space.

Both ICs now ready and tested.

Following photos are after soldering new DIY ICs on ECU board:

The ISC motor is controlled by 2 M5269L driver ICs. There are 6 ICs as you can see in photos, ICs labeled IC104 and IC105 are the ones which control ISC.

We replaced both so both coils of motor get same current rating.

Pajero Mini 1995 M/T

[chall3ng3r]

ECU now installed back in car after double checking ICs connections:

On first try, engine started perfectly and RPMs were 1400. As engine got warmed up, RPM dropped to around 1000.

Next, I started to calibrated TPS sensor to recommend values between 580mV to 690mV range.

One first try I set TPS to 640mV when engine was off, but after starting it went to 680mV.

Adjusted TPS to 600mV when engine was running.

This above photo was at 620mV during adjustment. The final value I settled at was 600mV while engine was on and warmed up to normal temperature (needle in almost middle).

These very fine values impact RPM.

RPM with AC off.

RPM with AC on.

Did a 22km test drive and it was so smooth driving experience. Turning AC on during drive also didn't feel impact on engine. There's no hesitation on acceleration and engine sound is much better, Alhamdulillah.

For now I am going to observe fuel average and use it as daily driver. I will post updates here of my findings.

I hope this technical info shared here will be helpful to someone fixing his car [emoji4].

Pajero Mini 1995 M/T

[DUDE007]

@chall3ng3r
Hats off to your brother. ECU repair is something that looks to me as impossible with all those tiny components arranged in the most compact design. I'll be sure to pay extra attention in my embedded systems course [emoji6]

Enviado desde mi GT-I9500 usando Tapatalk

[chall3ng3r]

@chall3ng3r
Hats off to your brother. ECU repair is something that looks to me as impossible with all those tiny components arranged in the most compact design. I'll be sure to pay extra attention in my embedded systems course [emoji6]

Enviado desde mi GT-I9500 usando Tapatalk

Thanks for appreciation [emoji4]

Yes, it was pretty difficult one, he's Masha Allah experienced with making similar designs professionally.

Pajero Mini 1995 M/T

[alimahr]

@chall3ng3r

Excellent work done bro,
hope your research will help other mini owners to resolve such type of issues
keep it up