Mitsy Pajero Starting Woes

Swaney · Post by **Swaney** » Wed Jul 25, 2007 8:43 pm

Heya

I am having some issues with starting my Pajero. It is a Gen1 1986 with the 4D56T and runs a 6.2v glowplug with a dual relay setup.

I recently changed the glow plugs and it was working a real treat (firing first pop), but after doing a "submarine mission" through the waimak in the weekend everything has turned to custard.

I got the light tester out found there was no power running to the buzzbar (I figured i should be seeing either 6v or 12v). Traced power going in to the relays but could not hear them clicking and could not find power going from relay.

Did some googling and have found that the glow relays can be an issue - so headed down to the local misty parts and found that 1 of the relays was $180+ - almost fainted and decided to go check the wreckers instead.

Falsgrave ended up having a pajero with the dual setup and he sold both for $70. Got home bolted all in and flicked the iginition and still no "click" from the relays. Still the same problem as earlier.

I guess it is possible for the relays from the wreckers to be bad but unlikely.

Any ideas?

PR · Post by PR » Wed Jul 25, 2007 9:08 pm

I had the same problem with my old pajero so I by passed the relay??

Run a wire from the battery to a switch on the dash, then to one of the glow plugs.

When you go to start it in the morning hold the switch on for 10 seconds (no more) then turn the key worked every time

Or you could go and buy some "START YOU BARSTED" that worked until I wired it up.

Swaney · Post by **Swaney** » Wed Jul 25, 2007 9:43 pm

yeah was gonna do that but have 6.2v glow plugs (a week old).. not too sure if the relay dumbs down the voltage to 6.2v or if the plugs take 12v in at the buzzbar

If the plugs take 6.2v in i guess i could put a resistor in power line?

edit:
thinking about it surely they take 6v in at the buzzbar (hence the voltage on the plug)

i could replace the plugs with 12v but then i just wasted just over a $100 on 1 week old 6v plugs

how do i step the voltage down to 6v cheaply? i guessing there is a fair few amps going through the glow plugs

Swaney · Post by **Swaney** » Thu Jul 26, 2007 1:19 pm

ok... getting somewhere now i think ? haha

there is definitely 12v going to the relay plug harness (tested with multimeter)- and when i test from the relay terminals (the plugs at the top) there is power going to that also - however it isn't switching the relay on and powering the buzz bar with the normal 5-8v.

If i take a wire directly from the battery and manually power the relay tab you hear it click and then it powers the buzz bar with 6v until the engine fires and then 8v once she is running - as soon as i take power away from switch the buzzbar loses power

i did a click test on the relay (earthed it and powered the tab) and it seems to be ok (clicked like mad)

im pretty damn sure ive wired the relays up the correct way to enable switching (wires are colour coded after all - plus i checked in the haynes)

Now i am not understanding why it is not working unless u add direct power to the tab.

is the relay poked? i brought it second hand for $70 (including start relay) - i could of got a new generic glow relay for around $30ish but only found that out today. :roll:

Steve_t647 · Post by **Steve_t647** » Thu Jul 26, 2007 2:15 pm

Sounds like the module in the dash that times the relay (only puts volts in for a short time) is buggered, I think you may have to rig up a manual push button or risk it happening again if you can find the little control box.

There soulds like there is nothing wrong with the relay, just something wrong or not sensing the ignition and starting the relay.

Good luck but I think I would put in the push button.

Swaney · Post by **Swaney** » Thu Jul 26, 2007 3:17 pm

Steve_t647 wrote:Sounds like the module in the dash that times the relay (only puts volts in for a short time) is buggered, I think you may have to rig up a manual push button or risk it happening again if you can find the little control box.

There soulds like there is nothing wrong with the relay, just something wrong or not sensing the ignition and starting the relay.

Good luck but I think I would put in the push button.

yup thats what i am now thinking.

easy bet it going to be a push button that wires directly to the relay.

I guess it would make sense to get some decent gauge wire as it will be carrying some good amps?

also what size inline fuse should i run? 80A? or is that too high? The fusable link for the glow system is 80A stock.

Swaney · Post by **Swaney** » Thu Jul 26, 2007 7:57 pm

OK tested powering my glow relay with direct power / switch and it was working like it should with 6v going to the buzzbar from the relay.

Decided it was time to mount it all in as the test work.

Started looking for spot to mount the push switch and came across the glow plug timer (Pan Pacific 20-147 12/24v - PBC says Staar products - which had replaced the stock one sometime ago)

Thought I didn't need the timer anymore so tested for the ignition 12V power to the timer and unsolder that lead to take my power for the switch - took all the other wires off and wrapped them up for protection and put timer on the bench. :oops:

Finished up putting switch / fuse in and ran it to the relay.

Came to test it and now have no power going to either relay (starter or glow) although the glow relay is definitely switching (with audible clicks now just no sodding power running through it

)

So now i figure i am gonna go get the wiring diagram for the timer to see what each lead does (if possible) otherwise trace back the power for the relays and wire them to the ignition.

sounds like a fun way to spend saturday morning

Swaney · Post by **Swaney** » Tue Jul 31, 2007 2:16 pm

Couldnt be assed with stuffing about so ran direct power to relay from battery (as the relays are powered 100% of the time anyway). And put a push switch in the dash that switches the relay.

Now works a treat - hasn't not fired in the morning as yet!

But now my clutch is poked - ahh the joys of off roading eh

- went to give the worsley track a crack on Sunday and noticed it was beginning to slip as i was heading out... thought "yea she will be right mate - its only just started" and gave the track a nudge anyway... then about 1/2way up i pussed out as the clutch was getting way way worse and slipping quite badly.

I guess i poked it when I was snatch towing my mate outta the waimak the w/end before. (still found it hard to believe his hilux went after sucking in insane amounts of water and stopping dead in the water- go the toy-motors!)

After doing a clutch in my MR2 i wasn't too keen to do another one (gear boxes are damn heavy - even little pissy 1600cc boxes) so the pajero is now in at the shop getting a replacement clutch.

Gonna go give the Worsely another shot this w/end but will take a mate as it has some pretty decent ruts to get stuck in!