Offroad-Express

hey all have just brought myself a swb pajero.

33x10.5r15 tyres
full rollcage
2.5 turbo deisel


it has got a blown head gasket does any 1 have any tips on replacing?? is it a real mission

h8ruba wrote:hey all have just brought myself a swb pajero.

33x10.5r15 tyres
full rollcage
2.5 turbo deisel


it has got a blown head gasket does any 1 have any tips on replacing?? is it a real mission

no harder than most other 4 cyl diesels , the biggest pain is making sure you set the cam/diesel pump timing up in the right place again, somewhere floating around here is a link to the 2.5 manual in pdf (or google it).. well worth grabbing if your going to tear down the motor, oh and take heaps of photos helps trying to figure out what the f**k that doo hicky was and where it went

the Allen key bolts holding the head down are a pain, use a high quality key .. the supercheap crap just dont cut it trying to crack those babys

also if I was you i would get the head crack tested while it's off, the 2.5 are notorious for cracking heads once they have been overheated and *most* times are a one hit wonder, ie almost sure to be cracked if she has gone into the red at any stage, would hate for you to have done the head gasket only to discover that the heads cracked as well oh and it's a given that while your that far in replace the cambelt, and check the waterpump and alternator while ya in there as well as are both are almost impossible to get at otherwise

Yep, what he said! ^ !!!

But I found the cam marks easy to find, they are cast into the head. Hardest thing for me was the jolly tensioner.
Make sure the balancing shaft is done as well as when it brakes its bad.

if you want the motor w/shop manual i can email you the copy I made.
just PM me your email.

Anyone else want it PM me also

mudbugga wrote:if you want the motor w/shop manual i can email you the copy I made.
just PM me your email.

Anyone else want it PM me also

PM Sent

On it's way to you Bolo!

mudbugga wrote:On it's way to you Bolo!

Legend

meece4x4 wrote:

h8ruba wrote:hey all have just brought myself a swb pajero.

33x10.5r15 tyres
full rollcage
2.5 turbo deisel


it has got a blown head gasket does any 1 have any tips on replacing?? is it a real mission

no harder than most other 4 cyl diesels , the biggest pain is making sure you set the cam/diesel pump timing up in the right place again, somewhere floating around here is a link to the 2.5 manual in pdf (or google it).. well worth grabbing if your going to tear down the motor, oh and take heaps of photos helps trying to figure out what the f**k that doo hicky was and where it went

the Allen key bolts holding the head down are a pain, use a high quality key .. the supercheap crap just dont cut it trying to crack those babys

also if I was you i would get the head crack tested while it's off, the 2.5 are notorious for cracking heads once they have been overheated and *most* times are a one hit wonder, ie almost sure to be cracked if she has gone into the red at any stage, would hate for you to have done the head gasket only to discover that the heads cracked as well oh and it's a given that while your that far in replace the cambelt, and check the waterpump and alternator while ya in there as well as are both are almost impossible to get at otherwise

thanks for the reply the water pump has been changed as previous owner thought that was the problem but it turns out it wasnt cambelt was also done at the same time. whats it worth to get the head crack tested?

thanks for the reply the water pump has been changed as previous owner thought that was the problem but it turns out it wasnt cambelt was also done at the same time. whats it worth to get the head crack tested?

I would ring around the automotive re-conditioners in your area to get a price, been a long time since i had a head crack tested *touching wood* I do believe it's money well worth spending though due to the 2.5's notorious reputation for hand-grenading heads. a "new" bare head is around $1000-1200 from memory and a good second hand one is like the pervebial rocking horse sh*t to find these days, that's why most Paj's get parted out when the head goes, just not economic to fix them. tardeme is full of Gen 1 and early Gen 2 Paj's with no motors.

shame really as my old Gen 1 is quite a capable 4wd, with the factory LSD and the Warn 9000lb winch she will get me into all sorts of trouble, but it's always at the back of my mind that these motors are quite delicate and dont like big revs, thrashing or neglect, and theres times when a decent amount of right-foot-curry is needed

next 4wd i get will prob be a v6 petrol powered one, the V6's have there own issues but long term i reckon it will be easier to transplant a commie V6 into the petrol version than the diesel ..thats my 5 year plan anyway lol

keep us informed on how things go

yea thought that might be the case lol will strip it down next weekend and see if i can get it fixed asap.

what other cars do these engine come out of mite start to look for a spare

h8ruba wrote:yea thought that might be the case lol will strip it down next weekend and see if i can get it fixed asap.

what other cars do these engine come out of mite start to look for a spare

From Memory (and thats dangerous in it's own right ) the 2.5TD Mitsi motors where also used in the L300 vans and the L200 utes (both 2wd and 4wd) however things like oil pickups, intakes, turbo's and sumps etc may need swapping for the Pajero ones. I used to have a 2006 Mitsi L300 non turbo Van as a work wagon, ... after some measuring up and a fair amount of poking around im pretty sure it would have bolted up to my box. Oh and i *think* the Hyundai H100 2.5 Diesel is the same basic block/head as well (as in they suffer from the same cracked or porous head issues as the mitsi's) .

theres a guy on trademe trading as johnjay, his name is john and he is in manawatu. he has heaps of pajero parts for most models, i have been getting parts of him for two years now parts are good and well priced, if you need anything

these area good motor aslong as they dont get hot, like most 80s jap diesels they get a bad name for cooking but it all comes down to past maintanance,once it is back together get the radiator flushed, the balance shaft is over rated and can be disconnected for more power,crank up the boost and fuel slap on a intercooler and they go suprisingly well, any one that has been at ngaroma when andy from kc4wd in his red gen 1 paj has been there would see .his will pull over 5k all day and has done for thousands of on and off road ks, if you want i can pm his number to you,
vaughan

spanky wrote:: .his will pull over 5k all day and has done for thousands of on and off road ks,

5 G's !!! sh*t mine sounds like its trying to come apart at 4000rpm ... let alone the 4500 redline

but yeah I agree with you maintanance is vital with these motors, well with any diesel but a nissan may go for ever without touching it a mitsi will be less forgiving. seems the badly maintained ones usually let go between 220-235k for some reason

Can we please just clarify what everyone is talking about here? The newer 4d56t engine or the older completely different turbo diesel 2.3-2.5 ish litre that came in the square boxy pajero's? I was under the impression that it was only the earlyier model engines that gave problems and that the 4d56t engines were good engines? Please clarify. Also is the 2.8 version of the 4d56t any better or worse? Thanks

The 2.3 is the 4D55, The 2.5 is the 4D56, The 2.8 is 4M40 and the 3.2 is the 4M41. The latter two being totally different engines.

gomulletgo wrote:Can we please just clarify what everyone is talking about here? The newer 4d56t engine or the older completely different turbo diesel 2.3-2.5 ish litre that came in the square boxy pajero's? I was under the impression that it was only the earlyier model engines that gave problems and that the 4d56t engines were good engines? Please clarify. Also is the 2.8 version of the 4d56t any better or worse? Thanks

the 2.5 TD (4d56t) have a looonnngggg list of known problems and (cracked heads, overheating, glow plug issues, smokey, injectors, pumps, balance shaft issues, rattly GUTLESS just to name a few) and are prob one of the worst motors that Mitsi have put into a 4wd, the 2.8 however is a FAR FAR better motor, still not without issues (head issues again) but way better than the 2.5.

the Old Boxy Pajero is a heavy beast, with the 2.3 or 2.5 motor they are slugs, the 2.8 was never fitted to the Gen 1 Pajeros, that came in in the Gen 2

As far as I know the only GEN 1 motors are

Petrol
2.6 Astron
2.0 Turbo Petrol (rare)
3.0 V6 Petrol

What they *should have got*
3.8 V6 Petrol ..sigh maybe one day

Diesel
2.3TD (4D55)
2.5TD (4D56)
2.5 TD Intercooled