So what goes wrong ?

[TinyTim]

Generally speaking the Pajero is very reliable but (as with any other car) problems can occur due to wear & tear or neglect.

Apparent bargains may be ten year plus, high mileage examples with little or no service history and trouble in store for a new owner.

Buyer beware then  - but of what exactly ?

Here are the most common problems, how to spot them, and how much to sort them.


Overheating The most common cause of serious problems - (strange in a vehicle designed for tropical and desert conditions) 

Low coolant level, blocked radiator, hose burst, or water pump failure can all send the engine temperature into the red.
If this is unchecked, the resulting heat build up is catastrophic and can lead to a blown head gasket and / or cracked cylinder head !
Likely cost will be £1200 ish

Fact - Most Pajeros have a blocked radiator !
Antifreeze with no corrosion inhibitor and tap water instead of de-mineralised (common practice in Japan) scales up the rad like a kettle.

On looking at a Pajero thoroughly check for any signs of leaks, overheating, water in oil, oil in coolant, or blocked radiator.

When you buy one, flush the entire coolant circuit. Replace radiator cap, expansion tank lid seal, thermostat, and water pump.
Above all - check the coolant level regularly !


Auto Gearbox The weakest link in the Mitsubishi auto gearbox is the overdrive clutch pack. When this wears out, the car will not stay in overdrive which should engage at 42 with lock up slightly after. If the car has been run with low ATF level for a long period, this is quite likely so worth checking carefully. Make sure your road test includes some 50 plus driving in over-drive to test this.

Check the ATF level and condition very carefully. Level when warm and after shifting though every gear. ATF should be bright red and not smell burnt.

If the car seems too eager to change down there may be other reasons such as badly adjusted kick-down cable but if this only happens in overdrive watch out.
Clutch pack is the worst scenaro as it will require a full gearbox overhaul costing about £800 plus VAT.


Glow Plugs (Diesels) Diesel engines rely on glow plugs igniting the diesel for the first few seconds of starting.
If these do not work correctly then starting is 'lumpy' especially in cold weather and will be accompanied by grey smoke for a short time after start.

The plugs themselves do wear out and aftermarket replacement kits costs about £65 with OEM plugs at around £150 to £200.

However, another reason for poor starting is the control relay that sometimes fails to deliver the correct voltage / time combination.
Replacing this relay will cost about £125 for a second hand unit.

A by-pass from battery to glow plug bus bar can be used to test if this is the case and can be installed with a push button in the cab as a low cost option.
(This must only be activated for a maximum 15 to 30 seconds).


Diesel Pump Seals This is quite a common problem with the 2.8 engine at around 80,000 km when the diesel pump seals simply wear out.
Poor quality diesel when the car was new has often been blamed for this.

The car is difficult to start and frequently cuts out within 10 minutes of starting, especially in colder weather.

The pump needs re-conditioning by a diesel specialist - costing between £150 and £600


Diesel Injectors These are subject to very high velocity flow and wear out as a matter of course resulting in poor performance, low mpg and failed emmissions tests.
Again poor quality diesel when the car was new has been blamed for premature failure.
For peak performance they should be replaced at 50,000 km intervals.

Injectors cost around £45 each (there are 4) exchange from a Mitsubishi dealer.


Turbocharger Lack of power or screeching under load could indicate a worn or damaged turbocharger, usually as result of neglected oil changes.

Peak boost is at around 3,500 rpm and the large intercooler hoses should be too rigid to squeeze at these revs if the turbo is working correctly.
With the engine stopped and turbo inlet hose removed it is also possible to check for play in the turbo rotor.

A replacement turbo cartridge will cost at least £450 plus fitting.


Timing Belts All Pajero petrol engines and the 2.5 diesel rely on rubber belts to drive the camshaft/s.

These MUST BE REPLACED every 87,000 km or 54,000 miles
(72,000 km or 45,000 miles for Pajero Evolution)

For 2.5 TD the balance shaft belt must also be replaced at the same time.
We further suggest replacing the belt tensioners and checking crankshaft pulley, bolt & woodruff key at the same time.

Cost varies with model and garage labour rate - say from around £200 for a 2.5 TD to £500 for a V6.

If service history cannot be proven do not assume this has been done but get them changed ASAP
Failure to do this can result in a catastrophic engine failure costing thousands !


Crankshaft Pulley

It has been known for the bolt securing this to loosen causing the pulley to wear then break with worst case major damage to the crankshaft.
This is rare but seems associated with the 2.5 TD engine following pulley removal or replacement.

Symptoms are a loud rumbling noise at tick-over, engine vibration, and eventually loss of ancillaries such as PAS, air con, and alternator as their belts are no longer driven.

Cost depends on exactly how bad the damage is ranging from about £500 to £1,500.