Pajero MAnual Button mod PLEASE HELP

tdpajero · Post by **tdpajero** » Sun Jan 20, 2013 1:01 pm

ok guys so here is my problem. I did the manual starting button on my pajero. It is a 1990 Mitsubishi pajero J-spec imported from japan with 146 000 kms auto tranny. Its got the 2.5L 4D56 Turbo Diesel Intercooled engine with the Fast startiing glow plugs sytem, with 6.2 Glow plugs, two batteries, two relays one pre-heating relay one post-heater relay for the glow plugs. Problem arose couple weeks ago when the cold canadian winters came this thing i would be sitting outside cranking it over trying to start it for quite a while. Ok i took out glow plugs, cleaned buss bar, cleaned glow plugs, tested every single glow plug and they light up within 5 seconds and their all bright red, and work perfectly fine, i put it back together still didnt do much to it. I read on anotehr forum and this forum about the manual button mod, and i bought every thing and decided to follow clear intructions from another forum and did it . However for once, when i put the key on 3rd position i still hear a weak click from a relay, when i turn the button on, i hear the relay click, however it clicks off by its self, and the time between these clicks is not long enough at all in order to properly heat the glow plugs, it hold about 3 seconds between cllicks. So its very confusing why other people have full control over these relay's and i have control over clicking the relay on with my button yet it still continues to click off by its-self. If someone on this forum from CALGARY, IS willing to HELP ME out in person, i will drive this thing to your garage to HELP ME wire this manual button and make it work along with me, becaus ethis is very confusing no one has answers to my quesitons on the other forums so i really need help in person, pm me or i can pm u to set up when someone can help me do this manual button. On to the pics of what i didd now

here is the actuall switch with on/off button, its got the yellow wire running to a 15AMP fuse and that fuse is going to the positive terminal of the battery. The White wire which both wires are 15AMP wires, is running to the pre-heating relay.

yet this thing still controls its relay clicks by its self only control i got over them with my little switch is to turno n the pre-heating relay and after that the pre-heating relay clicks off after 3 secs which is clearly not long enough to warm up the glow plugs properly. PLease someone help me out wetther it is over the forum or in person, but i prefer in person since i wasted money on this thing already and its been a big frustration for me. I bought brand new glow plugs, and those didnt have right resistance so i sent them back (money wasted), i bought resistance measure to measure the resistance of the old glow plugs and all of the old glow plugs checked out fine. Then i wasted time and a bit of money on this whole manual button thing, just to be where i was back at square 1. Plus all of the wasted weekend days trying to figure this thing out. SOmeone help. I have Pictures of what i did it wont let me post them since they are too big i will figure it out later

Post by **nxski** » Sun Jan 20, 2013 5:15 pm

Sorry to hear about your problems, get those pictures posted and it shouldn't be difficult to let you know how to proceed. Have you tried attaching a jumper cable from the battery to the busbar? Just hold it there for a few seconds and them start. When I was trying to figure out my manual system this was how I started it in order to get to work.

tdpajero · Post by **tdpajero** » Sun Jan 20, 2013 6:58 pm

i tried to post the pictures, it keeps giving me error that they cannot be past 960pixels wide, or whatever and i rezied them to something smaller than that but it still gives me that error and wont let me post them

Post by **Big-Bird** » Sun Jan 20, 2013 11:07 pm

I am somewhat familiar with what you are doing but with a 12v system on the 2.8L. A well versed tech who knows Delicas and Pajeros very well sent me the details involved in the bypass you are clearly attempting to get in place, but again for the 2.8L.

All that is really involved is getting switched power from the battery directly to the relay(s?) that operate the glow plugs, again this is for the 2.8L. However a weak relay will disconnect early even if you have battery power routed directly via that dash mounted switch. If you are hearing an early shutoff click ...3 seconds you say.....then you may have a failing relay.

Post#7 in the PLCUK forum advises coil checking for this Pajero owner which does have the 6.2V plug system.

http://www.plcuk.co.uk/showthread.php?1 ... ple-of-Q-s

Here's the link for the wiring of the 4D56 engine on the L300...I can't say if the wiring config on pg 39 is the same as your 90 Pajero but it gives you a good idea.

http://www.delica.ca/forum/l-300-electr ... -7333.html

Has anyone got info on the relay test procedure on this fellows 90 Pajero?

Kuan · Post by **Kuan** » Sun Jan 20, 2013 11:24 pm

Are you sure you did the correct relay?

I have an 1989 Pajero and I found that I had to replace the fuel lines front to back as they were heavily rusted in some places. Then I found that at the tank the pickups were rusty and had some pin hole leaks. This only caused starting problems in the cold. With all that said make sure you are not having any air in the fuel system as this can cause cold start issues as well.

Good luck

tdpajero · Post by **tdpajero** » Mon Jan 21, 2013 3:31 pm

here are the pictures that i posted on the other thread with still no response. Scroll to the bottom and those are the pics of how i wired it up.

http://www.pocuk.com/forums/viewtopic.p ... 2&start=15

First is the switch with yellow wire going to fuse and from the fuse going to positive battery terminal.

Second is the White wire going straight to the glow plug relay where i have un-plugged the ecu from the relay, but yet it still clicks when it wants to like i said i only got control of when i engage it, and it dis-engages by its self some how.

Also i noticed that from other pictures it appears that the rubber boots on the relays are switched up???

Post by **Big-Bird** » Tue Jan 22, 2013 8:04 am

I did suggest that you may have a bad relay which would explain why it seems to have a mind of its own and clicks off at random.

The fact you bypassed the glow plug control unit would lead me to check the relays as they should not be able to shutoff until the bypass power switch/button you installed is released.

tdpajero · Post by **tdpajero** » Thu Jan 24, 2013 5:54 pm

Big-Bird wrote:I did suggest that you may have a bad relay which would explain why it seems to have a mind of its own and clicks off at random.

The fact you bypassed the glow plug control unit would lead me to check the relays as they should not be able to shutoff until the bypass power switch/button you installed is released.

yes which is why it is soo confusing?!?! i did the intructions step by step as the thread said, and it was a thread that i read all 12 pages of posts and it worked for everyone but my self. Its like this pajero is possesed by the relay demon

Post by **Big-Bird** » Fri Jan 25, 2013 5:38 am

What part of calgary are you located? Lets discuss this face to face. I also have a very resourceful friend who has owned Montero's and Pajero's for 15 years. I'll pick his brain and see what info he can provide.

PM me a contact number and we'll get something arranged.

tdpajero · Post by **tdpajero** » Fri Jan 25, 2013 3:19 pm

pm sent

403delica · Post by **403delica** » Fri Jan 25, 2013 3:48 pm

Big bird saves the day... I heard he can look at cars and fix them with his eyes :)

Post by **Big-Bird** » Fri Jan 25, 2013 6:51 pm

403delica wrote:Big bird saves the day... I heard he can look at cars and fix them with his eyes :)

Really wow, I didn't know that.....although there are some who think the internet is where this all takes shape.

.:FoRuM56:. · Post by **.:FoRuM56:.** » Sun Jan 27, 2013 4:18 am

I would throw a volt meter on at the buzz bar end of the wiring. Disconnect it so your plugs aren't receiving any power and hit the switch. Monitor how long the wire is getting power for. You should be able to leave that switch on all day and have constant power.

I've got a 2.5 with the same 6.2V plugs...I'm running an On-Momentary switch. When I turn the key to the on position I still hear a click from the relay, but only once. With my switch, once I press it, I hear a click and then again a click when I release.

James

403delica · Post by **403delica** » Sun Jan 27, 2013 10:48 am

Lol big bird! Your a great tech! You can help me lift a car... Ill help you lower it... Soon you will be cruising in a S15

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