Pajero.org.uk

this information is priceless, ive just bought a pajero and like yourself dont know when the fuel filter was last changed, so rather than pay a garage to do this simple task, im going to do it myself, so thankyou very much for sharing this information with us other owners.

Hi Tam - thanks for your comment and kind words. Makes it all worth while. Good luck with your new Pajero.
Tim

Thanks for that, I too have just bought a Pajero and unfortunatly it wouldn’t pull the skin of the preverbial rice pudding, I have put this down to fuel starvation, therefore the filter is the first thing to go, hopefully that will do the trick, also I have a poor cold start problem, I’ll try new glow plugs and modify the buss bar ie make a new one, if that doesn’t do the trick I’ll wire in a pre heat button, save any mucking around, all this will have to wait until I get back from offshore off course, can’t wait to get back to it.

Hi John - thanks for the comment.
It’ll be interesting to know if a new filter does the trick. Must be pretty dirty if it does. Perhaps check the fuel lines as well for muck?
I’d also be interested to hear how you get on with the glow plugs/cold start situation. As the cold weather approaches mine’s getting a little harder to start in the morning so I might need to look into this.
Tim

Just an update on the fuel filter change, You should have seen the sludge that was in the filter, dirty brown sludge, it’s a wonder it was going at all, little wonder it was guttless, it’s gone from a maximum speed of 60mph with your foot to the boards to 85mph with ease, I realise the’re not built for speed but one must be able to overtake safely, so again thanks for your tips on removing the filter.
As for the poor starting, while I had the intercooler out of the way I took advantage of the free work space and removed the buss bar and glow plugs, the bar was perfect, not so for the plugs though, they were totaly burned out, not a very well maintaned vehicle at all.
A few niggley things to sort out now, My insurance company will not cover me for theft until I fit an immoboliser, any suggestions on a fairly easy one to fit anyone?
also the lights on the consul for the driving wheels indicator are not all illuminating, does anyone know if this is a sensor fault or simply bulbs?

Hi John, thanks for the interesting update.
Bet you’re glad that you changed the filter then! Just shows what a little servicing can do. Must say mine was pretty clean when I removed it, but the rest of the car’s in great condition too. Obviously new glow plugs were badly needed too.
Yeah, my truck had an immobiliser on when I bought it, so I was lucky. I’ve heard there are good alarm/immobilisers to be had on ebay for about £80 - self fit.
The lights for the wheels are a very common problem. Should be just replacement bulbs needed. One of mine doesn’t work so I’ll be sorting it soon and will write a post about it. I hear it’s an easy job.
Tim

Thanks this made the whole thing effotless

Hi Jay - glad it helped.

Thanks for the information you provided. It has been very helpful and provided me with the confidence to undertake a task I would not normaly risk, especially in a field in the middle of Spain !!!!!!!!!

Great stuff Andy, hope it works out OK for you. Hope the weather’s better there than it is here right now.

Thanks for this - it’s just the sort of site I need. I need to do an oil and fuel filter change tomorrow, so I’ll be following your lead.

Thanks for that Pete - hope it goes well for you (piece of cake!). I’m going to have to do a write up of an oil change next time I do one as well.

Good photos and writing. A tip worth noting, before bleeding the fuel filter, fill it with clean diesel, less pumping after refit so remove air. A worthwhile investment is a filer wrench, I like the nylon strap kind as I use it for tightening and untightening other things that I don´t want to leave marks on. I was also told by a mechanic friend of mine that when he changes fuel filters and they were very dirty, he actually fills the fuel filter with an injector cleaner (Wynns or Wurth I think) to clean the injectors and lines, the engine smokes for a short while, but a run at operating temp soon clears this and reduces emissions for the all important MOT test. As for how tight, hand tight + about half a turn but not too tight. All in all a great site.

Hi Adam - thanks for posting.
Excellent tips, especially filling up the filter before refitting - I’ll be doing that next time. Also interesting to hear about your mechanic mate’s tip for injector cleaner. Luckily for me every filter I remove on this Paj seems to be well clean, but I’ll bear it in mind in the future.
Glad you like the site - lots more work to do on it yet.
Tim

I found on my pajero, 2.8 D . If you remove the battery it saves a lot of time removing the intercooler. Please can someone tell me if there is a second filter around the fuel tank i am having problems with mine pajero. Thank you. pete london

Hi Pete. Yes there is another filter on the pick up pipe in the tank. Not sure how you get to it though as I’ve never done it.

Thanks…great help for me…my pajero is just like yours and the pictures are wonderful…really appreciate your efforts to share with the rest of us - like you say - took me ages to find the thing - and its evident no-one has changed it

Hi Ingrid.
Many thanks for your kind comments. They kind of make this site worthwhile to me!
Tim

We have had a 1996 2.8 in the family for ten years.
Since the death of my brother it now resides with me in France.
Very encouraging to find the enthusiasm shown by all the correspondants. I certainlly appreciate the helpfull hints and expertise sharing.
I suspect like most newcomers we only hook up when we have a problem to share.
My propblem not reading ###enese very well concerns a warning light between the handbrake and seat belt indications. This light has an ABS and circles imprime and was first noted when the autospeed control wouldn’t engage. It now comes on after driving for a few miles/kilometres and stays on until a delay and the next restart.
Can anyone help as assistance from Mitsubishi is difficult in France.
Thank you to all once again for such an an interesting site and hope that I can contribute in future rather than just pose a problem.
Stingray

Thanks for all the photos and information, changed the filter without any problems.The filter on my 2.8 had a pump on top which needed to be pressed quite a few times to fill it full of diesel and then started first time.
I found it easier to remove both the intercooler and battery for maximum access as this was the first time i have changed a fuel filter, come to think about it this is the first diesel i have owned. Many thanks

Hi Andy. Glad this helped.

I like what you have done mate looks good…

Keep it up shows a lot of people how to do it with out pay someone a lot of money to do it for you, and it around a £5.00 for a filter it is a cheap way as well.

When we do our we just take the battery out next to it and use a oil filter removal tool save taking it all out…

keep it up
thanks
john

If people want to change the filter in the tank it is not hard at all.

Fold the back seat up and lift the carpet up and you will see a plate with some 12 mm bolts. Undo them and lift the plate.

You will see the 10mm bolt in the top of the tank undo them then remove the two pipes but make sure you do not put them back on the wrong way.
now the hard bit lift the plate up but don’t break the rubber seal. As you will need a new one if you do. as you lift the plate off you will see the little filter on the end of the pipe, replace it or just clean it with washing up or any other cleaner (wash out all cleaners and let it dry right through) then put back on. then put it all back together.

30 min max.
thanks
john

Cheers John, I’m sure that will help a few people out there. I might just try that tank filter change myself now!

Fantastic post, as a complete newbie to pajero managed to change filter with no real problems, had no vice so took bit time. Appreciate post.

Glad it helped you James and thanks for the feedback

Good Man !!

I put my old girl in for servicing recently and i am sure the fuel filter aint been changed, now I can do it myself !!

Cheers kiddo.

Graham

Go for it Graham, could make a big difference to the running of your car if it’s not been done for a while.

Excellent advice. I changed the filter prior to seeing this advice and I didn’t bleed the filter. it runs alright. Should I replace the filter as I am told it could be damaged. Could the pump be damaged now. Regards
Richard

Hi Richard.
Not sure how the filter could be damaged from not bleeding it, but I’m no expert! Don’t know about the pump being damaged either, so I’m not much help really am I? I’d ask on one of the Pajero forums for some more educated advice. I’d be interested to know if you find out.

Done mine yesterday, exellent write up Tim, by taking it off it gives you a chance to clean and check the whole thing, Nice one mate, Never done a deisel before, was a bit worried about bleeding the system, But not anymore! regards Derek

Glad it helped Derek. Doing mine again next week, weather permitting.

hi i have the 2.5 exceed that has run out can that little pump on the fuel filter bring the fuel back or can turning the engine bring the fuel back to filter or do you think takeing the it off and re filling it will do can you let me no thank aaron

cheers tim just done fuel filter on my very loved pajero 2.8td great advice ..now runs like new again,,,thanks…robbie

after doin filter change..my loved pajero runs great again..loads of power…respect tim..fantastic easy to follow instructions..will do mine regular now.cheers again,,tim..

Hi what a Gent you are Fuel /Oil /Air Filtres Oil Change Rad Flushed ALL DONE in a DAY!! Many Thanks for YOUR HELP! Sit down and have a nice cuppa Cheers Tim

Well done Gary!

excuse my ignorance, but how exactly do you ‘work’ the pump?

Hi Zoe
Simply push it in and out.

oh great, thanks. i wasn’t sure if i needed to start up the car or what. i’m pretty new to all this. great post.
cheers

could you tell me if the pump that forces the air out should have a small o ring in it please????

Can’t remember Sean as it’s been a while since I’ve done it. Try asking here: http://www.pocuk.com/forums/

ok cheers mate

problem de recodement d’inter cooler entré et sorti merci.

Je ne parle pas Français - je Suis Désolé.

Well Done Tim, Great piece of work ! I have a question if anyone can help ?

My fuel filter was clogged and causing low power when under load. Changed the fuel filter (engine side) and air filter and also put in the injector cleaner. Now it runs like a dream apart from starting ! Before I did the work there wasn’t a problem starting now it’s very lumpy and kicks out a lot of black smoke. The exhaust pipe is really sooty too when 1st started. The glow worms were changed about 10 months ago

Thanks in advance for any help

Adam

Hi Adam

I suppose based on you having a clogged fuel system and the fact you’ve just changed the filter, there might still be a problem with the fuel system. Maybe changing the filter shifted the problem if you know what I mean.

I’d have a check over the fuel filter first and make sure it’s not got any air in and then check the rest of the fuel system. You know there’s also a filter in the fuel tank?

Just a process of elimination I guess. Good luck with it.

Thanks Tim

Yes I located the filter in the back of the Truck under the seats but can’t get the screws out. Think this is a good indication it’s never been touched ! I’ll give it a proper go at the weekend. Tested my glow plugs and had one that had shorted out so replaced. It’s a little better but not great. I have a hunch that the o’ring on the filter could be dodgy or could have been fitted incorrectly. Getting it checked out again tomorrow

I’ll keep you posted.

AB

Hi Adam
Interesting about the glow plug as it had new ones not long ago. Hmmmm…..
Good luck with the tank filter, probably worth doing anyway. Did you get a new O ring with your new filter? I know the Mitsubishi ones come with a new one. Sounds feasible that it’s not on right, easy to over or under tighten.
Let us know how you get on.

i have had my pajero for a year now, and i’ve had it serviced 3 times this year. my car runs really well for about a month but after that when i start it up it stalls a couple of times and feels like it loses power until it warms up. i’ve narrowed it down to a fuel problem, maybe the fuel filter. is this a common problem? and do you know what i can do about it? instead of changing the fuel filter once a month.

lee

Hi Lee
If you’re sure it’s a fuel problem and you’ve had the main fuel filter changed, have you also done the filter that’s near the fuel tank? Have a look in the comments above where someone describes how to do this.
Good luck.

Tim
How do I replace the pump seals or rubber seals in the fuel lift pump and where would I get them from please ?
(I can remove the pump and mechanism and it has 3 or 4 rubber seals inside, one is push and one is a pull, they resemble the rubbers in a break wheel cylinder on drum brakes.) Would appreciate any info you can give me. Thanx

I have just bought a Mitsubishi pajero 2.5TD 1993 model. I have driven it for a short period and it started switching off itself especially when I stop at traffic lights and put it in neutral. I also oberved that it was losing power when I change into gear four and the mechanic told me to buy the fuel housing unit which has a primer pump. when I look at this unit it has not got any provision for any electrical connection. The fuel filter together with the pump that are said to be defective are exactly same as the pictures you have shown.My question is what happens to the electrical connections that you mentioned that they should have contact with fuel because the housing unit with a primer pump has no eletric areas to connect electric cables?

probably sounds like a silly question but why did you take the whole filter and priming pump assembly off when you dont need to because doing so creates air locks in fuel lines that can be averted by just unscrewing the filter from the priming pump whilst it still in the vehicle because i havent had any problems doing this and ive changed the filter about 4 times on my 2.5td pajero i know you said your new to being on the spanners but the best tip that i always go by is dont over complicate simple tasks

Totally agree with you Allan and I’ve been told that before! Trouble is, when I tried to remove the filter only I couldn’t get enough force on it to unscrew it in the position it’s in. I’ve tried to do it that way every time I’ve done a new filter, but can never manage it, so I just end up taking the whole thing off.

The filter & water sensor can easily be removed & the intercooler & filter housing left in situ, having removed the fuel lines & bottom elec connector if it has one, get yourself an oil filter strap wrench (looks like a nylon belt with a 3/8 drive ‘buckle’ on it) put it round the filter & use a ratchet with a 12″ extension on it & it will simply unscrew, simply swap water sensor to new filter & reverse proceedure to fit it back on, you should manage the bleed pump ok.

I have a problem with my 2.8 the fuel stop solinoid on the pump lost a chip of rubber from the corner of the seal and the car continued to run when turned off at the key to stop it i would have to loosen 3 injector pipes then it lost power dramaticaly i found the stop solinoid and replaced it but still major power loss i found a filter of sorts in the solinoid valve above the stop one, and removed rubber traces from there but still no power is there another filter in the injector pump, and where is it, cheers craig.

Thanks for sharing that Craig - might help someone.

Hi tim you seem to know lots about these pajeros, i have not been able to find out on the net, about this injection pump, would you know where there is a likly area within the pump where the rubber bits could be caught up causing a fuel restriction, or if there is any internal diagrams of the injector pump layout on the net, many thanks craig.

Hi Tim

Thanks for this very helpful manual. I haven’t ever done any repairs to cars o trucks but with this instructions and the credit crunch pushing I think it’s time to give it a go so this will be the first thing I’ve ever done. I’ll try to do it by next week and let you know how did it go.

tim your a star . i have my pajero 2 years and only changed the fuel filter once with your help . jeep kept cutting out , found black sludge in the filter , so i would say two years for a change i drive about 40k miles a year . you made everything so simple .

cheers

andy

I have been having some problems with my 2.8 paj recently it had about as much acceleration as a JCB digger. As a last resort to solve the problem I decided to change the fuel filter. No issues with the job but i noticed that the haynes manual had a different filter housing description to mine (mine was the same as your diagram). Until i found your site i was not aware as to what the white disc was on the side and therefore could not bleed the system correctly.
After reading your information I returned to my workshop bled it and my God what a difference. I would say you have saved me at least £15000 as I had decided to get rid of the paj for an X5.
Thanks a lot, your sight will be my first port of call now as the information was invaluable.

Gareth

Had my pajero about 18 months now no probs. Due to bad weather tried 4 wheel drive last week had light on dash saying wheel lock next to 4 wheel drive light. Car felt like wheels going in different directions couldn’t drive it. When put back in 2 wheel drive wheels stayed locked. Only returned to normal after much turning on and off. Never had problem before when used 4 wheel drive. Any ideas?

Tim

Thanks for the instructions. Easy to follow and I managed the job in about an hour. Would have taken alot longer without your help and saved me a few quid.

Thanks again for this brilliant guide.

Luke

Glad it helped Luke

as i read the instructions first i wondered why he was doing it in such a difficult way, the easiest way is to remove the second battery and use a filter wrench to remove filter (after removing water sensor plug )then with filter out remove water sensor from bottom of filter and the rest has been well described

thanks a mill, brilliant article , just after suffering for last two hours trying to bleed filter, delighted to find this information, well done and thanks again..