Pajero 4x4
Living With A Mitsubishi Pajero
Tony’s Cold Starting Trick
Tony emailed me to share his experiences of Pajero ownership a while back. He’s been kind enough to let me publish it here.
Possibly the biggest problem us Pajero owners have at this time of year is cold starting, so it’s interesting to hear what Tony’s done to try and fix this.
Rather than edit, I’ll let Tony tell you all about his Pajero in his own words:
“Our youngest son Rob had a gardening business and we obtained a Brava twin cab which did the job very well, anyway, he found a job with the local agricultural society showground and no longer needed the capacity, a mate of his who managed a car supermarket site came home in a Paj 2.8 swb which was a bit flash compared to his Brava so he was sold!! Basically he had taken it in part ex and needed to get rid of it!
So, welcome to the world of automatics, climate control, adjustable suspension and overdrives etc. What a piece of kit and all for 2.5 grand.The original tool kit had never been used and everything was “as new”, of course we have since learned that many of these “grey” imports come into the UK like this over 10 years old and no rust! amazing! Meanwhile I had started to fancy this set of wheels despite the fact that it only has 3 doors and isn’t exactly the most fuel and space efficient thing around.
So, next the problems, as soon as the weather cooled down it became reluctant to start so we threw ourselves at the mercy of the local diesel specialist who tested the glow plugs and found that only one was working, a new set solved the problem, at about this time Rob found a job working for the M5 Motorway contractors working 05.00 to 13.00 or 13.00 to 21.00hrs which meant starting up at some unsocial hours, needless to say it was in summer last year so no problem – yet! When the cooler weather started it became difficult to start again so I did a few tests and it was obvious that the glow plugs were not working, the solenoid between the batteries was not kicking in so I made up a temporary fix which was a short length of jump lead with a couple of croc clips, just connect both terminals on the solenoid having downed the drivers window, walk round and instant start!! then disconnect the lead and off he goes without causing too much noise at 04.30 in the morning.
Now we are into increased fuel costs so Rob now needs to improve on 21mpg since his commute is 17 miles to the motorway services each way. The only alternative is for him to buy a more economical set of wheels. After much research he decided on a 2.2 Astra Sri which leaves him needing to dispose of the Paj. Needless to say Dad steps in and makes him a bid he can’t refuse. He reckons the Astra saves him £150 a month on fuel!
Now I have had the Paj for 6 months and I love it, Immediately the thing is reluctant to start so I decided to bite the bullet and buy a new solenoid, down to the local Mitsubishi dealer, he says sit down on one of the courtesy seats and I’ll tell you the price, £96, so I lie down until the feeling passes and, kind soul, he tells me how to repair the old solenoid. Take it apart gently, don’t pull on the leads and wrap a bit of emery tape round a small screwdriver to clean the copper contact bar. It worked! and now it was starting instantly again. After a few months starting got less reliable, same problem, so I talked to another auto electrician and diesel specialist, yes, he can get me a solenoid but they cost the earth so why not use a GR19 relay? I says what about the capacity? 100amp plus he says, are you sure I says then he says at £15 it’s worth a try and nobody has come back since I started suggesting it! Well, we got the relay, he charged me £12 cash, it has two large connections and two small spade terminals I connected it all up, one of the spade terminals to earth and now I have instant starting from cold. I honestly don’t know how long it’s going to last but at £12 it can’t be bad even if it doesn’t last indefinitely.”
Tony tells me these relays are available from any good auto electrical supplier. The one he uses is Droitwich Auto Electrics on 01905-778814. Can’t guarantee they will be able to do one for the cost shown above or post it, but might be worth a try if you can’t find one local.
Tony got back to me with an update on the cold starting after he’d been away on holiday:
“This morning it was covered in frost and started the instant the glow plug light went out, since I fitted the relay it has always started instantly, Rob my son, started it on Friday for the first time since it was parked up for a few weeks and said it started instantly. Last winter he owned it and had lots of starting issues caused by glow plugs not functioning.
It looks as though we have cracked the problem at a realistic price! however it remains to be seen how long the relay lasts.”
So I’ve asked Tony to keep us informed about his relay trick. Although it won’t fix everyone’s starting issues, it’s an interesting one to keep an eye on.
[Please note: as usual, any modifications shown on this site should be copied at your own risk. We cannot be held responsible for any problems arising from these ideas.]
Thanks again Tony!
The working Pajero!
If you’ve got problems starting a cold Pajero, you might also be interested in this post I did some time ago – Pajero Cold Starting
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December 10th, 2008 at 8:43 am
Where can you buy an GR36 relay and do they connect strait in.
January 6th, 2011 at 5:22 pm
HI , you should have used 2 of the relays , re wired so one did 2 plugs and so on ” easy peasy “!!
Now i have been to the factory in Japan for a tech course ” as i am a mitsi engineer ” and what i am about to reveal may shock you “!!
First i hear everyone saying “”its an import” never seen a british winter “?? that is the first myth ” as minus 26 down to minus55 can be had quite easily in japan ” ((hence they make winter pack models)) for the eastern area (as thay put it )) now they have seen how fords are built ” and think its very funny the way we accept the rubbish ” so they build a “SHOGUN”" for us , with ((you wont believe this ))?? thinner steel on the chassis,,unbalanced pistons , and crank “” all pajes ” are ballanced to within 100,000 of a gram ” the rear bumper is rubbish ” but look at the nice ones on pajes ” Also the salt used on there roads is twice what they use here ” and the dont run out ” it comes from aussie” and they use there brains (((SALT _SEA WATER ))
sprayed on the ice ” I live three hundred yards from the sea and they ran out of salt here in wales “”hahaha”" they walk amongst us ” EH “!!! thye paj also has seven more coats of paint including 2 more undercoats ” and cranks are tufftrided, as is the cam followers , unlike shoguns “”I could go on here all night ” but the fact is DO NOT TOUCH A SHOGUN”" on a quiet night ” you will here it rusting “” MPG,, shut the waste gate for good , have full boost ” you will get an extra 15 MPG, and watch that baby go ” the engine is easy strong enough ” have SAFE fun out there ” kev
December 10th, 2008 at 8:54 am
I’ve now updated the text above. It’s a GR19 relay that’s needed for this, not a GR36 as first written – available from any decent auto electrical supplier.
December 16th, 2010 at 1:34 pm
hi there a have put the gr19 relay in an new glow plugs an it still dosent start in the morning a have to use cold start to get it running any sugeitions on wot could b cousin it a have a j plate 2.5td inport
January 30th, 2012 at 4:11 pm
tim where can i pick up a gr19relay nobody in the local area seems to know code no and so cannot locate/ie is it a lucas part .
is there any other suggestions of what could be the problem starting a pajero in cold weather apart from fuel pump seals look forward to your reply / stuart
January 30th, 2012 at 4:35 pm
Couldn’t tell you Stuart to be honest as I’ve never bought one myself. A quick Google throws up a few places but I couldn’t vouch for any of them I’m afraid.
December 12th, 2008 at 8:26 pm
I had the same problem with my 1996 45,000 MILE swb 2.8 Pajero – Greinton Garage John Lewis Somerset, sorted it – fitted a button starter with relay, copper glow plug rail, removed the EGR system. Now starts first time everytime even after 3 days no go at 3 degrees of frost – I always get 29mpg plus
December 12th, 2008 at 10:11 pm
29mpg John? A lot of people reading this will be very jealous, me included! Thanks for your input.
October 20th, 2010 at 3:48 pm
Guys,
I have just bought Paj 2.8 5 doors and its been fine for the past month but today it was really cold and it didnt start I tried it 4 or 5 times but no use. I am not a techy at all infact knows very lil abt cars or any kinds work so I would really appreciate your help. I used the cars couple of nights back and it worked absolutely fine. I believe its the same cold start problem I have spoken to the people who sells this GR19 relay and they quoted me about £20 the only problem is even with the above clear instructions I am afraid if ill make a mess of it?
Does this relay GR19 replaces the solenoid completely?
“Now look at the picture and you will see the short earth wire I had to make up using a push on terminal (red) and a ring terminal, this I attached to the other solenoid bracket bolt behind the plastic cable holder” is this easy? how would I make the earth wire
apologies to be a pain
regards
December 13th, 2008 at 7:49 pm
Regard MPG I have found that turning the OD off when only on 40mph roads (Around the doors) seems to save some fuel, and only switch on the OD when I am on the motorway.
December 14th, 2008 at 10:42 am
Yeah, I’ve heard of that before Steven. To be honest I’m far too lazy!
December 31st, 2008 at 4:33 pm
Hi, thanks for the great blog. I am having exactly the same problem with a 93 SWB TD. I’ve changed the plugs, cleaned the busbar and still get jerking in at first start with really low idle, about 400rpm.
One question I had is how do you fit the GR19 relay into the existing setup? I didn’t understand that part of the blog on fitting it..
I am not too mechanically minded, would it be better for a mechanic to do?
December 31st, 2008 at 5:14 pm
Hi Amir
I’ll have a word with Tony and see if he can give us more details as it’s not something I’ve done myself.
December 31st, 2008 at 7:34 pm
Tim/Amir
Re fitting the GR19 relay, the picture tells the story. The original solenoid was fitted to two captive bolts between the batteries, the GR19 has a bracket with a single hole, this was fitted to the bolt nearest the engine. then I attached the two large terminals, the size is the same as the old solenoid so you shouldn’t need to alter them. Then I attached the existing small terminal wire to the one small terminal, again you still use the same terminal as the size is the same. Now look at the picture and you will see the short earth wire I had to make up using a push on terminal (red) and a ring terminal, this I attached to the other solenoid bracket bolt behind the plastic cable holder, I am not a skilled mechanic but I have a reasonable understanding of vehicles, it took me about half an hour but a good mechanic would probably do it in half that time! Also I used a proper pair of electrical terminal making pliers.
I understand that the way the system works is that with a cold engine when you turn the key the heater light illuminates for about 5 secs then you start it up when the light goes out, I beleive that another relay holds the current to the heater plugs for about another 10 secs to avoid uneven running/misfire for the initial start up. If you read my original story it was a sod to start when the weather got cold now it fires instantly from cold, today it was -3c and no problem!
Good luck with it!
November 14th, 2011 at 3:05 pm
hi toni, just bought a 2.5 td exceed iv had the usual probs starting the darn thing! changed both bats new glow plugs had reconned alternator, works great except i keep having to get the bonnet up every morn and also if the cars been standing for more than a couple of hrs to stick a wire on my batt to warm the plugs, well yeah thats been doing the trick but its getting colder and so decided to buy a gr19 and hopefully its going to work. how hard will it be to change? as im going to try and do this myself. the guy who i spoke to when i orederd the relay has had calls from all over the country for this part. and for under 25 squid inc postage i thinks mint just hope it works, its going to help no end wasnt looking forward to cleaning the 6″ of snow off before starting my moody paj. has any1 else used this part and how long has it lasted? thanks louise
January 1st, 2009 at 11:59 pm
Hi Tim/ Tony a very Happy New Year to you both and thanks for your advice. I’ll probably get auto electrician to take a look on installing it as I don’t want to destroy something else.
One final question though please: Can using this relay cause any damage to any part of the system? Relays, battery etc? in your opinions.
Thanks again.
Amir
January 4th, 2009 at 3:11 pm
hi tim . steven here ..my problem is the exact same.not starting. mine is a 2.5 td pajero . would i need 2 buy 2 gr19 relays as it looks as tho i hav 2 selinoids and is that a bigger problem 2 fit than u had with urs .. i await ur reply. urgently
January 4th, 2009 at 6:21 pm
I have problem startin my 2.8 pejeo in the mornings ,once it start it smoke abit (black and white) but then it clears and run fine can u give me a idea wot it could be cheers andy
January 6th, 2009 at 1:19 am
Hi Guys like the site, ref your starting problems i had the same probs, after replacing both relays and actualy repairing 2 as well i found out it was my ECU that burnt out, due to cost i am going to run a bypass from the relay to a push to make switch as per the instructions from cableguy at the following link good photos with it http://www.pocuk.com/forums/viewtopic.php?t=76976
March 13th, 2009 at 12:53 am
1994 paj 2.8d starts 1st time but when travelled bout 1/4m cuts out and difficulty starting,when started again cuts out for 2nd time then starts again,then when reached norm temp is ok for rest of day,anyone know problem please?
March 13th, 2009 at 7:57 am
Hi jj
What your describing are the typical symptoms of having knackered fuel pump seals. It’s a common problem with the Pajero. You’ll need a decent mechanic to sort that one out really.
March 28th, 2009 at 8:55 pm
I am having the problem where my pajero keeps cutting out ramdomly. (apparent fuel pump seals). However, if I bypass my fuel filter the car runs fine, I have put a new filter on but as soon as i connect it, the car cuts out again. Anybody have any ideas?
April 2nd, 2009 at 8:11 am
Hi,
If you’re worried about 100A not being a high enough rating, it’s entirely possible that you could wire up two of these relays in parallel for increased longevity.
Also, if you’re worried about damaging sensitive electronics with this setup, simply add a power diode between the coil terminals with it’s annode connected to the ground side. This will suppress any high voltage generated as the field collapses. However, I’d guess this isn’t much of a concern as the original system also drives a coil.
August 18th, 2009 at 6:55 am
I’ve got the same problems, but when I pump the manual fuel pump I can get it started, however I have to repeat this for about 5 min. before it runs normal. One machanic said it is the pump above the filter while another said it must be a fuel pump in the fuel tank which isn’t working. I have now no idea what it is.
Jack
August 20th, 2009 at 10:57 pm
Geree and Jack Willigers
It sounds as if your seals are gone on your diesel pump – most noticeable on a 2.8 which will always cut out at the same place after initial starting in the morning – but does happen to every engine using the bosch-type fuel pump.
What is happening is the seals being worn are allowing the fuel to drain back to the tank overnight then the pump needs to draw a load of air up before it gets fuel to deliver to the engine.
A pump rebuild should cure it but you’ll be looking at £250+ if you remove and replace the pump
December 3rd, 2009 at 5:07 pm
cold start problems 2.8 paj
i had the starting problems where the paj would run lumpy at start then eventually it cut out a short distance down the road.
the fuel pump i removed and got the fuel pump seal on the shaft only fitted for the second time it was fitted two year a by the previous owner two year ago but the previous owner had the paj standing on driveway, apparently if the engine stands for long periods this can cause the seals to fail? so a diesel specialist told me however the engine now has not cut out but runs lumpy again at start up on a cold morning. i have not yet checked the glow plugs as i was told the engine just would not start if they wer at fault it has always started right away. i suspect a leaking fuel line above the tank (accessed from in the boot) as from what i could view did not look in the best condition. i think i will try bypassing the fuel filter also just to see how it starts for a couple of days.
i wondered wht is the 2nd cable for alongside the throttle as it is like the engine needs choke on cold start up and the cable has a bit of slack in it any suggestions?
January 12th, 2010 at 9:31 pm
Pajero 2.8 oil pressure sensor removal.
Forget the 24mm sensor as it is easier to takle the 17mm bolt underneath it and then seperate them in a vice once it’s removed from the engine.
February 7th, 2010 at 5:28 pm
Hi,
running s J reg SWB 2.5TD with 2 batteries and 2 solenoids. Think 1 of the solenoids is knackered. When warm the it sometimes (getting more frequent) won’t start. Turn the key, clicking noise and nothing. Have temp solved the problem running a jump lead from the + on the battery direct to starter. How do I know which solenoid is knackered and is it okay to replace both with 1 relay or are 2 relays better? Your wisdom is greatly appreciated.
March 14th, 2010 at 6:53 pm
I have problems wih the overdrive, It connect and disconnect while is running on the road.
is a solenoid in the gear box wrong?
what can I do?
regards
June 21st, 2010 at 8:54 am
First start of the day has been terrible for weeks. Had some spurious relay readings on my multimeter and tried Tony’s GR19 Relay fix.
20 mins of effort and job done. Started first time. Long may it last :0)
Excellent advice. Many thanks.
June 21st, 2010 at 9:01 am
That’s great, glad it worked for you
July 24th, 2010 at 6:24 pm
hi my mitsubishi pajero has got a problem where it will run good for a few weeks then for a day it will not start i have change the altinator put new battery and still got the problem.wot shall i do?.
October 21st, 2010 at 7:19 pm
Hi, Didnt work for me and its only down to -2 in october. I have changed the relay for the GR19 and have fitted a new Zinc coated heater rail, still the same old cold start. The old girl will eventually start but it is in clouds of blue smoke and rather embarasing. The glow plus were changed last year and helped, but it has now got worse, anybogy got any ideas, dont want to put the old girl down yet, sehe still shines and performs very well once started.
Cheers
Tim
October 24th, 2010 at 6:26 pm
I have just done the above and it worked a treat.
Tim, I would say you need to replace the glowplugs as well as the old relay may have fried your existing glowplugs. I bet once you have installed new glowplugs she will fire up.
Daniel
November 10th, 2010 at 3:15 pm
Hi, I have a 1996 Pajero Fieldmaster which has the same cold starting problem. Before I setup a manual bypass or changing the solenoid to a relay, I need to test and ensure which part is at fault. ie, relay or ECU. I did a voltage test on the connection that goes from the ECU to relay and I didn’t get any current/voltage when turning the key, this leads me to think that the ECU may have packed-up. I also tried to connect a live feed from the battery to the same terminal (only for a few seconds obviously) and see if I can get the car started, but it doesn’t seem to start at all. I don’t even hear a click from the solenoid when i connect the live feed. If I connect a wire directly from the battery to the busbar, the car starts. Does this mean both my solenoid and ECU are at fault? I also checked the wiring and they seem fine. This car has only one relay (pre-heat only I think). Any help would help
Thanks, Lee
November 20th, 2010 at 2:55 pm
just fixed 2 shoguns with sme starting fault where the solenoids have gone causing a part of curcuit in the ECU to melt.which is really easy to spot.the ecu is on the side of the passenger floor well and comes offand apart easily.after replacing solenoid i made a quick fix of the ECu with some solder and both vehicles are starting straigt away
November 20th, 2010 at 3:10 pm
Thanks Paul, that might well help someone.
November 27th, 2010 at 6:40 am
Tim, any problems with this yet? is it still working?
i’m just about to give it a try, hope it works and thanks for the advice.
November 27th, 2010 at 7:57 am
Hi Lance
Last time I spoke to Tony it was still working fine, but it’s been a while.
Good luck with it and if you get chance, let us know how you get on.
December 10th, 2010 at 6:58 pm
I have a Shogun 2.8 diesel with the cold starting problem, I have bypassed the fuel filter with a straghit inline and now she runs fine, I would like to know what problems will be caused if i leave this in permenantly, and how can i find out if its the fuel filter that needs changing or the pump seals.
Thanks
December 10th, 2010 at 7:13 pm
First thing I’d do is change the fuel filter as it’s worth doing for the good of your engine anyway, then see if you’re still have problems before looking at the pump seals.
Easy to do – http://www.pajero.org.uk/pajero-fuel-filter-change/
December 11th, 2010 at 3:32 pm
Sounds like the best place to start, how long would you say is safe to leave the bypass straghit line filter in, and can this not be a permenant solution??? and the only difference to the previous set up it the primer pump.
Cheers
March 2nd, 2011 at 11:28 pm
hi i have a 2.8 paj with cold starting problems it would start then cut out after turning it over for about 5 min it would start and i first thought it was the batteries and still no luck so then took the filter out so it wasn’t that changed the tank pick up pipe and still had the problem then i knoticed that if i primed it by hand the fuel came out of the return so i bought and fitted a new seal set for the pump and that didn’t work it turned out it was the fuel return solenoid valve the one with the green top on the back of the pump i hope this will help some ppl and that my poor paj will be ok next winter
April 17th, 2011 at 10:03 pm
hi can you tell me more on the ecu problem and how to fix as i think it could be at fault on my shogun heater plug light lights up on the dash but only for about 2 seconds you can hear the selonoid cut in and out and is starting ok at the moment as weather is nice but who knows when it gets cold it may not start for me please reply anyone
August 30th, 2011 at 8:34 am
hi my 94 shogun will start 1st thing when cold but go to work turn it off and it doesnt want to fire up, will do eventually, with a puff of black smoke what can be wrong maybe glow plugs eh?
September 19th, 2011 at 4:47 pm
when the cold start relay packed up on my 95 shogun, it caused the control unit to fail,(or vis-versa). i got round this by substituting the relay with that of a starter relay from a morris minor and by- passing the control circui as previously described. so far so good.
October 18th, 2011 at 6:36 pm
My lad, Tyson (he is big,black,hard as f**k and eats the ears of Clio’s), will start first turn of the key but has a stutter and eventually he cant cope, so he coughs up a bit of smoke and stumbles to a halt which is totally embarassing and inconvenient. I haven’t even got off the front drive at this point! I have tried pumping the fuely thing by hand and this makes no differnce when he is cold in the mornings but once he has started and not collapsed he will go on all day without failing to start. I also find that when i put my foot down a little he seems to pull back on me and i get all juddered by him. I love my car and he is essential to me feeding my horses in the morning. I will try this relay thing and hopefully he will be back in the mix soon! Thank you all for your advice, now I need to find a man to do the job for me…any offers? lol!
October 18th, 2011 at 6:55 pm
Good luck with it Donna. I guess you’ll get plenty of men offering to do the job for you!
October 26th, 2011 at 2:06 pm
Hi all, great post.
I have. 97 shogun 2.8 and apart from the cold start issue it’s a great machine. It’s hard to start but once it does and spits out blue/black smoke she runs perfect after 30 seconds and for he rest of the day. Is there anything I should try before the relay ie. Fuel filter, glow plugs as I can tackle these but reluctant to do relay.
Any advice appreciated.
Abe
January 14th, 2012 at 3:01 am
How to fix mitsubishi pajero 2.8 powered steering pump makes over steer noise when it gets hot and loose 30%+ steering but ok when its cold yeas heaps of oil
January 16th, 2012 at 3:30 am
We have had 2 pajeros both with cold start problems,my man has tried mostly everything,glow plugs,relays,fuel pump,tank sender the lot,to no avail…..so he has fitted an electric fuel pump to feed the injector pump and bleed it clear of any air seems to work a treat,I know cos I use it for work every day and often found it very embarrassing sitting at the side of the road covered in Gray/black smoke trying to get it started again….give it a try folks ul a amazed how well it works……..
January 16th, 2012 at 7:38 am
Thanks for the advice Julie and glad to hear it worked for you.
January 23rd, 2012 at 2:00 am
i have recently went through a
fecking large puddle in mypajero 2.8 exceed i have changed the alternator and my batteries are nt holding there charge i have also noticed that my temp and compass gauge resets along with my stereo clock and cetral locking and in car lights when ever the car is turned off all work fine when car is running please help this is week 2 of trying to repair my big beauty any helpful advice people am only 31 a dont want to look 51 before a get it running properly again lol