[53BHP]

@ACM: You are absolutely right and spot on. I had already decided to go for the new MHI turbo. Bought it in fact. My rig is not IC just TC. Your experience is invaluable though. The 0.1% doubt is also cleared

Originally Posted by ACM

53 BHP

Guess you already decided.

Had got the turbo kit changed twice in my TCIC Safari till I finally had to replace the turbo. The Pajero components though of better quality would I guess follow the same logic. In short the Turbo kit does not have a long life, and eventually (especially if your rev the engine a bit) one will require to replace the turbo (sooner rather than later). Suggest you get the turbo replaced for 30K. 12K seems good deal but it is a bit low for a comparable replacement so the quality would be a ?. Also does 30K include a new intercooler as well, if not and if you plan to use the current one, then do make sure that it is really well serviced, as defective intercoolers are know to have an impact on the Turbo. Have replaced the turbo of the Laura also twice (intercooler once) and in that case there is no option of a kit to repair it. Compared to the Laura turbo (original after market unit), 30K seems to be a good deal, though of course more expensive than the Safari Turbo.

Alternators are easier to repair had again for my safari and even the cielo got them overhauled / repaired lots of times, so getting an original but used unit refurbished would be the way to go. Of course a new units woul give pemanent peace of mind, but yet for this case refurbished somehow seems to be a better idea.

@Gogi: Since we are doing work on the turbo, changing the manifold gaskets, cam belt, cam tensioner, timing belt, timing tensioner, maybe water pump, alternator, timing belt guard, I thought it wiser to pull it. Very much easier to go at it on a bench rather than struggling inside a confined engine bay. I want this to be an overlander (and capable of long distance travel in India). Pulling the engine also gives me a go at the engine bay. New insulation, paint and refurb of the bay and as much of the electricals as possible. Changing the clutch also

I am most likely to get an alternator from Dubai. My brother in law is hard at search as we speak

Problem is that some previous owner changed the alternator to a sierra one. For me to order a new one from Japan or elsewhere, i need the original part number to be sure of the mounting and the pulley size and width. Even if I do get one from Dubai, there is still a chance that I will have to do some jugaad to fit it right. Another option is to get Tim of TMC (our Mumbai offroaders will know him) to make a new pulley of the correct size to fit on a new alternator of an Indian make. Lets see how it works out

The turbo is leaking oil. And the car was driving like there was no turbo at all. For sure it has to be repaired or replaced. Steiger was thinking of taking it to Indian Railways and getting it done there, but his Dad Dominic said just go for a new one. I cant argue with a man with 55 years experience. He knows what he sayeth. So new turbo it is...

Yes I am totally kicked at the hoist. Worked like maska...

Originally Posted by V-16

Why?? I thought the engine was fine? Did something new come up that made u decide to redo the engine?

BTW that hoist is a great one!!





Absolutely a must. Original is the way to go.





Visit Pai AUto electric. Meet Ranjeet Singh the owner, who is called Paiji for some odd reason which even he does not know He might just have an excellent solution for you or even a new alternator with a dual offer. Straight buy and exchange with your old alternator which he will repair and sell. I would suggest you get it checked and if need be repaired from him. Ill come with you if you want to go to him.




I would also be inclined for option 3 but in this case its an old fog and maybe has hazaaar other issues too, just replace it. One thing though, how did you ascertain it is not working? First get that cleared.


You Vehicle's underbody is looking very very good. Im glad she is getting the treatment finally, what she should be. Im all eyes for this rebuild.

[Aroy]

Originally Posted by 53BHP

I am up against 2 major hurdles now and I need your help:

Alternator

The currently installed alternator is out of a Tata Sierra and the pulley is capable of handling like a 10mm belt. The recommended belt is 17mm wide. So I have 5 options:

1. Buy a brand new alternator from my source in Japan, original, costing 44,000/-

2. Buy a second hand but original one from here for 8000/- and refurbish for about 4000/-

3. Buy a brand new replacement alternator from australia/uk/singapore/dubai for around 18000/- most probably made in Malaysia/China/Taiwan

4. Make a new and proper matching pulley keep the existing alternator

5. Any other Team BHPian solution

Turbocharger

My turbo is most likely not working. Infact I am pretty sure its not. Again I have 3 options:

1. Buy a new replacement turbocharger for 30,000/-

2. Buy a kit for 10,000/- and redo the existing turbo

3. Any other Team BHPian idea

In the first case I am inclined towards option 3 and in the second case towards option 1

What say guys (and girls?)

Alternator. Is the alternator kaput, or the pulley bothering you. In case of latter, just get a new pulley. Most of the lathe shops can manufacture one if it is not available. In case the alternator is not upto the mark, it can be reconditioned easily (all wiring and coils changed). If you want more current then of course you need a new one.

Turbo. It is better to get the whole set - turbo and intercooler set new.

[53BHP]

@aroy: the alternator is working ok. but it is not original. And as far as possible I want all critical components to be original. Who doesnt want more current? Once you have your aux lights and winch on, not to mention maybe a Waeco, extra charging ability becomes critical!!

[Aroy]

Originally Posted by 53BHP

@aroy: the alternator is working ok. but it is not original. And as far as possible I want all critical components to be original. Who doesnt want more current? Once you have your aux lights and winch on, not to mention maybe a Waeco, extra charging ability becomes critical!!

So you need a beefed up alternator. The original one may not have enough capacity to run all the gadgets, get an after market high capacity one. now that you want to change it. For over landing a dual battery set up is usually installed, hence more power required from the alternator.

As long as you know the idle RPM and the load, you can install a large capacity alternator, and fabricate the pulley if required. If you get one ensure that it has heavy duty bearings at both the ends, that way you can run it faster (smaller pulley diameter) without damaging it to supply enough juice to all your gadgets.

Some Links
http://www.rareelectrical.com/Shop/C...FYQc6wodBXkyDA
http://www.zena.net/htdocs/alternators/alt_inf2.shtml
http://pangaea-expeditions.com/2009/...ing-gear-list/

[53BHP]

Its strange how events in another world can change things for a humble rebuild out here. I had ordered the turbo from japan. not happening now

last week it was decided to get a new turb and a second hand or replacement alternator. Since the last one week I have been looking around all over the world for a decent alternator at a reasonable price. Yesterday I went to Opera House to pick up some suspension comps from City Motors. I saw a shop selling electrical parts including alternators and starters. Gave him the part numbers, he said no, please you may try at City Motors. I said City dont have.Oh so he says why dont you try at Pioneer. I did just that and look what I got:









Original Mitsubishi, 75A. I got lucky!!

I was also scratching my head on the turb when Steiger made contact with this guy who deals turbos. He came over looked at it and said, hey i can fix this no problem. I expressed my feelings about rebuilding turbos. So he says no worries. I will fix it. If it does not work, i will give you brand new turbo, less cost of the failed fix. Hey how could i argue with that. So the turbo went off to be fixed. Should be back tomorrow

Also started work on the belts and tensioners. More pics tomorrow

Got a new clutch too. Nice:

[53BHP]

Today we got the turbo back from the specialist. Looking nice. Hope it works:



Took off the timing covers big and small. All broken and gone:



Internals:



Inlet and exhaust ports:

[53BHP]

Its been a long time since the last post. What with the financial year ending and Steiger doing a complete overhaul of his pa in laws zen. We have done quite a bit of work in the last week and here is the update. The engine is now completely front end overhauled

All belts changed. Both tensioners changed. The timing belt covers were changed. Out of the 2 covers 1 of them was not correct. It took a few days to get hold of the right one

All hoses replaced. Got the radiator completely overhauled at Ajanta (highly recommended. Sher Khan certainly knows his radiators) and they did a fantastic job

The turbo also completely overhauled and balanced

Today we got the engine in. Not as easy as getting it out as the alignment and angle had to be perfect. Took 3 of us nearly an hour to get the bolts in place. The lifting system worked flawlessly again. Money well spent

New engine and gear box foundation put in

Here are some pics:







































The new alternator was a good find. So we are into the last phase of mechanical and electrical rebuild. Once the car is on the road, I will start on the body and interiors

Really excited about cranking it up soon. Today has been a good day. Managed to get the engine back in without incident. Its a great feeling to be able to work with your own hands on your own car (albeit as an assistant to the experts)

And to top it all off a full engine gasket set I had ordered for my Honda CB350 Four motorcycle more than a month ago finally arrived in the post today

Have a great weekend you all. Happy Easter!!

Gogi ji, still waiting for that offroading trip you promised me

[V-16]

Originally Posted by 53BHP

Gogi ji, still waiting for that offroading trip you promised me

Seriously a great job done! Please accept my congratulations, botj you and Stieger.

As for the OTR, well its so hot that we'd get a sunstroke if we attempted one such trip. Let the weather tone down and expect a call from me suddenly!!

[breakneck]

hey,
could you pm me the turbo specialists contact details,want to get my pajero turbo rebuilt,thank you.

[53BHP]

Surely but surely the Pajero is taking shape. Gogi I remembered your advise on the alternator. The other day I was going to Mahesh's workshop at Mahim. Saw uncle Pai's place. Stopped by just for a chit chat. he turns out having a 120A alternator for my rig. Did not think twice:



Also plan to fit the 2nd alternator (which was the 1st alternator that i got from Pioneer auto) as an auxiliary top mounted unit. The problem with alternators burning out on mk1 Pajero's are apparently because they are mounted pretty low down and susceptible to water and dirt. So some owners have fitted a 2nd one for emergencies and to run additional stuff on their overlanders

Last week we finally got the engine running with the new alternator. We also put in the viscous fan cowl, the new radiator hoses and the radiator. Also got the fuel pump overhauled and recalibrated:




Opened and got the dash painted. Checked all the wiring. All original fortunately. The dash body is metal by the way. Cleaned out the fan blower and the evaporator. I need a new cluster. The oil light system on the pcb has shorted. Cant fix, have to replace. Also put in a new wiper linkage. They run like new now:



The car now starts and runs very very well. The suspension job has come out very well too. The damping is like a tennis ball sound. Its a very dubbin sound. Very satisfying. Trying to figure out how to connect the air filter box to the outside. The intake of the box is opposite of the hole in the body . Any suggestions?:



Over the weekend Chand did a super job on the body. Polished and coated. All the stickers and unoriginal stuff is off. So this morning this is what I saw. What a nice way to start the day:










@breakneck: As a newbie I dont think you have access to the PM service until you get confirmed as a BHPian. The turbo guy is Vinay from City Auto at Opera house. Not City Motors (the Pajero specialists). You should be able to get their numbers from google. If you dont, then quickly become a BHPian and PM me

[breakneck]

53bhp :could you post a link of city auto because i am not able to find them on google

[condor]

Originally Posted by 53BHP

Trying to figure out how to connect the air filter box to the outside. The intake of the box is opposite of the hole in the body . Any suggestions?:

Check the set-up in a Sumo Victa TCIC or an (old) TCIC Safari.

The air filter box in those is as seen in this post.

[53BHP]

I cannot seem to figure out how to add a poll to this thread. FAQ only gives you the option when creating a new thread. So I will have to count manually. I want your opinion on the graphics on the side panels:

Option 1

This is the original graphic. It will also be the most difficult to reproduce. Being a sucker for originality its what I have wanted from day 1. Now I am not so sure:





Option 2

This is the original scheme on the Aussie Pajero Mk1's. It will be easier to do and from an aesthetic point of view seems to be a lot less blingy than option 1 or shall I say its more subtle:





Option 3

Do nothing at all:

Originally Posted by condor

Check the set-up in a Sumo Victa TCIC or an (old) TCIC Safari.

The air filter box in those is as seen in this post.

@Condor: Thanks Mate. Thats a KA thread there...

Originally Posted by breakneck

53bhp :could you post a link of city auto because i am not able to find them on google

@breakneck: send me an email on rohituchil@hotmail.com. I will reply with the number

[condor]

Originally Posted by 53BHP

@Condor: Thanks Mate. Thats a KA thread there...

@53BHP, thanks !

But your Pajie is turning out to be a head-turning beauty. Getting the right guys for the work & the parts isnt easy, and you have been fortunate there. Take care of that baby, pls.

[ACM]

Liked Option 2 more. It is more understated and would go better with the age of he vehicle.