Nick's iO

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nick_io
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Hi everyone, Thought I'd start a build thread so I can document my progress and maybe help out/ give people ideas on modifying the io. My io is a 2002 2L manual QA. Bought it stock other then tint, roof racks, sound system and k&n filter. Originally was just going to be a daily run around but shortly after started to become more and more interested in 4wding. The io always manages to amaze me!

 

Engine

-K&N air filter in factory box

-Oil catch can

-Throttle body coolant bypassed

-Intake resonator removed

-Z150 oil filter

 

Body

-Roof Racks

-NL pajero TJM bullbar

-Bonnet protector

-Jeep XJ Cherokee snorkel

-Wheather Sheilds

-Early io black surround headlights

-Early io grille/front filler panel

-Hilux surf fender mirror

 

Suspension

FRONT

-KMFS-900 King springs

-X-trail shocks modified to fit

-Whiteline camber bolts (CB Lancer)

-12mm diff drop

 

REAR

-Mazda Astina front springs

 

Interior

-Tint

-Micro CB radio (ashtray removed)

 

Lighting

-LED square flood lamp (in rear bumper)

-Narva 120 plus headlight bulbs

-Hella spotties

 

dareqq
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Amazing job! What you need

Amazing job! What you need to modyfikate on cherokee snorkel? Ofc airbox and what else? Give us more photo

simmo777
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Mods

nick_io wrote:
Hi everyone, Thought I'd start a build thread so I can document my progress and maybe help out/ give people ideas on modifying the io. My io is a 2002 2L manual QA. Bought it stock other then tint, roof racks, sound system and k&n filter. Originally was just going to be a daily run around but shortly after started to become more and more interested in 4wding. The io always manages to amaze me! Engine -K&N air filter in factory box -Oil catch can -Throttle body coolant bypassed -Intake resonator removed -Z150 oil filter Body -Roof Racks -NL pajero TJM bullbar -Bonnet protector -Jeep XJ Cherokee snorkel -Wheather Sheilds -Early io black surround headlights -Early io grille/front filler panel -Hilux surf fender mirror Suspension FRONT -KMFS-900 King springs -X-trail shocks modified to fit -Whiteline camber bolts (CB Lancer) -12mm diff drop REAR -Mazda Astina front springs interior -Tint -Micro CB radio (ashtray removed) Lighting -LED square flood lamp (in rear bumper) -Narva 120 plus headlight bulbs -Hella spotties

 

Anymore info on the oil catch can?

Heard mixed things about a throttle body coolant bypass, any opinions?

and diff drop how'd you go about that?

2002 5dr Pajero IO QA 2.0L Auto - Lifted, Locked!! 1.925 Low Range - Muddies (205/80/16) - Redback Extractors to 200cell cat to dump at diff Exhaust 

Keith65
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So you ended up doing the

So you ended up doing the x-trail struts then ? how are they going and what do you think of them ??

Mine are going great now all the little kinks are fixed. Couldn't be happier with them.

so with you doing them the count is up to 4 people now with them on.

nick_io
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The snorkel wasn't as easy I

The snorkel wasn't as easy I thought it would be, under the guard there is very little room to play with. I had to make my own piping out of 2inch pvc. also had to make my own bracket to bolt onto the pillar.

Simmo, The catch can is very easy install, just taken line off the valve on rocker cover and directed into catch can. It won't really provide any power increase but helps stop the intake coating up with oil. Had it from my old car so thought why not, it helps more with a turbo set up, for intercooler coating up with oil and lowering fuel octane I think.

Diff drop spacers were just a simple 12mm flat bar and drilled two holes (I forgot to drill drain holes though)

Throttle body bypass is fairly simple mod, on my previous car worked well but I think there's to much heat soak on the io intake to make much of a gain.

Keith, Very happy with the xtrail strut. Everything works fine. Only had problem with to much positive camber.

Keith65
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I did correct the camber

I did correct the camber problem with mine and it is perfect, I did lower my car to the ground and mark the spacers and drilled them out but I can adjust my camber if I go to higher again or reduce it.

You also have the same snorkel as I have and yes they are a pain in the butt to put on, I bought a 90 degree 72mm bend from supercheap and used that instead of the 50mm pvc water pipe and my intake hole is a fraction higher than where you have put yours but I did cut away some of the plastic bracket moulding fit it .

nick_io
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edit

pics uploaded

Keith65
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My snorkel I bought this bend

My snorkel I bought this bend from supercheap.

I have put my clock back in but added a couple of LED lights in it to let me know if my LED spot lights are on and also added a volt meter in it so I can check the voltage on the main and 2nd batterys.

 

If you are keen go and buy some Gabrial 81318 shocks for the rear (hilux) and you will get an extra 65mm more travel but you will have to undo your rear brake lines and take them out of the bracket their in and bend them all so slightly towards the back about 1 inch and zip tie them so they hold in place, this is so you don't break your break lines when at full flex. 

Also you may need to try and find the commodore (VK - VS model) adjustable panhard rod and set it at 887mm from eye to eye so you don't snap your original panhard like i did last Saturday. The diff will drop that much that it twists the panhard and will break after some time if you don't do something about it and also your diff will be out of alignment so it needs to be rectified anyway.

 

Keith65
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My new looking bonnet.

My new looking bonnet.

Claude io
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Nick io

Welldone...some nice unseen mod and great looking beast.....

Keith65...you should make a built thread to show us all these mods in one place.

Happy io

Keith65
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Yeh I thought of that, there

Yeh I thought of that, there is just so much info i would need to put down and it would take me ages to write one up but it would be all in one spot then hey. Are you going to do the low ratio gear and change it from the 1.54 to 1.925 ? it makes a big difference for crawling over rocky stuff and steep hills.

I did mine not long ago and helped Simmo does his at my place and Claude has done his and same with Bob.

beastftw
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Where did you get that

Where did you get that snorkel?

bob_oz
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snorkel

beastftw wrote:

Where did you get that snorkel?

XJ jeep snorkel - fits ok
ebay

GU apparently better fit however no-one has tried them

 

.

beastftw
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Would this

Would this suit? http://www.ebay.com.au/itm/Snorkel-Kit-Holesaw-fits-Nissan-Patrol-GU-Series-1-2-3-Diesel-Petrol-11-97-to-/111800309270
I'm pretty handy with tools but have never done any major modifications to the bodywork, would you be able to give me some tips on how to make sure i cut the right holes?

bob_oz
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snorkel

no idea dude - just what people have said.

XJ jeep fits OK - no idea about others.

 

if you're heading to brazil you can buy genuine io ones sold for the tr4 (remanufactured io)

.

MadMax
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around one year ago now I

around one year ago now I found (lost details now) the supplier in Brazil, 800 USD .... :(

I live my life a 1/4 mile at the time

fordem
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dareqq
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Camber bolts

Yo! Which camber bolts you used? Like this one? http://allegro.pl/sruba-mimosrodowa-wahacza-colt-lancer-outlander-i53455...

fordem
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No - that won't work.

http://www.ebay.com.au/itm/Whiteline-Camber-Bolts-12mm-KCA412-S13-N14-N1...

This style is what you're looking for - 12mm size.

nick_io
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Hi guy's haven't updated in a

Hi guy's haven't updated in a while. Regarding the snorkel questions theres no right or wrong one to get, each will have to be modified to suit. The jeep one is ok not great.

Done a fair bit recently before my Fraser Island trip. I did the longer shocks that Claude discovered along with commodore panhard rod with 1" landcruiser spring spacers. Also dropped the gearbox crossmember as I was unsure with the extra lift and front diff drop if I'd have any issues with driveline angle.

Did a brake upgrade too, 276mm machined io rotors with twin pot calipers. Was a bit of drama as I decided to use big pajero calipers and the mounts aren't the same which I didn't know, so I swapped the mounts over with magna twin pots calipers I had. Needed new brake lines, although I think some twin pots come with a banjo fitting so maybe could use io brake lines I am unsure. Also rotors needed machining which is a pain, maybe a spacer will be made for next time to run the evo rotors. The pads do overhang a little on the io rotors too.

Made a bash plate using plans on the forum, and a power steering cooler was also added to stop the fluid getting too hot + with bigger wheels I figured it wouldn't hurt.

Pics to come..

nick_io
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Photos

Photos

Claude io
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bash plate

These brake pad are a LOT bigger ! How do they compare ?

Your last picture showing the bash plate, what have you made on the front section, bolted with the 3 bolts ? I don't think that I have seen that before but the picture doesn't show enough !

Your thread start with a white io...now a blue one....have I miss something !!

Happy io

nick_io
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Hard to explain the brakes,

Hard to explain the brakes, the old io brakes felt as if they were struggling/overwhelmed? especially once the car was loaded with gear and had some speed behind it. The new brakes don't seem to have this issue at all. On a scale of 1-5 I would rate the originals a 2 and these maybe a 3.5, obviously 5 would be something like a Mitsubishi evolution etc.

The 3 bolts on the bash plate are just to join it to the bullbar.

I think you have looked at the pictures Keith posted. That's the only thing I can think of, I still only have the white io haha.

izzy
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Bullbar

Just wondering how well the NL bullbar fits? Is there much overhang at the sides? And did you have to modify anything in regards to mounting it?
 

cheers,

Izzy

simmo777
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NL Bullbar

Interested in the NL bullbar idea!

my father has a SWB Pajero NL pajero V6 and we got a bullbar that looks like Nick IO on it cheap!

Interesting to see mounting and overhang etc!

Just sold my Pajero IO ECB bullbar because overhung the front too much in a LWB on deeper ruts...

Nick is your bullbar air bag compliant for the IO?

2002 5dr Pajero IO QA 2.0L Auto - Lifted, Locked!! 1.925 Low Range - Muddies (205/80/16) - Redback Extractors to 200cell cat to dump at diff Exhaust 

nick_io
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bullbar mounting

izzy wrote:

Just wondering how well the NL bullbar fits? Is there much overhang at the sides? And did you have to modify anything in regards to mounting it?
 

cheers,

Izzy

 

I think it fits quite well considering its not designed for it, there is a gap in front of the headlights though because the bullbar is much straighter then the slightly rounded io front. Off the top of my head it overhangs maybe 50mm on each side. I had to make my own mounting points on the car and also trim down the mounting point on the bullbar and drill my own holes on the bullbar. 

 

Simmo, 

The bullbar itself is airbag approved but it wouldnt be on the io because its wasnt designed or tested for it. Obviously overhangs more than a factory bumper, but its not any lower then the io bumper and actually tapers up on the sides and tapers in at bottom if that makes sense. 

 

Other option would be to reweld/make your own mounts on the bullbar itself and have them further apart so that it would slide over the side of the io chassis?

 

 

Claude io
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new brake

[quote= Did a brake upgrade too, 276mm machined io rotors with twin pot calipers. Was a bit of drama as I decided to use big pajero calipers and the mounts aren't the same which I didn't know, so I swapped the mounts over with magna twin pots calipers I had. Needed new brake lines, although I think some twin pots come with a banjo fitting so maybe could use io brake lines I am unsure. Also rotors needed machining which is a pain, maybe a spacer will be made for next time to run the evo rotors. The pads do overhang a little on the io rotors too. 

 

Do you have some pictures of your new front brake system on the car to see what it look like ?

Happy io

nick_io
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This is the only photo i have

This is the only photo i have on the computer atm. Dont mind the wheel spacer, long story but wheels didnt fit without the spacer. my fault for not test fitting the wheels properly .

naughtika
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magna caliper mount

nick_io wrote:
276mm machined io rotors with twin pot calipers. Was a bit of drama as I decided to use big pajero calipers and the mounts aren't the same which I didn't know, so I swapped the mounts over with magna twin pots calipers I had. Needed new brake lines, although I think some twin pots come with a banjo fitting so maybe could use io brake lines I am unsure. Also rotors needed machining which is a pain, maybe a spacer will be made for next time to run the evo rotors. The pads do overhang a little on the io rotors too..

 

just curious which magna model did you use? was it from a TJ model?

nick_io
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Sorry I couldnt tell you. I

Sorry I couldnt tell you. I picked them up almost 5 years ago, all I remember they were off an earlier magna v6 posiblly TS shape? if you get calipers from the earlier evo/vr4/magna (pre evo 4) then you should be right. 

bob_oz
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Evo 3, rvr hypergear, fto

Evo 3, rvr hypergear, fto gprx, airtrek turbo, outlander turbo.

that's what you want

.

nick_io
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Bit of an progress

Bit of an progress update..

Fitted Xj jeep steel rims 235 75 15. I didnt realise that they dont fit on the front without spacers which sucks. Must have accidently test fitted them without the calipers on. 

Mounted a section of pool fencing to my roof racks. Ive made a front and rear piece and two strips through the middle to add some strength to it. Its still not very strong compared to a proper steel roof cage but its pretty light and cheap if you get it all from your local scrap metal, and for what i need from it its more than enough. (swag, camp chairs etc)

 

 

nick_io
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Been a while since ive

Been a while since ive updated. Modded some sideteps to fit but I find they are too low and scrape all the time, might have to make my own. Also ive made front flares out of bunnings garden edging. I couldnt just rivert them under the guard so i had to bolt aluminum flat bar to the inner splash guard mounting bolts and then rivert the garden edging to the flat bar.

\

 

 

nick_io
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diff breathers

I wanted to high mount my breathers to prevent any chance of water being sucked in, this was a bit of a problem with the rear diff push in fitting, i tried silicone to join the hose to the original breather but that kept pulling out of the diff. eventually got a thick washer made up with a thread cut into it and welded that to the housing and sikaflex over the weld just to be 100% sure, and then the fitting just screws in.

nick_io
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latest mods

nick_io
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busy few months on the io

Claude io
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.

Maybe not finished but looking nice. Well done.

Happy io

simmo777
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Nice

Really like what you've done with that rear bar and the mudflaps look neat. Assuming you custom fabbed it up yourself (mig jobby?)... Should send one up to Brisbane wink

How do you find the wind resistance running dual awnings + gear on the roof, are the stock points holding up ok?

2002 5dr Pajero IO QA 2.0L Auto - Lifted, Locked!! 1.925 Low Range - Muddies (205/80/16) - Redback Extractors to 200cell cat to dump at diff Exhaust 

nick_io
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Cheers, yeah just a home mig

Cheers, yeah just a home mig job :P the wind resistance isnt great at high speeds, fuel economy goes up to about 12L/100km. Definitely recommend a side awning though!

bwangila
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Brilliant setup mate. Quick

Brilliant setup mate. 
Quick question: Where did you put the second battery? I just can't seem to find any space for it

nick_io
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I have mounted a secondary

I have mounted a secondary battery in the boot. 

Passenger side footwell

 

nick_io
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(No subject)

MadMax
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top cool, thats what I wanted

top cool, thats what I wanted for my back door, I need one table like that, well done :)

Ok, very long shot but... would you make another one? :) please :)

I live my life a 1/4 mile at the time

nick_io
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madmax, i could possibly just

madmax, i could possibly just make the table part not the backing on the door but it wouldnt exactly be cheap, postage materials etc. im abit busy atm but if your really keen pm me and ill try to price it up.

keith, thats actually the positive cable to the compressor. both negative and positive were black.

Keith65
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Is that a inline fuse on the

Is that a inline fuse on the black (negative) wire to battery ??

I have a 2nd battery in the boot also but thinking of taking out half the rear seat and extending the false floor around behind the front seat and putting the battery down on the floor instead of being in the very back of the car.

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