Pajero IO having issues can someone help diagnose? (Living remote)

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treid
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Hey everyone, first time poster here and quite new to the forums but it's been a great help reading them and all the resources that are on here.

 

Brought a 1998 Pajero IO mainly for the use of getting to work and being able to put scuba diving tanks into the back and go for a dive on my days off. I live and work in the East End of Grand Cayman island and in term's of parts and work shop's theres not a lot down this end and things can be quite hard to get too if you've not got a running or well reliable car.

 

#1 I brought the car and belived to been having battery issues... drove the car home parked it in the drive way and it wouldn't start again. It started from a jump start and I took it for a long drive to hopefully charge the battery, after the drive the car would start again and maybe one more time but I couldn't get a 3rd out of it.

Decided to replace the battery with a brand new one.... Checked with a multimeter the battery sits on about 12.6v or so when the car is off, 14.5.v when turned on and then 12.5v or so with AC + Highbeams on. Would this indicate that the alternater is ok and charging well enough ?

 

#2 Been unable to diagnose the follow issue yet. Randomly when driving the engine check light will come on. Car will lose almost all power, car wont shift gears while keeping acceleration on (auto transmittion) though it will shift once you release the gas a little and place it back on. Basically car is unable to be driven like this so pulling over and leaving the car off for 10-30sec reset's the fault and the car will start and run fine until it randomly does it again.

 

Hoping this is a good sign as it's just a sensor throwing and error for what ever reason ? I was told by the previous owner that it was a dodgy O2 sensor so to my knowledege i've replaced it, these cars only come with one sensor in the exhuast just before the CAT right ?

I also replaced the mass airflow sensor with another second hand unit as there is no new parts on this island!

Looking today to try and find out the check engine fault code by grounding out  pin 1 of the OBD unit but unsure if it has one or not will check today...

 

 

Really hoping to get this car sorted as I just moved to the island and needed a car to get to work which is making it quite hard to get to work on time! If anyones ever on Grand Cayman and a scuba diver feel free to hit me up for some diving at the shop I work at !

 

Cheers for any help!

Trent

 

 

treid
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got the error codes but cant

got the error codes but cant seem to find it relates to anything ? I get 9 long flashes of the engine light and 1 short flash which im taking is fault code 91 ?

 

ABS fault code i think is 62 but cannot find this anywhere ?

 

I cant seem to find fault code 91 listed anywhere as anything ? I've taken a video of the fault codes and have uploaded it to youtube maybe someone can help ?

 

maybe im just silly and reading it wrong?

treid
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https://youtu.be/-X2ujvIqngE

https://youtu.be/-X2ujvIqngE

 

link to the youtube video of the fault codes its a Mitsubishi Pajero iO 1998 1.8L GDI

fordem
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Quick charge rate test using only a volt meter.

Ideally charge rate should be checked with an ampere meter but very few people actually do this as it's fairly easy to get a good idea of what is happening with just a volt meter.

Start by connecting a voltmeter directly across the battery terminals and position it where you can see it from the driver's seat .

1 - With the engine off, make a note of the reading - in your case 12.6V.

2 - Start the engine, let it idle and observe the change in voltage - this should increase by 1~2V - in your case 14.5 - this indicates the alternator is charging the battery.

3 - With the engine idling, increase the electrical load - switch on the lights, a/c, etc., and observe the change in voltage - this should be more than step #1, but less than step #2 - in your case 12.5 - this indicates that your charge rate may be on the low side.

4 - Increase the engine rpms to approx 2000~2500 - and again observe the change in voltage - this should be more than both step #1 & #3 and may be less than step #2.

Because you have omitted step #4, we don't have a complete picture of what is happening - at this point I would not be too worried about your step #3 voltage being less than the step #1, as long as it increases to 13+ volts in step #4

Something else to be aware of is that these vehicles are fitted with ECU controlled alternators, and the ECU can reduce alternator output - this I believe is why you saw the voltage drop as much as it did in step #3, it is something I have witnessed myself with my car.

 

fordem
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Error codes

In the resource section of the forum there is a link to a downloadable copy of the factory service manuals - the various codes can be found in the appropriate sections.

The 91 code points to the throttle servo system - these vehicles do not have a cable linking the throttle pedal to the throttle plate, they use an electronic system where the throttle plate is controlled by a servo motor (sometimes known as "drive-by-wire").

The ABS code you're seeing is a 52 - which is either a relay or a power supply issue.

treid
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I've scanned the factory

I've scanned the factory service manuals and got overwhelmed by which one to use.. but couldn't find a listing of 91 fault code any where! Thanks so much for reply it's been a huge help ill look into the Throttle servo system and abs relay or power supply....

absolute legend! thanks mate!

 

Trent

had-z
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From memory, error codes are

From memory, error codes are on the engine section of the manual, abs codes are on the brakes section.

treid
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can anyone link me to the

can anyone link me to the exact manual i need i downloaded that big zip file with all of them but unsure which is for the GDI Pajero IO 1.8 model ?

 

https://

this is sort of the noise it's making too...

fordem
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Unzip the file and open the PININ folder.

The files you want will be in the PININ folder, start with the foreword pdf

treid
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having nothing but issues

having nothing but issues with this car.... did the silly thing a purchased it off a friend that said it was fine and in good condition and the fault code randomly showing up was due to O2 sensor...

 

now after all the work over the last few days im back in the same issue of the car not starting at all unless jump started... seems strange though as the battery I brought is literally 1 day old... it was initally doing this and i thought it may of been a dead battery so went and brought a new one, replaced it and cars started every time up until today.

 

I checked to see what the battery was doing under heavy load after installing it to see if the alternator was charging it and the battery was on roughly 12.4 when turned off 14v when running and with AC and headlights on around 12.6 or so.... figured the alternator was doing it's job ?

Now a few days later im back at square one with a car unable to start unless jump started with the old so called dead battery in the boot i replaced yesterday... any ideas ?

 

 

treid
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going to find a multimeter

going to find a multimeter and do some proper test's on the alternator and report back...

 

treid
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so just to report

so just to report back...

 

turned out to be a dead starter motor which I've replaced was a real pain to get too! also turned out to be the TPS sensor alignment was off and causing the car to throw up the engine check light anyone else had this issue ?

 

cheers

STK
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Glad to know that you've

Glad to know that you've identified the issue!

I'm going through a similar situation now. Check engine light still blinking, rev won't go past 2 or 3k.

After our iO stalled and had to tow it home, our mechanic has checked on the following:

-coil packs and sparkplugs, throttle body and sensor, air flow sensor, computer box, fuel pump, (soldered) wires, all seemed fine

*our best guess is a faulty sensor (the one attached to the gas pedal) "idle position sensor"?

 

It's been very challenging for parts esp (since iOs were not locally released here)

-I'm interested in what you said about TPS alignment? Can you give more details on that? Curious that it might help us in some way just to make sure we didn't miss it.

 

-Also in the past, I did experience the same with our iO, losing power with the check engine light going on while driving, sometime eventually stalling BUT would start normally after a minute or so. Learned later on that the battery terminal clamps were not tight enough to a point that a simple pothole on the road would rattle the battery causing the terminals to disconnecct for a split second throwing on the check engine light an so on..

Sigh, our iO has been down for more than a month now, trying to gather all the helpful info I could with the help of some very good people online here and on facebook...

treid
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Thanks for the reply, i've

Thanks for the reply, i've posted most of the replys to this in the other post you made on my TPS thread also :)

 

our battery terminals are all good but thanks for suggesting to check them

 

fjgomes79
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Hello   What are the problems

Hello

 

What are the problems that you still have?

syntoms, error codes, etc...

Pajero Pinin 2.0 GDI, 5 door (H77W)

treid
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it's still getting the same

it's still getting the same fault codes but very rarely now they don't show up for a few days or more some times... currently the car has not been into limp mode for 5 or so days after driving it into town etc...

I have repositioned the TPS sensor which I think has been the main issue with the car...

I've also replaced the starter motor, O2 sensor, mass airflow sensor and done a recent oil and filter replacement and the car is running 80% smoother then when I had picked it up....

Still feel as though its due to throw it into limp mode soon enough but hopefully it doesn't... looking to try replace the TPS sensor but have been told there is two sensors one at the pedal and one at the throttle body so will need too try trouble shoot which one is conflicting before replacing..

Also trying to hunt down a weird knocking noise under the car sounds like a worn bush and a metal on metal noise but doesn't look to be from the swaybar links or anything I cant seem to make it happen when jumping on the car to get the suspension to travel its only when drivng and 100% in the rear....

next up will be radiator flush and fill along with transmition fluids followed by brakes.... the car's been neglected for far to long and need's a bit of TLC thanks everyone for the help and input so far it's beeen a great help !

fjgomes79
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Hello It is more likely to be

Hello

It is more likely to be the throttle sensor and not the pedal. There is a procedure to adjust and test the sensor.

 

Try this with a multimeter. With the ignition key OFF...

Procedure for adjustment:

If everything is ok then tell me because it could be the throttle motor. There is a way to check or repair.

Pajero Pinin 2.0 GDI, 5 door (H77W)

treid
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this is the info i was after

this is the info i was after and couldn't find in the manual im thinking ive got the wrong manual or something thanks so much ill get back to you on my readings :)

 

only thing is i've noticed you need a harness to do this wondering if i can some how without one :/

fordem
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Nope.

If you have the manual from the resource section that I pointed you to in post #4, this information is in there, post #8 tells you how to find your way around the manual - and yes, the adjustment can be done without the harness - you'll need to "back probe" the connector.

fjgomes79
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Hello   If you make a harness

Hello

 

If you make a harness yo will be able to do this and much more.

I made one with normal electric materials. I will take a picture later and show you all.

 

 

Pajero Pinin 2.0 GDI, 5 door (H77W)

loisonnzali
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Hello thank you all for

Hello thank you all for explaining 

But I have the same problem with my pajero io 4g93 engine 1999 gdi 

It starts and idle properly but when I need to accelerate it stall and engine dies.

I have changed all engine sensors even the gdi pump but the problem continues

when on the road the check engine light blink and code 56 appears 

And when I disconnect pressure sensor harness the car run smoothly until the engine run out of the fuel through the system

loisonnzali
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By the way am from Dar es

By the way am from Dar es salaam, Tanzania Africa spare parts not a problem

fordem
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A code 56 is fuel pressure related.

A code 56 is defined as "abnormal fuel pressure system" - you can find the details, as well as the troubleshooting steps in section 13 of the manual in the resource section.

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