Pajero Owners Club of South Africa

Hi Guys, I reckon this can spoil n holiday!

I service a few Pajero's on a regular basis and for the first time I found a lot of dust on the "clean" side of the air-filter box (on a swb with 190k on the clock), and the flex pipe from the filter box to the turbo(see pic below).

Some further inspection and I found that the slide clips x2 (as per second pic) on the box was worn, so, the air that is supposed to enter via the air-filter bypasses the filter and enters strait from the engine bay into the motor. Not only is the dirty air entering the motor but also warm air.

I also checked my LWB(same km's) same issue, Mitsu in Brooklyn dit costing on the top box @ R660 (in stock) and an estimate on the bottom(body assy, Air Cleaner) @ R1 500. Felt a bit steep as wear shows on both units, I decided to make a plan, used some thin wood strips & some Q-Bond to get the box to seal again, then used some grease on the filter edge to see if the filter is sealing. Since this I've serviced 6x 3.2's and found 1 more @ 244000km with this issue.

An off-road trip with lots of dust and this problem might cost you an engine, pls check it.

CJ

@C J Jonker,

You could also add to this that the clip that you show in the bottom pic breaks off - whether that is because the service techs don't know how to remove the top of the airfilter box or whether because of design who knows.

I wonder if it wouldn't pay to fit (rivet) a pair of flexible toggle steel latch w/catch along the lines of http://uk.rs-online.com/web/p/latches/1 ... _346534|fp and then plug the rivet holes with silicone?

A significant cost saving on a complete new air filter box.

@ CJ Jonker, agree with you on this . When I checked mine the first time it seemed like a flimsy design. Ons has to be pretty careful to make sure the top locks properly. I don't like it one bit.
Could not replace the complete unit with someting more robust, perhaps a Donadson housing and filter.
Has anyone here changed their setup ?

Well is suppose you could try and nick some ideas from my dad's gen1 with the gen3 heart.


https://www.pajeroclub.co.za/forum/viewtopic.php?t=19

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Marius,

Your dad's solution certainly looks more robust than the original. Is that a Donaldson part? Do you know the part number?

I hear a snorkel calling my name......

I checked last night, mine broke off. I will have to make a plan this weekend.

andrew.ashton wrote:@C J Jonker,

You could also add to this that the clip that you show in the bottom pic breaks off - whether that is because the service techs don't know how to remove the top of the airfilter box or whether because of design who knows.

I wonder if it wouldn't pay to fit (rivet) a pair of flexible toggle steel latch w/catch along the lines of http://uk.rs-online.com/web/p/latches/1 ... _346534|fp and then plug the rivet holes with silicone?

A significant cost saving on a complete new air filter box.

So I attacked this problem today. When I was in Mana last year I saw that my one clip was broken, but there didn't seem to be any bypass into the clean air plenum of the filter.

Then when my paj went to Mitspro for a service they made a repair (by putting a screw in). But the filter box is made of a mix of plastic and paper (I kid you not - look in the workshop manual) so of course the screw quickly pulled out.

I knew I had to try something more rugged - so this is what I did:

1. Removed the filter box.
2. Cut off the broken bracket.
3. Made a new bracket (2 pieces of 3mm perspex glued together to make a 6mm thick piece = same dims as original).
4. Glued it to the filter housing using Bostick Btitzstick for Hard Plastic.
5. Drilled and tapped two holes for 4mm dia cheese head set screws.
6. Reassembled with set screws and washers.

The filter just fits with the protruding set screw heads so watch out for set screws with large heads.
I will report back on how this does in the rough of Mozambique next month.

Brilliant fix. Well done!

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Busy stripping mine for a service and noticed that there was dust in the filter box. Clips are still in good condition, so will inspect this and see where it is not sealing correctly.