Claude's io/ 2002 ZR/ Built thread only...happy io!
20/11/2016....I have SOLD my io....but I am still around the forum....thanks.
Last review on March 2019
Welcome to my built thread, what better way to start other than a few video to show you what can be done with these great Pajero io....enjoy....
Latest video from Yalwal, at around 5 min, you can see other 4wd doing the same hill that I have done in the next video.
brindabella 2 Pajero io and a Hummer H3 having fun.
Hello, I have a 2002 io, 3 doors, ZR option, manual and it now does have 207 000km. Since new, the car was serviced by the dealer; no longer since the 160 000km service.
In some post, I talk about a 99 model, I recently bought it without rego. It got fixed...and then sold it...
I live in Canberra, Australia, and I love fishing in the Brindabella and lake Tuross and go 4wd.
I bought my io to a lady colleague around 2007 with 45 000 km, I have tried in the past to change a few thing but got too often the reply that nothing was available for this car. This forum have help me improving my io. It all started in 2008 by my first mod !! new tyres BFG 215/70/65 A/T and they made the car a better 4wd. A lot more modification have been done since and the tyres got replaced by 245/70/16..
Some modification may have some downside or may be illegal or not covered by some insurance, check first!. I try to give information that include the good and the not so good!
This is what I have done:
- I fitted a tow bar.
- I bought four BFG KM2 225/75/16. done about 60 000 km, again they made the car a much better 4x4 and raised it as an extra. Now fitted with mags and 245/70/16 MT Maxiss
- I got made by "Kmac Sydney" a custom top strut plate for camber and caster adjustment to have a better behaved car at faster speed, car was wandering a bit (removed now)
- I installed some tint on the windows, (from ebay).
- I got ARB to fit a rear diff lock with upgraded compressor to inflate the tyres, fitted under the seat for easy access.
- I fitted a K&N pod filter.(removed to install the snorkel, a bit later...but I got a K&N filter to fit in the original air filter box) Removed the resonator.
- Replaced the complete exhaust system, fitted extractors and 2 inch high flow exhaust with dyno test done before and after.
- Fitted new improved headlight bulb called "philips x-treme vision"
- Custom made rear bumper access plate
- Custom made 5 mm checker plate aluminium bash plate
- I fitted rear air bag spring helper.
- NGK Irradium spark plug fitted.
- Fitted Mazda Astina spring in the rear (about 1.5 inch lift)
- Made some 1.5 inch spacer for the front strut (removed, testing new set up)
- Built and installed a Jaycar speedo corrector.
- Small lift
- Fitted a OGZ snokel from Brazil
- I fitted an UHF, a GME TX 3100, very small unit, in place of the ashtray. Moved to the top of the clock, with a bigger dashboard hoodhood.
- Fitted 60 mm longer rear shock.
- On the 13/02/15 I fitted new 7 inches wheels with wider tyres, 245/70/16 MT Maxiss Bighorn 764.
- Low gearing fitted ratio 2.85, original is 1.54. that about 85% reduction (1.925 is only 25% reduction)
- Custom fit a 9500 lbs winch behind the front bumper with in dash control switch and upgraded cable and Optima yello top battery
Link to my youtube channel, mainly some io fun....enjoy :)
http://www.youtube.com/user/AustraliaClaude/videos?flow=grid&view=0
Other video with my io
http://youtu.be/a6nn8S3c3Zo http://youtu.be/np6aQfu5r3s http://youtu.be/Uq2ZR7Kc_T8
My wife and I have done a solo Simpson desert crossing on the 17/07/14. For this trip I have installed a few more mod. I have installed a 20 litre jerry can holder on the spare wheel, a home made platform on the roof for extra fuel (with deflector), 2 USB kit to recharge electronic "toys", 3 roof bars instead of 2 to hold everything on the roof (pod included), extra led light in the rear, installed a system to swap the intake air filter (snorkel only or snorkel and original one)....and a bit more....
If you are in the area and would like to go for a drive or say hello, let me know. All welcome.
And don't forget.....HAPPY IO.....!!!
Here is my car with the BFG 215/70/16 A/T
With the new BFG KM2 225/75/16
Top of Mt Coree Brindabella
Again, I like that one...
With a bit of view
The io as it is today. Taken at Fraser Island
Thanks/window tint
Thanks all,
I have done the window tint, my wife is gone on holiday with my camera, I have to find another one to post a picture.
I am happy with the result, as KTM wrote, fidlly but it can be done. It is not as good as in the shop, but it is still great. One small crease and a tiny amount of dust and you have to put your nose on it to see it. I have been quoted $330 at the shop, and it cost me $75 on ebay (with some spare for another 2 or 3 windows) so it is a good saving too, and it will protect my right ear!
At first I wanted to tint the back with 15% and the front with 30%, but I have done the lot in 15%.
Happy io
old tint
Mine didn't have anything on the windows. I had removed some film out of a house and that wasn't too bad. It does work better if the windows are warmer, and I removed the rest of the glue with acetone and a flat blade, being careful not to scratch the glass. I would be extra careful in the car with all the trim (the acetone might damage them?)
Happy io.
arb diff
OH YES:) Can't wait 
. I have the car booked for the 19/01. Just a quick reminder. If you remember they rejected me... "diff too small"... I did send a written complain to Melbourne...and they reply to tell me that they were wrong...they called...I went to see them...sat down and listen and shut up, and they actually were very good, saying that Bob's diff was not recorded and apologized about it...they gave me a better price (not a bargain but still) and it is getting done on the 19/01, yeah next year...lol. At first I only wanted to get to my fishing spot, now I start to go to the brindabella just for a drive, taking some friends, and looking at some stupid steep hill thinking can I try that, and more and more "I have to try that one"...
Once it is done, I will make sure with the person who contacted me from Melbourne that the io is in they listing as I was told it would. That should save another io owner some headache.
I wish your trip would have been closer, it would have been really good to meet you guys...and see these io into action...:(
Happy io.
Edit ARB have the io listed now, no more fight to get it done !!
Good stuff Claud!Good to see
Good stuff Claud!
Good to see you make ARB accountable too! posting there replies and rep service on a public forum is a good way to make them think about the way they treat us "little, pretend 4x4" guys in future.
I want to see some video of you driving straight up this now :)
hehe
Thank Glen, I love the picture too, the up was easy you should see the down...lol...first paragliding io:)
It is funny that you mentioned the video, because I go fishing a lot and I often go alone (lots of walking, some climbing, and people don't come back for second!). I have decided to buy the gopro hero 2 video camera to try to film some trout catching, and some 4wd action to keep as memory and show other. both mixed up as an action package! I hope that it will be as good as I would like it to be:).
Anyway, back to business! I have removed the top bearing plate and it is going to K-Mac Sydney tomorrow. They have been very helpful and it is great to have some real professional helping the little io. I haven't done that sort of work for a few years and it took me one beer and half an hour with a lot of "where is this, where is that..." I got the reading of my wheel alignment today. I should get the new plate in under two weeks. I cross finger on that one, and hope that it will be, again, as good as I would like it to be:)
Happy io.
ARB
DONE, I just pick-up my car from ARB Fyswick with the rear diff lock fitted with a compressor able to inflate my tyres. Just have to try....
Happy....Claude...
I have contacted ARB Melboure to confirm that the io will be in they next application chart. This is the reply. So, it should all be good...
Friday, 20 January 2012 3:15 PM
Hello Claude,
It is very good to hear that you now have your locker. I will pass the information onto the relevant people here to make sure it is listed in future application information.
Regards
Roger Chestney
Roger Chestney
National Customer Service Coordinator
Occupational Health & Safety Manager
ARB Corporation Ltd
Head office and Manufacturing Complex
* 42 - 44 Garden St, Kilsyth, VIC, 3137
Diff Lock first drive
Hi Bob, the book they gave me say 2500 km for the first check, I will call them to double check. No fat food for me!! so I haven't had doughnuts for maybe 15 years, now that I think of it (torana slr v8, manual...)
First drive, what can I say MORE GRIP! First drive was close by with one short big dip across the dirt road. Only short wheel base go through, I have seen a few 4x4 turn back! I used to slowly put the front wheel in, then accelerate and use some momentum, and get the rear wheel to push the car out, all that with some lost of traction. Hum, this time the acceleration got me flying out without lost of grip, that was like being pushed from behind, I am not sure but I think that the front wheel lifted for a short time. I still got goose bump and a smile on my face...
Then I went down "gentle annie trail" and on an intersection with a difference in level, again I used to go through using some momentum, as one rear wheel does lift up, not much but enough to make you fail. I got through very slowly (didn't want to repeat the ...push...) and again no lost of grip. On the way up I used the diff lock to see how it would change the drive. Standard tyres would go up with lots of lost grip, the bfg a/t much better, with the km2 bloody unreal no lost of grip if going easy and slowly. Now with the diff lock, I can push the car more and go up faster with nearly no lost of grip.
The compressor is working very well to pump up the tyres.
One thing that I need to confirm, since the lsd diff is no longer. On the road on a particular bend, the back of the car would move, jump, slightly and I think the car moved a bit more than usual, this said the road was wet and I might have been going a bit faster that usual. No difference in town. I am wondering if the fact of not having the lsd diff would save me some petrol?
So, YES I am happy. The car is better and safer. It is not cheap, but I am going often by myself and improving the car could improve my safe return. It improve the fun too:)
I have my gopro, I just have to work out the way adobe premiere element works...
HAPPY IO
Lsd diff?
Hum? I though I had, but you are putting a big question mark in my mind now! I use to have the original paper from Mitsubishi with a list of options but I just can find it...again, you might be right!
I am working on the video, a very short one is on his way but no presentation...music...I am still a bit with 2 left hands on that one!...It won't be the best representation of the extra grip, as it is a bit difficult to show...but, at least, it will show the windows tint that i have done...and promised some pictures off...
Happy io.
essais video
This is a try, no spcecial effect or presentation!, it is a short passage in a place not to far from home. I have done 2 other in the Brindabella, but they are mainly steep hill and the video make them too flat:( On this on you can see a wheel not touching the ground a couple of time. I am going to add some more attach to this one where you will be able to see the out...
Edit, only the last part is interesting, to see the wheel "work" make lots of pause and start....
Happy io.
mushroomrock from Claude io on Vimeo.
video test
Hi Claude, After lgging in to Vimeo I get an error: "Sorry, you do not have permission to watch this private video". Is there a setting you can change to make it public (I'm not a regular user of Vimeo myself)?
Thanks, try now....cross finger! be kind, 2 left hand virgin video maker:) If you can watch it, I found to pause and play to fully see what is happening, or it goes to fast!
Happy io
tint supplier
Claud, love the window tint, Which ebay seller did you buy the tint from? Might give it a go myself also
John
I got it from proTinting, I got the black 15%, 500 mm, a bit dark but I like it. I contacted them first and told them the length, size, I needed. One film had a very small clear spot in it and after contacting them they send me a complete new roll. The faulty spot is that small that I didn't replace the film. The advantage of the darker tint is that it is great at hiding the dust mark and small bubble, but get the cut right! I got the small tool kit as well, worked well. The total cost was around $75, with lots of spare. They have different colour...some interesting one! Try this link.
http://www.ebay.com.au/itm/290359901912?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649
Good luck and Happy io.
Adjustable top strut plate
For the newcomer, after fitting bigger tyres 225/75/16 my car was a bit wandering and I decided to do something about it. I choose to have some adjustable top strut plates to increase the caster angle.
After contacting Kevin at K-mac, his first reply was that he is not working on 4wd. After a couple of email, he agreed to help, (our io is not a heavy vehicle, and much lighter than most family sedan). A few more emails, a visit to his shop and done! The plates are made so they wouldn't change the level of the car or the height of the shaft's insert, and they are design with the pillow ball in order to be that way. To compare the result, I made a wheel alignment before and after and I didn't change anything on the car that could change the end result (ie, new shocks)
I have fitted them on the week-end and got a wheel alignment done this morning.
Now the result,
The good thing, my io is no longer wandering and it does drive so much better and safer at higher speed (over 100km), I noticed the difference straight away, the 1 degrees increase in the caster angle made a big improvement . This is only for the wandering, the thickness of the tyres still make fast change lane unimproved (normal, but I just wanted to mention it). Camber can be adjusted to at least +/- 1 degrees as well.
The bad, (not that bad....!) the plate design would allow for more increase in the caster/camber but the top plate that hold the spring would touch the inner guard, as they are rotating while turning, a gap must be left (didn't need any more increase anyway!). You cannot have full adjustment of the camber and caster together (1 degrees of each, but you could have 0.5 degrees, or less, of one angle and 1 degrees of the other). The steering is very slightly heavier (normal), I broke my spring compressor half way during the work!...
The unknown, I don't know how strong they are, time will tell, but K-mac have been around for...a long time...and the plates come with warranty. Some internet site mentioned that the pillow ball design can transfer vibrations, I think this is more on lowered car with very low profile tyres and I haven't noticed anything.
Overall, I am very happy with the result.
The cost of the plates is $380 plus postage and now readily available at K-mac, Sydney.
. 
for K-mac, Kevin from K-mac is very good at what is doing, and very professional. They do other work on suspension and they are worth knowing. I had a very short visit of they workshop, and that will make any part maker dream for a few night!
One plate
On the car
Camber before -1 and 0, now -0.6 and -0.2. Caster before 3.5 and 3.5, now 4.6 and 4.5. Toe before 0 now 1.2mm.
As always, Happy io...
Edit, I have kept an eye on the plate for a while, and I added a couple of spacer (see below) but since everything is "all good" and, for me, it does improve the handling of the car and it is a very good mod.
Edit, Since doing some harder track, and having kept the original spring (too soft) these plate got slightly bent. They have been removed when I fitted kingspring spring. Since tyre wear is good and it drive fine (with the kingspring).
K&N air filter
I have found a second hand K&N apollo air filter, I am going to fit it and see if it does help for the fuel consumption and may be gain a bit of power (that should not be much, if anything!). I paid $160 with the cleaner and the oil for the filter, and some adaptor.
For the K-mac adjustable plate, I rechecked them after 500kms. I have found that one nuts was not tight. The top tower was slightly bending in, so I made a spacer to fit between the main plate and the tower mount. I should have rotate the plate to have the bolt close to the edge of the main plate, it was right in the middle of it (see above picture, top right nuts). I have since rechecked a few time, and it seems to be all good.
Happy io
Just fitted, I had to buy a pod adaptor to connect to the "air flow meter". This is not the final set up, but it will be good to see how it goes. It is a bit fidly as I could not find an adaptor of 70mm to match the outlet of the filter. So I got a 76mm and the blue connection is 76 mm as well. I just fitted a piece of the black conduct (70mm), that it sold with the air filter, on the outlet of the filter and fitted the blue section on the top of it.
I am not sure how it will work for the petrol, but it seems to be a bit better power wise. I love the noise that it makes, only under heavier load, a bit like a slow muffler leak.
Thanks to Ebs, as I never heard of a K&N filter before. I will get back to you regarding the petrol consumption, probably Friday.
Happy io.
Edit, this filter have been removed when I fitted the snorkel.
Just a word of caution
I've nothing against K&N filters, I've been using them for over a decade, and with very good results, both from a power & economy stand point (and the induction noise is simply stunning) - but on the street - I'm not certain I would put one on a vehicle that's going to see off road use.
Essentially a K&N filter is a wire mesh frame supporting a couple of layers of surgical cotton gauze coated with a "high tack" oil - the wire mesh doesn't filter, it's purpose is to support the cotton gauze, the cotton gauze doesn't filter, it's purpose is to hold the oil - and the oil doesn't really filter, the dust sticks to the oil as it passes through the gauze - some dust is pretty much guaranteed to make it through, and the more dust there is, or the finer the dust, the more you will have getting through.
A Google search will get you lots of controversial views on the subject.
K&N filter
I have just filled up my fuel tank and I haven't found a better fuel consumption 10.75l/100km and, I think, that it is similar as before, in town driving only. I may have stuff up somewhere...I am going to put the original filter and test again. I went fishing, got some nice trout (38/39cm), and I had the feeling that the car was drinking a bit less...hum I need more time, kms to make sure.
Yes, thanks Fordem, the extra dust while 4WDriving is something to keep in mind. Air filter working in oil tend to clog up as well, and in turn slow the air flow too.
Here a couple of pictures, nothing to do with air filter (may get the air a bit higher!) but I couldn't resist to share...yes, same spot. I am collecting some video, pics to do a small film...
Happy io...
pictures
Damn nice photos, I like how you have got the car into that position, then gotten out to take the photo. Any time I try something like that I have the feeling the shift in weight is going to make it roll over, haha.
I have to say that, yes, I think that they look good too:) but I am still in the car. I used my new gopro hero2 camera, on a stand. And yes sometime I have that feeling as well, but it is closely follow by a good smile:) , not if I roll it!
Yeah, Happy io...
Back with the K&N filter
Thanks Fielies.
Already 2 months! I have try to get some result regarding the fuel consumption of my io and the K&N filter pod. I had to do a few test, and then some more test again. As I fitted the pod, one part of the air filter have a small container to, I think, stop water going in the inlet manifold (black, plastic, and about an average glass size) and it got a bit too close to the exhaust manifold, and melted on a small section!!! As the engine was not idling properly I decided to check and found that the melted section was letting air going through...as I said I do stuff up...and yes you can ask her!
Anyway, I won't go to talk about the way the filter works, and I agree with Fordem as it might not be the best filter for very dusty condition or even a good replacement filter. After some research on the net, some love it, some not so much....
Here is what I think/found...
Power wise there is not a big difference, but you still can feel it. The engine seems to be more responsive in the higher range of rpm, but again not a big improvement. Fuel wise, it took me a while to work out what happen, as I got different results. For the every day "go to work...boring drive" the consumption is around, in average, 0.3l/100km better, 10.5 against 10.8. I have to say, not much, but better than nothing!
When I said that I found different results is because, my fuel consumption when I do some 4wd, is much higher. It is hard to give you a true figure because I do some normal road mixed with my 4wdriving. When I go to my favorite fishing spot (4x4 and normal road mixed), the car average around 15l/100km with the normal filter, with the K&N pod it went down to 11.5l/100km, and this is a massive fuel saving. I think that the K&N pod works better when the engine is under load (towing, 4wdriving...) which I can understand that (at least now!!)
When I swapped from one filter to the other the engine was idling at around 1000rpm, I found that letting the car idling for 5 minutes would bring the rpm back to normal (no I am not a unbelievable great mechanics, I just got a long wait at the red light!)
Cleaning the K&N filter takes longer than putting a new one in the normal air filter, but once you have bought the cleaner and the oil (that should last a while, as you don't use much of it) it is cost free.
I cannot advice anyone to fit one or not, but I hope that my finding will help you choose...
Happy io.
Water in filter
Thaks for the feedback Claude,
In your research what did you saw regarding water with the filter? The compartment you spoke about is it that it wont allow any water going in? Reason I ask, I have drowed my IO a couple of times and must say the std filter box really does the job by releasing the water out underneath. But the K&N does sound nice on the IO. I had a normal AM filter on with foam but after the first drowing I thru it away being affraid I might take in some water.
Whats you take on it?
Water
Hi fielies, I think that the little container is to catch some water, (not much!) condensation? but it may have other use, I have no idea!
I normally put a tarp that goes on the bonnet and the front grill, this have left the engine bay dry every time (don't stop in the middle!) this said this K&N pod filter is, as you said, not to be with water! I had a close call with water with the original filter too (lazy to put the tarp!) the same thing with the K&N would have been a costly mistake. I haven't, and I will stay away from water crossing with the K&N filter fitted, unless some big fish are the other side,emergency:)
I have installed this filter as part of future modification: extractors and high flow exhaust, (maybe more, I am still working on it) and I am looking to find ...a snokel...to keep everything...dry...and safe
Happy io
geezz
stop teasing me with that locker talking, Claude.... my "mental" lockers are still working...LOL...
Re the K&N, I use the inbox model...
My impression is: better idle rpm, a litlee better fuel consumption, a little better power..... all LITTLE improvments..
I found that I must clean my K&N every trail I do.... It becomes MUCH MUCH dirty than the regular filter...Don't know if this means it is flitering more?
i have a video of my cleaning...
(oh, yes... that nut brazilian and his videos.... he shot everything!!!!...LOL....)
That's an interesting comment
I found that I must clean my K&N every trail I do.... It becomes MUCH MUCH dirty than the regular filter...Don't know if this means it is flitering more?
If you're finding much more dirt it would suggest that the K&N is trapping more dirt than the regular filter - question is, are you seeing more dirt in the intake system downstream from the filter with the K&N, that would indicate it's passing more dirt.
Do be aware though - you'll need to replace the K&N in a lot less than the projected 1,000,000 miles - washing them frequently shortens the lifespan .
Indeed
I found that I must clean my K&N every trail I do.... It becomes MUCH MUCH dirty than the regular filter...Don't know if this means it is flitering more?
If you're finding much more dirt it would suggest that the K&N is trapping more dirt than the regular filter - question is, are you seeing more dirt in the intake system downstream from the filter with the K&N, that would indicate it's passing more dirt.
Do be aware though - you'll need to replace the K&N in a lot less than the projected 1,000,000 miles - washing them frequently shortens the lifespan .
Everytime I take the KN off to a cleaning session, I check the intake system downstream, at least visually and to the place my hand/fingers can reach, and it seems to me quite free of dust/dirt....
Bargain priced snorkle and other 4x4 stuff
Claude iO: If you are after a snorkel, and you are a "handy-dude", here's a suggestion.
Tigerz11 have several snorkle kits for sale on their website, for only $75. None of these are for the Pajero iO, but like I say, if you are handy I could see one of these kits giving you an excellent start for a snorkle project. The price is super-excellent for all the good junk that you get.
While you are looking at the Tigerz11 website, check out some of the other good stuff. I am going to buy a hi-lift jack ($59 including a bag), and a jack-mate so I can lift the car using the spokes of my steel wheels. I just need to decide whether to get a 48 inch jack or a 60 inch one (same price). The 48 in. one should do for the iO, but I have a Mazda BT-50 4WD as well. (maybe I should buy 2 jacks?). I also have a tyre deflator ($25) on my shopping list. I also like the look of their air tanks ($59), which are also cheap, and come with lots of bits and pieces for installation.
Dyno test/sport exhaust
Thanks R A Teabag, it is cheap! I don't remember seeing a snorkel for that price, but I don't think that I am good enough to modified it!
I have my car booked for next Tuesday for a sport exhaust. I hope that I will be happy with it....finger, and everything else, crossed!
At the exhaust shop we had a look at the original exhaust manifold, and we both though that it wasn't a bad design...too bad, I already got the extractors!...
To check what sort of power gain I am going to have the car is going tomorrow on the dyno and will go back after the exhaust is fitted. They told me that this will tell me if the car is still running fine as well. and they will advise me what else could be done power wise.
Happy io
sounds awesome mate. i think
sounds awesome mate. i think i might need a new exhaust or muffler or something. been thinking of taking it in somewhere as it just sounds funny, like theres a whole in it somewhere, but i can't see one. and its definately the exhaust i know that for a fact...
let us know what the results are...
Dyno first result
I have just done the Dyno test, 3 runs, the result is between 55kw and 57.4kw at close to 5000 rpm. This car is normally (in the book) 95kw at 5500rpm, the most I have at 5500rpm is around 54kw. The car is not new:( and the bigger tyres would probably explain the loss....I have to say that the car felt a bit slower after fitting the new tyres, but it is not bad at all! and I am happy the way it goes. Maybe it never had 95 kw??
At least I have some precise numbers and the new exhaust should go on Tuesday, and she will go on the dyno, again, a bit after that.
He connected the ecu and got the map and he will let me know, next week, if something can be done. From what I understood he will send it to someone in the U.K. I never work with ecu, so I can't explain it better!! but I think that some ecu can be played with (tuning...), some not and would required a piggy ecu if I want to go that way...not sure...$$$ Anyway, this will say what the exhaust does or doesn't. I think it is interesting...I should have done it before fitting my K&N pod filter.
Work done by ESP (Extreme Street Performance) Queanbeyan.
Happy io
.
That's really interesting Claude.
Though I imagine the manufacturer spec to be exaggerated.
Considering most IO's on here are well used, your results are probably the reality for us all.
Some shops quote 180 odd kW as max achievable for aspirated 4G94's.
Now that would be special!
I'm as keen as you, to see the results of your extractor/exhaust upgrade.
Edit:
- The torque curve is nice and flat.
- Your locker may rob some power as well?
Syndicate
.
Nice car.
Nice fish.
Nice scenery.
No wonder your so happy all the time.
"It should be assumed everything I say and do is incorrect ".