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Old 3rd December 2008, 15:58   #1
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Default MM540 Reborn

Hey Guys,

This is another story of a MM540 revived from the dead bed. This is how i got it, pretty bad shape. Engine was smoking, no brakes, steering needed constant attention.

This was the status when got it (pic below). Updates to follow.
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Old 3rd December 2008, 16:10   #2
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Wow, nice seeing starting of a new MM540 story here.
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Old 3rd December 2008, 16:29   #3
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Following are the upgrades / modifications that we planned.

1. TD 25 engine from a Nissan Navarra 4*4 (1999)
2. 5 Speed Aluminium Gear Box of Nissan Navarra
3. Booster brakes from Nissan Loadking
4. 5 Speed Aluminium Gear Box of Nissan Navarra
5. Tyres not decided ???
5. Patch work and painting
6. Colour 'engine silver;
7. Seats from Marshal
8. Disc Brakes from CL 550

The engine was bought from Dubai, of a old Nissan 4*4 pick up, my brother is there so he helped me in that.

Following are the Engine Specs:
2500 cc
80 Bhp @ 4300 rpm
163Nm @ 2200 rpm

Man for the Mission : Kunjettan ALIAS Ayyapan.

He is one of the closely held ‘secret’ of auto lovers in Kerala. His works had gained national and international (yes!!!) acclaims in the past. When there was no diesel Ambassadors available, he was the guy who showed us how to convert it into a diesel. He modified the factory produced petrol ambassador with a Matador diesel engine way back in 1972. And that wasn’t it. In 1985 he dieselized the Standard 2000 with an Isuzu diesel engine. This work gained attention even as far as London and they (Standard) send a team of experts to see his work; after visiting they extended an invitation to him to join them in London. But as luck would have it, some skeptics scared him by saying that they are taking him to kill him.. He continued here with his own workshop here working on local Ambis’, Contessas’, Toyotas’ and Benzs’.

Kunjettan (centre) and his workshop.
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Last edited by Samurai : 3rd December 2008 at 17:20. Reason: avoid back-to-back posts and font tags
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Old 3rd December 2008, 17:49   #4
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Well interesting story. Tremondous mechanics are present in kerala. Will any day prefer these guys. Waiting for more now
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Old 3rd December 2008, 18:27   #5
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Default Great setup!

This seems to be a good setup. Waiting to see it on road. Do upload more pics of the engine and the work as it progresses. I would be a great help to all those thinking on the same lines.
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Old 3rd December 2008, 19:18   #6
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Default What about spares

everything ok, but how are you going to manage with the spares requirement for the engine - are the spares available here in India or you shall import it from Dubai too.

looks like you have done your research before getting the engine - any legal hassles when you got the engine from Dubai - as far as I know they dont allow a used engine to be imported -

let us know more

Regards
Irfan
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Old 3rd December 2008, 19:18   #7
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Another babe on the board! Really nice to hear about a new work on 540.

BTW: Can you please elaborate how do you import the Nissan engine from Dubai? What are the procedure for it? Where is this workshop. In Cochin??

Awaiting your feed back.

tks/sali
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Old 3rd December 2008, 19:33   #8
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An old Indian Express article that came about Kunjethan.


The patchwork is on full swing. We took the jeep in this pathetic condition all the way to Kunjithany ( 13 km away from Munnar ) for this. They are probably the best guys in this, no rust for ages. The jeep had brakes and we need to use 'pedalling ' to get enough braking, ghat section was scary, buses coming down hill were literally giving us goose bumps, but there were lot of sand dunes on the road side for slowing down !!! The patchwork was time consuming, it took almost a month for this to finish and plus more delay was caused as we had to go everytime to Kunjithany from Cochin ( 130km) to monitor. We used to visit them atleast twice a week. And in between had to roam TN and Kerala for jeep parts. New doors were bought from Trissur ( 60km), bolero power steering was bought from Chennai ( 740 km), seats and brake boosters from Coimbatore ( 200km ). we had initially planned to get everything from Coimbatore, but we couldnt. Travelling was tiring but the enthusiasm that we might get the stuff bouyed us.

And on our way back after the initial patchworks along with my codriver (cousine).
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Old 3rd December 2008, 19:51   #9
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@prmd_cochin

nice 540.. can you tell me the cost of the 540 and where the workshop in cochin
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Old 3rd December 2008, 20:03   #10
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Hi prmd_cochin:

Where is Kunjettan's workshop?
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Old 3rd December 2008, 20:08   #11
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Quote:
Originally Posted by 4x4addict View Post
Hi prmd_cochin:

Where is Kunjettan's workshop?
Its near Kolenchery. Give a call on 9895180071.
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Old 3rd December 2008, 22:30   #12
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can't make out from the pics if it is 2WD or 4x4?
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Old 3rd December 2008, 23:06   #13
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i worked in kolencherry for few months.where exactly is it?
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Old 3rd December 2008, 23:29   #14
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Great to see another 540 restoration in progress.

Please keep updating us with loads of pics and details about the restoration process as well as the cost involved.
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Old 4th December 2008, 00:12   #15
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This 540 looks like it's a 2WD. Are you planning to convert it into a 4x4? It will be interesting to see how the Nissan Navara engine can squeeze into the engine bay and whether M&M's transfer-case can be mated to the gearbox you are using.

Cheers,
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