I took out each plug, and measured resistance with a digital multimeter. I made sure the contacts were good by etching the points onto the plug. I also cleaned the bus bar plate, wire brushed all contacts including the wires.
I'm planning on swapping glow plugs off a good starting Pajero onto mine and see if that improves anything.
BTW, have any of you heard of modifying the 4d56 glow plug module to a modern delco or bosch system?

yes that was me there. before the soccerball sized rock in the windshield and the hail damage haha.

Hey Torquemonster did you ever get your windshield replaced? If so where from and how much?

Yeah, I'd like to know for futures sake too!

So I swapped out the glow plugs from a good cold starting pajero to mine and no improvements.
My glow plugs were all pretty much white/silver except for the section close to the taps which had soot. It was in near identical condition as the good Pajero's glow plugs.
We compared the timing of the clicks and they were exact. 1 click, 2 click, then 3rd click after a minute or two at normal idle.
The resisitance on the good Pajero's glow plugs were the same at 0.4 OHM.
...So I guess the glow plugs, ECU/glow plug controller and temp sensor is fine.
Next up is the intercooler clean up, then injector cleaning, then injection timing.
I'm pretty sure air leak in the fuel system would be written off as the truck runs fine when warm/hot.
Any thoughts in this?

How old is the fuel filter?

The fuel filter is probably original since I have not changed it. I never thought a dirty fuel filter would contribute to cold start issues?
Hmmm...but I guess it should be replaced anyways.
Thanks!!

You should take another look-see under the hood. Some of the paj's have a timing advance and most of the gen 2's have it, it's easely recocnized by the 15mm coolant hoses coming from the side of the fuelpump. One goes to the back of the head the other one goes someplace I cant remember. If you don't have it there should be a almost circular lid with three bolt holes on the side of the fuelpump under the throttle assembly. These thing go bad for no reason and can be replaced.

Thanks! I'll check under the hood again and see if I can find it.
Cheers!