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Mitsubishi

Mitsubishi Pajero Service-Reparaturhandbuch 1991-1999

Mitsubishi Pajero Service-Reparaturhandbuch 1991-1999

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Vehicle data plateRef 580765
Brand
Mitsubishi
Vehicle
Car
Models covered
Engines, Mitsubishi Engines Manuals, Pajero
Years
1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

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🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Pajero
Generation:
Second Generation (1991-1999)
Codes
Chassis Codes:
V20, V30, V40, V55, V60, V70 series
Engine Codes Covered:
4G54, 4G63, 4G64, 4M40, 6G72
👋 Introduction
Market Position
Segment:
Mid-size SUV / Off-road Vehicle
Key Differentiators:
Renowned off-road capability, durable construction, available Super Select 4WD system, comfortable for its class.
Competitive Analysis
Competitors Circa 1991 1999:
Toyota Land Cruiser Prado, Nissan Pathfinder/Terrano, Land Rover Discovery, Jeep Grand Cherokee, Ford Explorer
Key Features Of Model
Body Styles:
3-door short wheelbase, 5-door long wheelbase (wagon), and convertible (rare).
Off Road Systems:
Part-time 4WD, Full-time 4WD, and the advanced Super Select 4WD (SS4) system with locking center differential and various terrain modes.
📋 Manual Details
Coverage Areas
Regions Covered:
Global (specific applicability may vary by market)
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, valve train, timing systems (belt/chain), lubrication, cooling
Engine Management:
Fuel injection systems (MPI, GDI), ignition systems, emission control systems, diagnostic trouble codes (DTCs), sensors, actuators, ECU
Transmission Manual:
Clutch, gearbox assembly, internal components, shift mechanisms, fluid specifications
Transmission Automatic:
Torque converter, planetary gear sets, valve body, hydraulic control system, electronic control unit (ECU), fluid specifications
Transfer Case:
Operation, maintenance, repair of 2WD/4WD/Super Select systems
Suspension:
Front independent suspension (Double Wishbone), rear multi-link or coil sprung solid axle, springs, shock absorbers, control arms, bushings, alignment specifications
Steering:
Power steering system, steering gear, column, linkage, hydraulic pump, fluid specifications
Brakes:
Front disc brakes (vented/solid), rear drum or disc brakes, ABS system, hydraulic lines, master cylinder, brake booster, parking brake
Electrical System:
Battery, charging system (alternator, starter), lighting, horn, wiper system, power windows, mirrors, door locks, fuses, relays, wiring diagrams
HVAC:
Air conditioning system, heater core, blower motor, climate control, refrigerant, system diagnostics
Body Interior:
Body panel removal/installation, trim components, seats, dashboard, interior panels, sound deadening
Body Exterior:
Doors, hood, tailgate, bumpers, fenders, glass, seals, paint code information
Procedures Included
Maintenance Routine:
Oil changes, filter replacements, fluid checks and top-offs, tire rotation, brake inspection
Troubleshooting Guides:
Systematic diagnostic procedures for common and complex issues, symptom-based troubleshooting
Repair And Rebuild:
Engine overhaul, transmission rebuild, brake caliper replacement, suspension component renewal, starter/alternator replacement
Component Removal Installation:
Step-by-step instructions for removing and installing all major and minor components
Diagnostic Procedures:
On-board diagnostics (OBD-I/OBD-II), signal tracing, component testing using multimeters and oscilloscopes
Adjustment And Calibration:
Wheel alignment, brake adjustment, idle speed adjustment, clutch adjustment
Technical Depth
Depth:
Comprehensive: Covers routine maintenance to major component overhauls and advanced diagnostics.
Diagnostic Tools:
Details on using specific Mitsubishi diagnostic tools (MUT-II/MUT-III) and general automotive tools.
📊 Manual Specifications
File Format
Digital Format:
Searchable PDF with hyperlinked table of contents.
Print Quality
Image Resolution:
High resolution images, diagrams, and schematics suitable for printing.
Binding Type
Binding:
N/A (Digital format)
Paper Type
Paper Quality:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine 1:
3.0L V6 SOHC (6G72)
Engine 1 Power:
Approx. 145-175 hp (varies by market and specific tune)
Engine 1 Torque:
Approx. 170-190 lb-ft
Engine 2:
2.8L 4-Cylinder Turbo Diesel (4M40)
Engine 2 Power:
Approx. 125 hp
Engine 2 Torque:
Approx. 200-220 lb-ft
Engine 3:
2.4L 4-Cylinder SOHC (4G64)
Engine 3 Power:
Approx. 130-145 hp
Engine 3 Torque:
Approx. 150-160 lb-ft
Fuel System
Fuel Delivery Gasoline:
Multi-Point Fuel Injection (MPI)
Fuel Delivery Diesel:
Indirect Injection (IDI) with Turbocharging
Performance
Acceleration 0 60 Mph:
10-13 seconds (approx., dependent on engine and configuration)
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
4-speed Automatic Transmission
Features
Transfer Case Options:
Part-time 4WD, Full-time 4WD, Super Select 4WD (SS4) with center differential lock and low range.
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 or 80W-90
Automatic Transmission Fluid:
Mitsubishi Diaqueen ATF SP-II or equivalent
Transfer Case Fluid:
API GL-5, SAE 75W-90 (check manual for specific type)
Differential Fluid:
API GL-5, SAE 80W-90 (front and rear, limited slip if equipped)
📐 Dimensions
Exterior
Wheelbase Short Wb:
2,300 mm (90.6 in)
Wheelbase Long Wb:
2,725 mm (107.3 in)
Overall Length Short Wb:
4,070 mm (160.2 in)
Overall Length Long Wb:
4,775 mm (188.0 in)
Width:
1,775 mm (69.9 in)
Height:
1,850 mm (72.8 in) (approx., varies by trim)
Weights
Curb Weight:
1,700 - 2,000 kg (3,750 - 4,400 lbs) (varies by configuration)
Gross Vehicle Weight Rating:
2,300 - 2,500 kg (5,070 - 5,510 lbs)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Not extensively tested by NHTSA under current standards, but generally considered robust.
Active Features
ABS:
Available, standard on higher trims and later models.
Passive Features
Airbags:
Driver and passenger airbags available on later models and higher trims.
Body Construction:
Body-on-frame construction, known for durability and off-road resilience.
💡 Technology Features
Infotainment
Audio System:
AM/FM radio, cassette player, CD player optional on higher trims and later models.
Climate Control:
Manual climate control standard, automatic climate control available on top trims.
Driver Assistance
Cruise Control:
Available on most models.
Power Features:
Power windows, power door locks, power mirrors standard or optional depending on trim level.
Connectivity
OBD Version:
Primarily OBD-I, transitioning to OBD-II towards the end of the generation for some markets.
🔧 Maintenance
Service Intervals
Engine Oil And Filter Change:
Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions.
Engine Coolant Change:
Every 30,000 miles (48,000 km) or 2-3 years.
Timing Belt Replacement:
Every 60,000 miles (96,000 km) or 5 years for gasoline engines. Diesel engines often use chains or have different intervals.
Spark Plug Replacement:
Every 30,000-60,000 miles (48,000-96,000 km) depending on plug type (standard vs. platinum/iridium).
Fluid Specifications
Engine Oil Capacity 30L V6:
Approx. 4.5 - 5.0 liters (4.8 - 5.3 US quarts) with filter.
Engine Oil Spec:
API SG/SH or higher, SAE 10W-30 or 10W-40 recommended (consult manual for specific viscosity based on climate).
Known Issues
Common Issues Diesel:
Potential for head gasket failure on early 4M40 diesel engines, glow plug issues, injector pump seals.
Common Issues Gasoline V6:
Intake manifold gasket leaks, occasional ignition coil failure, radiator leaks.
Common Issues Suspension Steering:
Worn ball joints, tie rod ends, and bushings due to off-road use; power steering leaks.
Common Issues Transfer Case:
Actuator failures in electronically controlled 4WD systems, vacuum line leaks affecting engagement.
📚 Vehicle History
Brand Heritage
Mitsubishi SUV Legacy:
Mitsubishi has a long history in producing rugged and capable off-road vehicles, including the original Pajero (Montero in North America).
Model Evolution
Pajero Generation 2 Launch:
Launched in 1991, significantly redesigning the previous generation with more car-like comfort and advanced technology.
Pajero Generation 2 Updates:
Received facelifts and powertrain updates throughout its production run, including the introduction of the Super Select 4WD system and more powerful engines.
Pajero Generation 2 End:
Production for this generation concluded in 1999, succeeded by the third generation Pajero.
Production
Manufacturing Locations:
Japan (primarily), with assembly plants in other regions.
🏆 Awards & Recognition
Recognitions
Off Road Championships:
Pajero models have a strong history of success in endurance off-road rallies, notably the Dakar Rally, winning multiple times in the 1990s.

Delivery & file format

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Check the model year and engine before you buy

Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.

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