🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero Year: 1991-1999 Codes Chassis Codes: V10-V50 Series (Short Wheelbase & Long Wheelbase) 👋 Introduction Market Position Market Position: The Mitsubishi Pajero (also known as the Mitsubishi Montero in North America) during this era was a highly regarded, capable, and versatile off-road SUV. It competed against popular models like the Toyota Land Cruiser, Jeep Cherokee, and Ford Explorer, often praised for its robust build, excellent four-wheel-drive system, and comfortable ride. Competitive Analysis Competitive Analysis: This manual provides the specific technical documentation required to maintain and repair the Pajero to factory standards, mirroring the resources used by authorized service centers. Its specificity ensures accurate diagnostics and repairs, crucial for a vehicle known for its off-road prowess and complex systems. Key Features Key Features: Provides in-depth information essential for DIY mechanics and professional technicians alike. Offers immediate digital access, saving time and shipping costs. Empowers owners to understand their vehicle's maintenance and repair needs, preventing potential overcharging by unqualified repair shops. 📋 Manual Details Coverage Areas Covered Generations: Second Generation (1991-1999) Covered Regions: Global Markets (specifics may vary by region, but manual provides core data) Page Count Estimated Page Count: Over 2000 pages (typical for comprehensive service manuals of this era) Manual Type Manual Type: Factory Authorized Service and Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine overhaul, fuel delivery, ignition, emissions control, cooling system, exhaust system, manual and automatic transmissions, transfer cases, differentials. Chassis: Steering system (hydraulic power steering), suspension (front independent, rear solid axle), brakes (hydraulic, ABS systems), wheels and tires, driveline components. Body And Interior: Body structure, exterior panels, doors, windows, interior trim, seating, HVAC system, body electrical components. Electrical: Wiring diagrams, lighting, charging system, starting system, instruments and gauges, audio system, power accessories, ECU diagnosis and wiring. Procedures Included Maintenance Procedures: Scheduled maintenance, fluid changes, filter replacements, lubrication, tune-up procedures, component inspection. Diagnostic Procedures: Troubleshooting guides for common issues, diagnostic trouble codes (DTCs) for applicable models, component testing, electrical system diagnostics. Repair Procedures: Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for all major systems. Technical Specifications: Torque specifications, clearances, tolerances, fluid capacities, resistance values, voltage readings. Technical Depth Depth: Comprehensive: Covers everything from basic fluid checks and tire rotations to complete engine and transmission overhauls, including advanced electrical diagnostics and bodywork repairs. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution scans for clarity, enabling precise reading of text and diagrams. Searchable text for quick information retrieval. Binding Type Binding Type: N/A (Digital Download - Printable by user) Paper Type Paper Type: N/A (Digital Download - User selectable printing paper) ⚙️ Engine Specifications Primary Engine Engine Options: Commonly included engines: 3.0L V6 (6G72), 3.5L V6 (6G73/6G74), 2.4L 4-cylinder (4G64), 2.8L Turbo Diesel (4M40). Specific engine variants will be detailed within the manual. Performance Engine Performance Details: The manual details horsepower, torque, and specific performance curves for each engine option. It covers engine management systems, including fuel injection and ignition timing, critical for optimal performance and efficiency. Fuel System Fuel System Coverage: Comprehensive coverage of fuel injection systems (MPI, GDI for later models), fuel pumps, fuel filters, injectors, fuel pressure regulators, and emission control systems including catalytic converters and evaporative emission controls (EVAP). 🔧 Transmission Standard Transmission Transmission Types: Available with both manual (5-speed) and automatic transmissions (4-speed overdrive). Specific models and their associated transmissions are covered. Optional Transmission Transfer Case Coverage: Detailed information on the Super Select 4WD system (on many models), including its operation, maintenance, and repair of the transfer case and front differentials. Features Transmission Features: Coverage includes clutch systems, transmission fluid types and capacities, gear ratios, torque converter operation, electronic transmission control modules (if applicable), and drivetrain component diagnostics. 📐 Dimensions Exterior Wheelbase Options: Offered in both short-wheelbase (SWB) and long-wheelbase (LWB) configurations, impacting overall length, interior space, and off-road articulation. Weights Curb Weight Range: Varies significantly by configuration (SWB vs. LWB), engine, and drivetrain. Manual provides specific weight data for different configurations. 🛡️ Safety Features Ratings Safety Equipment: While specific crash test ratings for this era are less standardized than today, the manual covers safety features like seat belts, chassis integrity, and brake system design. Later models may include ABS. Passive Features Passive Safety: Reinforced body structure, crumple zones, advanced seat belt systems, and padded interior components are discussed in the context of body construction and repair. 💡 Technology Features Infotainment Infotainment Features: Covers the factory-installed audio systems, speaker configurations, and antenna systems. Later models may feature early forms of CD players or more advanced radio units. Driver Assistance Driver Assistance Systems: Details on Anti-lock Braking Systems (ABS) for models equipped with it, including sensor diagnostics, hydraulic unit operation, and ABS control module information. Connectivity Connectivity Features: Covers basic vehicle...
The Mitsubishi Pajero (also known as the Mitsubishi Montero in North America) during this era was a highly regarded, capable, and versatile off-road SUV. It competed against popular models like the Toyota Land Cruiser, Jeep Cherokee, and Ford Explorer, often praised for its robust build, excellent four-wheel-drive system, and comfortable ride.
Competitive Analysis
Competitive Analysis:
This manual provides the specific technical documentation required to maintain and repair the Pajero to factory standards, mirroring the resources used by authorized service centers. Its specificity ensures accurate diagnostics and repairs, crucial for a vehicle known for its off-road prowess and complex systems.
Key Features
Key Features:
Provides in-depth information essential for DIY mechanics and professional technicians alike. Offers immediate digital access, saving time and shipping costs. Empowers owners to understand their vehicle's maintenance and repair needs, preventing potential overcharging by unqualified repair shops.
📋 Manual Details
Coverage Areas
Covered Generations:
Second Generation (1991-1999)
Covered Regions:
Global Markets (specifics may vary by region, but manual provides core data)
Page Count
Estimated Page Count:
Over 2000 pages (typical for comprehensive service manuals of this era)
Manual Type
Manual Type:
Factory Authorized Service and Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine overhaul, fuel delivery, ignition, emissions control, cooling system, exhaust system, manual and automatic transmissions, transfer cases, differentials.
Chassis:
Steering system (hydraulic power steering), suspension (front independent, rear solid axle), brakes (hydraulic, ABS systems), wheels and tires, driveline components.
Body And Interior:
Body structure, exterior panels, doors, windows, interior trim, seating, HVAC system, body electrical components.
Electrical:
Wiring diagrams, lighting, charging system, starting system, instruments and gauges, audio system, power accessories, ECU diagnosis and wiring.
Troubleshooting guides for common issues, diagnostic trouble codes (DTCs) for applicable models, component testing, electrical system diagnostics.
Repair Procedures:
Step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for all major systems.
Technical Specifications:
Torque specifications, clearances, tolerances, fluid capacities, resistance values, voltage readings.
Technical Depth
Depth:
Comprehensive: Covers everything from basic fluid checks and tire rotations to complete engine and transmission overhauls, including advanced electrical diagnostics and bodywork repairs.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution scans for clarity, enabling precise reading of text and diagrams. Searchable text for quick information retrieval.
Binding Type
Binding Type:
N/A (Digital Download - Printable by user)
Paper Type
Paper Type:
N/A (Digital Download - User selectable printing paper)
⚙️ Engine Specifications
Primary Engine
Engine Options:
Commonly included engines: 3.0L V6 (6G72), 3.5L V6 (6G73/6G74), 2.4L 4-cylinder (4G64), 2.8L Turbo Diesel (4M40). Specific engine variants will be detailed within the manual.
Performance
Engine Performance Details:
The manual details horsepower, torque, and specific performance curves for each engine option. It covers engine management systems, including fuel injection and ignition timing, critical for optimal performance and efficiency.
Fuel System
Fuel System Coverage:
Comprehensive coverage of fuel injection systems (MPI, GDI for later models), fuel pumps, fuel filters, injectors, fuel pressure regulators, and emission control systems including catalytic converters and evaporative emission controls (EVAP).
🔧 Transmission
Standard Transmission
Transmission Types:
Available with both manual (5-speed) and automatic transmissions (4-speed overdrive). Specific models and their associated transmissions are covered.
Optional Transmission
Transfer Case Coverage:
Detailed information on the Super Select 4WD system (on many models), including its operation, maintenance, and repair of the transfer case and front differentials.
Features
Transmission Features:
Coverage includes clutch systems, transmission fluid types and capacities, gear ratios, torque converter operation, electronic transmission control modules (if applicable), and drivetrain component diagnostics.
📐 Dimensions
Exterior
Wheelbase Options:
Offered in both short-wheelbase (SWB) and long-wheelbase (LWB) configurations, impacting overall length, interior space, and off-road articulation.
Weights
Curb Weight Range:
Varies significantly by configuration (SWB vs. LWB), engine, and drivetrain. Manual provides specific weight data for different configurations.
🛡️ Safety Features
Ratings
Safety Equipment:
While specific crash test ratings for this era are less standardized than today, the manual covers safety features like seat belts, chassis integrity, and brake system design. Later models may include ABS.
Passive Features
Passive Safety:
Reinforced body structure, crumple zones, advanced seat belt systems, and padded interior components are discussed in the context of body construction and repair.
💡 Technology Features
Infotainment
Infotainment Features:
Covers the factory-installed audio systems, speaker configurations, and antenna systems. Later models may feature early forms of CD players or more advanced radio units.
Driver Assistance
Driver Assistance Systems:
Details on Anti-lock Braking Systems (ABS) for models equipped with it, including sensor diagnostics, hydraulic unit operation, and ABS control module information.
Connectivity
Connectivity Features:
Covers basic vehicle electrical systems, including power windows, door locks, mirrors, and lighting systems. It also details the wiring for the keyless entry system if equipped.
🔧 Maintenance
Service Intervals
Recommended Maintenance Schedule:
The manual provides detailed service intervals for oil changes, filter replacements, coolant flushes, transmission fluid changes, brake fluid replacement, timing belt replacement (critical for non-interference engines), and other scheduled maintenance tasks based on mileage or time.
Fluid Specifications
Engine Oil Specifications:
Details specific API service classifications (e.g., SF, SG, SH) and SAE viscosity grades (e.g., 10W-30, 10W-40, 5W-30 for colder climates) for gasoline and diesel engines. Also covers coolant types (e.g., Mitsubishi DiaQueen Super Long Life Coolant), brake fluid (DOT 3 or DOT 4), power steering fluid, and manual/automatic transmission fluids.
Known Issues
Common Issues Addressed:
While the manual is not solely a 'common issues' guide, it provides the diagnostic and repair procedures to address common wear items and potential problems for this generation, such as cooling system leaks, suspension component wear, and drivetrain component maintenance. For example, timing belt replacement interval for the 6G72 V6 is crucial to prevent catastrophic engine damage.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mitsubishi has a long-standing reputation for producing durable and capable off-road vehicles, with the Pajero line being a flagship model synonymous with adventure and reliability.
Model Evolution
Second Generation Evolution:
The 1991-1999 Pajero marked a significant evolution from its predecessor, featuring a more modern chassis, improved styling, enhanced interior comfort, and a wider range of engine and transmission options. It solidified the Pajero's reputation as a premium off-road SUV.
Production
Production Period:
This second generation was produced globally from 1991 to 1999, with some markets receiving facelifts or continued production of certain variants beyond these years.