Mitsubishi Pajero 1982-1991 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero Generation: First Generation (L040) Model Years Covered: 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991 Codes Chassis Codes: L040 series 👋 Introduction Market Position Vehicle Segment: Compact/Mid-size SUV, Off-Road Vehicle Target Audience: Off-road enthusiasts, adventurers, families requiring robust utility Competitive Analysis Key Competitors: Toyota Land Cruiser (early models), Nissan Patrol (early models), Suzuki Samurai/Jimny, Jeep Cherokee (XJ) Competitive Advantages: Strong off-road capability, reliable powertrain options, good value proposition Key Features Chassis Design: Body-on-frame construction for durability and off-road resilience Drivetrain Technology: Shift-on-the-fly 4WD system (part-time and full-time options depending on year/trim) Body Styles: Short-wheelbase (2-door), Long-wheelbase (3-door and 5-door station wagon) Engine Options: Robust and reliable 4-cylinder gasoline and diesel engines 📋 Manual Details Coverage Areas Engine Coverage: All gasoline and diesel engines for the specified model years Transmission Coverage: Manual and automatic transmissions Drivetrain Coverage: 4WD systems (Super Select, etc.), transfer cases, differentials Electrical Coverage: Complete electrical schematics, wiring diagrams, components Body And Chassis Coverage: Frame, body panels, interior trim, glass, suspension, steering Brake Coverage: Hydraulic systems, disc and drum brakes, parking brake HVAC Coverage: Heating, ventilation, and air conditioning systems Page Count Estimated Page Count: Extensive (typically 1000+ pages for a comprehensive factory service manual) Manual Type Manual Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF File Format Quality: High-resolution PDF with searchable text and clear image reproduction. Printability: Printable pages for workshop use. Binding Type: N/A (Digital PDF) Paper Type: N/A (Digital PDF) 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, lubrication, cooling, fuel delivery (carburetor/injection), ignition, emissions control, turbocharging (if applicable) Transmission Systems: Clutch, gearbox, overdrive, power take-off (PTO) systems Suspension And Steering Systems: Front and rear suspension components, steering gear, power steering Chassis And Frame: Frame inspection, repair, and alignment Wheel And Tire Systems: Wheel bearing, hub assembly, tire specifications, rotation Body And Interior Systems: Door mechanisms, seat adjustments, interior trim removal and installation, body panel repair Lighting And Visibility Systems: Headlights, taillights, interior lights, wipers, washers Instrumentation And Controls: Gauges, switches, indicators, driver controls Safety Systems: Seat belts, passive restraint systems (if applicable) Procedures Included Maintenance Procedures: Routine servicing, lubrication, filter changes, fluid top-offs Repair Procedures: Component disassembly, inspection, repair, and reassembly for all major systems Troubleshooting Guides: Systematic diagnostic procedures for common and uncommon faults Diagnostic Codes: OBD I codes and diagnostic procedures (where applicable for the era) Wiring Diagram Analysis: Detailed instructions on reading and interpreting electrical schematics Specification Data: Torque values, clearances, alignment settings, fluid capacities, resistance values Special Tools: Identification and usage of Mitsubishi-specific or recommended tools Technical Depth Depth Of Information: Comprehensive, covering everything from basic maintenance to full engine and transmission overhauls. Diagnostic Capabilities: Advanced troubleshooting for electrical, fuel, and mechanical systems. Rebuild Instructions: Detailed step-by-step instructions for major component rebuilds (engine, transmission, differentials). ⚙️ Engine Specifications Primary Engine Gasoline Engine Options: 2.0L Sirius SOHC I4 (4G63), 2.6L Astron SOHC I4 (4G54) Diesel Engine Options: 2.3L 4D55 (Turbodiesel), 2.5L 4D56 (Turbodiesel) Performance 2.0L Sirius (4G63) Estimated Hp: 99 hp @ 5000 rpm 2.0L Sirius (4G63) Estimated Torque: 115 lb-ft @ 3000 rpm 2.6L Astron (4G54) Estimated Hp: 105 hp @ 4500 rpm 2.6L Astron (4G54) Estimated Torque: 145 lb-ft @ 2500 rpm 2.3L Turbodiesel (4D55T) Estimated Hp: 81 hp @ 3800 rpm 2.3L Turbodiesel (4D55T) Estimated Torque: 135 lb-ft @ 2500 rpm 2.5L Turbodiesel (4D56T) Estimated Hp: 97 hp @ 4000 rpm 2.5L Turbodiesel (4D56T) Estimated Torque: 152 lb-ft @ 2500 rpm Fuel System Gasoline Fuel System: Carburetor (e.g., Hitachi, Mikuni) or Electronic Fuel Injection (EFI) depending on year and market Diesel Fuel System: Direct Injection, Diesel Injection Pump (e.g., Bosch VE) Fuel Type: Unleaded gasoline (for gasoline engines), Diesel fuel (for diesel engines) 🔧 Transmission Standard Standard Transmission: 5-speed manual transmission Optional Optional Transmission: 4-speed automatic transmission (e.g., KM145) Features Transfer Case: 2-speed transfer case with 2H, 4H, 4HLc, 4LLc modes (part-time 4WD initially, later models offered full-time options) Gear Ratios Manual: Specific ratios vary by engine and model, detailed in manual Gear Ratios Automatic: Specific ratios vary by model, detailed in manual Clutch Type: Dry single plate (for manual transmission) Transmission Fluid Type Manual: API GL-4 or GL-5 gear oil (specific viscosity like 75W-90 or 80W-90 recommended) Transmission Fluid Type Automatic: Dexron II or equivalent ATF 📐 Dimensions Exterior Wheelbase Short Wb: Approx. 2,200 mm (86.6 in) Wheelbase Long Wb: Approx. 2,650 mm (104.3 in) Overall Length Short Wb: Approx. 3,830 mm (150.8 in) Overall Length Long Wb: Approx. 4,555 mm (179.3 in) Track Width Front: Varies by model, approx. 1,400-1,450 mm Track Width Rear: Varies by model, approx. 1,400-1,450 mm Weights Curb Weight: Approx. 1,600 - 1,900 kg (3,527 - 4,189 lbs) depending on configuration Gross Vehicle Weight Rating: Details vary by specific model and market, typically around 2,200...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Pajero

Generation:

First Generation (L040)

Model Years Covered:

1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991

Codes

Chassis Codes:

L040 series

👋 Introduction

Market Position

Vehicle Segment:

Compact/Mid-size SUV, Off-Road Vehicle

Target Audience:

Off-road enthusiasts, adventurers, families requiring robust utility

Competitive Analysis

Key Competitors:

Toyota Land Cruiser (early models), Nissan Patrol (early models), Suzuki Samurai/Jimny, Jeep Cherokee (XJ)

Competitive Advantages:

Strong off-road capability, reliable powertrain options, good value proposition

Key Features

Chassis Design:

Body-on-frame construction for durability and off-road resilience

Drivetrain Technology:

Shift-on-the-fly 4WD system (part-time and full-time options depending on year/trim)

Body Styles:

Short-wheelbase (2-door), Long-wheelbase (3-door and 5-door station wagon)

Engine Options:

Robust and reliable 4-cylinder gasoline and diesel engines

📋 Manual Details

Coverage Areas

Engine Coverage:

All gasoline and diesel engines for the specified model years

Transmission Coverage:

Manual and automatic transmissions

Drivetrain Coverage:

4WD systems (Super Select, etc.), transfer cases, differentials

Electrical Coverage:

Complete electrical schematics, wiring diagrams, components

Body And Chassis Coverage:

Frame, body panels, interior trim, glass, suspension, steering

Brake Coverage:

Hydraulic systems, disc and drum brakes, parking brake

HVAC Coverage:

Heating, ventilation, and air conditioning systems

Page Count

Estimated Page Count:

Extensive (typically 1000+ pages for a comprehensive factory service manual)

Manual Type

Manual Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

File Format Quality:

High-resolution PDF with searchable text and clear image reproduction.

Printability:

Printable pages for workshop use.

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine mechanical, lubrication, cooling, fuel delivery (carburetor/injection), ignition, emissions control, turbocharging (if applicable)

Transmission Systems:

Clutch, gearbox, overdrive, power take-off (PTO) systems

Suspension And Steering Systems:

Front and rear suspension components, steering gear, power steering

Chassis And Frame:

Frame inspection, repair, and alignment

Wheel And Tire Systems:

Wheel bearing, hub assembly, tire specifications, rotation

Body And Interior Systems:

Door mechanisms, seat adjustments, interior trim removal and installation, body panel repair

Lighting And Visibility Systems:

Headlights, taillights, interior lights, wipers, washers

Instrumentation And Controls:

Gauges, switches, indicators, driver controls

Safety Systems:

Seat belts, passive restraint systems (if applicable)

Procedures Included

Maintenance Procedures:

Routine servicing, lubrication, filter changes, fluid top-offs

Repair Procedures:

Component disassembly, inspection, repair, and reassembly for all major systems

Troubleshooting Guides:

Systematic diagnostic procedures for common and uncommon faults

Diagnostic Codes:

OBD I codes and diagnostic procedures (where applicable for the era)

Wiring Diagram Analysis:

Detailed instructions on reading and interpreting electrical schematics

Specification Data:

Torque values, clearances, alignment settings, fluid capacities, resistance values

Special Tools:

Identification and usage of Mitsubishi-specific or recommended tools

Technical Depth

Depth Of Information:

Comprehensive, covering everything from basic maintenance to full engine and transmission overhauls.

Diagnostic Capabilities:

Advanced troubleshooting for electrical, fuel, and mechanical systems.

Rebuild Instructions:

Detailed step-by-step instructions for major component rebuilds (engine, transmission, differentials).

⚙️ Engine Specifications

Primary Engine

Gasoline Engine Options:

2.0L Sirius SOHC I4 (4G63), 2.6L Astron SOHC I4 (4G54)

Diesel Engine Options:

2.3L 4D55 (Turbodiesel), 2.5L 4D56 (Turbodiesel)

Performance

2.0L Sirius (4G63) Estimated Hp:

99 hp @ 5000 rpm

2.0L Sirius (4G63) Estimated Torque:

115 lb-ft @ 3000 rpm

2.6L Astron (4G54) Estimated Hp:

105 hp @ 4500 rpm

2.6L Astron (4G54) Estimated Torque:

145 lb-ft @ 2500 rpm

2.3L Turbodiesel (4D55T) Estimated Hp:

81 hp @ 3800 rpm

2.3L Turbodiesel (4D55T) Estimated Torque:

135 lb-ft @ 2500 rpm

2.5L Turbodiesel (4D56T) Estimated Hp:

97 hp @ 4000 rpm

2.5L Turbodiesel (4D56T) Estimated Torque:

152 lb-ft @ 2500 rpm

Fuel System

Gasoline Fuel System:

Carburetor (e.g., Hitachi, Mikuni) or Electronic Fuel Injection (EFI) depending on year and market

Diesel Fuel System:

Direct Injection, Diesel Injection Pump (e.g., Bosch VE)

Fuel Type:

Unleaded gasoline (for gasoline engines), Diesel fuel (for diesel engines)

🔧 Transmission

Standard

Standard Transmission:

5-speed manual transmission

Optional

Optional Transmission:

4-speed automatic transmission (e.g., KM145)

Features

Transfer Case:

2-speed transfer case with 2H, 4H, 4HLc, 4LLc modes (part-time 4WD initially, later models offered full-time options)

Gear Ratios Manual:

Specific ratios vary by engine and model, detailed in manual

Gear Ratios Automatic:

Specific ratios vary by model, detailed in manual

Clutch Type:

Dry single plate (for manual transmission)

Transmission Fluid Type Manual:

API GL-4 or GL-5 gear oil (specific viscosity like 75W-90 or 80W-90 recommended)

Transmission Fluid Type Automatic:

Dexron II or equivalent ATF

📐 Dimensions

Exterior

Wheelbase Short Wb:

Approx. 2,200 mm (86.6 in)

Wheelbase Long Wb:

Approx. 2,650 mm (104.3 in)

Overall Length Short Wb:

Approx. 3,830 mm (150.8 in)

Overall Length Long Wb:

Approx. 4,555 mm (179.3 in)

Track Width Front:

Varies by model, approx. 1,400-1,450 mm

Track Width Rear:

Varies by model, approx. 1,400-1,450 mm

Weights

Curb Weight:

Approx. 1,600 - 1,900 kg (3,527 - 4,189 lbs) depending on configuration

Gross Vehicle Weight Rating:

Details vary by specific model and market, typically around 2,200 kg

Towing Capacity:

Details vary by specific model and market, typically around 1500-2500 kg (3300-5500 lbs)

🛡️ Safety Features

Ratings

Crash Test Ratings:

No formal crash test ratings from modern agencies like NHTSA or Euro NCAP are readily available for this early generation.

Active Features

Active Safety Features:

Primarily mechanical systems; no advanced electronic aids common in modern vehicles.

Passive Features

Passive Safety Features:

Seat belts (lap and shoulder belts in front), reinforced chassis and body structure for impact absorption.

Braking System:

Front disc brakes, rear drum brakes. Power assist common on later models and higher trims.

Steering Wheel:

Standard steering wheel, optional power steering available on some trims.

💡 Technology Features

Infotainment

Infotainment System Era:

Basic for its time, typically featuring an AM/FM radio, cassette player, and analog gauges.

Speaker Configuration:

Usually 2 or 4 speakers, depending on trim level.

Driver Assistance

Driver Assistance Features:

Virtually none by modern standards. Focus is on mechanical systems for off-road traversal.

Connectivity

Connectivity Options:

No Bluetooth, USB, or satellite connectivity. Analog connections for external devices might be possible if an aftermarket stereo is installed.

🔧 Maintenance

Service Intervals

Oil Change Interval Gasoline:

Every 5,000 - 7,500 km (3,000 - 5,000 miles) or 6 months, whichever comes first.

Oil Change Interval Diesel:

Every 7,500 - 10,000 km (5,000 - 6,000 miles) or 6 months, whichever comes first.

Air Filter Replacement:

Every 15,000 - 20,000 km (9,000 - 12,000 miles) or annually.

Fuel Filter Replacement Diesel:

Every 20,000 - 30,000 km (12,000 - 18,000 miles).

Spark Plug Replacement:

Every 30,000 - 40,000 km (18,000 - 25,000 miles) for gasoline engines.

Coolant Flush:

Every 2 years or 40,000 km (25,000 miles).

Fluid Specifications

Engine Oil Viscosity Gasoline:

10W-30, 10W-40, or 20W-50 depending on ambient temperature and specific engine. Refer to manual for exact specs.

Engine Oil Viscosity Diesel:

10W-30, 10W-40, or 15W-40 CI-4 or higher rated diesel engine oil.

Coolant Type:

Ethylene glycol based antifreeze, mixed 50/50 with distilled water.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid:

Dexron II or equivalent ATF (if equipped with power steering).

Known Issues

Rust And Corrosion:

Common on older vehicles, especially in salt-prone environments. Frame and body panels are susceptible.

Engine Overheating:

Can occur due to aging cooling system components (radiator, hoses, water pump). Turbodiesels can be prone to overheating under heavy load if not maintained.

4Wd System Wear:

Transfer case, hubs, and drive shafts can wear over time, especially with hard off-road use. U-joints require regular lubrication.

Ignition System Problems:

Distributor cap, rotor, spark plug wires can degrade and cause misfires.

Carburetor Issues:

Carburetor adjustments may be needed periodically for optimal performance and fuel economy.

Diesel Injector Pump Issues:

Diesel injection pumps can require rebuilding or replacement over high mileage.

📚 Vehicle History

Brand Heritage

Mitsubishi Motors History:

Mitsubishi Motors, a subsidiary of the Mitsubishi Group, has a long history in automotive manufacturing, known for robust and often innovative vehicles.

Model Evolution

Pajero Debut:

The Mitsubishi Pajero (also known as Montero in North America and other markets, and Shogun in the UK) debuted in 1981 at the Tokyo Motor Show, with production commencing shortly after. This manual covers the first generation, which was a significant success for Mitsubishi.

Key Milestones First Gen:

Introduction of turbodiesel engines, longer wheelbase versions, automatic transmissions, and upgrades to the 4WD system (e.g., Super Select 4WD introduced later in the generation). The Pajero quickly established itself as a capable off-roader.

Production

Production Period:

1982-1991 for the first generation (L040 series)

Manufacturing Locations:

Primarily manufactured in Japan by Mitsubishi Motors.

Sales Performance:

The Pajero was a strong seller globally, particularly in markets valuing off-road capability and durability.

🏆 Awards & Recognition

Recognitions

Off Road Competitions:

The Pajero has a strong rally heritage, notably winning the Dakar Rally multiple times in later generations, but this first generation laid the groundwork for that reputation.

General Reputation:

Known for its ruggedness, reliability, and excellent off-road capability, earning it a loyal following.