🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero

Generation:

First Generation (L040 Series)

Chassis Codes:

L040 Series (e.g., L043, L044, L045, L046, L047, L048, L049, L0410, L0411, L0412)

👋 Introduction

Market Positioning:

The Mitsubishi Pajero (known as Montero in some markets) of this era was a formidable contender in the burgeoning SUV segment, known for its ruggedness, off-road capability, and versatility. It competed with vehicles like the Toyota Land Cruiser, Nissan Patrol, and Range Rover.

Key Competitors:

Toyota Land Cruiser (J60/J70), Nissan Patrol (Y60), Ford Bronco, Jeep Cherokee (XJ), Land Rover Defender.

Design Philosophy:

Body-on-frame construction, robust 4WD system, high ground clearance, and durable powertrains emphasized its off-road prowess and utility.

📋 Manual Details

Applicable Years:

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

Page Count:

300

Manual Type:

Workshop Repair Service Manual

Language:

English (Assumed based on typical market availability)

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Complete overhaul, troubleshooting, diagnosis, and repair of all engine variants, including cylinder head, block, pistons, crankshaft, camshafts, timing components, lubrication system, cooling system, and fuel injection/carburetion systems.

Engine Electrical:

Ignition system, starting system, charging system (alternator, starter motor), ECU diagnosis, sensors, wiring diagrams for all engine-related components.

Transmission Manual:

Repair, overhaul, troubleshooting, clutch replacement, gearshift mechanism, lubrication, and performance diagnosis for manual transmissions.

Transmission Automatic:

Troubleshooting, diagnosis, fluid service, external adjustments, and repair procedures for automatic transmissions (if applicable to specific models covered).

Drivetrain 4Wd:

Operation and repair of the Super Select 4WD system (or similar, depending on market), transfer case, front and rear differentials, drive shafts, constant velocity (CV) joints, and hubs.

Suspension Steering:

Front and rear suspension (independent front, solid rear axle), shock absorbers, springs, control arms, bushings, steering gearbox, power steering system, alignment specifications, and troubleshooting.

Brakes:

Hydraulic brake system diagnosis and repair, front disc brakes, rear drum brakes (or discs), parking brake system, master cylinder, wheel cylinders, brake lines, bleeding procedures, and component replacement.

Electrical System:

Complete vehicle wiring diagrams, lighting system (headlights, taillights, interior), accessories (wipers, horn, power windows), fuse box locations and ratings, relay functions, and diagnostic procedures for electrical faults.

Body Chassis:

Body panel removal and installation, interior trim, door mechanisms, glass, chassis lubrication points, rust prevention, and basic structural repair guidance.

HVAC:

Heating, ventilation, and air conditioning system diagnosis, component testing, refrigerant handling (if applicable), blower motor, evaporator, condenser, and heater core service.

Preventative Maintenance:

Detailed maintenance schedules for oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections, and tire rotations.

Troubleshooting Diagnostics:

Systematic diagnostic flowcharts and symptom-based troubleshooting guides for common drivability, electrical, and mechanical issues.

Component Overhaul:

Step-by-step instructions for disassembling, inspecting, repairing, and reassembling major vehicle components like engines, transmissions, differentials, and brake calipers.

Replacement Procedures:

Clear instructions for replacing wear items and components such as timing belts/chains, water pumps, alternators, starters, brake pads/shoes, and suspension bushings.

Specifications Data:

Torque specifications for all fasteners, engine compression ratios, valve clearances, fluid capacities, tire pressures, and alignment settings.

Wiring Diagrams:

Detailed and organized wiring diagrams for all major electrical systems, aiding in fault finding and component testing.

Depth Level:

Comprehensive, covering basic maintenance to full engine and transmission rebuilds, with detailed diagnostic procedures.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High-resolution scans suitable for printing and digital viewing. Clear text and diagrams.

Binding Type:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Options:

Common engines included the 2.5L 4D56 I4 Turbo Diesel, 2.6L 4G54 I4 Petrol, and 3.0L 6G72 V6 Petrol. (Specific availability varied by market).

2 5L Turbo Diesel Power:

Approximately 84-95 PS (62-70 kW) depending on turbocharger and tuning.

2 6L Petrol Power:

Approximately 103-114 PS (76-84 kW).

3 0L V6 Petrol Power:

Approximately 145-155 PS (107-114 kW).

Diesel Fuel System:

Indirect injection, often with a turbocharger and intercooler. Fuel injection pump calibration and nozzle testing are crucial maintenance points.

Petrol Fuel System:

Carburetor (early models) or Electronic Fuel Injection (EFI) depending on year and engine variant.

🔧 Transmission

Standard Transmission:

5-speed manual transmission was common.

Optional Transmission:

4-speed automatic transmission was available on select models.

4Wd System:

Part-time 4WD system with selectable 2WD (RWD), 4WD High, and 4WD Low range. Some later models or higher trims might feature a more advanced 'Super Select' system.

📐 Dimensions

Wheelbase Short Wheelbase:

Approximately 2,350 mm (92.5 in)

Wheelbase Long Wheelbase:

Approximately 2,650 mm (104.3 in)

Ground Clearance:

Typically around 200-220 mm (7.9-8.7 in), varying with tire size and suspension setup.

Curb Weight:

Ranges from approximately 1,600 kg to 2,000 kg (3,527 - 4,409 lbs) depending on configuration and equipment.

🛡️ Safety Features

Safety Ratings Era:

Safety standards and testing protocols were less stringent in this era compared to modern vehicles. Specific crash test ratings from organizations like NHTSA or Euro NCAP for this exact generation are limited or non-existent.

Active Safety Features:

Primarily mechanical systems like reliable 4WD for traction. Anti-lock Braking System (ABS) was an optional feature on some higher-trim models towards the end of this generation's run.

Passive Safety Features:

Reinforced chassis, seatbelts, and basic impact-absorbing structures. Airbags were not standard and rarely offered during most of this generation's production.

💡 Technology Features

Infotainment Features:

Basic AM/FM radio with cassette player. Speakers were typically two or four. Display technology was rudimentary by modern standards.

Driver Assistance Features:

Minimal. Features like power steering and power windows were optional or standard on higher trims. ABS became available late in the generation.

Connectivity Features:

No modern connectivity features such as Bluetooth, USB, or smartphone integration. Connectivity was limited to basic wiring for radio and accessories.

🔧 Maintenance

Engine Oil Change Petrol:

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

Engine Oil Change Diesel:

Every 5,000 km (3,000 miles) or 3 months, particularly for turbo diesel models.

Timing Belt Replacement:

Every 60,000 - 100,000 km (37,000 - 60,000 miles) or 4-5 years, depending on engine type and material. Critical for preventing catastrophic engine damage.

Engine Oil Petrol:

API SF/SG or equivalent. Viscosity 10W-30, 10W-40, or 5W-30 depending on climate.

Engine Oil Diesel:

API CD/CE or equivalent. Viscosity 15W-40 or 10W-40.

Transmission Fluid Manual:

API GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90.

Transmission Fluid Automatic:

Dexron II or Dexron III compatible ATF.

Coolant:

Ethylene Glycol based coolant (green or pink type depending on original fill), mixed 50/50 with distilled water.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Diesel Engine Glow Plugs:

Glow plug failure leading to hard starting in cold weather.

Turbo Diesel Overheating:

Potential for overheating if cooling system is not maintained, especially under load or in hot climates. Intercooler issues can also impact performance.

Suspension Bushings:

Wear and tear on rubber bushings in control arms, sway bars, and leaf springs (if equipped) leading to clunks and poor handling.

Rust Corrosion:

Common for vehicles of this age and type, particularly in the chassis, wheel arches, and fuel tank area. Regular inspection and undercoating are recommended.

Cv Joint Wear:

Front CV joints can wear out, producing clicking noises during turns, especially when the 4WD system is engaged.

Electrical Connectors:

Corrosion or looseness in electrical connectors can cause intermittent issues with lights, sensors, or power accessories.

📚 Vehicle History

Mitsubishi Heritage Offroad:

Mitsubishi has a long history of producing rugged vehicles, dating back to its origins and military vehicle production, which laid the groundwork for the Pajero's capabilities.

First Generation Launch:

The first-generation Pajero was introduced in 1982, establishing Mitsubishi as a major player in the 4x4 market.

L040 Series Updates:

The L040 series saw several minor updates and engine introductions throughout its production life, including the introduction of the potent V6 engine and turbo-diesel options.

Production Period:

1982-1991

Key Production Regions:

Japan. Exported globally to various markets.

🏆 Awards & Recognition

Offroad Accolades:

The Pajero gained significant recognition and success in off-road rallies, most notably winning the Dakar Rally multiple times during and after this generation, solidifying its reputation for durability and performance.