Market Segment:
Rugged, body-on-frame SUV, known for off-road capability and versatility. Competed against vehicles like Toyota Land Cruiser Prado, Nissan Patrol, Jeep Grand Cherokee.
Key Competitors:
Toyota Land Cruiser Prado, Nissan Patrol, Land Rover Discovery, Jeep Grand Cherokee, Ford Explorer.
Off Road Capability:
Renowned for its Super Select 4WD system, robust chassis, and available locking differentials, offering exceptional off-road performance.
Versatility:
Available in short-wheelbase (3-door) and long-wheelbase (5-door) configurations, with various seating options, making it suitable for families and adventurers.
Durability:
Built with durable construction and reliable powertrains, designed for demanding conditions and longevity.
Coverage Years:
1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999
Page Count:
Est. 1500+ pages (typical for comprehensive workshop manuals of this era)
Manual Type:
Workshop Service Repair Manual
Powertrain:
Engine mechanical, fuel system (injection & carbureted), ignition system, exhaust system, cooling system, lubrication system, engine electricals, automatic & manual transmissions, transfer case, differentials, drive shafts, axles.
Chassis:
Suspension (front & rear independent/solid axle depending on model), steering system, braking system (ABS, power assist), wheels, tires.
Electrical:
Wiring diagrams, lighting, instrumentation, power accessories, starter system, charging system, ECUs, sensors, actuators, body control modules, audio systems.
Body:
Exterior body panels, interior trim, glass, doors, windows, locks, seating, HVAC (heating, ventilation, air conditioning), body sealant and corrosion protection.
Maintenance:
Scheduled maintenance (oil changes, filter replacements, fluid checks), lubrication, inspections.
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs), electrical system diagnostics.
Repair:
Step-by-step repair procedures for all major components and systems, including disassembly, inspection, repair, and reassembly.
Overhaul:
Detailed procedures for engine, transmission, and differential overhauls, including specifications for machining and assembly.
Adjustment:
Adjustments for brakes, clutch, parking brake, ignition timing, fuel mixture (where applicable).
Depth:
Comprehensive, suitable for professional technicians and advanced DIY mechanics. Covers from basic maintenance to complex engine rebuilds and electrical diagnostics.
Engine Name:
3.5L V6 SOHC (6G74)
Engine Displacement:
3497 cc
Horsepower:
Approx. 200-230 hp (depending on market and specific tuning)
Torque:
Approx. 220-235 lb-ft
Engine Options:
3.0L V6 SOHC (6G72), 2.8L Diesel Turbo (4M40), 2.8L Diesel Direct Injection (4M40), 2.5L Diesel Turbo (4D56 - less common in this generation's early years)
0 60 Mph:
Varies greatly by configuration and engine, typically 9-12 seconds.
Fuel Delivery:
Multi-point fuel injection (MPI) for gasoline engines, direct injection or rotary pump for diesel engines.
Fuel Type:
Unleaded gasoline (RON 91-95), Diesel fuel
Coolant Capacity:
Approx. 8.5 - 10.5 liters (check specific model)
Oil Capacity With Filter:
Approx. 4.5 - 5.5 liters (check specific model and engine)
Transmission Type:
5-speed Manual (e.g., W5MG1)
Transmission Type:
4-speed Automatic (e.g., V4A51)
Transfer Case:
Super Select 4WD system (electronically controlled, with 2H, 4H, 4HLC, 4LLC modes)
Differentials:
Optional rear differential lock.
Wheelbase:
Short Wheelbase (SWB): ~2,500 mm; Long Wheelbase (LWB): ~2,700 mm (approximate, varies by body style)
Length:
SWB: ~4,170 mm; LWB: ~4,750 mm (approximate)
Height:
Approx. 1,800 - 1,850 mm (depending on roof rack and suspension)
Curb Weight:
Approx. 1,700 kg - 2,100 kg (depending on configuration)
Gross Vehicle Weight Rating:
Approx. 2,400 kg - 2,800 kg
Cargo Volume:
Varies significantly between SWB and LWB models, with or without third-row seating.
Crash Test Results:
Limited standardized crash test data available for this specific generation's early years from global agencies like NHTSA or Euro NCAP. Focus was often on structural integrity for off-road use.
ABS:
Anti-lock Braking System (ABS) available on higher trims and later models.
Traction Control:
Traction Control System (TCL) available on select higher-spec models.
Airbags:
Driver and front passenger airbags standard on most models from 1991 onwards, expanding to more trims.
Seatbelts:
Three-point inertia-reel seatbelts for front occupants, two-point lap belts for rear occupants (three-point belts in rear often became standard later).
Rollover Protection:
Body-on-frame construction and reinforced cabin structure for improved rollover resistance.
Audio System:
Factory fitted AM/FM radio with cassette player and CD changer (optional on higher trims). Speaker configurations vary by trim level.
Cruise Control:
Available on most models, particularly those with automatic transmissions.
Keyless Entry:
Available on higher trim levels as an optional feature.
Aux Input:
Not standard; aftermarket solutions typically required for modern audio connectivity.
Oil Change Interval Gasoline:
Every 5,000 - 7,500 miles or 6-12 months, whichever comes first.
Oil Change Interval Diesel:
Every 5,000 miles or 6 months, whichever comes first.
Air Filter Replacement:
Every 15,000 - 30,000 miles or as needed based on driving conditions.
Spark Plug Replacement Gasoline:
Every 30,000 - 60,000 miles, depending on spark plug type (standard, platinum, iridium).
Timing Belt Replacement V6:
Every 60,000 - 90,000 miles (critical maintenance item for 6G72/6G74 engines).
Transmission Fluid Change Auto:
Every 30,000 - 50,000 miles (or as per manual, often with filter replacement).
Engine Oil Viscosity:
API SG or higher. Viscosity typically 10W-30, 10W-40, or 5W-30 depending on climate (refer to manual for exact specification).
Coolant Type:
Ethylene glycol-based, typically a green or pink coolant (check manual for specific type, e.g., Mitsubishi DiaQueen Super Long Life Coolant).
Automatic Transmission Fluid:
Dexron III or equivalent (e.g., Mitsubishi DiaQueen ATF-SP III).
Manual Transmission Fluid:
API GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90 (check manual).
Brake Fluid Type:
DOT 3 or DOT 4.
Head Gaskets V6:
Some V6 engines (especially 6G72) can be prone to head gasket failure, particularly if maintenance is neglected.
Diesel Glow Plugs:
Diesel models may experience issues with glow plugs or relay failures, impacting cold starting.
Transfer Case Actuator:
The electronic actuator for the Super Select 4WD system can sometimes fail, preventing mode changes.
Suspension Bushings:
Wear and tear on suspension bushings and ball joints are common due to the vehicle's weight and off-road usage.
Radiator Leaks:
Older radiators can develop leaks over time.
Mitsubishi 4X4 Legacy:
Mitsubishi has a long and distinguished history in off-road vehicles, starting with the iconic Jeep CJ-3B licensed production in the 1950s, evolving into the Pajero (and Montero in North America) which became a global benchmark for SUVs.
Pajero Generations:
The 1991-1999 models represent the second generation (L040/V20/V40), which was a significant evolution from the first generation, introducing more refined styling, independent front suspension on some models, and advanced 4WD systems. This manual covers the latter part of this highly successful generation, leading into the third generation.
Manufacturing Locations:
Primarily manufactured in Japan (Okazaki Plant).
Sales Figures:
Globally successful, with millions of units sold across its various generations. The second generation (including the years covered by this manual) solidified its reputation as a capable and reliable SUV.
