The Pajero, first generation (L040 series), represents a cornerstone in the evolution of capable off-road vehicles. Produced from 1982 through 1991, this rugged SUV established a benchmark for durability and versatility, offering a robust platform designed for both demanding terrains and everyday driving. Available with a range of reliable engine options, including the 2.6L inline-four, various turbo-diesel variants and the powerful 3.0L V6, the Pajero catered to diverse performance needs. Its engineering emphasized a strong body-on-frame construction, advanced 4WD systems, and a comfortable coil-spring suspension, making it a formidable competitor in the SUV market and a celebrated performer in off-road challenges, including multiple Dakar Rally victories.
This comprehensive Factory Service Manual provides in-depth guidance for owners and technicians responsible for the maintenance and repair of the Pajero (L040 series) from 1982 to 1991. It covers all essential systems, including the powertrain (engine mechanical, fuel, cooling, exhaust, transmission, transfer case, differentials), chassis (suspension, steering, brakes), electrical systems (wiring diagrams, lighting, starting, charging, ECU diagnostics, body electrics), and bodywork (construction, trim, HVAC). The manual details routine maintenance procedures, complex repair operations, troubleshooting guides for common issues, and essential technical specifications such as torque values, fluid capacities, and performance data, ensuring the vehicle remains in optimal condition.
Generation:
First Generation (L040 series)
Chassis Code:
L040 Series (various sub-codes based on configuration)
Engine Code Common:
4G54 (2.6L I4), 4D55/4D56 (2.3L/2.5L I4 Diesel), 6G72 (3.0L V6)
Positioning:
The Mitsubishi Pajero (also known as the Montero in many markets) established itself as a highly capable and rugged off-road utility vehicle, often competing with vehicles like the Toyota Land Cruiser, Nissan Patrol, and Range Rover. This first generation offered a blend of utility, comfort, and off-road prowess.
Key Competitors:
Toyota Land Cruiser, Nissan Patrol, Jeep Cherokee (XJ), Ford Bronco, Range Rover Classic.
Highlights:
Robust construction, powerful engine options (including diesel and V6), sophisticated 4WD system (Super Select 4WD on later models), coil spring suspension for improved ride comfort, wide range of body styles (short-wheelbase, long-wheelbase, canvas top, hardtop).
Covered Years:
1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991
Estimated Page Count:
1000+
Type:
Factory Service Manual / Workshop Manual
Powertrain:
Engine mechanical, fuel system, ignition system, cooling system, exhaust system, transmission (manual and automatic), transfer case, differentials, driveshafts.
Chassis:
Suspension (front and rear), steering system, braking system (front and rear), wheel alignment, lubrication.
Electrical:
Wiring diagrams, lighting, charging system, starting system, instrument cluster, engine control unit (ECU) diagnostics, body electricals (wipers, horn, interior lights, power windows/locks if equipped).
Body:
Body construction, exterior trim, doors, windows, interior trim, HVAC system (heating, ventilation, and air conditioning).
Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, lubrication, belt adjustments, spark plug replacement, air filter replacement.
Repair:
Engine overhaul, transmission overhaul, brake component replacement, suspension component replacement, steering system repair, electrical component diagnosis and repair, body panel repair and replacement.
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting, pinpoint tests for electrical issues, engine performance diagnostics.
Specifications:
Torque specifications for fasteners, engine performance data, fluid capacities, component dimensions, electrical resistance values.
Depth:
Comprehensive, covering everything from basic scheduled maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and electrical schematics.
File Format:
Searchable PDF
Print Quality:
High-resolution, suitable for printing individual pages or the entire manual.
Binding Type:
N/A (Digital PDF)
Paper Type:
N/A (Digital PDF)
Engine Options:
2.6L 4G54 Sirius I4 (petrol), 2.3L 4D55 I4 Turbo-Diesel, 2.5L 4D56 I4 Turbo-Diesel, 3.0L 6G72 V6 SOHC (petrol).
2.6L 4G54 Horsepower:
Approx. 105-115 PS (depending on market and tune)
2.5L 4D56 Turbo-Diesel Horsepower:
Approx. 84-95 PS (depending on market and tune)
3.0L 6G72 V6 Horsepower:
Approx. 145-155 PS (depending on market and tune)
2.6L Petrol:
Carburetor (e.g., Aisan)
3.0L V6 Petrol:
Fuel Injection (MPI)
Diesel Variants:
Injection Pump (e.g., Bosch)
Transmission Options:
4-speed manual, 5-speed manual (common on later models), 4-speed automatic.
Transmission Features:
Transfer case with selectable 2WD, 4WD High, 4WD Low. Later models featured 'Super Select 4WD' with a center differential for full-time 4WD capability.
Gear Ratios:
Varies by transmission and engine; manual typically has a lower first gear for off-road use. Specific ratios detailed in the manual.
Wheelbase Short:
Approx. 2,350 mm (92.5 in)
Wheelbase Long:
Approx. 2,650 mm (104.3 in)
Length Short:
Approx. 3,990 mm (157.1 in)
Length Long:
Approx. 4,545 mm (178.9 in)
Curb Weight Approx:
1,600 kg - 2,000 kg (depending on configuration)
Safety Features General:
Generally basic by modern standards. Primarily relied on robust construction for occupant protection. Seat belts (3-point front, 2-point rear), padded dashboard, collapsible steering column.
Braking System:
Front: Ventilated Disc Brakes. Rear: Drum Brakes. Some higher trims may have disc brakes all around. ABS was not widely available on early models.
Body Structure:
Body-on-frame construction for durability and off-road resilience.
Audio System:
Basic AM/FM radio, optional cassette player. Speaker configurations varied by trim level.
ABS:
Not standard on most models within this year range. Available as an option on some later, higher-trim variants.
Auxiliary Inputs:
None standard (e.g., no USB, Bluetooth).
Oil Change Interval Petrol:
Typically every 5,000 km (3,100 miles) or 6 months, whichever comes first. (Consult manual for exact mileage/time).
Oil Change Interval Diesel:
Typically every 7,500 km (4,600 miles) or 6 months, whichever comes first. (Consult manual for exact mileage/time).
Air Filter Replacement:
Every 15,000-20,000 km (9,300-12,400 miles) or annually. Inspect more frequently in dusty conditions.
Spark Plug Replacement:
Every 30,000-40,000 km (18,600-24,800 miles) for standard plugs, or per manual recommendation for specific types.
Engine Oil Petrol 2.6L:
API SF/SG or equivalent, SAE 10W-30 or 10W-40 (viscosity based on ambient temperature). Capacity approx. 4.5 L (with filter).
Engine Oil Diesel 2.5L:
API CD/CE or equivalent, SAE 15W-40 or 20W-50 (viscosity based on ambient temperature). Capacity approx. 6.5 L (with filter).
Coolant:
Ethylene glycol based antifreeze mixed with distilled water (50/50 ratio). Capacity approx. 8.0-9.0 L depending on engine and radiator size.
Brake Fluid:
DOT 3 or DOT 4.
Transmission Fluid Manual:
API GL-4, SAE 75W-90 or 80W-90 gear oil. Capacity varies by transmission type (e.g., 2.5-3.0 L for main gearbox).
Transmission Fluid Automatic:
Dexron II or Dexron III compatible ATF. Capacity approx. 5.0-6.0 L.
Transfer Case Fluid:
API GL-4, SAE 75W-90 or 80W-90 gear oil. Capacity approx. 2.0 L.
Differential Fluid Front Rear:
API GL-5, SAE 80W-90 or 85W-140 gear oil. Capacity approx. 1.5 L each.
Common Problems:
Rust (especially on chassis, wheel arches, and body mounts), seized brake calipers, overheating (particularly 4D55/56 diesel engines), worn suspension bushings and ball joints due to off-road use, carburetor issues on 4G54, potential timing belt issues if not replaced on schedule for 6G72 V6 (though many were chain-driven).
Mitsubishi Motors History:
Mitsubishi Motors has a long history of producing rugged vehicles, including military vehicles and trucks. The Pajero nameplate (derived from the Leopardus pajeros, a Patagonian wildcat) debuted in 1981.
First Generation Debut:
The L040 series Pajero was introduced in 1982, marking Mitsubishi's significant entry into the SUV market. It evolved through various engine, drivetrain, and trim updates during its production run.
Production Period:
1982-1991 (for this specific generation covered by the manual).
Manufacturing Locations:
Japan (Okazaki Plant)
Off Road Capability Awards:
The Pajero has a strong reputation in off-road racing, notably winning the Dakar Rally multiple times, starting with its first victory in 1985 in the Marathon class.
Consumer Ratings:
While specific ratings for this early era are scarce, the Pajero was consistently praised for its durability, off-road performance, and value for money in automotive press reviews of the time.
