Segment:
Compact/Mid-size SUV, Off-road oriented
Primary Competitors:
Toyota 4Runner, Jeep Cherokee XJ, Ford Explorer, Nissan Pathfinder
Off Road Capability:
Renowned for its Super Select 4WD system (on many models), robust chassis, and suspension articulation.
Durability:
Built with a focus on reliability and long-term durability, particularly in demanding conditions.
Versatility:
Available in various body styles (short wheelbase, long wheelbase wagon, canvas top) and configurations, suitable for family use and serious off-roading.
Purpose:
This manual provides exhaustive guidance for the maintenance, repair, and servicing of the 1991-1999 Mitsubishi Pajero/Montero, empowering owners and technicians with the knowledge to keep these capable vehicles in optimal condition.
Years Covered:
1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999
Estimated Page Count:
2000+
Type:
Workshop Repair Service Manual
Engine Systems:
Engine mechanical, cooling, lubrication, fuel, ignition, exhaust, emission control
Transmission Systems:
Manual transmission, automatic transmission, transfer case, driveline
Brake Systems:
Hydraulic systems, ABS (if equipped), parking brake
Electrical Systems:
Wiring diagrams, lighting, starting and charging, instrumentation, body electrical, ECU diagnosis
Suspension Steering:
Front and rear suspension, steering components, power steering
Body Chassis:
Body structure, interior components, exterior panels, doors, windows, HVAC
Maintenance Procedures:
Scheduled maintenance, oil changes, filter replacements, fluid checks and flushes
Repair Procedures:
Engine rebuild, transmission overhaul, brake caliper replacement, suspension arm replacement
Troubleshooting:
Diagnostic procedures, symptom-based troubleshooting, electrical fault finding
Diagnostic Procedures:
OBD-I scan tool usage (where applicable), component testing, sensor diagnostics
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds
Special Tools:
Identification and usage of specialized tools for specific repairs
Torque Specifications:
Detailed torque values for all critical fasteners
Wiring Diagrams:
Extensive, color-coded wiring diagrams for all electrical systems
Illustrations Diagrams:
Step-by-step illustrations and exploded views for clarity
Engine Code Gasoline:
6G72 (3.0L SOHC V6), 6G74 (3.5L SOHC V6), 6G74 (3.5L DOHC V6 - GDi in later models)
Engine Code Diesel:
4D56 (2.5L Turbo-Diesel I4), 4M40 (2.8L Turbo-Diesel I4)
Horsepower 6G72:
Approx. 145-170 hp (depending on variant and market)
Torque 6G72:
Approx. 165-185 lb-ft (depending on variant and market)
Horsepower 6G74:
Approx. 195-230 hp (depending on variant and market)
Torque 6G74:
Approx. 200-230 lb-ft (depending on variant and market)
Horsepower 4D56:
Approx. 95-125 hp
Torque 4D56:
Approx. 170-200 lb-ft
Fuel Delivery Gasoline:
Electronic Fuel Injection (EFI) - Multi-port injection (MPI)
Fuel Delivery Diesel:
Indirect injection (IDI) or Direct injection (DI) depending on model and year, often with turbocharging
Recommended Fuel:
Unleaded gasoline (Octane rating as per market specification), Diesel fuel
Ignition Type:
Distributor-based ignition system with electronic control (CDI)
Type Manual:
5-speed manual transmission
Type Automatic:
4-speed automatic transmission with electronically controlled overdrive
Drivetrain Options:
Part-time 4WD (with available 2WD mode), Full-time 4WD (Super Select 4WD system)
Transfer Case Features:
Two-speed transfer case with neutral and lockable differential (on some 4WD systems)
Automatic Transmission Fluid:
Dexron II or equivalent (refer to manual for exact specification)
Manual Transmission Fluid:
API GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90 (refer to manual for exact specification)
Exterior Dimensions Lwb Wagon
Length:
Approx. 4,600-4,700 mm (181.1-185.0 in)
Width:
Approx. 1,755-1,800 mm (69.1-70.9 in)
Height:
Approx. 1,800-1,870 mm (70.9-73.6 in)
Length:
Approx. 4,010-4,150 mm (157.9-163.4 in)
Wheelbase:
Approx. 2,405 mm (94.7 in) for SWB, 2,725 mm (107.3 in) for LWB
Curb Weight:
Approx. 1,700-2,000 kg (3,748-4,409 lbs) depending on configuration
Crash Test Information:
As a 1990s vehicle, official NCAP or IIHS ratings may be limited or non-existent. Refer to specific market safety certifications.
Braking System:
Ventilated front disc brakes, rear drum brakes (or disc on some later models). Optional Anti-lock Braking System (ABS).
Stability Control:
Not typically equipped with Electronic Stability Control (ESC) in this generation.
Airbags:
Driver's airbag became standard on later models; passenger airbag optional or unavailable depending on market and trim.
Seat Belts:
Three-point inertia reel seatbelts in the front, two-point or three-point in the rear (depending on seating position and configuration).
Rollover Protection:
Reinforced body structure designed for SUV applications.
Audio System:
Factory cassette or CD players with AM/FM radio, often with 4-6 speaker configurations.
Navigation:
Aftermarket navigation systems were the primary option; factory navigation was rare or non-existent for this era.
Cruise Control:
Standard on many higher trim levels.
Traction Control:
Limited to ABS on some models; advanced traction control systems were not common.
Bluetooth:
Not available from the factory; requires aftermarket integration.
Usb Ports:
Not available from the factory.
Service Intervals General
Oil Change Interval:
Every 5,000 - 7,500 miles or 6-12 months, depending on driving conditions (refer to manual).
Air Filter Replacement:
Every 15,000 - 30,000 miles or as needed based on inspection (refer to manual).
Spark Plug Replacement:
Approx. 30,000 - 60,000 miles for standard plugs, longer for platinum/iridium (refer to manual).
Coolant Flush:
Every 30,000 - 50,000 miles or 2-3 years (refer to manual).
Timing Belt Replacement:
Crucial for 6G7 engines. Typically 60,000 - 100,000 miles (refer to specific engine and manual). Failure can cause catastrophic engine damage.
Engine Oil Capacity 3 0L:
Approx. 4.5 - 5.0 liters (4.8 - 5.3 US quarts) with filter change (refer to manual).
Engine Oil Type:
API SG or higher, SAE 10W-30 or 10W-40 recommended (refer to manual for specific climate and model year)
Coolant Type:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Use Asian vehicle specific if available.
Engine Mounts:
Can degrade over time, leading to increased vibration.
Head Gaskets:
While not as prevalent as some other SUVs, older engines can develop head gasket leaks.
Transfer Case Actuator:
Electronic components in the 4WD system can fail, especially on higher mileage vehicles.
Window Motors Regulators:
Common wear item, leading to slow or inoperative power windows.
Fuel Pump Reliability:
Can become weak or fail over time, leading to poor performance or no-start conditions.
Mitsubishi Off Road History:
Mitsubishi has a strong heritage in off-road vehicles and rallying, with the Pajero participating and winning the Dakar Rally multiple times, cementing its off-road credentials.
Second Generation Introduction:
Introduced in late 1991 (as a 1992 model year in some markets), this generation featured a significant redesign with a more modern, car-like appearance and improved comfort.
Facelifts Updates:
Received updates throughout its production run, including engine upgrades (e.g., introduction of the 3.5L V6 and turbo-diesel engines), styling revisions, and feature enhancements.
Manufacturing Locations:
Primarily manufactured in Japan. Also assembled in other countries through knock-down kits.
Production Span:
1991-2000 (for the second generation globally, this manual covers up to 1999).
Dakar Rally Success:
The Mitsubishi Pajero (Montero) has achieved numerous victories in the Dakar Rally, a testament to its robust engineering and off-road prowess. These wins significantly boosted its global reputation.
Consumer Reports Historical:
Often rated as a reliable and capable SUV, particularly praised for its off-road ability and durability, though some criticisms might have been leveled at fuel economy or refinement compared to more car-like competitors of the era.
