🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero / Montero

Product Type:

Workshop Service Repair Manual

Chassis Codes Covered:

K90 Series (e.g., K94W, K96W, K97W, K99W)

Engine Codes Covered:

4D56, 6G72, 6G74, 4M40, 4M41 (depending on specific region and year)

👋 Introduction

Segment:

Full-size SUV, Body-on-frame, capable off-road vehicle.

Key Selling Points:

Ruggedness, off-road capability, reliability, spacious interior, powerful engine options.

Primary Competitors:

Toyota Land Cruiser, Nissan Patrol, Ford Explorer, Chevrolet Tahoe, Jeep Grand Cherokee.

Off Road Features:

Super Select 4WD system (on some models), locking differentials, robust suspension, ample ground clearance.

Powertrain Options:

Availability of potent V6 and V8 engines, and efficient diesel options in certain markets.

Body Styles:

Offered in short-wheelbase (2-door) and long-wheelbase (4-door) variants, with various seating configurations.

📋 Manual Details

Market Regions:

Global (includes variations for North America - Montero, and other international markets - Pajero)

Estimated Page Count:

1500+

Manual Type:

Comprehensive Workshop Service & Repair Manual

Language:

English

Format:

Digital Download (typically PDF)

📖 Manual Coverage

Engine Mechanical:

Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, camshafts, valvetrain, timing (belt/chain), lubrication, cooling systems.

Engine Management:

Fuel injection (MPI/GDI), ignition system, emission control systems, engine control module (ECM/ECU) diagnostics, sensors and actuators.

Transmission Drivetrain:

Manual transmission, automatic transmission (AT), transfer case, differentials (front, rear, center), drive shafts, CV joints, hub systems.

Suspension Steering:

Independent front suspension (double wishbone), multi-link rear suspension, shock absorbers, springs, stabilizer bars, power steering system, steering column.

Brakes:

Front disc brakes, rear drum/disc brakes, ABS (Anti-lock Braking System) components and diagnostics, parking brake system.

Electrical Electronics:

Battery, charging system (alternator, starter), lighting (headlights, taillights, interior), power windows, locks, mirrors, wipers, horn, fuse box diagrams, wiring schematics.

Body Chassis:

Body construction, doors, hood, tailgate, bumpers, interior trim, seats, glass, rust prevention, structural repairs.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system components, operation, and servicing.

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, fluid checks and changes (coolant, brake fluid, transmission fluid, power steering fluid, differential fluid), tire rotation.

Engine Repair:

Engine tune-ups, head gasket replacement, piston ring replacement, bearing replacement, timing belt/chain replacement, complete engine overhaul.

Transmission Service:

Clutch replacement (manual), transmission fluid and filter change (automatic), transmission overhaul (manual and automatic).

Brake Service:

Brake pad/shoe replacement, rotor/drum replacement, brake caliper servicing, bleeding brake system, ABS component replacement.

Electrical Diagnostics:

Troubleshooting electrical faults, testing components, wiring harness repair, ECU/ECM diagnosis, sensor testing.

Suspension Steering Repair:

Replacement of ball joints, tie rod ends, control arms, shock absorbers, springs, power steering pump and rack replacement.

Troubleshooting Guides:

Detailed symptom-based troubleshooting charts and diagnostic procedures for various systems.

Depth Of Coverage:

In-depth technical information suitable for professional mechanics and experienced DIY enthusiasts, covering everything from routine maintenance to full engine and transmission rebuilds.

Diagnostic Information:

Includes diagnostic trouble codes (DTCs), diagnostic flowcharts, and specifications for testing sensors, actuators, and control modules.

Torque Specifications:

Comprehensive list of torque specifications for all critical fasteners and components.

Component Removal Installation:

Step-by-step instructions with diagrams for component removal and installation.

📊 Manual Specifications

Digital File Format:

PDF (Portable Document Format)

Scan Resolution:

High resolution, ensuring clarity of diagrams and text.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Text Searchability:

Searchable text for quick information retrieval.

Hyperlinks:

May include internal hyperlinks for easier navigation between sections.

⚙️ Engine Specifications

Engine Options:

4D56 (2.5L I4 Diesel), 4M40 (2.8L I4 Diesel), 4M41 (3.2L I4 Diesel - later years), 6G72 (3.0L V6 Petrol), 6G74 (3.5L V6 Petrol), 6G75 (3.8L V6 Petrol - later years).

Horsepower Range:

Approximately 100 HP (diesel) to 240 HP (V6 petrol), varying by engine and year.

Torque Range:

Approximately 170 lb-ft (diesel) to 260 lb-ft (V6 petrol), varying by engine and year.

Fuel Delivery:

Indirect Injection (IDI) or Direct Injection (DI) for diesel engines; Multi-Point Fuel Injection (MPFI) or Gasoline Direct Injection (GDI) for petrol engines.

Fuel Type:

Diesel, Unleaded Petrol.

🔧 Transmission

Standard Transmission:

5-speed Manual Transmission.

Optional Transmission:

4-speed or 5-speed Automatic Transmission (depending on engine and trim).

Drivetrain System:

Part-time 4WD or Full-time 4WD (Super Select 4WD system on higher trims/later models).

Transfer Case:

2-speed transfer case with various modes (e.g., 2H, 4H, 4HLc, 4LLc).

📐 Dimensions

Wheelbase:

Approx. 109.7 inches (SWB) / 119.2 inches (LWB), varies slightly by generation and market.

Length:

Approx. 175.5 inches (SWB) / 189.4 inches (LWB), varies slightly by generation and market.

Width:

Approx. 69.1 - 71.2 inches, varies by generation and market.

Height:

Approx. 73.0 - 74.4 inches, varies by generation and market.

Curb Weight:

Approximately 4,000 - 5,000 lbs, depending on configuration.

Towing Capacity:

Typically rated between 5,000 - 7,000 lbs, depending on engine and market regulations.

🛡️ Safety Features

Crash Test Ratings:

Varies by year and testing agency (e.g., NHTSA, IIHS). Early models generally had fewer advanced safety features and lower ratings compared to later models.

Active Safety Features:

ABS (Anti-lock Braking System) standard on most models, Electronic Brakeforce Distribution (EBD) on some later models.

Passive Safety Features:

Driver and front passenger airbags (standard on later models), seatbelt pretensioners, reinforced body structure.

💡 Technology Features

Audio System:

Factory fitted AM/FM stereo with cassette and CD player. Higher trims may feature premium audio systems (e.g., Rockford Fosgate) and CD changers.

Driver Assistance Features:

Limited by era. Primarily ABS. Some later models might have offered basic cruise control.

Connectivity Options:

No integrated Bluetooth or advanced connectivity features standard for this period. Aftermarket solutions available.

🔧 Maintenance

Oil Change Interval:

Typically 3,000-5,000 miles or 6 months for older models, consult manual for specific engine/oil type recommendations.

Timing Belt Replacement:

Critical maintenance item for petrol engines. Typically every 60,000-100,000 miles or 5-7 years. Specific interval varies by engine (e.g., 6G72, 6G74). Diesel models may use timing chains or belts with different intervals.

Engine Oil Spec:

API SG or higher. Viscosity varies by temperature: 5W-30, 10W-30, 10W-40, 20W-50. Consult manual for exact recommendations based on engine and climate.

Coolant Spec:

Ethylene glycol-based coolant with corrosion inhibitors. Typically a 50/50 mix with distilled water. Refer to manual for specific type (e.g., green or long-life pink).

Transmission Fluid Auto:

Dexron IIE or equivalent for older 4-speed automatics. Dexron III or MERCON for later 5-speed automatics. Consult manual for specific fluid type and capacity.

Differential Fluid Spec:

Hypoid gear oil, API GL-5, SAE 80W-90 (for front/rear differentials). Center differential may use a different specification.

Common Problems:

Head gasket leaks (V6 petrol engines), radiator leaks, ABS sensor failures, transfer case actuator issues (on some models), rust in common areas (wheel wells, rockers), timing belt failure (if not replaced on schedule).

Diesel Engine Considerations:

Glow plug issues, injection pump timing, turbocharger maintenance (if applicable), exhaust manifold cracking (on some 4M40 models).

📚 Vehicle History

Mitsubishi SUV Legacy:

Mitsubishi has a long history of producing capable off-road vehicles, dating back to the 1970s with the original Pajero.

Generation Covered:

Primarily covers the second generation (1991-2000) and early third generation (2001-2002) models of the Pajero/Montero.

Second Gen Updates:

Significant redesign from the first generation, introducing more refined styling, improved comfort, and advanced features like the Super Select 4WD system.

Production Period:

1991-2002 for the specific models covered by this manual.

Manufacturing Locations:

Primarily Japan, with assembly in other global locations for various markets.

🏆 Awards & Recognition

Off Road Awards:

The Mitsubishi Pajero has a strong reputation and numerous victories in off-road endurance events like the Dakar Rally, underscoring its capability.

Consumer Reports Rankings:

Ratings vary significantly by year and specific model. Often praised for capability but sometimes criticized for fuel economy and reliability compared to some competitors.