Parts for your 1989 Mitsubishi Pajero-Exhaust gasket

1989 Mitsubishi Pajero exhaust gasket — what it does and when to replace it

Technical sources confirm the 1989 Mitsubishi Pajero uses exhaust gaskets at several joints. The Mitsubishi Pajero/Montero factory service manuals for late‑1980s models, the Gregory’s/Haynes workshop manuals for 1983–1993 Pajero, and the Mitsubishi ASA parts catalogue all specify exhaust manifold-to-head gaskets, pipe “donut”/ring gaskets at the manifold/downpipe, and, on 4D56T turbo-diesel variants, additional turbine outlet gaskets. Walker and Victor Reinz gasket catalogues list direct-fit gasket sets for the 4G54, 6G72, and 4D56 engines used in 1989, so the exhaust gasket is absolutely relevant to this vehicle.

On this classic Pajero, the exhaust gasket’s job is to seal hot gases at the manifold and pipe flanges, keeping things quiet, preventing fumes from sneaking into the cabin, and helping the engine breathe properly. A tight seal also protects nearby components from heat erosion and soot, and on petrol models helps the engine management get accurate readings.

There’s no set kilometre-based replacement interval, gaskets are serviced when they leak or whenever the exhaust is removed. Telltale signs include a sharp ticking on cold start, a sooty line around the flange, exhaust odour, reduced low-end torque, or a noisy WOF/RWC inspection. If the 1989 Pajero has the 4D56T, also look at the turbo outlet and EGR pipe joints. Address leaks promptly—hot gas can cook wiring, melt nearby plastics, and warp mating faces.

When replacing, it pays to:

• Match the gasket to the engine code (4G54 2.6 petrol, 6G72 3.0 V6, or 4D56T 2.5 turbo-diesel) and body series.
• Inspect manifold flatness and cracks, resurface if warped.
• Use new studs, nuts, and spring bolts where specified, apply high-temp anti-seize to nuts only if the manual permits.
• Clean mating faces to bare metal, avoid abrasives that gouge.
• Follow the factory torque specs and sequence from the service manual, re-check after a heat cycle.

A workshop with experience on older Mitsis will knock this over quickly, but a handy owner can DIY with patience, penetrating oil, and a torque wrench. A fresh, quality gasket restores that tight, quiet note and keeps the Pajero happy on long outback or back-country runs.

Popular questions

What are the signs of a leaking exhaust gasket on a 1989 Pajero?
Common signs are a ticking sound that’s louder on cold start and fades as things heat up, visible soot around the flange, a whiff of exhaust in or around the cabin, and a rougher note or loss of grunt down low. A WOF/RWC inspector may also note excessive exhaust noise or leaks.

Does the 2.5 turbo-diesel use different exhaust gaskets than the petrol models?
Yes. The 4D56T turbo-diesel uses different manifold shapes and has a turbine outlet gasket the petrol engines don’t. Always order by engine code and VIN, parts catalogues and the Mitsubishi ASA system list the correct pattern for each variant.

Is it safe to drive with a blown exhaust manifold gasket?
It’s not recommended. Hot escaping gases can damage nearby components, leak fumes toward the cabin, and in time can erode the manifold or head face. It may also trigger inspection failures. Best to repair soon to avoid bigger bills.