Parts for your 1996 Mitsubishi Pajero-Heater core

1996 Mitsubishi Pajero Heater Core: What it does and how to look after it

The 1996 Mitsubishi Pajero is fitted with a heater core. This is confirmed by factory documentation: the Mitsubishi Pajero (V2/V4/V6 series) Workshop Manual, Group 55A Heating & Air Conditioning (1991–1999), and the Mitsubishi ASA Electronic Parts Catalogue for 1996 VINs both list a front “heater radiator/heater core” housed in the HVAC unit behind the dash. Aftermarket service guides such as Gregory’s/Haynes for the era also include heater core removal procedures for second‑gen Pajero models.

Think of the heater core as a small radiator inside the cabin. Engine coolant flows through it, the blower pushes air across it to provide warm air for demisting and cabin heating. On a ’96 Pajero, it’s a constant‑flow setup with temperature managed by blend doors, so a healthy core is key to fast demisting and comfy winter drives.

• Common symptoms of trouble: sweet coolant smell in the cabin, oily film on the windscreen, damp carpet under the dash, poor heater performance, or unexplained coolant loss.
• Preventative care: refresh coolant with the correct ethylene glycol mix every 2–3 years or 40,000–50,000 km, use demineralised water, and inspect heater hoses and clamps at the firewall.

Replacement is a dash‑out job on the Pajero and best tackled with patience. It’s doable at home for a competent DIYer, but many owners prefer a workshop due to SRS and HVAC disassembly.

1. Disconnect the battery and wait at least 10 minutes for SRS capacitors to discharge. Handle airbag connectors carefully.
2. Drain coolant. Under the bonnet, disconnect the two heater hoses at the firewall and cap them to avoid spills.
3. Remove trim and the HVAC box as per the workshop manual. Label plugs and linkages, photograph as you go.
4. Swap in a quality heater core, renewing O‑rings/foam seals. Pressure‑test the core and box before refitting.
5. Reassemble, reconnect hoses, refill with a 50/50 coolant mix (roughly 9–10 litres total system, check the manual for exact spec), and bleed with the heater set to HOT. Verify for leaks and proper demist.

Good practice while you’re in there: replace aged heater hoses and clamps, inspect blend doors and actuator operation, and clean the evaporator core. A tidy job here saves chasing creaks, odours, and coolant seeps later.

Popular questions about 1996 Mitsubishi Pajero heater cores

Where is the heater core located on a 1996 Pajero?
It sits inside the HVAC/heater box behind the dashboard, roughly centre to passenger side. Access requires removing dash trim and the heater/evaporator assembly from the cabin side, after disconnecting the heater hoses at the firewall.

How long does heater core replacement take?
A workshop will usually quote 6–10 hours depending on model variant and accessories. DIY time varies with experience. Allow a weekend if working methodically, as careful dash removal and reassembly are key.

Can the heater core be bypassed temporarily?
Yes, joining the two heater hoses under the bonnet will bypass it in an emergency to stop a leak. It’s only a short‑term fix: you’ll lose demist performance and risk overheating if the cooling system isn’t properly refilled and bled. Repair or replace the core as soon as practical.