Parts for your 2005 Mitsubishi Pajero-Manifold gasket

2005 Mitsubishi Pajero Manifold Gasket — Purpose, Service Tips, and Replacement

Yes, a manifold gasket is used on the 2005 Mitsubishi Pajero. Mitsubishi’s factory Workshop Manual for the Pajero/Montero (circa 2001–2006, Group 11 – Engine, Intake and Exhaust) details intake and exhaust manifold removal and refit procedures that specify gasket replacement. The Mitsubishi ASA/EPC parts catalogue for 2005 models (including the 3.2 DI‑D 4M41 diesel and 3.8 V6 6G75 petrol) also lists dedicated intake manifold gaskets and exhaust manifold gaskets, confirming the part is fitted from factory.

On this Pajero, the manifold gasket is a simple but vital seal. The intake manifold gasket keeps unmetered air out of the engine, preserving proper air/fuel mix (and boost on the turbo‑diesel), while the exhaust manifold gasket keeps hot exhaust gases sealed to the head and turbo plumbing. When these gaskets age, get disturbed during other jobs, or are fitted without the correct torque sequence, they can leak. That can mean rough idle, a hissing or whistling under the bonnet, soot marks at the exhaust flange, ticking on cold start, poor fuel economy, and even fault codes.

While manifold gaskets aren’t a routine “every service” item, they’re a smart replace‑on‑removal part. If the intake or exhaust manifold comes off for any reason—common on the 4M41 when cleaning EGR deposits—new gaskets should go in. The same applies during exhaust or turbo work. On higher‑kilometre Pajeros that have done lots of heat cycles and towing, preventative replacement can save headaches down the track.

• Use quality OEM‑equivalent gaskets and new manifold nuts/washers where specified.
• Clean mating surfaces carefully, don’t gouge aluminium. Avoid sealants unless the manual explicitly calls for them.
• Follow the factory torque specs and tightening sequence to the letter, and recheck fasteners after the first heat cycle if the manual advises.
• Inspect manifolds for warpage with a straight edge, resurfacing or replacement may be needed if they’re out of spec.
• On the V6 petrol, remember there are upper plenum gaskets as well as lower intake gaskets, replace them as a set when disturbed.

Done right, a fresh manifold gasket keeps the Pajero quiet, torquey and efficient, whether it’s commuting or towing the boat up the Kaimais.

Popular questions about the 2005 Mitsubishi Pajero manifold gasket

What are the signs my Pajero’s manifold gasket is leaking?
Typical clues include a hiss at idle, a whistling under boost (DI‑D), rough idle or hunting, soot around the exhaust manifold flange, ticking on cold start that quietens as it warms, and a noticeable exhaust smell. You might also see a drop in fuel economy or power and, on petrol models, lean‑mixture fault codes.

Should I replace the gasket every time the manifold comes off?
Yes. The factory guidance expects a new gasket whenever an intake or exhaust manifold is removed. Reusing a compressed, heat‑cycled gasket risks immediate leaks. It’s inexpensive insurance compared with doing the job twice.

How much does replacement usually cost in Australia or New Zealand?
Parts are generally modest—often under a couple of hundred dollars for a full set. Labour varies with engine and whether other work (EGR clean, studs, turbo hardware) is bundled, but a straightforward intake or exhaust manifold gasket job typically runs a few hours at local labour rates.