Mitsubishi Pajero NP 2002-2006 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero Generation: NP (Fourth Generation) Codes Chassis Code: V7_W, V8_W Platform: Mitsubishi Pajero (1999-2006) platform 👋 Introduction Market Position Segment: Full-size SUV, Off-road capable, Body-on-frame construction. Target Audience: Enthusiasts, off-roaders, families requiring robust and capable transportation. Competitive Analysis Competitors: Toyota Land Cruiser Prado, Nissan Patrol, Land Rover Discovery, Jeep Grand Cherokee. Key Features Off Road Capability: Robust chassis, sophisticated 4WD system (Super Select II), good ground clearance, durable suspension components. Engine Options: Choice of potent V6 gasoline and efficient diesel engines. Durability: Known for its robust construction and ability to withstand demanding conditions. Utility: Spacious interior, ample cargo capacity, often configured for towing and expedition use. 📋 Manual Details Coverage Areas Years Covered: 2002, 2003, 2004, 2005, 2006 Regions Covered: Global (specific variations may apply, consult model-specific sections) Page Count Estimated Page Count: 1500+ Manual Type Type: Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, crankshaft, pistons, connecting rods, lubrication, cooling system, fuel delivery, exhaust system, timing components. Engine Electrical: Ignition system, starting system, charging system, fuel injection system (MPI), engine control module (ECM), sensors, actuators. Transmission: Manual transmission (G5M-P), Automatic transmission (V5A51, Aisin Warner), transfer case, drive shafts, differentials (front, rear, center). Drivetrain: 4WD system (Super Select II), drive axles, CV joints, wheel bearings, hub assemblies. Suspension: Front independent suspension (double wishbone), Rear multi-link suspension, shock absorbers, springs, control arms, sway bars, steering knuckles. Steering: Power steering system (hydraulic), steering rack, steering column, steering linkage. Brakes: Front ventilated discs, Rear discs, ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution), brake calipers, master cylinder, brake lines, parking brake. Body And Chassis: Unibody construction, body panels, doors, hood, tailgate, bumpers, glass, interior trim, chassis components. Electrical System: 12V electrical system, battery, alternator, starter motor, fuse box, wiring diagrams, lighting (headlights, taillights, interior), horn, wipers, washers. HVAC: Air conditioning system, heater, ventilation, blower motor, refrigerant lines, evaporator, condenser, climate control panel. Safety Systems: Airbags (front), seat belts, seat belt pretensioners, SRS (Supplemental Restraint System) module. Procedures Included Maintenance: Oil change, filter replacement (oil, air, fuel, cabin), spark plug replacement, coolant flush, brake fluid replacement, transmission fluid change, differential fluid change, tire rotation, lubrication points. Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based diagnostics, electrical system troubleshooting, engine performance issues, transmission problems, brake system malfunctions. Repair: Engine overhaul, cylinder head gasket replacement, timing belt/chain replacement, clutch replacement (manual), brake pad/rotor replacement, suspension component replacement, steering rack repair, HVAC system repair, electrical component replacement. Diagnostics: OBD-II diagnostics, sensor testing, actuator testing, circuit testing, using diagnostic scan tools. Adjustments: Idle speed adjustment, brake adjustment (parking brake), headlight aiming. Installation: Accessory installation guidance (limited, primarily OEM components), component replacement procedures. Technical Depth Depth: Comprehensive factory-level repair and maintenance information, suitable for professional technicians and advanced DIYers. Detail Level: Detailed step-by-step instructions, torque specifications, diagnostic flowcharts, wiring diagrams, exploded views, specifications and measurements. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text for quick access to information. Print Quality Printability: Printable pages for workshop use. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Quality: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Gasoline Engine 1: 6G74 SOHC V6 Gasoline Engine 1 Displacement: 3.5 Liters (3497cc) Gasoline Engine 1 Configuration: V6, SOHC Gasoline Engine 1 Horsepower: 197 hp @ 5000 rpm (approx.) Gasoline Engine 1 Torque: 215 lb-ft @ 3000 rpm (approx.) Gasoline Engine 1 Fuel System: Electronic Multi-Point Fuel Injection (MPI) Gasoline Engine 1 Fuel Type: Unleaded Gasoline Gasoline Engine 1 Cooling System: Water-cooled Gasoline Engine 1 Ignition System: Electronic Distributorless Ignition System (DIS) Diesel Engine Diesel Engine 1: 4M41 DOHC Intercooled Turbo Diesel Diesel Engine 1 Displacement: 3.2 Liters (3200cc) Diesel Engine 1 Configuration: Inline 4-cylinder, DOHC Diesel Engine 1 Horsepower: 165 hp @ 3800 rpm (approx.) Diesel Engine 1 Torque: 295 lb-ft @ 2000 rpm (approx.) Diesel Engine 1 Fuel System: Direct Injection, Common Rail, Turbocharged with Intercooler Diesel Engine 1 Fuel Type: Diesel Performance Acceleration 0 60 Mph: Approx. 9-11 seconds (varies by engine and transmission) Towing Capacity: Up to 2500 kg (5511 lbs) (check local regulations and vehicle specifics) 🔧 Transmission Standard Standard Transmission: 5-speed Manual Transmission (G5M-P) Optional Optional Transmission: 4-speed Automatic Transmission (V5A51 - Aisin Warner) Features Drivetrain: Part-time 4WD with Center Differential (standard on some models) or Full-time 4WD with Center Differential (Super Select II) Transfer Case: Two-speed transfer case with locking center differential (Super Select II system) Fluid Specifications Automatic Transmission Fluid: Mitsubishi DiaQueen ATF SP-III or equivalent Manual Transmission Fluid: API GL-4, SAE 75W-90 or SAE 75W-85 Transfer Case Fluid: API GL-4, SAE 75W-90 Front Differential Fluid: API GL-5, SAE 80W-90 Rear Differential Fluid: API GL-5, SAE 80W-90 (or synthetic equivalent) 📐 Dimensions Exterior Length: Approx. 4740 mm (186.6 in) Width: Approx. 1875 mm (73.8 in) Height: Approx....

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Typ: Car

Anbieter:

Art.-Nr: 500495

Sammlungen: ALL Mitsubishi

Verfügbarkeit: Auf Lager

Stichworte: 2002 2003 2004 2005 2006 Car Cars Misc Mitsubishi Pajero NP

Produktvarianten

Beschreibung

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Pajero

Generation:

NP (Fourth Generation)

Codes

Chassis Code:

V7_W, V8_W

Platform:

Mitsubishi Pajero (1999-2006) platform

👋 Introduction

Market Position

Segment:

Full-size SUV, Off-road capable, Body-on-frame construction.

Target Audience:

Enthusiasts, off-roaders, families requiring robust and capable transportation.

Competitive Analysis

Competitors:

Toyota Land Cruiser Prado, Nissan Patrol, Land Rover Discovery, Jeep Grand Cherokee.

Key Features

Off Road Capability:

Robust chassis, sophisticated 4WD system (Super Select II), good ground clearance, durable suspension components.

Engine Options:

Choice of potent V6 gasoline and efficient diesel engines.

Durability:

Known for its robust construction and ability to withstand demanding conditions.

Utility:

Spacious interior, ample cargo capacity, often configured for towing and expedition use.

📋 Manual Details

Coverage Areas

Years Covered:

2002, 2003, 2004, 2005, 2006

Regions Covered:

Global (specific variations may apply, consult model-specific sections)

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, crankshaft, pistons, connecting rods, lubrication, cooling system, fuel delivery, exhaust system, timing components.

Engine Electrical:

Ignition system, starting system, charging system, fuel injection system (MPI), engine control module (ECM), sensors, actuators.

Transmission:

Manual transmission (G5M-P), Automatic transmission (V5A51, Aisin Warner), transfer case, drive shafts, differentials (front, rear, center).

Drivetrain:

4WD system (Super Select II), drive axles, CV joints, wheel bearings, hub assemblies.

Suspension:

Front independent suspension (double wishbone), Rear multi-link suspension, shock absorbers, springs, control arms, sway bars, steering knuckles.

Steering:

Power steering system (hydraulic), steering rack, steering column, steering linkage.

Brakes:

Front ventilated discs, Rear discs, ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution), brake calipers, master cylinder, brake lines, parking brake.

Body And Chassis:

Unibody construction, body panels, doors, hood, tailgate, bumpers, glass, interior trim, chassis components.

Electrical System:

12V electrical system, battery, alternator, starter motor, fuse box, wiring diagrams, lighting (headlights, taillights, interior), horn, wipers, washers.

HVAC:

Air conditioning system, heater, ventilation, blower motor, refrigerant lines, evaporator, condenser, climate control panel.

Safety Systems:

Airbags (front), seat belts, seat belt pretensioners, SRS (Supplemental Restraint System) module.

Procedures Included

Maintenance:

Oil change, filter replacement (oil, air, fuel, cabin), spark plug replacement, coolant flush, brake fluid replacement, transmission fluid change, differential fluid change, tire rotation, lubrication points.

Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based diagnostics, electrical system troubleshooting, engine performance issues, transmission problems, brake system malfunctions.

Repair:

Engine overhaul, cylinder head gasket replacement, timing belt/chain replacement, clutch replacement (manual), brake pad/rotor replacement, suspension component replacement, steering rack repair, HVAC system repair, electrical component replacement.

Diagnostics:

OBD-II diagnostics, sensor testing, actuator testing, circuit testing, using diagnostic scan tools.

Adjustments:

Idle speed adjustment, brake adjustment (parking brake), headlight aiming.

Installation:

Accessory installation guidance (limited, primarily OEM components), component replacement procedures.

Technical Depth

Depth:

Comprehensive factory-level repair and maintenance information, suitable for professional technicians and advanced DIYers.

Detail Level:

Detailed step-by-step instructions, torque specifications, diagnostic flowcharts, wiring diagrams, exploded views, specifications and measurements.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text for quick access to information.

Print Quality

Printability:

Printable pages for workshop use.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Quality:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Gasoline Engine 1:

6G74 SOHC V6

Gasoline Engine 1 Displacement:

3.5 Liters (3497cc)

Gasoline Engine 1 Configuration:

V6, SOHC

Gasoline Engine 1 Horsepower:

197 hp @ 5000 rpm (approx.)

Gasoline Engine 1 Torque:

215 lb-ft @ 3000 rpm (approx.)

Gasoline Engine 1 Fuel System:

Electronic Multi-Point Fuel Injection (MPI)

Gasoline Engine 1 Fuel Type:

Unleaded Gasoline

Gasoline Engine 1 Cooling System:

Water-cooled

Gasoline Engine 1 Ignition System:

Electronic Distributorless Ignition System (DIS)

Diesel Engine

Diesel Engine 1:

4M41 DOHC Intercooled Turbo Diesel

Diesel Engine 1 Displacement:

3.2 Liters (3200cc)

Diesel Engine 1 Configuration:

Inline 4-cylinder, DOHC

Diesel Engine 1 Horsepower:

165 hp @ 3800 rpm (approx.)

Diesel Engine 1 Torque:

295 lb-ft @ 2000 rpm (approx.)

Diesel Engine 1 Fuel System:

Direct Injection, Common Rail, Turbocharged with Intercooler

Diesel Engine 1 Fuel Type:

Diesel

Performance

Acceleration 0 60 Mph:

Approx. 9-11 seconds (varies by engine and transmission)

Towing Capacity:

Up to 2500 kg (5511 lbs) (check local regulations and vehicle specifics)

🔧 Transmission

Standard

Standard Transmission:

5-speed Manual Transmission (G5M-P)

Optional

Optional Transmission:

4-speed Automatic Transmission (V5A51 - Aisin Warner)

Features

Drivetrain:

Part-time 4WD with Center Differential (standard on some models) or Full-time 4WD with Center Differential (Super Select II)

Transfer Case:

Two-speed transfer case with locking center differential (Super Select II system)

Fluid Specifications

Automatic Transmission Fluid:

Mitsubishi DiaQueen ATF SP-III or equivalent

Manual Transmission Fluid:

API GL-4, SAE 75W-90 or SAE 75W-85

Transfer Case Fluid:

API GL-4, SAE 75W-90

Front Differential Fluid:

API GL-5, SAE 80W-90

Rear Differential Fluid:

API GL-5, SAE 80W-90 (or synthetic equivalent)

📐 Dimensions

Exterior

Length:

Approx. 4740 mm (186.6 in)

Width:

Approx. 1875 mm (73.8 in)

Height:

Approx. 1855 mm (73.0 in)

Wheelbase:

Approx. 2780 mm (109.4 in)

Ground Clearance:

Approx. 210 mm (8.3 in) (unladen)

Weights

Curb Weight:

Approx. 1950-2100 kg (4300-4630 lbs) (varies by configuration)

Gross Vehicle Weight Rating Gvw:

Approx. 2600-2750 kg (5732-6063 lbs)

Cargo

Cargo Volume:

Varies by seating configuration; significant capacity in rear cargo area.

Wheels And Tires

Wheel Bolt Pattern:

6 x 139.7 mm (6 x 5.5 inches)

Standard Tire Size:

265/70R16, 265/65R17 (varies by trim)

Standard Wheel Size:

16x7JJ or 17x7.5JJ Alloy

🛡️ Safety Features

Ratings

NHTSA Front Crash Test:

4-star (for driver and front passenger in certain configurations, consult specific vehicle data)

IIHS Side Impact Test:

Good (for models equipped with side airbags, consult specific vehicle data)

Active Features

Standard Anti-lock Braking System (ABS)

Standard Electronic Brake-force Distribution (EBD)

Traction Control:

Optional Electronic Traction Control (Active Traction Control - ATC) on some models.

Stability Control:

Not typically standard on this generation.

Passive Features

Airbags:

Driver and front passenger airbags standard. Optional side airbags available on higher trims.

Seat Belts:

3-point seat belts with pretensioners for front occupants; 3-point seat belts for rear occupants.

💡 Technology Features

Infotainment

Audio System:

Factory-installed AM/FM stereo with CD player, often with premium Rockford Fosgate audio system on higher trims.

Navigation:

Optional factory navigation system (less common, early generation).

Driver Assistance

Cruise Control:

Standard cruise control on most models.

Connectivity

Connectivity Options:

Limited connectivity by modern standards; may feature auxiliary input on some audio systems.

🔧 Maintenance

Service Intervals

Engine Oil And Filter Change:

Every 7,500 miles (12,000 km) or 6 months, whichever comes first (refer to owner's manual for specific conditions).

Engine Air Filter:

Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).

Fuel Filter Diesel:

Replace every 30,000 miles (48,000 km).

Cabin Air Filter:

Replace every 15,000 miles (24,000 km) or annually.

Spark Plugs Gasoline:

Replace at 60,000 miles (96,000 km) for standard plugs, or 100,000 miles (160,000 km) for iridium-tipped plugs (consult vehicle specifics).

Timing Belt Gasoline:

Replace every 60,000 miles (96,000 km) or 4 years (critical component for 6G74 engine).

Coolant Flush:

Replace coolant every 30,000 miles (48,000 km) or 2 years.

Fluid Specifications

Engine Oil Gasoline:

SAE 10W-30 or 10W-40, API SJ/SL or higher. (Capacity: approx. 5.4 US quarts / 5.1 liters with filter)

Engine Oil Diesel:

API CH-4 or CI-4, SAE 15W-40 or 5W-40 (synthetic). (Capacity: approx. 8.2 US quarts / 7.8 liters with filter)

Brake Fluid:

DOT 3 or DOT 4, low viscosity.

Known Issues

Diesel Glow Plugs:

Glow plugs can fail over time, leading to hard starting in cold weather for diesel models.

Automatic Transmission Issues:

Some units may experience harsh shifting or transmission slipping, often related to fluid degradation or valve body issues.

Suspension Bushings:

Wear in suspension bushings and ball joints can lead to knocking noises and imprecise handling, especially with higher mileage or off-road use.

Radiator Leaks:

Radiators can develop leaks over time, especially at the plastic end tanks.

Oxygen Sensors:

Oxygen sensors can degrade, affecting fuel economy and emissions.

📚 Vehicle History

Brand Heritage

Mitsubishi SUV Legacy:

Mitsubishi has a long history in producing capable off-road vehicles, with the Pajero lineage tracing back to the Mitsubishi Pajero Evolution and earlier off-road vehicles.

Model Evolution

Generation Np:

The NP Pajero (2002-2006) represents the latter part of the third generation (1999-2006), known for its monocoque body structure and advanced independent suspension, moving away from traditional body-on-frame construction of earlier generations.

Np Updates:

The NP Pajero received minor updates during its production run, including refreshed styling, improved engine options (especially the 4M41 diesel in some markets), and technology enhancements.

Production

Production Locations:

Primarily manufactured in Japan.

Production Years:

2002-2006 (NP generation)

🏆 Awards & Recognition

Recognitions

Off Road Accolades:

The Pajero lineage has a strong reputation in off-road events like the Dakar Rally, though the NP generation's direct competitive accolades might be more market-specific.

Ratings

Consumer Reports Reliability:

Variable; generally good but can be prone to specific issues as outlined in maintenance section. Consult specific model year reviews.