Mitsubishi Pajero III Complete Workshop Service Repair Manual 2001 2002 2003
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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero III Generation: Third Generation Years Covered: 2001, 2002, 2003 Codes Chassis Codes: V60 Series (e.g., V73W, V75W, V77W, V78W) 👋 Introduction Market Position Vehicle Segment: Full-size SUV, known for off-road capability and robust construction. Target Audience: Enthusiasts, DIY mechanics, owners seeking in-depth maintenance and repair knowledge for their Pajero. Competitive Analysis Key Competitors Era: Toyota Land Cruiser Prado, Nissan Patrol, Land Rover Discovery, Jeep Grand Cherokee. Key Features Off Road Prowess: Renowned for its sophisticated 'Super Select 4WD II' system, robust chassis, and long-travel suspension. Versatility: Suitable for daily driving, family transport, and serious off-road adventuring. Reliability: Generally considered a reliable vehicle with proper maintenance. 📋 Manual Details Coverage Areas Manual Type: Complete Workshop Service Repair Manual Language: English Format: Downloadable Digital Format (PDF likely) Source: Official Mitsubishi Service Documentation 📖 Manual Coverage Systems Covered Engine: Detailed overhaul, diagnostics, tuning, fuel injection, ignition, cooling, lubrication, emissions control, engine management system (ECU). Transmission: Manual and Automatic transmission repair, overhaul, fluid changes, diagnostics, clutch service, torque converter. Drivetrain: Front and rear axles, differentials, driveshafts, transfer case, 4WD system operation and repair, Super Select 4WD II system. Suspension: Front independent suspension (double wishbone), rear multi-link suspension, shock absorbers, springs, control arms, sway bars, alignment procedures. Brakes: Front and rear disc brake systems, ABS (Anti-lock Braking System) diagnostics and repair, brake fluid, parking brake. Steering: Power steering system, steering gear, tie rods, steering column, alignment. Electrical: Complete wiring diagrams, battery, charging system, starting system, lighting, gauges, accessories, power windows, central locking, ECU diagnostics, fuses, relays. Body: Body construction, panels, doors, windows, sunroof, interior trim, exterior trim, bumpers, corrosion protection. HVAC: Heating, ventilation, and air conditioning system service, refrigerant handling, component replacement. Safety Systems: Airbag system diagnostics and service, seatbelt mechanisms. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement. Diagnostics: Troubleshooting guides, fault code interpretation, diagnostic connector locations, step-by-step diagnostic procedures for all major systems. Repair Overhaul: Complete engine rebuild procedures, transmission overhaul, suspension component replacement, brake caliper overhaul, starter and alternator replacement. Installation Replacement: Component replacement for major systems, including fuel pump, radiator, power steering pump, alternator, starter motor, various sensors. Torque Specifications: Precise torque values for all critical fasteners throughout the vehicle. Special Tools: Identification and usage instructions for specialized tools required for specific repair procedures. Technical Depth Depth: Comprehensive from basic scheduled maintenance to complete engine and transmission rebuilds, including detailed electrical system diagnostics and wiring diagrams. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Text-searchable for quick information retrieval. Print Quality Printability: Printable for physical use in a workshop environment. Binding Type Binding Format: Digital Download (No physical binding specified) Paper Type Paper Format: Digital Format (No physical paper type) ⚙️ Engine Specifications Primary Engine Engine Options Available: 3.0L V6 SOHC (6G72), 3.5L V6 SOHC/DOHC (6G74), 3.2L Direct Injection Diesel (4M41). Engine Displacement 3.0L: 2972 cc Engine Displacement 3.5L: 3497 cc Engine Displacement 3.2L Diesel: 3200 cc Performance Horsepower 3.0L V6: Approx. 170-180 hp Torque 3.0L V6: Approx. 180-190 lb-ft Horsepower 3.5L V6 (Sohc): Approx. 192-200 hp Torque 3.5L V6 (Sohc): Approx. 215-220 lb-ft Horsepower 3.5L V6 (DOHc Mivec): Approx. 215-230 hp Torque 3.5L V6 (DOHc Mivec): Approx. 230-240 lb-ft Horsepower 3.2L Di-D: Approx. 165 hp Torque 3.2L Di-D: Approx. 275 lb-ft Fuel System Fuel Delivery Gasoline: Electronic Fuel Injection (EFI) Fuel Type Gasoline: Unleaded Gasoline Fuel Delivery Diesel: Common Rail Direct Injection (CRDI) Fuel Type Diesel: Diesel Fuel 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission Optional Transmission Type Optional: 4-speed Automatic Transmission (INVECS-II with G-shift) Features 4Wd System: Super Select 4WD II System (selectable 2H, 4H, 4HLc, 4LLc), Electronic Traction Control (optional). Transfer Case: 2-speed transfer case with center differential lock. 📐 Dimensions Exterior Wheelbase: Approx. 2780 mm (109.4 in) Length: Approx. 4755-4805 mm (187.2-189.2 in) depending on trim/body style Width: Approx. 1875 mm (73.8 in) Height: Approx. 1855-1905 mm (73.0-75.0 in) depending on suspension/roof options Weights Curb Weight: Approx. 1900-2100 kg (4189-4630 lbs) depending on engine and configuration Gross Vehicle Weight Rating: Typically around 2600-2800 kg (5732-6173 lbs) Towing Capacity: Varies by market and configuration, typically 2500-3500 kg (5500-7700 lbs) for braked trailers. Cargo Cargo Volume: Generous for its class, configurable with folding rear seats. 🛡️ Safety Features Ratings Crash Test Information: Varies by market and testing agency. Generally good for its era, focusing on a robust body-on-frame construction. Active Features ABS: Standard Anti-lock Braking System (ABS). Traction Control: Optional Electronic Traction Control (ETC) or Active Stability Control (ASC) on some models. Passive Features Airbags: Driver and front passenger airbags standard. Side airbags and curtain airbags available on higher trims or later models. Seatbelts: Three-point seatbelts with pre-tensioners for front seats. Body Construction: Reinforced Impact Safety Evolution (RISE) body construction. 💡 Technology Features Infotainment...
Component replacement for major systems, including fuel pump, radiator, power steering pump, alternator, starter motor, various sensors.
Torque Specifications:
Precise torque values for all critical fasteners throughout the vehicle.
Special Tools:
Identification and usage instructions for specialized tools required for specific repair procedures.
Technical Depth
Depth:
Comprehensive from basic scheduled maintenance to complete engine and transmission rebuilds, including detailed electrical system diagnostics and wiring diagrams.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Text-searchable for quick information retrieval.
Print Quality
Printability:
Printable for physical use in a workshop environment.
4-speed Automatic Transmission (INVECS-II with G-shift)
Features
4Wd System:
Super Select 4WD II System (selectable 2H, 4H, 4HLc, 4LLc), Electronic Traction Control (optional).
Transfer Case:
2-speed transfer case with center differential lock.
📐 Dimensions
Exterior
Wheelbase:
Approx. 2780 mm (109.4 in)
Length:
Approx. 4755-4805 mm (187.2-189.2 in) depending on trim/body style
Width:
Approx. 1875 mm (73.8 in)
Height:
Approx. 1855-1905 mm (73.0-75.0 in) depending on suspension/roof options
Weights
Curb Weight:
Approx. 1900-2100 kg (4189-4630 lbs) depending on engine and configuration
Gross Vehicle Weight Rating:
Typically around 2600-2800 kg (5732-6173 lbs)
Towing Capacity:
Varies by market and configuration, typically 2500-3500 kg (5500-7700 lbs) for braked trailers.
Cargo
Cargo Volume:
Generous for its class, configurable with folding rear seats.
🛡️ Safety Features
Ratings
Crash Test Information:
Varies by market and testing agency. Generally good for its era, focusing on a robust body-on-frame construction.
Active Features
ABS:
Standard Anti-lock Braking System (ABS).
Traction Control:
Optional Electronic Traction Control (ETC) or Active Stability Control (ASC) on some models.
Passive Features
Airbags:
Driver and front passenger airbags standard. Side airbags and curtain airbags available on higher trims or later models.
Seatbelts:
Three-point seatbelts with pre-tensioners for front seats.
Body Construction:
Reinforced Impact Safety Evolution (RISE) body construction.
💡 Technology Features
Infotainment
Audio System:
Factory radio with CD player, AM/FM tuner, and often an auxiliary input or cassette player. Premium Rockford Fosgate sound system available on higher trims.
Navigation:
Optional factory GPS navigation system on some models.
Driver Assistance
Cruise Control:
Standard cruise control system.
Parking Sensors:
Rear parking sensors available on some later models or as an aftermarket addition.
Connectivity
Phone Integration:
No integrated Bluetooth or smartphone connectivity from the factory in this era; aftermarket solutions are common.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions (consult manual for specific recommendations).
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.
Spark Plug Replacement:
Gasoline engines: 30,000-60,000 miles (48,000-96,000 km) depending on plug type (standard or iridium).
Timing Belt Replacement:
For 6G72 and 6G74 engines, typically around 60,000-90,000 miles (96,000-144,000 km). The 4M41 diesel uses a timing chain.
Fluid Specifications
Engine Oil Type:
API SJ or SL, SAE 5W-30 or 10W-30 (check manual for exact grade and capacity based on engine variant).
Transmission Fluid Automatic:
DIA QUEEN ATF SP-III or equivalent (check manual for capacity).
Transmission Fluid Manual:
API GL-4 or GL-5, SAE 75W-90 or 80W-90 (check manual for capacity).
Transfer Case Fluid:
API GL-4 or GL-5, SAE 75W-90 or 80W-90 (check manual for capacity).
Differential Fluid:
API GL-5, SAE 80W-90 or 85W-140 (check manual for capacity).
Coolant:
Mitsubishi Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based antifreeze with corrosion inhibitors (typically 50/50 mix).
Known Issues
Common Wear Items:
CV joints, tie rod ends, ball joints, wheel bearings, exhaust system components, radiator.
Engine Specific Issues:
Potential for head gasket issues on some V6 engines if overheated; 4M41 diesel can be prone to injector or glow plug issues if poorly maintained.
Transmission Specific Issues:
Automatic transmission can develop issues if fluid is not changed regularly; manual transmissions are generally robust but clutch wear is normal.
4Wd System Issues:
Actuator or sensor issues in the Super Select system can occur, requiring diagnostic attention. Regular use helps prevent seizing.
📚 Vehicle History
Brand Heritage
Mitsubishi SUV Legacy:
Mitsubishi has a long history of producing capable off-road vehicles, with the Pajero (Montero in North America) being a flagship model since its introduction in 1982.
Model Evolution
Pajero Iii Introduction:
Introduced in 1999 globally, the third generation marked a significant departure with its monocoque chassis with integrated frame (unibody construction with reinforcing beams), independent front suspension for improved on-road comfort, and the advanced Super Select 4WD II system.
Pajero Iii Facelift:
Minor styling updates and powertrain refinements occurred during its lifecycle. The 2001-2003 models represent the initial phase of this generation.
Production
Manufacturing Locations:
Primarily Japan (Okazaki Plant), with significant assembly in other countries like Brazil and Australia.
🏆 Awards & Recognition
Recognitions
Off Road Awards:
The Pajero (as a model line) has a distinguished history in off-road racing, including numerous wins in the Dakar Rally, cementing its reputation as a highly capable machine.
Ratings
Consumer Reports Era:
Consumer Reports and similar publications often highlighted its off-road prowess but sometimes noted its less refined on-road manners compared to more car-like SUVs of the time.