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2001-2003 Mitsubishi Pajero Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero Year: 2001-2003 Codes Chassis Code: V60, V70 series (Global market nomenclature) Platform Name: Pajero V60/V70 Series 👋 Introduction Market Position Segment: Full-size SUV (Sport Utility Vehicle) Reputation: Renowned for off-road capability, durability, and comfortable ride; positioned as a versatile family and adventure vehicle. Competitive Analysis Competitors 2001 2003: Toyota Land Cruiser, Land Rover Discovery, Jeep Grand Cherokee, Ford Explorer, Chevrolet Tahoe/Suburban, Nissan Pathfinder Key Features Off Road Systems: Super Select II 4WD system (typically), locking differentials, advanced suspension articulation Powertrain Options: Available with robust V6 gasoline engines and efficient diesel options in certain markets Interior Comfort: Spacious and comfortable interior, often with third-row seating options 📋 Manual Details Coverage Areas Coverage: Comprehensive service and repair information for 2001-2003 Mitsubishi Pajero Page Count Estimated Pages: Varies by specific release, typically 1000+ pages for complete factory service manuals. Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English (Assumed based on product description and common availability) Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, lubrication, cooling, fuel delivery, ignition, emission control, engine diagnostics Transmission Drivetrain: Manual transmission, automatic transmission, transfer case, differentials, driveshafts, CV joints Brakes: Front and rear brake systems (disc/drum), ABS, parking brake Suspension Steering: Front suspension (independent), rear suspension (multi-link independent or solid axle depending on variant), steering system, power steering Electrical Electronics: Battery, charging system, starting system, lighting, instrument cluster, infotainment, body control modules, power accessories, wiring diagrams Body Chassis: Body construction, exterior trim, interior trim, doors, windows, glass, seat mechanisms, chassis frame HVAC: Heating, ventilation, and air conditioning (HVAC) system operation, diagnosis, and repair Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups Diagnostics Troubleshooting: Symptom-based troubleshooting, diagnostic trouble codes (DTCs), diagnostic procedures for all major systems Repair Rebuild: Engine component removal and installation, transmission overhaul, brake caliper replacement, suspension component repair, electrical component repair Special Tools: Identification and usage of specialized tools required for specific repair procedures Technical Depth Depth: In-depth technical information, including detailed torque specifications, component tolerances, diagnostic flowcharts, and step-by-step repair instructions. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval Print Quality Printability: Printable pages for workshop use Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code Gasoline: 6G72 (3.0L V6 SOHC/DOHC), 6G74 (3.5L V6 SOHC/DOHC) Engine Code Diesel: 4M41 (3.2L DOHC DI-D Common Rail Turbo Diesel) Performance 3.0L V6 (6G72) Horsepower: Approximately 177-190 hp (varies by specific tune and market) 3.0L V6 (6G72) Torque: Approximately 240-260 Nm (varies by specific tune and market) 3.5L V6 (6G74) Horsepower: Approximately 190-215 hp (varies by specific tune and market) 3.5L V6 (6G74) Torque: Approximately 300-330 Nm (varies by specific tune and market) 3.2L Di-D Diesel Horsepower: Approximately 160-175 hp (varies by specific tune and market) 3.2L Di-D Diesel Torque: Approximately 350-370 Nm (varies by specific tune and market) Fuel System Gasoline Injection: Electronic Fuel Injection (EFI) / Multi-Point Fuel Injection (MPI) Diesel Injection: Direct Injection Common Rail (DI-CR) with turbocharging and intercooler Emissions Emission Control: Catalytic converters, oxygen sensors, EGR system (depending on market and engine) 🔧 Transmission Standard Manual Transmission: 5-speed manual transmission Optional Automatic Transmission: 4-speed automatic transmission (INVECS-II system) Features 4Wd System: Super Select II 4WD system with lockable center differential and often available rear differential lock Fluid Specifications Automatic Transmission Fluid: DIA Queen ATF-SP II M or equivalent (consult manual for exact specification) Manual Transmission Fluid: API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil (consult manual for exact specification) Transfer Case Fluid: DIA Queen Gear Oil LSD 2 or equivalent (consult manual for exact specification) Differential Fluid: API GL-5, SAE 80W-90 or 85W-140 gear oil (consult manual for exact specification) 📐 Dimensions Exterior Length: Approx. 4,700-4,850 mm (depending on body style - short/long wheelbase, spare tire carrier) Width: Approx. 1,870-1,900 mm Height: Approx. 1,850-1,900 mm (depending on roof rack and suspension height) Weights Curb Weight: Approx. 1,900-2,200 kg (depending on engine, drivetrain, and equipment) Gross Vehicle Weight Rating Gvwr: Approx. 2,600-2,800 kg (consult manual for exact specification) 🛡️ Safety Features Ratings NHTSA Crash Test Ratings: Varied by year and market; generally good for its class and era, though specific ratings should be verified from official sources. Active Features ABS: Anti-lock Braking System (ABS) typically standard or optional Traction Control: Traction Control System (TCS) available on some higher trims or optional Passive Features Airbags: Front airbags for driver and passenger; side airbags available on some higher trims Seatbelts: 3-point seatbelts with pretensioners 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player, often with premium sound system options (e.g., Rockford Fosgate in some markets/trims) Navigation: Optional factory GPS navigation system available on higher trims. Driver Assistance Cruise Control: Standard or optional cruise...
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2001-2003 Mitsubishi Pajero Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Pajero
Year:
2001-2003
Codes
Chassis Code:
V60, V70 series (Global market nomenclature)
Platform Name:
Pajero V60/V70 Series
👋 Introduction
Market Position
Segment:
Full-size SUV (Sport Utility Vehicle)
Reputation:
Renowned for off-road capability, durability, and comfortable ride; positioned as a versatile family and adventure vehicle.
Competitive Analysis
Competitors 2001 2003:
Toyota Land Cruiser, Land Rover Discovery, Jeep Grand Cherokee, Ford Explorer, Chevrolet Tahoe/Suburban, Nissan Pathfinder
Key Features
Off Road Systems:
Super Select II 4WD system (typically), locking differentials, advanced suspension articulation
Powertrain Options:
Available with robust V6 gasoline engines and efficient diesel options in certain markets
Interior Comfort:
Spacious and comfortable interior, often with third-row seating options
📋 Manual Details
Coverage Areas
Coverage:
Comprehensive service and repair information for 2001-2003 Mitsubishi Pajero
Page Count
Estimated Pages:
Varies by specific release, typically 1000+ pages for complete factory service manuals.
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English (Assumed based on product description and common availability)
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, lubrication, cooling, fuel delivery, ignition, emission control, engine diagnostics
Transmission Drivetrain:
Manual transmission, automatic transmission, transfer case, differentials, driveshafts, CV joints
Brakes:
Front and rear brake systems (disc/drum), ABS, parking brake
Suspension Steering:
Front suspension (independent), rear suspension (multi-link independent or solid axle depending on variant), steering system, power steering
Electrical Electronics:
Battery, charging system, starting system, lighting, instrument cluster, infotainment, body control modules, power accessories, wiring diagrams
Body Chassis:
Body construction, exterior trim, interior trim, doors, windows, glass, seat mechanisms, chassis frame
HVAC:
Heating, ventilation, and air conditioning (HVAC) system operation, diagnosis, and repair
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups
Diagnostics Troubleshooting:
Symptom-based troubleshooting, diagnostic trouble codes (DTCs), diagnostic procedures for all major systems
Repair Rebuild:
Engine component removal and installation, transmission overhaul, brake caliper replacement, suspension component repair, electrical component repair
Special Tools:
Identification and usage of specialized tools required for specific repair procedures
Technical Depth
Depth:
In-depth technical information, including detailed torque specifications, component tolerances, diagnostic flowcharts, and step-by-step repair instructions.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content for quick information retrieval
Print Quality
Printability:
Printable pages for workshop use
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code Gasoline:
6G72 (3.0L V6 SOHC/DOHC), 6G74 (3.5L V6 SOHC/DOHC)
Engine Code Diesel:
4M41 (3.2L DOHC DI-D Common Rail Turbo Diesel)
Performance
3.0L V6 (6G72) Horsepower:
Approximately 177-190 hp (varies by specific tune and market)
3.0L V6 (6G72) Torque:
Approximately 240-260 Nm (varies by specific tune and market)
3.5L V6 (6G74) Horsepower:
Approximately 190-215 hp (varies by specific tune and market)
3.5L V6 (6G74) Torque:
Approximately 300-330 Nm (varies by specific tune and market)
3.2L Di-D Diesel Horsepower:
Approximately 160-175 hp (varies by specific tune and market)
3.2L Di-D Diesel Torque:
Approximately 350-370 Nm (varies by specific tune and market)
Fuel System
Gasoline Injection:
Electronic Fuel Injection (EFI) / Multi-Point Fuel Injection (MPI)
Diesel Injection:
Direct Injection Common Rail (DI-CR) with turbocharging and intercooler
Emissions
Emission Control:
Catalytic converters, oxygen sensors, EGR system (depending on market and engine)
🔧 Transmission
Standard
Manual Transmission:
5-speed manual transmission
Optional
Automatic Transmission:
4-speed automatic transmission (INVECS-II system)
Features
4Wd System:
Super Select II 4WD system with lockable center differential and often available rear differential lock
Fluid Specifications
Automatic Transmission Fluid:
DIA Queen ATF-SP II M or equivalent (consult manual for exact specification)
Manual Transmission Fluid:
API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil (consult manual for exact specification)
Transfer Case Fluid:
DIA Queen Gear Oil LSD 2 or equivalent (consult manual for exact specification)
Differential Fluid:
API GL-5, SAE 80W-90 or 85W-140 gear oil (consult manual for exact specification)
📐 Dimensions
Exterior
Length:
Approx. 4,700-4,850 mm (depending on body style - short/long wheelbase, spare tire carrier)
Width:
Approx. 1,870-1,900 mm
Height:
Approx. 1,850-1,900 mm (depending on roof rack and suspension height)
Weights
Curb Weight:
Approx. 1,900-2,200 kg (depending on engine, drivetrain, and equipment)
Gross Vehicle Weight Rating Gvwr:
Approx. 2,600-2,800 kg (consult manual for exact specification)
🛡️ Safety Features
Ratings
NHTSA Crash Test Ratings:
Varied by year and market; generally good for its class and era, though specific ratings should be verified from official sources.
Active Features
ABS:
Anti-lock Braking System (ABS) typically standard or optional
Traction Control:
Traction Control System (TCS) available on some higher trims or optional
Passive Features
Airbags:
Front airbags for driver and passenger; side airbags available on some higher trims
Seatbelts:
3-point seatbelts with pretensioners
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, often with premium sound system options (e.g., Rockford Fosgate in some markets/trims)
Navigation:
Optional factory GPS navigation system available on higher trims.
Driver Assistance
Cruise Control:
Standard or optional cruise control system
Connectivity
Power Accessories:
Power windows, power locks, power mirrors, often with power seats and sunroof on higher trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions (refer to manual for specific recommendations).
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on dusty conditions.
Spark Plug Replacement:
100,000 miles (160,000 km) for iridium or platinum plugs; lower for older conventional types.
Timing Belt Replacement:
For V6 gasoline engines (6G7 series), replacement is crucial around 60,000-100,000 miles (96,000-160,000 km) due to non-interference design risk. Diesel (4M41) uses a timing chain, which is generally more durable.
Fluid Specifications
Engine Oil Type:
API SJ or higher, SAE 5W-30 or 10W-30 (consult manual for exact viscosity based on temperature range)
Engine Oil Capacity:
Approx. 4.5-5.5 liters for V6 engines (with filter, consult manual)
Coolant Type:
Mitsubishi Super Long Life Coolant (MS-9764) or equivalent ethylene glycol-based coolant with corrosion inhibitors (typically pink or red).
Known Issues
Common Problems:
Rear main seal leaks, exhaust manifold cracks (V6 engines), cooling system leaks (radiator, hoses), ABS sensor failures, automatic transmission shift issues, front suspension component wear (ball joints, bushings), potential for rust on chassis components in corrosive environments.
Diesel Specific Issues:
Fuel injector issues, turbocharger problems, glow plug failures, EGR valve clogging (common in many diesels).
📚 Vehicle History
Brand Heritage
Mitsubishi SUV Legacy:
The Mitsubishi Pajero (also known as Montero in North America and some other markets) has a long and successful history in the SUV segment, beginning with its first generation in 1982. It is renowned for its off-road prowess and durability.
Model Evolution
Third Generation V60 V70:
The 2001-2003 models represent the early phase of the third generation (codename V60/V70, introduced in 1999). This generation saw a significant redesign, moving to a unibody construction (monocoque with integrated chassis) for improved on-road handling and ride comfort, while retaining strong off-road capabilities.
Production
Manufacturing Locations:
Primarily manufactured in Japan (Okazaki Plant), with production also occurring in other global facilities.
🏆 Awards & Recognition
Recognitions
Off Road Awards:
The Pajero lineage has a storied history of success in off-road rallies, most notably the Dakar Rally, underscoring its legendary durability and capability.
Ratings
Consumer Ratings:
Generally received positive reviews for its utility, comfort, and off-road performance during its production years, though specific reliability ratings can vary.
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