Mitsubishi Montero Pajero Complete Workshop Service Repair Manual 2007 2008 2009 2010 2011 2012

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🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Pajero Years Covered: 2007, 2008, 2009, 2010, 2011, 2012 Common Name Variations: Mitsubishi Shogun (UK/Europe), Mitsubishi Galloper (some markets) 👋 Introduction Market Position Segment: Full-size body-on-frame SUV Key Selling Points: Off-road capability, ruggedness, spacious interior, V6 engine power, advanced 4WD system. Competitive Analysis Primary Competitors: Toyota Land Cruiser Prado, Nissan Patrol, Jeep Grand Cherokee, Ford Explorer (older generations), Land Rover Discovery. Key Features Platform: Body-on-frame construction for durability and off-road articulation. 4Wd System: Mitsubishi's renowned Super Select II 4WD system offering various modes (2H, 4H, 4HLC, 4LLC) with a locking center differential. Engine Availability: Primarily V6 gasoline engines, with potential for diesel variants in certain markets not explicitly covered by this manual's likely focus. 📋 Manual Details Coverage Areas Primary Market Coverage: Global (specific engine/feature variations may apply by region) Regional Variations Acknowledged: Yes, manual typically accounts for different specifications based on market (e.g., engine options, emissions controls) Page Count Estimated Page Count: Over 1500 pages (typical for a complete workshop manual) Manual Type Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul, cylinder head, block assembly, pistons, crankshaft, camshafts, timing belt/chain, lubrication system, cooling system, fuel injection system (MPI, GDI), exhaust system (including catalytic converter operation), emissions control systems. Engine Electrical: Ignition system, starting system, charging system, ECU (Engine Control Unit) diagnosis and repair, sensor data (MAP, MAF, O2, Crankshaft Position, Camshaft Position), wiring diagrams, diagnostic trouble codes (DTCs). Transmission Manual: Clutch system, manual gearbox overhaul, gear shifting mechanisms, maintenance procedures. Transmission Automatic: Automatic transmission overhaul (e.g., INVECS-II Sport Mode), torque converter, valve body, electronic controls, transmission fluid (ATF) specifications and service, troubleshooting. Drivetrain: 4WD system (Super Select II), transfer case operation and repair, differential overhaul (front, rear, center), drive shafts, CV joints, propshafts, wheel bearings. Suspension: Independent front suspension (double wishbone), multi-link rear suspension, shock absorbers, springs, control arms, bushings, alignment specifications, ride height adjustments. Steering: Power steering system (hydraulic), steering gear/rack and pinion, steering column, tie rods, power steering fluid specifications. Brakes: Front disc brakes, rear disc brakes (vented/solid depending on spec), ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), brake calipers, master cylinder, brake booster, brake fluid specifications (DOT 3/4), parking brake system. Body Exterior: Body panel removal and installation, door mechanisms, hinges, latches, bumpers, fenders, hood, tailgate, sunroof operation, glass replacement, weatherstripping, rust prevention. Body Interior: Dashboard removal, instrument panel, seats, seat belts, airbags (SRS system diagnosis and component replacement), interior trim panels, headliner, HVAC system (controls, ducting, actuators). Electrical Body: Lighting systems (headlights, taillights, interior lights), power windows, power locks, central locking, mirrors, wipers, horn, fuses and relays, body control module (BCM) diagnosis, wiring harnesses. HVAC: Air conditioning system (compressor, condenser, evaporator, refrigerant), heating system (heater core), climate control operation, diagnostic procedures, refrigerant type and charge capacity. Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, fluid level checks and top-offs, tire rotation, brake pad inspection, battery checks. Major Repairs: Engine rebuilds, transmission overhauls, differential repairs, suspension component replacement, brake system overhauls, steering system repairs. Troubleshooting Diagnostics: Step-by-step diagnostic flowcharts for common issues, symptom-based troubleshooting, DTC interpretation, electrical system diagnostics using multimeters and oscilloscopes, engine performance diagnostics. Electrical Diagnostics: Reading and interpreting wiring diagrams, testing circuits for continuity, voltage drop, and shorts, component testing (sensors, actuators), troubleshooting modules. Component Replacement: Detailed instructions for replacing virtually all components, from minor items like bulbs and belts to major ones like engines and transmissions. Bodywork Restoration: Procedures for minor body repairs, panel alignment, rust treatment basics, glass replacement. Technical Depth Depth: Comprehensive (from basic maintenance to complete engine and transmission rebuilds) Diagnostic Level: Advanced (includes ECU troubleshooting, sensor data analysis, and wiring diagrams) Specification Detail: Extensive torque specifications, clearances, fluid capacities, electrical resistance values, etc. 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text (assuming OCR'd if scanned) Printability: Printable Print Quality Image Resolution: High resolution images and diagrams (typical for factory manuals) Binding Type Binding Type: N/A (Downloadable PDF) Paper Type Paper Type: N/A (Downloadable PDF) ⚙️ Engine Specifications Primary Engine Engine Code Gasoline: Likely 6G72 (3.0L V6 SOHC/DOHC MPI) or 6G74 (3.5L V6 SOHC/DOHC MPI), possibly 6G75 (3.8L V6 SOHC MIVEC) for later models. Engine Displacement Common: 3.0L (2972 cc) and 3.5L (3497 cc) gasoline V6 are most prevalent for these years. Performance Horsepower 3.0L: Approximately 175-215 hp (depending on SOHC/DOHC and market tuning). Torque 3.0L: Approximately 180-225 lb-ft (depending on SOHC/DOHC and market tuning). Horsepower 3.5L: Approximately 200-235 hp (depending on SOHC/DOHC and market tuning). Torque 3.5L: Approximately 220-245 lb-ft (depending on SOHC/DOHC and market tuning). Horsepower 3.8L: Approximately 250-265 hp (if 6G75 is present). Torque 3.8L: Approximately 250-260 lb-ft (if 6G75 is present). Fuel System Fuel Delivery: Electronic Multi-Point Fuel Injection (MPI) or Gasoline Direct...

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Mots clés: 2007 2008 2009 2010 2011 2012 Car Cars Misc Mitsubishi Montero Pajero

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Montero Pajero

Years Covered:

2007, 2008, 2009, 2010, 2011, 2012

Common Name Variations:

Mitsubishi Shogun (UK/Europe), Mitsubishi Galloper (some markets)

👋 Introduction

Market Position

Segment:

Full-size body-on-frame SUV

Key Selling Points:

Off-road capability, ruggedness, spacious interior, V6 engine power, advanced 4WD system.

Competitive Analysis

Primary Competitors:

Toyota Land Cruiser Prado, Nissan Patrol, Jeep Grand Cherokee, Ford Explorer (older generations), Land Rover Discovery.

Key Features

Platform:

Body-on-frame construction for durability and off-road articulation.

4Wd System:

Mitsubishi's renowned Super Select II 4WD system offering various modes (2H, 4H, 4HLC, 4LLC) with a locking center differential.

Engine Availability:

Primarily V6 gasoline engines, with potential for diesel variants in certain markets not explicitly covered by this manual's likely focus.

📋 Manual Details

Coverage Areas

Primary Market Coverage:

Global (specific engine/feature variations may apply by region)

Regional Variations Acknowledged:

Yes, manual typically accounts for different specifications based on market (e.g., engine options, emissions controls)

Page Count

Estimated Page Count:

Over 1500 pages (typical for a complete workshop manual)

Manual Type

Type:

Complete Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine overhaul, cylinder head, block assembly, pistons, crankshaft, camshafts, timing belt/chain, lubrication system, cooling system, fuel injection system (MPI, GDI), exhaust system (including catalytic converter operation), emissions control systems.

Engine Electrical:

Ignition system, starting system, charging system, ECU (Engine Control Unit) diagnosis and repair, sensor data (MAP, MAF, O2, Crankshaft Position, Camshaft Position), wiring diagrams, diagnostic trouble codes (DTCs).

Transmission Manual:

Clutch system, manual gearbox overhaul, gear shifting mechanisms, maintenance procedures.

Transmission Automatic:

Automatic transmission overhaul (e.g., INVECS-II Sport Mode), torque converter, valve body, electronic controls, transmission fluid (ATF) specifications and service, troubleshooting.

Drivetrain:

4WD system (Super Select II), transfer case operation and repair, differential overhaul (front, rear, center), drive shafts, CV joints, propshafts, wheel bearings.

Suspension:

Independent front suspension (double wishbone), multi-link rear suspension, shock absorbers, springs, control arms, bushings, alignment specifications, ride height adjustments.

Steering:

Power steering system (hydraulic), steering gear/rack and pinion, steering column, tie rods, power steering fluid specifications.

Brakes:

Front disc brakes, rear disc brakes (vented/solid depending on spec), ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), brake calipers, master cylinder, brake booster, brake fluid specifications (DOT 3/4), parking brake system.

Body Exterior:

Body panel removal and installation, door mechanisms, hinges, latches, bumpers, fenders, hood, tailgate, sunroof operation, glass replacement, weatherstripping, rust prevention.

Body Interior:

Dashboard removal, instrument panel, seats, seat belts, airbags (SRS system diagnosis and component replacement), interior trim panels, headliner, HVAC system (controls, ducting, actuators).

Electrical Body:

Lighting systems (headlights, taillights, interior lights), power windows, power locks, central locking, mirrors, wipers, horn, fuses and relays, body control module (BCM) diagnosis, wiring harnesses.

HVAC:

Air conditioning system (compressor, condenser, evaporator, refrigerant), heating system (heater core), climate control operation, diagnostic procedures, refrigerant type and charge capacity.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, fluid level checks and top-offs, tire rotation, brake pad inspection, battery checks.

Major Repairs:

Engine rebuilds, transmission overhauls, differential repairs, suspension component replacement, brake system overhauls, steering system repairs.

Troubleshooting Diagnostics:

Step-by-step diagnostic flowcharts for common issues, symptom-based troubleshooting, DTC interpretation, electrical system diagnostics using multimeters and oscilloscopes, engine performance diagnostics.

Electrical Diagnostics:

Reading and interpreting wiring diagrams, testing circuits for continuity, voltage drop, and shorts, component testing (sensors, actuators), troubleshooting modules.

Component Replacement:

Detailed instructions for replacing virtually all components, from minor items like bulbs and belts to major ones like engines and transmissions.

Bodywork Restoration:

Procedures for minor body repairs, panel alignment, rust treatment basics, glass replacement.

Technical Depth

Depth:

Comprehensive (from basic maintenance to complete engine and transmission rebuilds)

Diagnostic Level:

Advanced (includes ECU troubleshooting, sensor data analysis, and wiring diagrams)

Specification Detail:

Extensive torque specifications, clearances, fluid capacities, electrical resistance values, etc.

📊 Manual Specifications

File Format

Format:

Searchability:

Searchable text (assuming OCR'd if scanned)

Printability:

Printable

Print Quality

Image Resolution:

High resolution images and diagrams (typical for factory manuals)

Binding Type

Binding Type:

N/A (Downloadable PDF)

Paper Type

Paper Type:

N/A (Downloadable PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code Gasoline:

Likely 6G72 (3.0L V6 SOHC/DOHC MPI) or 6G74 (3.5L V6 SOHC/DOHC MPI), possibly 6G75 (3.8L V6 SOHC MIVEC) for later models.

Engine Displacement Common:

3.0L (2972 cc) and 3.5L (3497 cc) gasoline V6 are most prevalent for these years.

Performance

Horsepower 3.0L:

Approximately 175-215 hp (depending on SOHC/DOHC and market tuning).

Torque 3.0L:

Approximately 180-225 lb-ft (depending on SOHC/DOHC and market tuning).

Horsepower 3.5L:

Approximately 200-235 hp (depending on SOHC/DOHC and market tuning).

Torque 3.5L:

Approximately 220-245 lb-ft (depending on SOHC/DOHC and market tuning).

Horsepower 3.8L:

Approximately 250-265 hp (if 6G75 is present).

Torque 3.8L:

Approximately 250-260 lb-ft (if 6G75 is present).

Fuel System

Fuel Delivery:

Electronic Multi-Point Fuel Injection (MPI) or Gasoline Direct Injection (GDI) on later/higher spec models.

Recommended Fuel:

Unleaded gasoline (Octane rating varies by market and specific engine tuning, typically 87-91 AKI).

Fuel Tank Capacity:

Typically around 88-92 Liters (23-24 US Gallons).

🔧 Transmission

Standard

Transmission Type Standard:

5-speed manual transmission (less common in North America for these years, more prevalent globally) or 4-speed/5-speed automatic transmission.

Optional

Transmission Type Optional:

Automatic Transmission (4-speed INVECS-II or 5-speed INVECS-II Sport Mode) likely standard on most North American models and higher trims globally.

Features

Automatic Transmission Features:

Sport Mode (manual override), Adaptive shift control (learns driving style), sometimes a Low Range gear selector for the transfer case.

Fluid Specifications

Automatic Transmission Fluid:

DIAMOND ATF SP-III or equivalent (verify exact specification for specific transmission model).

Fluid Capacity

Automatic Transmission Fluid Capacity:

Approximately 8-9 Liters (for a complete drain and fill, may vary).

📐 Dimensions

Exterior

Length:

Approximately 4700-4900 mm (185-193 inches) depending on front/rear bumper and spare tire carrier.

Width:

Approximately 1870-1895 mm (73.6-74.6 inches).

Height:

Approximately 1850-1900 mm (72.8-74.8 inches) depending on roof rails and suspension height.

Wheelbase:

Approximately 2780 mm (109.4 inches).

Weights

Curb Weight:

Approximately 1900-2100 kg (4189-4630 lbs) depending on engine, drivetrain, and equipment.

Gross Vehicle Weight Rating Gvw:

Typically around 2700-2900 kg (5952-6393 lbs).

🛡️ Safety Features

Ratings

NHTSA Ratings Us Models:

Varies by model year and specific configuration. Likely achieved 4-star or 5-star ratings in front and side impact tests for models equipped with all safety features.

Active Features

Standard Anti-lock Braking System (ABS) with Electronic Brakeforce Distribution (EBD).

Traction Control:

Available Active Traction Control (ATC) system.

Electronic Stability Control:

Available Electronic Stability Control (ESC) or Active Stability Control (ASC).

Passive Features

Airbags:

Front driver and passenger airbags, available side curtain airbags and front side-impact airbags.

Seatbelts:

Three-point seatbelts with pre-tensioners and load limiters for front seats, three-point seatbelts for rear seats.

Rollover Protection:

Body-on-frame construction and integrated safety cage contribute to rollover resistance.

💡 Technology Features

Infotainment

Head Unit Features:

Typically a factory AM/FM/CD stereo, possibly with cassette player. Higher trims may have premium audio systems (e.g., Rockford Fosgate) and in-dash CD changer.

Navigation:

Optional factory GPS navigation system available on higher trims.

Driver Assistance

Cruise Control:

Standard cruise control.

Rear View Camera:

Optional rear-view camera system available on some models.

Connectivity

Auxiliary Input:

Commonly features an auxiliary audio input jack (3.5mm) for connecting external devices.

Bluetooth:

Bluetooth connectivity for hands-free calling and audio streaming was an option on later models.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first, using the correct oil viscosity.

Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on driving conditions (dusty environments require more frequent checks).

Spark Plug Replacement:

Platinum-tipped plugs typically last 60,000-100,000 miles (96,000-160,000 km). Iridium plugs may last longer. Consult manual for exact type and interval.

Timing Belt Replacement:

If equipped with a timing belt (less common on V6s of this era which often use chains), typically around 60,000-90,000 miles (96,000-145,000 km). Check if engine uses belt or chain.

Coolant Flush Replacement:

Every 30,000-50,000 miles (48,000-80,000 km) or 2-4 years.

Fluid Specifications

Engine Oil Viscosity Gasoline:

Likely 5W-30 or 5W-40 synthetic or semi-synthetic oil (verify with owner's manual or specific engine spec).

Engine Oil Capacity:

Around 4.5-5.5 Liters (4.8-5.8 US Quarts) for V6 engines, including filter (verify).

Brake Fluid Type:

DOT 3 or DOT 4 (check reservoir cap or manual).

Power Steering Fluid:

Likely ATF Dexron II/III or specific Mitsubishi power steering fluid (verify).

Transfer Case Fluid:

DIAMOND ATF SP-III or equivalent (verify).

Differential Fluid Front Rear:

API GL-5 gear oil, SAE 75W-90 or 80W-90 (verify specific viscosity and LSD additive requirements if applicable).

Known Issues

Common Wear Items:

Suspension bushings, ball joints, tie rod ends due to age and load. Radiator and cooling system components (hoses, thermostat) can also degrade.

Engine Reliability:

Generally robust V6 engines, but like all high-mileage engines, can experience issues like oil leaks, carbon buildup, and sensor failures. Timing chain issues are rare if maintenance is kept up.

Transmission Issues:

Automatic transmission shifting issues or solenoid failures can occur. Regular fluid changes are critical. Manual transmissions are typically robust.

Electrical Gremlins:

Corrosion in wiring harnesses, failing window regulators, and sensor issues are not uncommon in older vehicles, especially those used in harsh environments.

Rust Concerns:

Body-on-frame SUVs can be susceptible to frame rust, especially in areas with road salt. Check frame rails, body mounts, and suspension components.

📚 Vehicle History

Brand Heritage

Mitsubishi Motors Legacy:

Mitsubishi has a long history of producing robust 4x4 vehicles, with the Pajero lineage dating back to the early 1980s, renowned for its off-road prowess and durability.

Model Evolution

Third Generation Pajero V70:

The 2007-2012 models fall within the third generation (1999-2006 internationally, extended in some markets like North America where it was called Montero) or the early part of the fourth generation (2006-2021 globally, known as Pajero/Montero depending on region). The North American Montero for these years is generally considered a carry-over of the third generation with updates.

Production

Manufacturing Locations:

Primarily manufactured in Japan. Some regional assembly might have occurred.

🏆 Awards & Recognition

Recognitions

Off Road Acclaim:

The Pajero/Montero line has a strong reputation and numerous outright wins in demanding off-road races like the Dakar Rally, highlighting its inherent capability.

Consumer Reports Ratings:

Consumer Reports ratings for these model years often cited good powertrain reliability but average or below-average ratings for fuel economy and interior materials compared to unibody SUVs.