Mitsubishi Pajero Service & Repair Manual 2001 2002 2003 (5 500+ pages)

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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero Generation: Third Generation Production Years Covered: 2001, 2002, 2003 Codes Chassis Codes: V63W, V65W, V68W, V73W, V75W, V77W, V78W Internal Project Codes: Series 2000 👋 Introduction Market Position Vehicle Segment: Full-size SUV, capable off-road vehicle Target Audience: Enthusiasts, off-roaders, families seeking robust and versatile transportation Competitive Analysis Key Competitors: Toyota Land Cruiser Prado, Nissan Patrol, Jeep Grand Cherokee, Land Rover Discovery Key Features Off Road Capability: Renowned for its robust chassis, advanced Super Select 4WD-II system, and long-travel suspension Versatility: Comfortable for daily driving, capable for towing, and highly competent in off-road conditions Durability: Built with rugged construction and reliable mechanicals, earning a reputation for longevity 📋 Manual Details Coverage Areas Coverage Scope: All styles and configurations Page Count Page Count: 5500+ Manual Type Manual Type: Comprehensive Service and Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, overhaul, repair for V6 3.5L (6G74), V6 3.8L (6G75 - if applicable to this generation/region), 3.2L DI-D Diesel (4M41) Transmission: Automatic (INVECS-II Sport Mode, INVECS-III) and Manual transmission overhaul, diagnostics, repair Drivetrain: Four-wheel drive system (Super Select 4WD-II), differentials (front, rear, center), drive shafts, axles, hubs Suspension: Front independent suspension (double wishbone), Rear multi-link suspension, shock absorbers, springs, bushings, alignment procedures Brakes: Front disc brakes (ventilated), Rear disc brakes, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), brake fluid specifications, caliper overhaul, rotor replacement Steering: Power steering system, steering rack, linkage, column, fluid specifications Electrical System: Battery, charging system (alternator, starter), lighting system (headlamps, taillamps, interior), ignition system, fuses, relays, wiring diagrams Body And Chassis: Frame structure, body panels, doors, hood, tailgate, interior trim, glass, weatherstripping, chassis lubrication Climate Control: HVAC system (heating, ventilation, air conditioning), refrigerant types, compressor, condenser, evaporator, cabin filter replacement Fuel System: Fuel pump, injectors, fuel filter replacement, fuel tank, pressure specifications Exhaust System: Exhaust manifold, catalytic converter, mufflers, pipes, oxygen sensors Cooling System: Radiator, coolant specifications, thermostat, water pump, hoses, fan clutch/electric fan Safety Systems: Airbags (SRS - Supplemental Restraint System), seatbelt pre-tensioners, ABS diagnostics Diagnostics: OBD-II (On-Board Diagnostics) procedures, diagnostic trouble codes (DTCs), scan tool usage, troubleshooting flowcharts Procedures Included Maintenance Procedures: Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, fluid checks and top-offs, tire rotation, brake pad/rotor inspection and replacement Repair Procedures: Engine component replacement (e.g., alternators, starters, water pumps), transmission R&R, suspension component replacement, brake system repairs, steering component replacement Overhaul Procedures: Complete engine disassembly, inspection, and reassembly; transmission overhaul; differential rebuild Troubleshooting: System-specific diagnostic guides, symptom-based troubleshooting charts, electrical circuit tracing Installation Procedures: Accessory installation guidelines (e.g., tow hitches, auxiliary lighting - if covered), replacement of major components Technical Depth Diagnostic Depth: Advanced diagnostics including sensor data analysis, actuator testing, and circuit resistance/voltage checks Repair Detail: Step-by-step instructions with torque specifications, special tool requirements, and critical tolerances Electrical Diagrams: Complete, high-resolution wiring diagrams for all vehicle systems, including color coding and component locations Specifications: Extensive listing of all technical specifications, including engine data, torque values, clearances, and fluid capacities 📊 Manual Specifications File Format File Type: PDF Searchability: Fully searchable text content for quick information retrieval Printability: Printable pages for physical reference Print Quality Image Resolution: High-resolution images, diagrams, and schematics Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code 1: 6G74 (3.5L V6 SOHC/DOHC MPI) Displacement 1: 3497 cc (3.5 Liters) Configuration 1: V6, 24 Valves (SOHC or DOHC) Bore X Stroke 1: 93.0 mm x 85.8 mm Compression Ratio 1: Approx. 8.8:1 to 9.5:1 (varies by DOHC/SOHC and market) Horsepower 1: Approx. 180-200 hp (134-149 kW) at 5000-5500 rpm Torque 1: Approx. 220-250 lb-ft (298-339 Nm) at 3500-4500 rpm Fuel Delivery 1: Multi-Point Fuel Injection (MPI) Engine Code 2: 4M41 (3.2L DI-D DOHC Turbo Diesel) Displacement 2: 3200 cc (3.2 Liters) Configuration 2: Inline 4-Cylinder, 16 Valves, DOHC, Turbocharged Horsepower 2: Approx. 160-175 hp (119-130 kW) at 4000-4200 rpm Torque 2: Approx. 270-315 lb-ft (366-427 Nm) at 2000-2500 rpm Fuel Delivery 2: Direct Injection (DI), Turbocharged with Intercooler Performance 0 60 Mph: Approx. 9-11 seconds (varies by engine and configuration) Fuel System Fuel Type Gasoline: Unleaded Gasoline (Octane rating as per owner's manual recommendation, typically 87-89) Fuel Type Diesel: Diesel Fuel 🔧 Transmission Standard Transmission Type Gasoline: 4-speed Automatic (INVECS-II Sport Mode) Optional Transmission Type Gasoline Optional: 5-speed Manual Transmission Transmission Type Diesel: 5-speed Automatic (INVECS-II Sport Mode) Features 4Wd System: Super Select 4WD-II System (with 2H, 4H, 4HLc, 4LLc modes) Center Differential: Locking Center Differential (on 4HLc and 4LLc modes) Transfer Case: 2-speed transfer case with reduction gears 📐 Dimensions Exterior Length: Approx. 4765 mm (187.6 in) Width: Approx. 1875 mm (73.8 in) Height: Approx. 1855 mm (73.0 in) (varies with roof rack) Wheelbase: Approx. 2780 mm (109.4 in) Ground...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Pajero

Generation:

Third Generation

Production Years Covered:

2001, 2002, 2003

Codes

Chassis Codes:

V63W, V65W, V68W, V73W, V75W, V77W, V78W

Internal Project Codes:

Series 2000

👋 Introduction

Market Position

Vehicle Segment:

Full-size SUV, capable off-road vehicle

Target Audience:

Enthusiasts, off-roaders, families seeking robust and versatile transportation

Competitive Analysis

Key Competitors:

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

Key Features

Off Road Capability:

Renowned for its robust chassis, advanced Super Select 4WD-II system, and long-travel suspension

Versatility:

Comfortable for daily driving, capable for towing, and highly competent in off-road conditions

Durability:

Built with rugged construction and reliable mechanicals, earning a reputation for longevity

📋 Manual Details

Coverage Areas

Coverage Scope:

All styles and configurations

Page Count

Page Count:

5500+

Manual Type

Manual Type:

Comprehensive Service and Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnostics, overhaul, repair for V6 3.5L (6G74), V6 3.8L (6G75 - if applicable to this generation/region), 3.2L DI-D Diesel (4M41)

Transmission:

Automatic (INVECS-II Sport Mode, INVECS-III) and Manual transmission overhaul, diagnostics, repair

Drivetrain:

Four-wheel drive system (Super Select 4WD-II), differentials (front, rear, center), drive shafts, axles, hubs

Suspension:

Front independent suspension (double wishbone), Rear multi-link suspension, shock absorbers, springs, bushings, alignment procedures

Brakes:

Front disc brakes (ventilated), Rear disc brakes, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), brake fluid specifications, caliper overhaul, rotor replacement

Steering:

Power steering system, steering rack, linkage, column, fluid specifications

Electrical System:

Battery, charging system (alternator, starter), lighting system (headlamps, taillamps, interior), ignition system, fuses, relays, wiring diagrams

Body And Chassis:

Frame structure, body panels, doors, hood, tailgate, interior trim, glass, weatherstripping, chassis lubrication

Climate Control:

HVAC system (heating, ventilation, air conditioning), refrigerant types, compressor, condenser, evaporator, cabin filter replacement

Fuel System:

Fuel pump, injectors, fuel filter replacement, fuel tank, pressure specifications

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, pipes, oxygen sensors

Cooling System:

Radiator, coolant specifications, thermostat, water pump, hoses, fan clutch/electric fan

Safety Systems:

Airbags (SRS - Supplemental Restraint System), seatbelt pre-tensioners, ABS diagnostics

Diagnostics:

OBD-II (On-Board Diagnostics) procedures, diagnostic trouble codes (DTCs), scan tool usage, troubleshooting flowcharts

Procedures Included

Maintenance Procedures:

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

Repair Procedures:

Engine component replacement (e.g., alternators, starters, water pumps), transmission R&R, suspension component replacement, brake system repairs, steering component replacement

Overhaul Procedures:

Complete engine disassembly, inspection, and reassembly; transmission overhaul; differential rebuild

Troubleshooting:

System-specific diagnostic guides, symptom-based troubleshooting charts, electrical circuit tracing

Installation Procedures:

Accessory installation guidelines (e.g., tow hitches, auxiliary lighting - if covered), replacement of major components

Technical Depth

Diagnostic Depth:

Advanced diagnostics including sensor data analysis, actuator testing, and circuit resistance/voltage checks

Repair Detail:

Step-by-step instructions with torque specifications, special tool requirements, and critical tolerances

Electrical Diagrams:

Complete, high-resolution wiring diagrams for all vehicle systems, including color coding and component locations

Specifications:

Extensive listing of all technical specifications, including engine data, torque values, clearances, and fluid capacities

📊 Manual Specifications

File Format

File Type:

Searchability:

Fully searchable text content for quick information retrieval

Printability:

Printable pages for physical reference

Print Quality

Image Resolution:

High-resolution images, diagrams, and schematics

Binding Type

Binding Type:

N/A (Digital PDF)

Paper Type

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

6G74 (3.5L V6 SOHC/DOHC MPI)

Displacement 1:

3497 cc (3.5 Liters)

Configuration 1:

V6, 24 Valves (SOHC or DOHC)

Bore X Stroke 1:

93.0 mm x 85.8 mm

Compression Ratio 1:

Approx. 8.8:1 to 9.5:1 (varies by DOHC/SOHC and market)

Horsepower 1:

Approx. 180-200 hp (134-149 kW) at 5000-5500 rpm

Torque 1:

Approx. 220-250 lb-ft (298-339 Nm) at 3500-4500 rpm

Fuel Delivery 1:

Multi-Point Fuel Injection (MPI)

Engine Code 2:

4M41 (3.2L DI-D DOHC Turbo Diesel)

Displacement 2:

3200 cc (3.2 Liters)

Configuration 2:

Inline 4-Cylinder, 16 Valves, DOHC, Turbocharged

Horsepower 2:

Approx. 160-175 hp (119-130 kW) at 4000-4200 rpm

Torque 2:

Approx. 270-315 lb-ft (366-427 Nm) at 2000-2500 rpm

Fuel Delivery 2:

Direct Injection (DI), Turbocharged with Intercooler

Performance

0 60 Mph:

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

Fuel System

Fuel Type Gasoline:

Unleaded Gasoline (Octane rating as per owner's manual recommendation, typically 87-89)

Fuel Type Diesel:

Diesel Fuel

🔧 Transmission

Standard

Transmission Type Gasoline:

4-speed Automatic (INVECS-II Sport Mode)

Optional

Transmission Type Gasoline Optional:

5-speed Manual Transmission

Transmission Type Diesel:

5-speed Automatic (INVECS-II Sport Mode)

Features

4Wd System:

Super Select 4WD-II System (with 2H, 4H, 4HLc, 4LLc modes)

Center Differential:

Locking Center Differential (on 4HLc and 4LLc modes)

Transfer Case:

2-speed transfer case with reduction gears

📐 Dimensions

Exterior

Length:

Approx. 4765 mm (187.6 in)

Width:

Approx. 1875 mm (73.8 in)

Height:

Approx. 1855 mm (73.0 in) (varies with roof rack)

Wheelbase:

Approx. 2780 mm (109.4 in)

Ground Clearance:

Approx. 215 mm (8.5 in)

Interior

Seating Capacity:

7-seater (with third-row seating)

Cargo

Cargo Volume:

Variable depending on seat configuration (approx. 360-1200+ liters)

Weights

Curb Weight:

Approx. 2000-2200 kg (4400-4850 lb)

Gross Vehicle Weight Rating:

Approx. 2700-2900 kg (5950-6390 lb)

🛡️ Safety Features

Ratings

Crash Test Ratings:

NHTSA: Varies by model year and specific testing. Generally considered a safe vehicle for its class.

Active Features

Standard Anti-lock Braking System (ABS)

Standard Electronic Brakeforce Distribution (EBD)

Passive Features

Airbags:

Driver and front passenger airbags. Side airbags may be optional depending on trim.

Seatbelts:

Three-point seatbelts with pretensioners for front seats.

Rollover Protection:

Designed with a high-strength chassis and roll-over protection structure.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player with optional premium sound system (e.g., Rockford Fosgate on higher trims). Auxiliary input may be present on some models.

Navigation:

Optional factory navigation system available on some models.

Driver Assistance

Cruise Control:

Standard cruise control

Parking Sensors:

Optional rear parking sensors on some later models.

Connectivity

Bluetooth:

Not typically integrated from factory for this period; aftermarket solutions are common.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first (under normal driving conditions). Severe conditions may require shorter intervals.

Oil Filter Replacement:

With every oil change

Air Filter Replacement:

Every 15,000 miles (24,000 km) or 12 months

Fuel Filter Replacement Gasoline:

Every 30,000 miles (48,000 km)

Fuel Filter Replacement Diesel:

Every 15,000 miles (24,000 km) or as per manual recommendation for DI-D system

Spark Plug Replacement Gasoline:

Every 60,000 miles (96,000 km) (for standard spark plugs); Platinum/Iridium may have longer intervals.

Transmission Fluid Change Automatic:

Every 30,000 miles (48,000 km) or 24 months (severe duty recommended). Check manual for specific fluid type.

Transmission Fluid Change Manual:

Every 60,000 miles (96,000 km) or 48 months

Coolant Replacement:

Every 45,000 miles (72,000 km) or 36 months

Brake Fluid Replacement:

Every 30,000 miles (48,000 km) or 24 months

Fluid Specifications

Engine Oil Type:

API SJ or SL, SAE 10W-30 or 5W-30 (check manual for exact viscosity based on climate)

Engine Oil Capacity:

Approx. 4.5 - 5.0 liters (4.8 - 5.3 quarts) for V6 gasoline engines

Transmission Fluid Automatic:

DIA Queen ATF-SP II M or equivalent (check manual for specific part number, e.g., Mitsubishi ATF-SP III)

Transmission Fluid Manual:

API GL-4 or GL-5, SAE 75W-90

Transfer Case Fluid:

API GL-4 or GL-5, SAE 75W-90

Differential Fluid Front Rear:

API GL-5, SAE 80W-90 (or 75W-140 for heavy loads/off-road)

Coolant Type:

Mitsubishi Super Long Life Coolant (Green or Pink based on regional spec), or equivalent ethylene glycol-based coolant

Brake Fluid Type:

DOT 3 or DOT 4

Power Steering Fluid:

Mitsubishi Genuine Power Steering Fluid or Dexron III ATF

Known Issues

Common Issues Gasoline:

Occasional intake manifold gasket leaks, EGR valve issues (if equipped), spark plug blow-out (less common on this generation), transmission shifting concerns (early models).

Common Issues Diesel:

Potential for turbocharger issues, injector problems (DI-D), glow plug failure, exhaust gas recirculation (EGR) system clogging.

Suspension Wear:

Front control arm bushings and rear trailing arm bushings can wear out, leading to noise and alignment issues. Shock absorbers may also require replacement.

Electrical Gremlins:

Corrosion in wiring harnesses or connectors, especially in areas exposed to moisture, can cause intermittent electrical faults.

Body Rust:

While generally robust, rust can develop on the chassis and lower body panels in corrosive environments, particularly around wheel wells and rocker panels.

📚 Vehicle History

Brand Heritage

Mitsubishi Off Road Legacy:

Mitsubishi has a long and successful history in off-road racing, notably the Dakar Rally, with the Pajero lineage.

Model Evolution

Third Generation Introduction:

The third generation Pajero (model code V60/V70) was introduced in 1999 and represented a significant redesign, moving to an integrated body-on-frame construction.

Design Changes:

Independent front suspension, a new independent rear suspension (replacing the solid axle), and monocoque construction (body-frame integral) contributed to improved on-road manners and handling.

Production

Manufacturing Locations:

Primarily produced in Japan (Okazaki Plant), with assembly also occurring in other global locations.

Market Name Variants:

Known as Mitsubishi Montero in North America, and Mitsubishi Shogun in the UK.

🏆 Awards & Recognition

Recognitions

Off Road Awards:

Consistently recognized for its off-road prowess and durability, often receiving positive reviews from off-road publications.

Consumer Reports:

Consumer Reports ratings can vary; often noted for reliability but sometimes flagged for fuel economy or certain mechanical components.

Certifications

Emissions Standards:

Compliant with US EPA and CARB emissions standards applicable to the model year and region of sale.