🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero Generation: Third Generation Model Years Covered: 2001, 2002, 2003, 2004, 2005, 2006 Codes Chassis Codes: V63W, V64W, V65W, V68W, V73W, V74W, V75W, V78W Engine Codes: 6G72, 6G74, 4M41 👋 Introduction Market Position Segment: Full-size SUV, known for off-road capability and versatility. Competitive Analysis Competitors: Toyota Land Cruiser Prado, Land Rover Discovery, Nissan Patrol, Jeep Grand Cherokee Key Features Off Road Capability: Renowned for its Super Select 4WD system, robust chassis, and suspension for challenging terrains. Versatility: Suitable for family transport, towing, and serious off-roading. 📋 Manual Details Coverage Areas Regions Covered: Global (North America, Europe, Asia, Australia, etc.) Page Count Estimated Page Count: Thousands (typical for comprehensive workshop manuals) Manual Type Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Engine: Engine mechanical, lubrication, cooling, fuel, ignition, emission control, turbocharging (if applicable) Transmission: Manual and Automatic Transmission: overhaul, maintenance, diagnostics, fluid specifications Drivetrain: Front and Rear Axles, Differentials, Driveshafts, Transfer Case, Super Select 4WD System Suspension: Front and Rear Suspension components, geometry, shock absorbers, springs, bushings Steering: Power Steering system, steering column, linkage, adjustments Brakes: Brake system: hydraulic components, ABS, EBD, disc/drum brakes, parking brake Electrical: Wiring diagrams, starting system, charging system, lighting, instrumentation, power accessories, body electrical Body And Chassis: Body panels, doors, windows, roof, interior trim, chassis frame, corrosion protection HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system: diagnosis and repair Safety Systems: Airbag system, seatbelt pre-tensioners Procedures Included Maintenance: Routine maintenance, oil changes, filter replacements, fluid checks and changes, tune-ups Diagnostics: Troubleshooting guides, symptom-based diagnosis, DTC (Diagnostic Trouble Code) interpretation Repair: Step-by-step repair procedures for all major mechanical and electrical components Overhaul: Complete engine, transmission, and differential overhaul procedures Installation: Installation procedures for replacement parts and accessories Specifications: Torque specifications, clearances, alignment data, electrical specifications Technical Depth Depth: Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds, including in-depth diagnostics and electrical troubleshooting. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Searchable text content for quick information retrieval Print Quality Quality: High-resolution scans, clear diagrams, and legible text Binding Type Binding: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Options: 3.5L V6 (6G74), 3.8L V6 (6G75 - later models), 3.2L Diesel (4M41) Performance 3.5L V6 (6G74) Horsepower: Approx. 200-215 hp (varies by market and tuning) 3.5L V6 (6G74) Torque: Approx. 220-230 lb-ft (varies by market and tuning) 3.2L Diesel (4M41) Horsepower: Approx. 160-175 hp (varies by market and tuning) 3.2L Diesel (4M41) Torque: Approx. 250-275 lb-ft (varies by market and tuning) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Direct Injection (for some diesel models) Fuel Type: Unleaded Gasoline (for V6), Diesel (for 4M41) 🔧 Transmission Standard Transmission Options: 5-speed Manual, 4-speed or 5-speed Automatic (depending on engine and trim) Optional Optional Transmission: 5-speed Automatic transmission on some higher-trim V6 models. Features Drivetrain System: Mitsubishi's Super Select II 4WD system (allows on-the-fly switching between 2WD, 4WD High, 4WD High with locked center differential, and 4WD Low). 📐 Dimensions Exterior Wheelbase: Approximately 2780 mm (109.4 inches) Length: Approximately 4740-4810 mm (186.6-189.4 inches) depending on body style Width: Approximately 1830-1870 mm (72.0-73.6 inches) Height: Approximately 1855-1930 mm (73.0-76.0 inches) Weights Curb Weight: Approximately 1900-2150 kg (4189-4740 lbs), varies by configuration 🛡️ Safety Features Ratings Crash Test Ratings: Varies by region and specific test. Generally received good ratings for its era in front and side impacts, though side curtain airbags were not universally standard early on. Active Features Active Safety: ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), Traction Control (optional/standard on higher trims), Active Stability Control (ASC) on later models. Passive Features Passive Safety: Front airbags, optional side airbags, reinforced safety cell construction. 💡 Technology Features Infotainment Infotainment System: Basic radio/cassette or CD player with optional premium sound system. Later models may feature a touchscreen navigation system. Driver Assistance Driver Assistance Features: Cruise control, parking sensors (on some later models). Connectivity Connectivity Options: Limited by era; typically no integrated Bluetooth or advanced smartphone connectivity. Aftermarket solutions often available. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first, depending on driving conditions and oil type. Timing Belt Replacement: For 6G72 and 6G74 engines: approximately 60,000-90,000 miles (96,000-144,000 km) or 4-5 years. Crucial due to potential interference engine design. Fluid Specifications Engine Oil Type: API SG or higher, SAE 10W-30 or 10W-40 recommended for gasoline engines. Refer to manual for diesel specifications (e.g., API CF or CH-4). Transmission Fluid Automatic: Mitsubishi Diamond SP-III (or equivalent DEXRON-III/MERCON compatible fluid, but SP-III is preferred). Transmission Fluid Manual: GL-4 or GL-5 gear oil (specific viscosity to be confirmed in manual, e.g., 75W-90). Coolant Type: Long-life (pink) ethylene glycol based coolant, typically a 50/50...
Approx. 220-230 lb-ft (varies by market and tuning)
3.2L Diesel (4M41) Horsepower:
Approx. 160-175 hp (varies by market and tuning)
3.2L Diesel (4M41) Torque:
Approx. 250-275 lb-ft (varies by market and tuning)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Direct Injection (for some diesel models)
Fuel Type:
Unleaded Gasoline (for V6), Diesel (for 4M41)
🔧 Transmission
Standard
Transmission Options:
5-speed Manual, 4-speed or 5-speed Automatic (depending on engine and trim)
Optional
Optional Transmission:
5-speed Automatic transmission on some higher-trim V6 models.
Features
Drivetrain System:
Mitsubishi's Super Select II 4WD system (allows on-the-fly switching between 2WD, 4WD High, 4WD High with locked center differential, and 4WD Low).
📐 Dimensions
Exterior
Wheelbase:
Approximately 2780 mm (109.4 inches)
Length:
Approximately 4740-4810 mm (186.6-189.4 inches) depending on body style
Width:
Approximately 1830-1870 mm (72.0-73.6 inches)
Height:
Approximately 1855-1930 mm (73.0-76.0 inches)
Weights
Curb Weight:
Approximately 1900-2150 kg (4189-4740 lbs), varies by configuration
🛡️ Safety Features
Ratings
Crash Test Ratings:
Varies by region and specific test. Generally received good ratings for its era in front and side impacts, though side curtain airbags were not universally standard early on.
Active Features
Active Safety:
ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), Traction Control (optional/standard on higher trims), Active Stability Control (ASC) on later models.
Passive Features
Passive Safety:
Front airbags, optional side airbags, reinforced safety cell construction.
💡 Technology Features
Infotainment
Infotainment System:
Basic radio/cassette or CD player with optional premium sound system. Later models may feature a touchscreen navigation system.
Driver Assistance
Driver Assistance Features:
Cruise control, parking sensors (on some later models).
Connectivity
Connectivity Options:
Limited by era; typically no integrated Bluetooth or advanced smartphone connectivity. Aftermarket solutions often available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first, depending on driving conditions and oil type.
Timing Belt Replacement:
For 6G72 and 6G74 engines: approximately 60,000-90,000 miles (96,000-144,000 km) or 4-5 years. Crucial due to potential interference engine design.
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 10W-30 or 10W-40 recommended for gasoline engines. Refer to manual for diesel specifications (e.g., API CF or CH-4).
Transmission Fluid Automatic:
Mitsubishi Diamond SP-III (or equivalent DEXRON-III/MERCON compatible fluid, but SP-III is preferred).
Transmission Fluid Manual:
GL-4 or GL-5 gear oil (specific viscosity to be confirmed in manual, e.g., 75W-90).
Coolant Type:
Long-life (pink) ethylene glycol based coolant, typically a 50/50 mix with distilled water.
Known Issues
Common Issues:
Radiator leaks, transmission solenoid issues (especially on earlier automatics), transfer case actuator problems, exhaust manifold cracks (V6 engines), diesel glow plug issues, oil cooler hose leaks.
Suspension Wear:
Bushings and ball joints can wear over time, especially with off-road use, leading to clunks and alignment issues.
📚 Vehicle History
Brand Heritage
Brand Legacy:
Mitsubishi has a long history in off-road vehicles, with the Pajero lineage tracing back to the original 1970s Pajero.
Model Evolution
Third Generation Introduction:
Introduced in 1999 (for some markets), this generation marked a significant shift with a unibody construction (monocoque chassis) for improved ride comfort and handling, moving away from the traditional body-on-frame design of its predecessors.
Production
Manufacturing Locations:
Japan (Okazaki Plant), and also assembled in various international locations under license or joint ventures.
🏆 Awards & Recognition
Recognitions
Off Road Awards:
The Pajero (and its sibling, the Montero) has a strong reputation in off-road competitions, including multiple Dakar Rally victories across its generations, showcasing its inherent durability and capability.
Ratings
Consumer Ratings:
Generally well-regarded for durability and off-road prowess, though fuel economy and on-road refinement were sometimes criticized compared to more modern monocoque SUVs.
Certifications
Emission Standards:
Compliant with emissions standards of the respective model years and regions (e.g., EPA, Euro III/IV).