🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero / Montero Model Variant: Full-size SUV Chassis Code: V63W, V65W, V68W Codes Product Code: MPM200205WRS 👋 Introduction Market Position Segment: Full-size, body-on-frame SUV, known for off-road capability and durability. Competitive Analysis Competitors: Toyota Land Cruiser, Land Rover Discovery, Chevrolet Tahoe, Ford Expedition, Nissan Pathfinder. Key Features Vehicle Strengths: Robust construction, reliable powertrains, excellent off-road performance (with Super Select II 4WD), spacious interior, strong towing capacity. Manual Value Proposition Purpose: Empowers owners and technicians with comprehensive knowledge for efficient maintenance, repair, and troubleshooting of the Mitsubishi Pajero/Montero. 📋 Manual Details Coverage Areas Regions Covered: North America, Global Variants (where applicable) Page Count Estimated Page Count: 2000+ Manual Type Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Powertrain: Engine, Fuel System, Ignition, Exhaust, Cooling, Lubrication, Turbocharger (if applicable) Drivetrain: Transmission (Automatic & Manual), Transfer Case, Driveshafts, Differentials, Axles, AWD System Chassis: Suspension (Front & Rear), Steering, Brakes (Front & Rear, ABS), Wheels & Tires Electrical: Battery, Charging System, Starting System, Lighting, Instrumentation, HVAC Electrical, Powertrain Control Module (PCM), Body Control Module (BCM), SRS Airbag System, Audio System, Power Accessories Body: Body Panels, Doors, Windows, Seats, Interior Trim, Exterior Trim, Bumpers, Hood, Tailgate, Glass Procedures Included Maintenance: Oil Changes, Filter Replacements, Fluid Checks & Top-offs, Belt Inspection & Replacement, Spark Plug Service, Tune-ups Repair: Engine Overhaul, Transmission Rebuild, Brake System Overhaul, Suspension Component Replacement, Electrical Component Diagnosis & Repair, Body Panel Repair Diagnostics: Troubleshooting charts, DTC (Diagnostic Trouble Code) interpretation, Component testing procedures, Wiring diagrams Specifications: Torque specifications, Clearances, Fluid capacities, Electrical resistance values, Piston ring end gap, Valve lash adjustments Technical Depth Depth: Comprehensive: From basic scheduled maintenance to complete engine and transmission rebuilds, including detailed diagnostics and electrical troubleshooting. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Fully searchable text for quick information retrieval. Print Quality Resolution: High-resolution, suitable for printing. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code Gas: 6G75 (3.8L V6 SOHC MPI) Engine Code Diesel: 4M41 (3.2L DI-D DOHC Turbo Diesel) - Market Dependent Displacement Gas: 3.8 Liters (3828 cc) Displacement Diesel: 3.2 Liters (3200 cc) Performance Horsepower Gas: Approx. 215-235 HP (varies by market and specific tuning) Torque Gas: Approx. 255-275 lb-ft (varies by market and specific tuning) Horsepower Diesel: Approx. 160-190 HP (varies by market and specific tuning) Torque Diesel: Approx. 280-315 lb-ft (varies by market and specific tuning) Fuel System Fuel Delivery Gas: Multi-Point Fuel Injection (MPI) Fuel Delivery Diesel: Direct Injection (DI) with Common Rail Turbo Diesel Fuel Type: Unleaded Gasoline (87 Octane minimum) / Diesel Fuel 🔧 Transmission Standard Transmission Type Gas: 5-Speed Automatic (INVECS-II) Optional Transmission Type Gas: 6-Speed Manual (Rare in North America) Transmission Type Diesel: 5-Speed Automatic (INVECS-II) / 5-Speed Manual Features Drivetrain System: All-Wheel Drive (AWD) with Super Select II (SS4-II) Transfer Case Transfer Case Modes: 2H, 4H, 4HLC (Locking Center Diff), 4LLC (Low Range with Locking Center Diff) 📐 Dimensions Exterior Length: Approx. 192.5 - 194.7 inches (4890 - 4945 mm) depending on configuration Width: Approx. 75.8 inches (1925 mm) Height: Approx. 74.4 - 76.0 inches (1890 - 1930 mm) depending on configuration Wheelbase: Approx. 112.6 inches (2860 mm) Weights Curb Weight: Approx. 4,700 - 5,200 lbs (2130 - 2360 kg) depending on engine and trim Towing Capacity: Up to 5,000 lbs (2268 kg) typically 🛡️ Safety Features Ratings NHTSA Front Driver: 5-Star (for models equipped with side airbags) NHTSA Front Passenger: 5-Star (for models equipped with side airbags) IIHS Frontal Offset: Good (for models tested) Active Features ABS: Standard Anti-lock Braking System Traction Control: Standard Active Traction Control (ATC) on AWD models Electronic Stability: Electronic Stability Control (ESC) - Market Dependent Passive Features Airbags: Front Airbags, Optional Front Side Airbags, Optional Curtain Airbags Seatbelts: 3-point height-adjustable front seatbelts with pretensioners, 3-point rear seatbelts Body Structure: Reinforced impact energy-absorbing body structure 💡 Technology Features Infotainment Head Unit: Factory AM/FM CD Player, Optional Rockford Fosgate Premium Audio System. Navigation: Optional factory navigation system (early generation touch screen). Driver Assistance Cruise Control: Standard Cruise Control Parking Sensors: Optional Rear Parking Sensors Connectivity Auxiliary Input: Optional Aux-In Jack (market dependent) 🔧 Maintenance Service Intervals Oil Change Interval: Every 7,500 miles or 6 months, whichever comes first (check manual for specific conditions). Air Filter Replacement: Every 15,000 miles or 12 months, or as needed based on driving conditions. Spark Plug Replacement Gas: Platinum-tipped: 105,000 miles. Iridium-tipped: 120,000 miles (refer to manual for exact type). Timing Belt Replacement: N/A (This generation primarily uses timing chains). Fluid Specifications Engine Oil Type: SAE 5W-30 API SM or higher (check manual for exact specification and viscosity) Engine Oil Capacity: Approx. 5.5 Quarts (5.2 Liters) with filter for 3.8L V6 Transmission Fluid Type...
Torque specifications, Clearances, Fluid capacities, Electrical resistance values, Piston ring end gap, Valve lash adjustments
Technical Depth
Depth:
Comprehensive: From basic scheduled maintenance to complete engine and transmission rebuilds, including detailed diagnostics and electrical troubleshooting.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Fully searchable text for quick information retrieval.
SAE 5W-30 API SM or higher (check manual for exact specification and viscosity)
Engine Oil Capacity:
Approx. 5.5 Quarts (5.2 Liters) with filter for 3.8L V6
Transmission Fluid Type Auto:
DIAQueen ATF-SP III (or equivalent)
Transmission Fluid Type Manual:
GL-4 SAE 75W-90 gear oil
Coolant Type:
Mitsubishi Super Long Life Coolant (SLLC) - Pink/Red
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Common Wear Items:
CV Axle Boots, Suspension Bushings, Sway Bar Links, Wheel Bearings.
Engine Specific Concerns:
Occasional oil leaks from valve cover gaskets or oil pan. Spark plug blow-out (rare but documented). Overheating if cooling system maintenance is neglected.
Transmission Specific Concerns:
Failure of the torque converter lock-up clutch in high-mileage automatics. Some reports of solenoid issues.
Electrical Concerns:
Window regulator failures, HVAC blower motor resistor failure, minor sensor issues.
📚 Vehicle History
Brand Heritage
Brand Origins:
Mitsubishi Motors Corporation, a Japanese multinational automotive manufacturer with a long history in vehicle production.
Model Evolution
Generation:
Third Generation (2000-2006)
Styling Update:
Introduced a more modern, rounded design compared to the previous generation. Significant interior and chassis updates.
Production
Manufacturing Location:
Japan (Okazaki Plant), and assembly plants in other countries depending on market.
Production Years Covered:
2002, 2003, 2004, 2005
🏆 Awards & Recognition
Recognitions
Off Road Acclaim:
Frequently recognized for its exceptional off-road prowess, often compared favorably to more premium off-road vehicles.
Ratings
Consumer Reports Rating:
Variable - typically rated well for reliability in powertrain, but some consumer complaints regarding minor electrical or body components.