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Mitsubishi Pajero Montero Workshop Manual 2002

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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero / Montero Year: 2002 Codes Chassis Codes: V60, V70 Series (e.g., V73W, V75W, V77W, V78W) Engine Codes: 6G72 (3.0L V6), 6G74 (3.5L V6), 4M41 (3.2L DI-D Diesel) Generation Generation: Third Generation (1999-2006) 👋 Introduction Market Position Market Position: The Mitsubishi Pajero/Montero of this era was a highly regarded mid-size SUV, known for its off-road capability, durability, and comfortable ride. It competed against vehicles like the Toyota Land Cruiser Prado, Nissan Pathfinder, and Jeep Grand Cherokee. Competitive Analysis Competitive Analysis: The 2002 model year represented a mature third generation, offering advanced features for its time, including independent front suspension for better on-road manners and robust 4WD systems (Super Select II). This manual provides the essential technical data to maintain and repair these advanced systems. Key Features Key Features: Iconic off-road SUV, monocoque chassis with body-on-frame construction (hybrid), advanced Super Select II 4WD system with locking center and rear differentials (on some models), comfortable interior, robust powertrain options. 📋 Manual Details Coverage Areas Coverage Areas: Global (covers variations for different markets) Page Count Page Count: Extensive (Full FSM, likely over 2000 pages) Manual Type Manual Type: Factory Service Manual (FSM) / Workshop Manual Language Language: English, Espanol, Francais, Deutsch Format Format: Software Database Download (RAR archive containing PDF files) 📖 Manual Coverage Systems Covered Systems Covered: General Information, Maintenance, Engine Mechanical, Engine Lubrication & Cooling Systems, Engine Fuel & Emission Control System, Accelerator Control, Fuel and Exhaust Systems, Clutch, Manual Transmission, Automatic Transmission, Propeller Shaft & Differential Carrier, Front Axle, Rear Axle, Front Suspension, Rear Suspension, Brake System, Steering System, Restraint System, Body and Trim, Heater, Air Conditioner, Electrical System, ETC (referring to a comprehensive list of vehicle systems) Electrical System Details: Comprehensive wiring diagrams, component testing, diagnostic procedures for all electrical systems including lighting, ignition, charging, fuel injection, body electronics, and HVAC controls. Procedures Included Procedures Included: All service and repair procedures, maintenance schedules, diagnostic procedures, component removal and installation, electrical wiring diagrams, troubleshooting guides, specifications. Engine Repair Procedures: Engine assembly/disassembly, cylinder head service, piston and connecting rod installation, crankshaft and bearing replacement, valve timing, component torque specifications, diagnostic trouble codes (DTCs) and troubleshooting. Transmission Repair Procedures: Automatic and manual transmission overhaul, torque converter replacement, clutch service, gear inspection, transmission fluid and filter changes, electronic control unit (ECU) diagnostics. Suspension And Steering Repair: Front and rear suspension component replacement (shocks, struts, springs, control arms, bushings), wheel alignment specifications, power steering system service and repair, steering rack and linkage replacement. Brake System Repair: Brake pad and rotor replacement, caliper overhaul, brake line and hose replacement, master cylinder and brake booster service, ABS system diagnostics and repair. Technical Depth Technical Depth: Comprehensive, technician-level detail suitable for dealership use. Includes in-depth diagnostics, component-level repair, and full rebuild procedures. Diagnostic Capabilities: Detailed diagnostic flowcharts for common problems, specific electrical diagnostic procedures, explanation of sensor inputs and outputs, and guidance on using diagnostic tools. Component Specifications: Includes critical specifications such as torque values for fasteners, piston ring end gap, bearing clearances, valve seat recession, and cylinder head flatness tolerances. 📊 Manual Specifications File Format File Format: RAR archive containing PDF files. Requires WinRAR or compatible software for extraction. Print Quality Print Quality: Likely high-resolution scans of original factory documents, suitable for printing clear diagrams and text. Binding Type Binding Type: Digital Download (Not applicable to physical binding) Paper Type Paper Type: Digital PDF (Not applicable to physical paper type) ⚙️ Engine Specifications Primary Engine Primary Engine: 3.5L V6 SOHC/DOHC (6G74). Also common are the 3.0L V6 (6G72) and 3.2L DI-D Turbo Diesel (4M41). Performance 3.5L V6 Horsepower: Approximately 200-215 hp (depending on DOHC/SOHC and market) 3.5L V6 Torque: Approximately 230-245 lb-ft (depending on DOHC/SOHC and market) Fuel System Fuel System: Multi-point Fuel Injection (MPI) Engine Mechanical Engine Block Material: Aluminum Alloy (for V6 gasoline engines) Cylinder Head Design: DOHC (Double Overhead Camshaft) or SOHC (Single Overhead Camshaft) depending on specific engine variant. Valvetrain: Timing belt driven DOHC/SOHC. Hydraulic lash adjusters (on some models) or shims for valve clearance adjustment. Cooling System Coolant Type: Mitsubishi DiaQueen Super Long Life Coolant (Green) or equivalent ethylene glycol-based coolant with corrosion inhibitors. Capacity: Approx. 8.7-9.5 liters. 🔧 Transmission Standard Standard Transmission: 4-speed Automatic Transmission (INVECS-II) Optional Optional Transmission: 5-speed Manual Transmission (on some models/markets) Features 4 Speed Automatic Features: INVECS-II (Intelligent & Innovative Vehicle Electronic Control System) with adaptive shift control. Fluid Specs Automatic Transmission Fluid: DiaQueen SPII-ATF or equivalent Dexron III/Mercon ATF. Capacity: Approx. 8.0-9.5 liters (depending on model). 📐 Dimensions Exterior Wheelbase: Approx. 2780 mm (109.4 inches) Length: Approx. 4750-4860 mm (187.0-191.3 inches) Width: Approx. 1815-1855 mm (71.5-73.0 inches) Height: Approx. 1860-1910 mm (73.2-75.2 inches) Weights Curb Weight: Approx. 1950-2150 kg (4300-4740 lbs) Gross Vehicle Weight Rating: Approx. 2700-2800 kg (5950-6170 lbs) Interior Seating Capacity: 7 passengers (with third-row seating)...
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Mitsubishi Pajero Montero Workshop Manual 2002
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Pajero / Montero
Year:
2002
Codes
Chassis Codes:
V60, V70 Series (e.g., V73W, V75W, V77W, V78W)
Engine Codes:
6G72 (3.0L V6), 6G74 (3.5L V6), 4M41 (3.2L DI-D Diesel)
Generation
Generation:
Third Generation (1999-2006)
👋 Introduction
Market Position
Market Position:
The Mitsubishi Pajero/Montero of this era was a highly regarded mid-size SUV, known for its off-road capability, durability, and comfortable ride. It competed against vehicles like the Toyota Land Cruiser Prado, Nissan Pathfinder, and Jeep Grand Cherokee.
Competitive Analysis
Competitive Analysis:
The 2002 model year represented a mature third generation, offering advanced features for its time, including independent front suspension for better on-road manners and robust 4WD systems (Super Select II). This manual provides the essential technical data to maintain and repair these advanced systems.
Key Features
Key Features:
Iconic off-road SUV, monocoque chassis with body-on-frame construction (hybrid), advanced Super Select II 4WD system with locking center and rear differentials (on some models), comfortable interior, robust powertrain options.
📋 Manual Details
Coverage Areas
Coverage Areas:
Global (covers variations for different markets)
Page Count
Page Count:
Extensive (Full FSM, likely over 2000 pages)
Manual Type
Manual Type:
Factory Service Manual (FSM) / Workshop Manual
Language
Language:
English, Espanol, Francais, Deutsch
Format
Format:
Software Database Download (RAR archive containing PDF files)
📖 Manual Coverage
Systems Covered
Systems Covered:
General Information, Maintenance, Engine Mechanical, Engine Lubrication & Cooling Systems, Engine Fuel & Emission Control System, Accelerator Control, Fuel and Exhaust Systems, Clutch, Manual Transmission, Automatic Transmission, Propeller Shaft & Differential Carrier, Front Axle, Rear Axle, Front Suspension, Rear Suspension, Brake System, Steering System, Restraint System, Body and Trim, Heater, Air Conditioner, Electrical System, ETC (referring to a comprehensive list of vehicle systems)
Electrical System Details:
Comprehensive wiring diagrams, component testing, diagnostic procedures for all electrical systems including lighting, ignition, charging, fuel injection, body electronics, and HVAC controls.
Procedures Included
Procedures Included:
All service and repair procedures, maintenance schedules, diagnostic procedures, component removal and installation, electrical wiring diagrams, troubleshooting guides, specifications.
Engine Repair Procedures:
Engine assembly/disassembly, cylinder head service, piston and connecting rod installation, crankshaft and bearing replacement, valve timing, component torque specifications, diagnostic trouble codes (DTCs) and troubleshooting.
Transmission Repair Procedures:
Automatic and manual transmission overhaul, torque converter replacement, clutch service, gear inspection, transmission fluid and filter changes, electronic control unit (ECU) diagnostics.
Suspension And Steering Repair:
Front and rear suspension component replacement (shocks, struts, springs, control arms, bushings), wheel alignment specifications, power steering system service and repair, steering rack and linkage replacement.
Brake System Repair:
Brake pad and rotor replacement, caliper overhaul, brake line and hose replacement, master cylinder and brake booster service, ABS system diagnostics and repair.
Technical Depth
Technical Depth:
Comprehensive, technician-level detail suitable for dealership use. Includes in-depth diagnostics, component-level repair, and full rebuild procedures.
Diagnostic Capabilities:
Detailed diagnostic flowcharts for common problems, specific electrical diagnostic procedures, explanation of sensor inputs and outputs, and guidance on using diagnostic tools.
Component Specifications:
Includes critical specifications such as torque values for fasteners, piston ring end gap, bearing clearances, valve seat recession, and cylinder head flatness tolerances.
📊 Manual Specifications
File Format
File Format:
RAR archive containing PDF files. Requires WinRAR or compatible software for extraction.
Print Quality
Print Quality:
Likely high-resolution scans of original factory documents, suitable for printing clear diagrams and text.
Binding Type
Binding Type:
Digital Download (Not applicable to physical binding)
Paper Type
Paper Type:
Digital PDF (Not applicable to physical paper type)
⚙️ Engine Specifications
Primary Engine
Primary Engine:
3.5L V6 SOHC/DOHC (6G74). Also common are the 3.0L V6 (6G72) and 3.2L DI-D Turbo Diesel (4M41).
Performance
3.5L V6 Horsepower:
Approximately 200-215 hp (depending on DOHC/SOHC and market)
3.5L V6 Torque:
Approximately 230-245 lb-ft (depending on DOHC/SOHC and market)
Fuel System
Fuel System:
Multi-point Fuel Injection (MPI)
Engine Mechanical
Engine Block Material:
Aluminum Alloy (for V6 gasoline engines)
Cylinder Head Design:
DOHC (Double Overhead Camshaft) or SOHC (Single Overhead Camshaft) depending on specific engine variant.
Valvetrain:
Timing belt driven DOHC/SOHC. Hydraulic lash adjusters (on some models) or shims for valve clearance adjustment.
Cooling System
Coolant Type:
Mitsubishi DiaQueen Super Long Life Coolant (Green) or equivalent ethylene glycol-based coolant with corrosion inhibitors. Capacity: Approx. 8.7-9.5 liters.
🔧 Transmission
Standard
Standard Transmission:
4-speed Automatic Transmission (INVECS-II)
Optional
Optional Transmission:
5-speed Manual Transmission (on some models/markets)
Features
4 Speed Automatic Features:
INVECS-II (Intelligent & Innovative Vehicle Electronic Control System) with adaptive shift control.
Fluid Specs
Automatic Transmission Fluid:
DiaQueen SPII-ATF or equivalent Dexron III/Mercon ATF. Capacity: Approx. 8.0-9.5 liters (depending on model).
📐 Dimensions
Exterior
Wheelbase:
Approx. 2780 mm (109.4 inches)
Length:
Approx. 4750-4860 mm (187.0-191.3 inches)
Width:
Approx. 1815-1855 mm (71.5-73.0 inches)
Height:
Approx. 1860-1910 mm (73.2-75.2 inches)
Weights
Curb Weight:
Approx. 1950-2150 kg (4300-4740 lbs)
Gross Vehicle Weight Rating:
Approx. 2700-2800 kg (5950-6170 lbs)
Interior
Seating Capacity:
7 passengers (with third-row seating)
🛡️ Safety Features
Ratings
NHTSA Crash Test Results:
Results vary by year and specific test. Generally received good ratings for its class at the time, with some models offering advanced safety features.
Active Features
Active Features:
ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), Traction Control System (TCS), Active Stability Control (ASC) on some higher trims.
Passive Features
Passive Features:
Front airbags, optional side airbags, front and rear crumple zones, reinforced passenger cabin.
💡 Technology Features
Infotainment
Infotainment Features:
Basic audio systems with cassette and CD players, optional premium sound systems. Climate control systems can be manual or automatic.
Driver Assistance
Driver Assistance Features:
Cruise control, park assist sensors (on some later models/trims), advanced 4WD system with electronic controls.
Connectivity
Connectivity Features:
Limited by 2002 standards. May include power outlets and basic antenna systems for radio.
Electrical System
Battery:
Typically a 12V system. Battery size and CCA depend on engine and market (e.g., Group 34R or similar).
Alternator:
Capacity varies by model and equipment, typically 90-110 Amps.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first, depending on driving conditions. Consult manual for specific recommendations.
Timing Belt Replacement:
For 6G72 and 6G74 V6 gasoline engines, typically every 60,000-100,000 miles (96,000-160,000 km). Crucial to follow the manual's interval as failure is catastrophic.
Fluid Specifications
Engine Oil Specification:
API SG, SH, or SJ certified. Viscosity typically SAE 10W-30 or 5W-30 (check manual for temperature-dependent recommendations). Capacity: Approx. 4.5-5.0 liters.
Brake Fluid Specification:
DOT 3 or DOT 4.
Power Steering Fluid:
Use genuine Mitsubishi power steering fluid or Dexron II/III ATF.
Differential Oil Specification:
Front and Rear Differential: Hypoid gear oil API GL-5, viscosity SAE 80W-90. Capacity: Front approx. 1.2-1.3L, Rear approx. 1.6-1.8L (depending on differential type).
Transfer Case Oil:
Mitsubishi DiaQueen SS II or equivalent. Viscosity SAE 75W-90. Capacity: Approx. 1.4-1.6L.
Grease Points:
Includes lubrication points for suspension, steering linkage, and driveshaft U-joints, specifying NLGI #2 multi-purpose grease.
Known Issues
Common Issues:
Timing belt failure if not replaced on schedule, radiator leaks, front CV joint wear, differential seal leaks, potential for transmission issues on high-mileage vehicles. Interior trim can be prone to wear.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mitsubishi has a long history in off-road vehicles, with the Pajero nameplate dating back to 1982. The Pajero is renowned for its Dakar Rally success, cementing its off-road credentials.
Model Evolution
Model Evolution:
The third generation (1999-2006) marked a significant shift with a monocoque chassis incorporating a 'space frame' for improved rigidity and on-road comfort compared to traditional body-on-frame designs. It introduced more sophisticated electronics and amenities.
4Wd System:
Super Select II 4WD system, offering 2WD High, 4WD High (with center differential unlocked or locked), and 4WD Low (with center differential locked). Features a planetary gear center differential.
Production
Production Locations:
Japan (primarily Mizushima Plant), and assembly plants in other countries like Brazil, China, and Iran.
🏆 Awards & Recognition
Recognitions
Recognitions:
The Pajero line has a storied history of winning the Dakar Rally, which significantly boosted its image as a capable off-road vehicle. Specific awards for the 2002 model year would vary by publication and region.
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