🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero (Montero) Production Years Covered: 1991-2002 Platform Generation: Second Generation (1991-2000), Third Generation (2000-2006) 👋 Introduction Market Position Market Position: The Mitsubishi Pajero/Montero is a legendary, highly capable off-road focused SUV renowned for its durability, versatility, and advanced four-wheel-drive systems. This manual caters to owners and technicians who value in-depth technical knowledge for maintaining and repairing these robust vehicles. Competitive Analysis Competitive Analysis: During its production run, the Pajero/Montero competed with vehicles such as the Toyota Land Cruiser Prado, Nissan Patrol, Jeep Cherokee, Land Rover Discovery, and Ford Explorer. Its key differentiators were often its sophisticated Super Select II 4WD system, robust chassis, and excellent off-road capability. Key Features Key Features: This manual provides factory-level repair and maintenance procedures. Its comprehensive nature, multilingual support, and digital format make it an invaluable resource for DIY enthusiasts and professional mechanics alike. The inclusion of detailed illustrations and step-by-step instructions ensures clarity and accuracy in all repair tasks. 📋 Manual Details Coverage Coverage Areas: Global (North America, Europe, Asia, Australia, etc.) Pages Page Count: > 9,800 Type Manual Type: Workshop Service Repair Manual Language Language: English, French, German, Spanish Format Format: PDF 📖 Manual Coverage Systems Systems Covered: Engine Mechanical, Engine Control System, Emission Control Systems, Cooling System, Fuel System, Lubrication System, Ignition System, Starting System, Charging System, Exhaust System, Drive Shaft, Drive Belt, Differential Case Assy, Clutch System, Transmission (Manual & Automatic), Transfer Case, Power Steering System, Suspension System (Front & Rear), Brake System (Front & Rear), Wheel & Tire System, Electrical System, Body & Chassis, Interior Components, HVAC System, Supplemental Restraint System (SRS), Security System, Lighting System, Wiper & Washer System Procedures Procedures Included: Routine Maintenance, Troubleshooting, Diagnostics, Component Removal & Installation, Engine Overhaul, Transmission Repair, Brake System Service, Suspension & Steering Repair, Electrical Component Diagnosis & Repair, Body Panel Repair, HVAC System Service, SRS System Service, Wiring Diagram Interpretation, Fluid Capacities & Specifications, Torque Specifications, Alignment Specifications Depth Technical Depth: Comprehensive (from basic maintenance to complete engine rebuilds and advanced electrical diagnostics) 📊 Manual Specifications File Details File Format: PDF (Portable Document Format) File Size: 471MB Indexing: Indexed (searchable content) Compatibility: iPad-ready, PC (Windows), Mac, Linux Printability Print Quality: Printable (high-resolution pages) Delivery Delivery Method: Instant Digital Download Protection Digital Rights Management: DRM-free (no restrictions) ⚙️ Engine Specifications Engine Variants Primary Engine: 3.0L V6 SOHC (6G72), 3.5L V6 SOHC/DOHC (6G74), 2.5L 4D56 Turbodiesel, 2.8L 4M40 Turbodiesel, 3.2L 4M41 Turbodiesel Performance Engine Performance Notes: Specific horsepower and torque figures vary significantly by engine variant, year, and market. The manual details specifications for each engine type, including compression ratios, bore, stroke, and power output. Fuel System Fuel System Types: Multi-Point Fuel Injection (MPI) for gasoline engines, Direct Injection/Common Rail (for later diesel models), Turbocharging (for diesel engines) Engine Management Engine Management System: Electronic Engine Control (ECU) with detailed sensor and actuator diagnostic procedures, including camshaft position sensor, crankshaft position sensor, throttle body control, and fuel injector testing. 🔧 Transmission Standard Transmission Standard Transmission Type: 5-speed Manual Transaxle, 4-speed Automatic Transmission Optional Transmission Optional Transmission Type: 5-speed Automatic Transmission (for some models) Features Transmission Features: Super Select II 4WD System (allowing on-the-fly switching between 2H, 4H, 4HLC, and 4LLC), Center Differential Lock, Rear Differential Lock (on some models). 📐 Dimensions Body Styles Body Styles Covered: 3-door Short Wheelbase (SWB), 5-door Long Wheelbase (LWB) Wagon, Canvas Top Weights Curb Weight Range: Approximately 1,700 kg to 2,100 kg (3,748 lbs to 4,630 lbs), depending on configuration. Tire Size Common Tire Sizes: 265/70R16, 265/70R15 (varies by model and trim) Wheel Bolt Pattern Wheel Bolt Pattern: 6x139.7 mm (6x5.5 inches) 🛡️ Safety Features Passive Features Passive Safety Features: Driver and passenger airbags, seat belt pretensioners, reinforced body structure. Active Features Active Safety Features: Anti-lock Braking System (ABS), Traction Control System (TCS - on some models), Electronic Stability Control (ESC - on later models) Ratings Safety Ratings Notes: Safety ratings vary by year and testing jurisdiction. The manual provides guidance on servicing SRS components and ensuring the integrity of safety systems. 💡 Technology Features Infotainment Infotainment Systems: Base models featured basic radio/cassette players. Higher trims offered CD players, and later models in the range may have included rudimentary touchscreens or premium audio systems. The manual covers audio system repairs and diagnostics. Driver Assistance Driver Assistance Features: Limited by modern standards; primarily ABS, cruise control, and power accessories. Later models might have had parking sensors or more advanced traction aids. Connectivity Connectivity Features: Very limited; primarily focused on power outlets for accessories. No factory-installed Bluetooth or USB ports in early models. 🔧 Maintenance Service Intervals Typical Oil Change Interval: Every 5,000-10,000 km (3,000-6,000 miles) or 6-12 months, depending on driving conditions and oil type. The manual details specific intervals for each engine. Fluid Specifications Engine Oil Specification: API SG or higher; viscosity...
Second Generation (1991-2000), Third Generation (2000-2006)
👋 Introduction
Market Position
Market Position:
The Mitsubishi Pajero/Montero is a legendary, highly capable off-road focused SUV renowned for its durability, versatility, and advanced four-wheel-drive systems. This manual caters to owners and technicians who value in-depth technical knowledge for maintaining and repairing these robust vehicles.
Competitive Analysis
Competitive Analysis:
During its production run, the Pajero/Montero competed with vehicles such as the Toyota Land Cruiser Prado, Nissan Patrol, Jeep Cherokee, Land Rover Discovery, and Ford Explorer. Its key differentiators were often its sophisticated Super Select II 4WD system, robust chassis, and excellent off-road capability.
Key Features
Key Features:
This manual provides factory-level repair and maintenance procedures. Its comprehensive nature, multilingual support, and digital format make it an invaluable resource for DIY enthusiasts and professional mechanics alike. The inclusion of detailed illustrations and step-by-step instructions ensures clarity and accuracy in all repair tasks.
📋 Manual Details
Coverage
Coverage Areas:
Global (North America, Europe, Asia, Australia, etc.)
Pages
Page Count:
> 9,800
Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English, French, German, Spanish
Format
Format:
PDF
📖 Manual Coverage
Systems
Systems Covered:
Engine Mechanical, Engine Control System, Emission Control Systems, Cooling System, Fuel System, Lubrication System, Ignition System, Starting System, Charging System, Exhaust System, Drive Shaft, Drive Belt, Differential Case Assy, Clutch System, Transmission (Manual & Automatic), Transfer Case, Power Steering System, Suspension System (Front & Rear), Brake System (Front & Rear), Wheel & Tire System, Electrical System, Body & Chassis, Interior Components, HVAC System, Supplemental Restraint System (SRS), Security System, Lighting System, Wiper & Washer System
Specific horsepower and torque figures vary significantly by engine variant, year, and market. The manual details specifications for each engine type, including compression ratios, bore, stroke, and power output.
Fuel System
Fuel System Types:
Multi-Point Fuel Injection (MPI) for gasoline engines, Direct Injection/Common Rail (for later diesel models), Turbocharging (for diesel engines)
Engine Management
Engine Management System:
Electronic Engine Control (ECU) with detailed sensor and actuator diagnostic procedures, including camshaft position sensor, crankshaft position sensor, throttle body control, and fuel injector testing.
Super Select II 4WD System (allowing on-the-fly switching between 2H, 4H, 4HLC, and 4LLC), Center Differential Lock, Rear Differential Lock (on some models).
📐 Dimensions
Body Styles
Body Styles Covered:
3-door Short Wheelbase (SWB), 5-door Long Wheelbase (LWB) Wagon, Canvas Top
Weights
Curb Weight Range:
Approximately 1,700 kg to 2,100 kg (3,748 lbs to 4,630 lbs), depending on configuration.
Tire Size
Common Tire Sizes:
265/70R16, 265/70R15 (varies by model and trim)
Wheel Bolt Pattern
Wheel Bolt Pattern:
6x139.7 mm (6x5.5 inches)
🛡️ Safety Features
Passive Features
Passive Safety Features:
Driver and passenger airbags, seat belt pretensioners, reinforced body structure.
Active Features
Active Safety Features:
Anti-lock Braking System (ABS), Traction Control System (TCS - on some models), Electronic Stability Control (ESC - on later models)
Ratings
Safety Ratings Notes:
Safety ratings vary by year and testing jurisdiction. The manual provides guidance on servicing SRS components and ensuring the integrity of safety systems.
💡 Technology Features
Infotainment
Infotainment Systems:
Base models featured basic radio/cassette players. Higher trims offered CD players, and later models in the range may have included rudimentary touchscreens or premium audio systems. The manual covers audio system repairs and diagnostics.
Driver Assistance
Driver Assistance Features:
Limited by modern standards; primarily ABS, cruise control, and power accessories. Later models might have had parking sensors or more advanced traction aids.
Connectivity
Connectivity Features:
Very limited; primarily focused on power outlets for accessories. No factory-installed Bluetooth or USB ports in early models.
🔧 Maintenance
Service Intervals
Typical Oil Change Interval:
Every 5,000-10,000 km (3,000-6,000 miles) or 6-12 months, depending on driving conditions and oil type. The manual details specific intervals for each engine.
Fluid Specifications
Engine Oil Specification:
API SG or higher; viscosity grade varies by ambient temperature (e.g., 10W-30, 10W-40, 20W-50). The manual provides precise specifications for each engine and operating condition. Check for API SN, ILSAC GF-5 for later models.
Transmission Fluid Type:
Automatic: ATF SP-III (or equivalent). Manual: SAE 75W-90 GL-4 gear oil. Transfer Case: ATF SP-III (or equivalent). The manual lists specific fluid types and capacities for all drivetrain components.
Coolant Specification:
Ethylene glycol-based coolant with a 50/50 mix of antifreeze and distilled water. Specific Mitsubishi Long Life Coolant (LLC) or equivalent is recommended.
Known Issues
Common Issues:
Premature wear of front ball joints and tie rod ends, radiator leaks, transfer case actuator failure (on some models), timing belt replacement intervals (critical for interference engines), EGR system clogging (diesel models), turbocharger issues (diesel models).
Filter Part Numbers
Oil Filter Part Number Example:
MD135594 (for many 6G72 engines), or equivalent aftermarket filters. The manual lists specific part numbers for all serviceable filters.
Spark Plugs
Spark Plug Recommendations:
Specific spark plug types (e.g., iridium, platinum) and gap specifications are detailed for each engine model. Examples include NGK BPR5ES, BPR6ES, or performance equivalents.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mitsubishi has a long history of producing robust off-road vehicles, with the Pajero lineage dating back to the early 1980s. The name Pajero is derived from the Leopardus pajeros, a wild cat native to South America, while Montero is its Spanish equivalent, used in North America and other markets.
Model Evolution
Model Evolution Second Gen:
The second generation (1991-2000) introduced more refined styling, independent front suspension (on many models), and the advanced Super Select II 4WD system. It was offered in various body styles and with a range of gasoline and diesel engines.
Model Evolution Third Gen
Model Evolution Third Gen:
The third generation (2000-2006) saw a significant redesign with a monocoque chassis (unibody construction) for improved on-road manners and reduced weight. It featured updated engines and a more modern interior.
Production Notes
Production Locations:
Primary manufacturing was in Japan, with assembly also occurring in other international locations.
🏆 Awards & Recognition
Recognitions
Off Road Awards:
The Pajero/Montero has a strong rally heritage, notably winning the Dakar Rally multiple times, underscoring its off-road prowess and durability. This manual is a testament to the engineering that allowed for such performance.