Mitsubishi Pajero 2001-2003 Workshop Repair & Service Manual in English 2001 2002 2003 [Complete & Informative for DIY Repair]
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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero Model Generation: Third Generation (1999-2006) Applicable Years: 2001, 2002, 2003 Codes Chassis Codes: V60 Series (e.g., V73W, V75W, V77W, V78W) 👋 Introduction Market Position Vehicle Segment: Full-size SUV, known for off-road capability and durability. Vehicle Type: Full-size, body-on-frame SUV with significant off-road capabilities. Competitive Analysis Key Competitors: Toyota Land Cruiser Prado, Nissan Patrol, Land Rover Discovery. Key Features Manual Value Proposition: Comprehensive coverage for DIYers and professionals, official factory information, instant download, high quality. Vehicle Strengths: Robust construction, capable off-road performance, versatile for family and utility use. 📋 Manual Details Coverage Areas Manual Coverage Scope: All models and configurations for the specified years. Page Count Page Count: Complete (specific count not provided, but stated as 'Absolutely No Missing Pages') Manual Type Manual Type: Workshop Repair & Service Manual Language Language: English Format File Format: PDF Operating Systems Compatibility: Windows, Mac, Linux 📖 Manual Coverage Systems Covered Engine Systems: Engine disassembly, reassembly, servicing, fuel and lubrication systems, cooling system, timing chain service. Drivetrain Systems: Transmission service, gearbox removal and installation, clutch removal and installation, U-joint service, CV joint service. Chassis Systems: Wheels, brakes, steering, suspension, axles, chassis assembly. Electrical Systems: Ignition, charging system, starter, battery, switches, wiring diagrams, wire/cable/hose routing. Bodywork: Bodywork repair procedures. Fuel System Details: Carburetor rebuild and adjustments (if applicable to specific markets/engines), fuel injection system service, fuel pump, fuel filter replacement. Exhaust System: Exhaust service procedures, component replacement. Procedures Included Maintenance And Tune Up: Periodic maintenance, tune-up procedures, factory maintenance schedules. Repair And Rebuilding: Engine servicing, rebuilding, fuel system service, exhaust system service, brake servicing, gearbox service. Troubleshooting And Diagnostics: Fault finding, diagnostic procedures. Torque Specifications: Extensive listing of tightening torques for critical fasteners across all systems. Illustrations And Diagrams: Abundant illustrations, lots of pictures & diagrams for visual guidance. Technical Depth Depth Of Coverage: Comprehensive, suitable for DIY repair and professional technicians, includes factory repair procedures and data. Diagnostic Procedures: Includes detailed diagnostic flowcharts and procedures for various systems. 📊 Manual Specifications File Format PDF Quality: High Quality, Printable, Searchable (implied by PDF format and description) Print Quality Printable Pages: Yes Binding Type Binding Type: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Options: Likely includes 3.0L V6 (6G72), 3.5L V6 (6G74), and potentially diesel variants (e.g., 3.2L 4M41 Di-D). Performance Engine Performance Details: Specific horsepower and torque figures vary by engine and market, but generally focus on torque for off-road and towing. Fuel System Fuel Delivery: Fuel injection systems (MPI), potentially common rail direct injection for diesel variants. Engine Codes Common Engine Codes: 6G72, 6G74, 4M41 Engine Codes Examples: 6G72 (3.0L V6), 6G74 (3.5L V6 SOHC/DOHC), 4M41 (3.2L DI-D Diesel). Lubrication Oil Types: Refer to manual for specific API/ACEA classifications and viscosity grades (e.g., 5W-30, 10W-30). Cooling Coolant Type: Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. 🔧 Transmission Standard Transmission Standard Transmission Type: Likely a 5-speed manual transmission for some variants. Optional Transmission Optional Transmission Type: Likely a 4-speed or 5-speed automatic transmission for most variants. Features Drivetrain Layout: Part-time or full-time 4WD system with transfer case, Super Select 4WD system on some models. Fluid Specifications Transmission Fluid Type: Specific ATF for automatics (e.g., Mitsubishi DiaQueen ATF SP-III), gear oil for manual transmissions and differentials (e.g., GL-5). 📐 Dimensions Exterior Wheelbase: Approx. 2780 mm (109.4 in) for LWB models, shorter for SWB. Length: Approx. 4780 mm (188.2 in) for LWB models. Width: Approx. 1875 mm (73.8 in). Height: Approx. 1850 mm (72.8 in). Weights Curb Weight: Varies significantly by configuration, typically 1900-2100 kg (4189-4630 lbs). Towing Capacity: Typically around 2500 kg (5511 lbs) braked trailer. Wheels And Tires Wheel Bolt Pattern: 6x139.7 mm (6x5.5 inches). Common Tire Sizes: 265/70R16, 265/65R17, 275/60R18. 🛡️ Safety Features Ratings Crash Test Results: NCAP ratings vary by region and test year; check specific market data. Likely good for its era. Active Features Braking System: Front ventilated disc brakes, rear disc brakes or drum brakes depending on configuration. ABS often standard or optional. Stability Control: Active Stability Control (ASC) and Active Traction Control (ATC) available on higher trims or later models within this range. Passive Features Airbags: Front airbags standard, side airbags optional on some trims. Seatbelts: Three-point seatbelts with pretensioners for front occupants. 💡 Technology Features Infotainment Audio System: Factory radio with CD player, cassette player, and AM/FM tuner. Premium sound systems with subwoofers available on higher trims. Navigation: Optional GPS navigation system available on select higher-trim models. Driver Assistance Cruise Control: Standard or optional depending on trim level. Connectivity Power Accessories: Power windows, power door locks, power mirrors, and often power seats on higher trims. 🔧 Maintenance Service Intervals Oil Change Interval: Typically 7,500 to 10,000 miles (12,000 to 15,000 km) or 6-12 months, depending on driving conditions...
Refer to manual for specific API/ACEA classifications and viscosity grades (e.g., 5W-30, 10W-30).
Cooling
Coolant Type:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water.
🔧 Transmission
Standard Transmission
Standard Transmission Type:
Likely a 5-speed manual transmission for some variants.
Optional Transmission
Optional Transmission Type:
Likely a 4-speed or 5-speed automatic transmission for most variants.
Features
Drivetrain Layout:
Part-time or full-time 4WD system with transfer case, Super Select 4WD system on some models.
Fluid Specifications
Transmission Fluid Type:
Specific ATF for automatics (e.g., Mitsubishi DiaQueen ATF SP-III), gear oil for manual transmissions and differentials (e.g., GL-5).
📐 Dimensions
Exterior
Wheelbase:
Approx. 2780 mm (109.4 in) for LWB models, shorter for SWB.
Length:
Approx. 4780 mm (188.2 in) for LWB models.
Width:
Approx. 1875 mm (73.8 in).
Height:
Approx. 1850 mm (72.8 in).
Weights
Curb Weight:
Varies significantly by configuration, typically 1900-2100 kg (4189-4630 lbs).
Towing Capacity:
Typically around 2500 kg (5511 lbs) braked trailer.
Wheels And Tires
Wheel Bolt Pattern:
6x139.7 mm (6x5.5 inches).
Common Tire Sizes:
265/70R16, 265/65R17, 275/60R18.
🛡️ Safety Features
Ratings
Crash Test Results:
NCAP ratings vary by region and test year; check specific market data. Likely good for its era.
Active Features
Braking System:
Front ventilated disc brakes, rear disc brakes or drum brakes depending on configuration. ABS often standard or optional.
Stability Control:
Active Stability Control (ASC) and Active Traction Control (ATC) available on higher trims or later models within this range.
Passive Features
Airbags:
Front airbags standard, side airbags optional on some trims.
Seatbelts:
Three-point seatbelts with pretensioners for front occupants.
💡 Technology Features
Infotainment
Audio System:
Factory radio with CD player, cassette player, and AM/FM tuner. Premium sound systems with subwoofers available on higher trims.
Navigation:
Optional GPS navigation system available on select higher-trim models.
Driver Assistance
Cruise Control:
Standard or optional depending on trim level.
Connectivity
Power Accessories:
Power windows, power door locks, power mirrors, and often power seats on higher trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 7,500 to 10,000 miles (12,000 to 15,000 km) or 6-12 months, depending on driving conditions and oil type. Refer to manual for exact specification.
Spark Plug Replacement:
Varies by spark plug type (standard, iridium). Refer to manual; typically 60,000-100,000 miles for iridium plugs.
Timing Belt Chain Service:
Models with timing belts require replacement around 60,000-100,000 miles. Models with timing chains generally do not have a fixed replacement interval but require inspection.
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid Type:
Refer to manual; typically ATF Dexron III or a dedicated power steering fluid.
Engine Oil Capacity:
Varies by engine, typically 4.5-5.5 liters (approx. 4.7-5.8 US quarts) with filter change. Consult manual for exact capacity.
Known Issues
Common Wear Items:
Suspension components (bushings, ball joints), exhaust system rust, automatic transmission shifting issues (less common in this generation), cooling system components (radiator, hoses).
Engine Specific Concerns:
Potential for intake manifold leaks, oil cooler seal leaks on V6 engines, and glow plug issues on diesel variants.
Electrical Gremlins:
Corroded grounds, faulty window regulators, and intermittent sensor failures can occur with age.
📚 Vehicle History
Brand Heritage
Mitsubishi Brand Focus:
Known for its robust 4x4 vehicles, including the Pajero (Montero in some markets) and Lancer Evolution.
Model Evolution
Pajero Third Generation Introduction:
Introduced in 1999 globally, featuring a new monocoque chassis (unibody construction) for improved ride and handling compared to previous generations.
Key Third Gen Updates:
Independent front suspension, integrated body-frame construction, revised styling, and enhanced interior comfort.
Production
Production Locations:
Primarily manufactured in Japan, with assembly also occurring in other Mitsubishi plants globally.
🏆 Awards & Recognition
Recognitions
Off Road Awards:
The Pajero lineage is renowned for its Dakar Rally success and general off-road prowess, though specific awards for the 2001-2003 models would be for individual tests or market reviews.
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