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2002 Mitsubushi PAJERO Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero Year: 2002 Codes Chassis Code: V63W, V64W, V65W, V68W 👋 Introduction Market Position Segment: Mid-size SUV (Sport Utility Vehicle), known for off-road capability and ruggedness. Competitive Analysis Competitors 2002: Toyota Land Cruiser Prado, Nissan Patrol, Ford Explorer, Jeep Grand Cherokee, Land Rover Discovery. Key Features Platform: Body-on-frame construction for durability and off-road prowess. 4Wd System: Super Select II 4WD system (optional on some trims) offering 2H, 4H, 4HLC, 4LLC modes. Suspension Type: Independent front suspension, solid rear axle (on some models) or multi-link rear for improved on-road manners. 📋 Manual Details Coverage Areas Primary Markets: Global (North America, Europe, Asia, Australia) Regions Covered: All regions where the 2002 Mitsubishi Pajero was sold Page Count Estimated Pages: 1500+ Manual Type Type: Factory Service Manual (FSM) Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, diagnostics, repair procedures, torque specifications, timing belt replacement, piston/ring inspection, cylinder head assembly Engine Electrical: Ignition system, fuel injection system (MPI), starting system, charging system, ECU diagnosis, wiring diagrams, sensor data Transmission Manual: Clutch operation, gearbox overhaul, gear ratio details, shift mechanism repair, torque specifications Transmission Automatic: ATF specifications, valve body diagnostics, torque converter testing, shift control system repair, overhaul procedures Drivetrain: Transfer case operation and repair, front and rear differential overhaul, driveshaft maintenance, hub bearing replacement Suspension: Front independent suspension (Double Wishbone), rear multi-link suspension, shock absorber replacement, spring specifications, alignment procedures Steering: Power steering system diagnosis and repair, steering gear assembly, tie rod end replacement, steering column service Brakes: Front disc brakes (Vented), rear disc brakes, ABS system diagnosis and repair, brake fluid specifications, brake caliper overhaul, parking brake mechanism Body Exterior: Panel replacement, door/window mechanisms, body repair techniques, rust prevention, trim removal and installation Body Interior: Dashboard removal, seat mechanisms, upholstery repair, headliner service, HVAC ducting Electrical Chassis: Lighting systems (headlights, taillights, interior), power windows, power locks, sunroof operation, horn system HVAC: Air conditioning system diagnosis, refrigerant recharge, heater core replacement, blower motor service, climate control panel repair Safety Systems: Airbag system diagnosis and replacement, seatbelt pre-tensioner service, SRS warning light troubleshooting Procedures Included Preventive Maintenance: Oil change intervals, filter replacement schedules, spark plug replacement, coolant flushes, brake fluid changes, tire rotation Troubleshooting: Diagnostic trouble codes (DTCs), common symptom analysis, electrical circuit tracing, fuel system diagnostics, engine performance issues Repair Procedures: Step-by-step instructions for all major component repairs and replacements Diagnostic Tools: Information on specific scan tools and diagnostic equipment required Technical Depth Depth: Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds, including complex electrical diagnostics. 📊 Manual Specifications File Format File Type: PDF Searchability: Fully searchable text content Printability: Printable pages Print Quality Image Resolution: High-resolution diagrams and illustrations Binding Type Binding: Not Applicable (Digital Format) Paper Type Paper: Not Applicable (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code 1: 6G72 (3.0L SOHC V6) Engine Code 2: 6G74 (3.5L SOHC/DOHC V6) Engine Code 3: 4D56 (2.5L Turbocharged Diesel I4) Performance Horsepower 3.0L V6: Approx. 177 hp @ 5500 rpm Torque 3.0L V6: Approx. 245 Nm (181 lb-ft) @ 4500 rpm Horsepower 3.5L V6: Approx. 203 hp (SOHC) / 237 hp (DOHC) @ 5000-5500 rpm Torque 3.5L V6: Approx. 314 Nm (231 lb-ft) (SOHC) / 329 Nm (243 lb-ft) (DOHC) @ 3000-4500 rpm Horsepower 2.5L Diesel: Approx. 114 hp @ 4000 rpm Torque 2.5L Diesel: Approx. 240 Nm (177 lb-ft) @ 2000 rpm Fuel System Fuel Delivery: Multi-Point Fuel Injection (MPI) for gasoline engines, Direct Injection for some diesel variants. Fuel Type: Unleaded Gasoline (Octane Rating 91+ recommended for V6), Diesel 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission Optional Transmission Type Optional: 4-speed Automatic Transmission (INVECS-II) Features Transfer Case: Part-time 4WD with 2-speed transfer case (standard) or Full-time 4WD with Active Center Differential and lockable rear differential (Super Select II - optional). 📐 Dimensions Exterior Length Mm: 4730-4785 Width Mm: 1875 Height Mm: 1855-1920 Wheelbase Mm: 2725 Ground Clearance Mm: 205-220 Weights Curb Weight Kg: 1900-2100 (approximate, varies by engine and trim) Towing Capacity Kg: 2500-3500 (depending on market and equipment) 🛡️ Safety Features Ratings NHTSA Rating: Not directly rated by NHTSA in the same format as modern vehicles; structural integrity generally considered robust for its class and era. Active Features ABS: Anti-lock Braking System (ABS) standard on most models. Traction Control: Traction Control System (TCS) available on higher trims. Passive Features Airbags: Front airbags for driver and passenger standard. Side airbags optional on select trims. Seatbelts: 3-point seatbelts with pre-tensioners for front occupants. 💡 Technology Features Infotainment Audio System: Factory fitted AM/FM/CD player with optional premium sound system and subwoofer. Cassette player was also common. Navigation: Optional GPS navigation system on higher trim levels. Driver Assistance Cruise Control: Standard on most models. Parking Sensors: Not commonly equipped. Connectivity Phone Integration: No...
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2002 Mitsubushi PAJERO Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Pajero
Year:
2002
Codes
Chassis Code:
V63W, V64W, V65W, V68W
👋 Introduction
Market Position
Segment:
Mid-size SUV (Sport Utility Vehicle), known for off-road capability and ruggedness.
Competitive Analysis
Competitors 2002:
Toyota Land Cruiser Prado, Nissan Patrol, Ford Explorer, Jeep Grand Cherokee, Land Rover Discovery.
Key Features
Platform:
Body-on-frame construction for durability and off-road prowess.
4Wd System:
Super Select II 4WD system (optional on some trims) offering 2H, 4H, 4HLC, 4LLC modes.
Suspension Type:
Independent front suspension, solid rear axle (on some models) or multi-link rear for improved on-road manners.
📋 Manual Details
Coverage Areas
Primary Markets:
Global (North America, Europe, Asia, Australia)
Regions Covered:
All regions where the 2002 Mitsubishi Pajero was sold
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Factory Service Manual (FSM)
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, diagnostics, repair procedures, torque specifications, timing belt replacement, piston/ring inspection, cylinder head assembly
Engine Electrical:
Ignition system, fuel injection system (MPI), starting system, charging system, ECU diagnosis, wiring diagrams, sensor data
Transmission Manual:
Clutch operation, gearbox overhaul, gear ratio details, shift mechanism repair, torque specifications
Transmission Automatic:
ATF specifications, valve body diagnostics, torque converter testing, shift control system repair, overhaul procedures
Drivetrain:
Transfer case operation and repair, front and rear differential overhaul, driveshaft maintenance, hub bearing replacement
Suspension:
Front independent suspension (Double Wishbone), rear multi-link suspension, shock absorber replacement, spring specifications, alignment procedures
Steering:
Power steering system diagnosis and repair, steering gear assembly, tie rod end replacement, steering column service
Brakes:
Front disc brakes (Vented), rear disc brakes, ABS system diagnosis and repair, brake fluid specifications, brake caliper overhaul, parking brake mechanism
Body Exterior:
Panel replacement, door/window mechanisms, body repair techniques, rust prevention, trim removal and installation
Body Interior:
Dashboard removal, seat mechanisms, upholstery repair, headliner service, HVAC ducting
Electrical Chassis:
Lighting systems (headlights, taillights, interior), power windows, power locks, sunroof operation, horn system
HVAC:
Air conditioning system diagnosis, refrigerant recharge, heater core replacement, blower motor service, climate control panel repair
Safety Systems:
Airbag system diagnosis and replacement, seatbelt pre-tensioner service, SRS warning light troubleshooting
Procedures Included
Preventive Maintenance:
Oil change intervals, filter replacement schedules, spark plug replacement, coolant flushes, brake fluid changes, tire rotation
Troubleshooting:
Diagnostic trouble codes (DTCs), common symptom analysis, electrical circuit tracing, fuel system diagnostics, engine performance issues
Repair Procedures:
Step-by-step instructions for all major component repairs and replacements
Diagnostic Tools:
Information on specific scan tools and diagnostic equipment required
Technical Depth
Depth:
Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds, including complex electrical diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Fully searchable text content
Printability:
Printable pages
Print Quality
Image Resolution:
High-resolution diagrams and illustrations
Binding Type
Binding:
Not Applicable (Digital Format)
Paper Type
Paper:
Not Applicable (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
6G72 (3.0L SOHC V6)
Engine Code 2:
6G74 (3.5L SOHC/DOHC V6)
Engine Code 3:
4D56 (2.5L Turbocharged Diesel I4)
Performance
Horsepower 3.0L V6:
Approx. 177 hp @ 5500 rpm
Torque 3.0L V6:
Approx. 245 Nm (181 lb-ft) @ 4500 rpm
Horsepower 3.5L V6:
Approx. 203 hp (SOHC) / 237 hp (DOHC) @ 5000-5500 rpm
Torque 3.5L V6:
Approx. 314 Nm (231 lb-ft) (SOHC) / 329 Nm (243 lb-ft) (DOHC) @ 3000-4500 rpm
Horsepower 2.5L Diesel:
Approx. 114 hp @ 4000 rpm
Torque 2.5L Diesel:
Approx. 240 Nm (177 lb-ft) @ 2000 rpm
Fuel System
Fuel Delivery:
Multi-Point Fuel Injection (MPI) for gasoline engines, Direct Injection for some diesel variants.
Fuel Type:
Unleaded Gasoline (Octane Rating 91+ recommended for V6), Diesel
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
4-speed Automatic Transmission (INVECS-II)
Features
Transfer Case:
Part-time 4WD with 2-speed transfer case (standard) or Full-time 4WD with Active Center Differential and lockable rear differential (Super Select II - optional).
📐 Dimensions
Exterior
Length Mm:
4730-4785
Width Mm:
1875
Height Mm:
1855-1920
Wheelbase Mm:
2725
Ground Clearance Mm:
205-220
Weights
Curb Weight Kg:
1900-2100 (approximate, varies by engine and trim)
Towing Capacity Kg:
2500-3500 (depending on market and equipment)
🛡️ Safety Features
Ratings
NHTSA Rating:
Not directly rated by NHTSA in the same format as modern vehicles; structural integrity generally considered robust for its class and era.
Active Features
ABS:
Anti-lock Braking System (ABS) standard on most models.
Traction Control:
Traction Control System (TCS) available on higher trims.
Passive Features
Airbags:
Front airbags for driver and passenger standard. Side airbags optional on select trims.
Seatbelts:
3-point seatbelts with pre-tensioners for front occupants.
💡 Technology Features
Infotainment
Audio System:
Factory fitted AM/FM/CD player with optional premium sound system and subwoofer. Cassette player was also common.
Navigation:
Optional GPS navigation system on higher trim levels.
Driver Assistance
Cruise Control:
Standard on most models.
Parking Sensors:
Not commonly equipped.
Connectivity
Phone Integration:
No Bluetooth or integrated smartphone connectivity; aftermarket solutions are common.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first (depending on driving conditions).
Timing Belt Replacement:
Every 60,000 miles (96,000 km) or 4 years for 6G72 and 6G74 engines (critical maintenance item).
Transmission Fluid Change:
Every 30,000 miles (48,000 km) for automatic transmission; manual transmission fluid inspection based on driving conditions.
Fluid Specifications
Engine Oil:
API SJ or SL, SAE 5W-30 or 10W-30 (check owner's manual for specific viscosity based on ambient temperature). Capacity: Approx. 4.7L (4.9 US qt) for 3.0L V6, 5.7L (6.0 US qt) for 3.5L V6.
Coolant:
Mitsubishi DiaQueen Super Long Life Coolant (Green) or equivalent ethylene glycol-based coolant. Capacity: Approx. 9.0L (9.5 US qt).
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Automatic Transmission Fluid:
Mitsubishi DiaQueen ATF-SP II M or equivalent ATF SP-II M. Capacity: Approx. 8.0L (8.5 US qt) for a fluid change.
Manual Transmission Fluid:
GL-4 SAE 75W-90 gear oil. Capacity: Approx. 2.0L (2.1 US qt).
Transfer Case Fluid:
GL-4 SAE 75W-90 gear oil. Capacity: Approx. 2.0L (2.1 US qt).
Differential Fluid:
GL-5 SAE 80W-90 gear oil. Capacity: Approx. 1.5L (1.6 US qt) for front and rear.
Known Issues
Common Wear Items:
Tie rod ends, ball joints, wheel bearings due to off-road use. Radiator leaks, A/C compressor failure.
Engine Specific:
Timing belt failure if not replaced on schedule (catastrophic engine damage). Potential head gasket issues on some V6 engines with high mileage.
Transmission Specific:
Occasional issues with automatic transmission solenoids or valve body wear.
📚 Vehicle History
Brand Heritage
Mitsubishi Legacy:
Mitsubishi has a long history in vehicle manufacturing, with the Pajero lineage tracing back to the early 1970s, establishing a reputation for ruggedness and off-road capability.
Model Evolution
Generation 2002:
This 2002 model represents the third generation (2000-2006) of the Pajero, also known as Montero in North America and other markets. It introduced a significant redesign with a unibody construction (except for the chassis subframe), improved on-road comfort, and advanced electronic systems.
Production
Production Plant:
Primarily manufactured in Japan (e.g., Okazaki Plant), with some assembly in other countries.
🏆 Awards & Recognition
Recognitions
Off Road Acclaim:
The Mitsubishi Pajero has a decorated history in off-road racing, including multiple wins in the Dakar Rally, contributing to its global reputation for durability and off-road performance.
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