Mitsubishi Pajero Nm 2000-2006 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero NM Model Nickname: Montero (North America), Shogun (UK) Codes Chassis Code: V60, V70 Series Engine Code Primary: 6G72 (3.0L V6 SOHC) Engine Code Secondary: 6G74 (3.5L V6 SOHC/DOHC) Engine Code Tertiary: 4M41 (3.2L I4 DI-D Turbo Diesel) 👋 Introduction Market Position Positioning: The Mitsubishi Pajero NM represents a robust, capable, and versatile SUV known for its off-road prowess and comfortable on-road manners. It competed in the premium SUV segment against vehicles like the Toyota Land Cruiser Prado, Nissan Patrol, and Land Rover Discovery. Competitive Analysis Competitors: Key competitors during its production run included the Toyota Land Cruiser Prado (J90/J120), Nissan Patrol (Y61), Land Rover Discovery (Series II/LR3), Jeep Grand Cherokee, and Ford Explorer. Key Features Features: Renowned for its 'Super Select II' 4WD system, independent front suspension for improved on-road ride, robust chassis construction, choice of powerful V6 petrol engines and efficient turbo-diesel engines, and spacious interior. Manual Value Proposition Value: This factory service manual is an indispensable resource for maintaining, diagnosing, and repairing the Mitsubishi Pajero NM. It provides the official, detailed procedures and specifications used by Mitsubishi technicians, ensuring accurate and effective work, saving time and money compared to guesswork or inferior aftermarket guides. 📋 Manual Details Coverage Areas Model Years: 2000, 2001, 2002, 2003, 2004, 2005, 2006 Regions: Global (specific variations may exist per region, this manual aims for comprehensive coverage) Page Count Estimated Pages: Hundreds of pages (exact count not specified but implies comprehensive detail) Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, overhaul, cylinder head, block, crankshaft, pistons, connecting rods, timing system, lubrication system, cooling system, fuel injection system (gasoline and diesel), ignition system, emission control systems. Transmission Drivetrain: Manual transmission...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Pajero NM

Model Nickname:

Montero (North America), Shogun (UK)

Codes

Chassis Code:

V60, V70 Series

Engine Code Primary:

6G72 (3.0L V6 SOHC)

Engine Code Secondary:

6G74 (3.5L V6 SOHC/DOHC)

Engine Code Tertiary:

4M41 (3.2L I4 DI-D Turbo Diesel)

👋 Introduction

Market Position

Positioning:

The Mitsubishi Pajero NM represents a robust, capable, and versatile SUV known for its off-road prowess and comfortable on-road manners. It competed in the premium SUV segment against vehicles like the Toyota Land Cruiser Prado, Nissan Patrol, and Land Rover Discovery.

Competitive Analysis

Competitors:

Key competitors during its production run included the Toyota Land Cruiser Prado (J90/J120), Nissan Patrol (Y61), Land Rover Discovery (Series II/LR3), Jeep Grand Cherokee, and Ford Explorer.

Key Features

Features:

Renowned for its 'Super Select II' 4WD system, independent front suspension for improved on-road ride, robust chassis construction, choice of powerful V6 petrol engines and efficient turbo-diesel engines, and spacious interior.

Manual Value Proposition

Value:

This factory service manual is an indispensable resource for maintaining, diagnosing, and repairing the Mitsubishi Pajero NM. It provides the official, detailed procedures and specifications used by Mitsubishi technicians, ensuring accurate and effective work, saving time and money compared to guesswork or inferior aftermarket guides.

📋 Manual Details

Coverage Areas

Model Years:

2000, 2001, 2002, 2003, 2004, 2005, 2006

Regions:

Global (specific variations may exist per region, this manual aims for comprehensive coverage)

Page Count

Estimated Pages:

Hundreds of pages (exact count not specified but implies comprehensive detail)

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, overhaul, cylinder head, block, crankshaft, pistons, connecting rods, timing system, lubrication system, cooling system, fuel injection system (gasoline and diesel), ignition system, emission control systems.

Transmission Drivetrain:

Manual transmission (W5MBB), Automatic transmission (V5A51, V5M33), Transfer case (Super Select II), Front and rear differentials, drive shafts, CV joints, hub bearings.

Suspension Steering:

Front independent suspension (double wishbone), Rear multi-link suspension, shock absorbers, springs, control arms, sway bars, power steering system, steering column, steering rack/gearbox.

Brakes:

Front and rear brake systems (ventilated discs, solid discs), brake calipers, master cylinder, brake booster, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), parking brake.

Electrical Electronics:

12V electrical system, battery, alternator, starter motor, lighting systems (headlights, taillights, interior), fuse box diagrams, relay locations, wiring diagrams for all systems, ECU (Engine Control Unit), TCU (Transmission Control Unit), SRS (Supplemental Restraint System - Airbags).

Body Chassis:

Body panel removal and installation, door mechanisms, glass replacement, interior trim, seats, roof rack, chassis frame, underbody protection, towing information.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system operation, refrigerant circuits, blower motor, evaporator, condenser, controls.

Procedures Included

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flushes, brake fluid replacement, transmission fluid service, differential fluid service.

Troubleshooting:

Diagnostic procedures for common and uncommon faults, symptom-based troubleshooting charts, diagnostic trouble codes (DTCs) and their meanings, electrical system troubleshooting, engine performance issues.

Repair Rebuild:

Step-by-step instructions for component removal, installation, overhaul, and replacement. Includes detailed procedures for major component repairs such as engine rebuilds, transmission overhauls, brake caliper replacement, and suspension component replacement.

Special Tools:

Identification and usage of specialized tools required for specific diagnostic and repair procedures.

Technical Depth

Depth:

Comprehensive. Covers everything from basic preventative maintenance and fluid checks to complete engine and transmission rebuilds, advanced electrical diagnostics, and bodywork repairs. Suitable for professional technicians and advanced DIY mechanics.

📊 Manual Specifications

File Format

Format:

Searchability:

Likely text-searchable if originally digitized from an OCR-capable source, allowing for quick navigation to specific topics.

Print Quality

Quality:

Assumed high quality, as it's a factory service manual, ensuring clear diagrams and legible text.

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine 1:

3.0L 6G72 V6 SOHC MPI

Engine 1 Power:

Approx. 133 kW (178 hp) @ 5000 rpm

Engine 1 Torque:

Approx. 255 Nm (188 lb-ft) @ 4000 rpm

Secondary Engine

Engine 2:

3.5L 6G74 V6 SOHC MPI (some markets)

Engine 2 Power:

Approx. 150 kW (201 hp) @ 5000 rpm

Engine 2 Torque:

Approx. 317 Nm (234 lb-ft) @ 3500 rpm

Engine 2 Variant:

3.5L 6G74 V6 DOHC GDI (Galant VR-4 derived, performance variant)

Engine 2 Variant Power:

Approx. 180 kW (241 hp) @ 5500 rpm

Engine 2 Variant Torque:

Approx. 343 Nm (253 lb-ft) @ 3750 rpm

Tertiary Engine

Engine 3:

3.2L 4M41 I4 DI-D Turbo Diesel

Engine 3 Power:

Approx. 121 kW (162 hp) @ 4000 rpm

Engine 3 Torque:

Approx. 373 Nm (275 lb-ft) @ 2000 rpm

Fuel System

Fuel Type Petrol:

Unleaded Petrol (91 RON recommended for 3.0L, 95 RON for 3.5L GDI)

Fuel Type Diesel:

Diesel (low sulfur)

Injection Type:

Multi-Point Fuel Injection (MPI) for petrol, Direct Injection (DI) with Common Rail for diesel.

Cooling System

Cooling Type:

Water-cooled, pressurized system

🔧 Transmission

Standard

Transmission Type Standard:

5-speed Manual Transmission (W5MBB) on base models

Optional

Transmission Type Optional:

4-speed Automatic Transmission (V5A51) with electronically controlled modes

Transmission Type Optional 2:

5-speed Automatic Transmission (V5M33) on higher trims/later models

Features

Drivetrain:

Full-time 4WD with electronically controlled center differential and locking function (Super Select II system allows shifting between 2H, 4H, 4HLC, 4LLC while moving).

Fluid Specs

Automatic Transmission Fluid:

DIA QUEEN ATF SP-III or equivalent (refer to manual for specific capacity and change intervals)

Manual Transmission Fluid:

API GL-4 or GL-5, SAE 75W-90 gear oil (refer to manual for specific capacity and change intervals)

📐 Dimensions

Exterior

Length:

Approx. 4710-4730 mm (185.4-186.2 in)

Width:

Approx. 1800-1830 mm (70.9-72.0 in)

Height:

Approx. 1855-1915 mm (73.0-75.4 in)

Wheelbase:

Approx. 2780 mm (109.4 in)

Interior

Seating Capacity:

5 or 7 seats (optional third row)

Cargo

Cargo Volume:

Substantial, with foldable rear seats providing ample space. Specific volume figures vary by configuration.

Weights

Curb Weight:

Approx. 1900-2100 kg (4189-4630 lbs), depending on engine and trim.

Gross Vehicle Weight Rating:

Typically around 2700-2800 kg (5952-6173 lbs).

🛡️ Safety Features

Ratings

NHTSA Rating:

Varies by year and region. Generally considered a safe vehicle for its era, but specific official ratings may be scarce for all global markets.

Active Features

Active Safety:

ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), Traction Control System (TCS) on some models.

Passive Features

Passive Safety:

Front airbags for driver and passenger, side impact door beams, crumple zones, seat belt pre-tensioners.

💡 Technology Features

Infotainment

Infotainment System:

Base models featured an AM/FM radio with CD player. Higher trims offered premium audio systems (e.g., Rockford Fosgate), optional navigation systems, and in-dash CD changers. Touchscreen interfaces became more common in later models or facelifts.

Driver Assistance

Driver Assistance:

Key driver aids include ABS, EBD, and optional Traction Control (TCL) and Stability Control (ASTC - Active Stability and Traction Control) on some later models. Cruise control was standard on many variants.

Connectivity

Connectivity:

Limited by modern standards. Early models had basic audio connectivity. Later models or optional upgrades might have included auxiliary inputs or basic Bluetooth phone integration.

Lighting

Headlights:

Halogen headlights were standard. Some higher trims or optional packages may have featured projector-beam headlights or HID (High-Intensity Discharge) headlamps.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 10,000-15,000 km (6,000-9,000 miles) or 6-12 months, depending on driving conditions. Refer to manual for exact intervals based on engine type.

Transmission Service Interval:

Automatic Transmission: 60,000-100,000 km (37,000-62,000 miles). Manual Transmission: 80,000-120,000 km (50,000-75,000 miles). Refer to manual for specific fluid and filter change recommendations.

Timing Belt Replacement:

For 6G72 and 6G74 engines (if equipped with a belt), typically every 90,000-105,000 km (56,000-65,000 miles) or 5-7 years. The 4M41 diesel uses a timing chain. Crucial to confirm via manual.

Fluid Specifications

Engine Oil Petrol:

API SJ or SL, SAE 10W-30 or 5W-30 (check manual for specific viscosity based on climate). Capacity approx. 4.5-5.5L depending on engine.

Engine Oil Diesel:

API CF-4 or CG-4, SAE 15W-40 or 10W-30 (check manual for specific viscosity). Capacity approx. 7.5-8.0L.

Coolant:

Long-life ethylene glycol coolant. Mitsubishi Super Long Life Coolant (MS-4) or equivalent. Capacity approx. 8-9L.

Brake Fluid:

DOT 3 or DOT 4 (refer to manual). Capacity approx. 0.5-0.7L.

Known Issues

Common Problems:

Potential issues can include ABS sensor failures, minor electrical gremlins, exhaust manifold cracks (especially on diesel models), rear differential whine, and radiator leaks. Certain transmission issues may arise with high mileage. Fuel injector issues on diesel engines. Early NM models may have had some issues with the transfer case actuator.

📚 Vehicle History

Brand Heritage

Heritage:

Mitsubishi has a long and distinguished history in off-road vehicles, dating back to the original Mitsubishi JEEP in the 1930s. The Pajero (or Montero/Shogun) lineage began in 1982, establishing Mitsubishi as a leader in the SUV market.

Model Evolution

Nm Generation:

The NM Pajero (introduced in 1999 for the 2000 model year) was the third generation of the Pajero. It marked a significant departure from the previous generations with a more modern, monocoque body-on-frame construction (integrated body frame), independent front suspension, and advanced electronic 4WD systems.

Production

Production Period:

The NM Pajero was produced from late 1999 through 2006. It was succeeded by the NP Pajero, which featured styling and mechanical updates.

Production Locations

Manufacturing:

Primarily manufactured in Japan, with potential assembly in other global locations.

🏆 Awards & Recognition

Recognitions

Off Road Awards:

The Pajero (and its variants) has a storied history in off-road motorsport, notably winning the Dakar Rally multiple times, which bolstered its reputation for durability and off-road capability. While specific awards for the NM model itself might be less publicized than its rally wins, its engineering reflects this heritage.