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Mitsubishi Pajero 2000-2002 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero Generation Code: Third Generation (V60/V70 Series) Codes Platform Code: V60/V70 👋 Introduction Market Position Segment: Full-size SUV, known for off-road capability and...
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Mitsubishi Pajero 2000-2002 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Pajero
Generation Code:
Third Generation (V60/V70 Series)
Codes
Platform Code:
V60/V70
👋 Introduction
Market Position
Segment:
Full-size SUV, known for off-road capability and ruggedness.
Key Competitors:
Toyota Land Cruiser, Nissan Patrol, Land Rover Discovery, Jeep Grand Cherokee.
Competitive Analysis
Strengths:
Renowned off-road prowess, robust chassis, comfortable ride, strong engine options, good value proposition.
Key Features
Off Road Systems:
Advanced four-wheel-drive systems (Super Select 4WD II), available locking differentials, robust suspension, high ground clearance.
Body Styles:
Available in short-wheelbase (2-door) and long-wheelbase (3-door or 5-door) configurations.
📋 Manual Details
Coverage Areas
Covered Years:
2000, 2001, 2002
Regions Covered:
Global markets, with specific attention to common configurations
Page Count
Estimated Pages:
1000+
Manual Type
Type:
Full Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnosis, repair, and overhaul procedures for all applicable engine variants (e.g., 3.0L V6 SOHC, 3.5L V6 SOHC/DOHC, 2.8L Diesel).
Transmission:
Automatic and Manual transmission repair, overhaul, clutch service, fluid specifications, and diagnosis.
Drivetrain:
Four-Wheel Drive (4WD) system operation, Super Select 4WD II (SS4-II) system, differential overhaul, driveshafts, CV joints, and transfer case service.
Suspension:
Independent front suspension (double wishbone), multi-link rear suspension, shock absorbers, springs, bushings, wheel alignment specifications.
Brakes:
Front and rear brake systems (disc/drum configurations), ABS operation, brake fluid specifications, caliper and rotor service, parking brake.
Steering:
Power steering system diagnosis and repair, steering rack and pump service, steering column.
Electrical System:
Full wiring diagrams, fuse and relay locations, battery, charging system (alternator), starting system, lighting, accessories, ECUs, and diagnostic trouble codes (DTCs).
Climate Control:
Air conditioning system (HVAC) service, refrigerant handling, heater core, blower motor, climate control module diagnosis.
Fuel System:
Fuel injection system components (injectors, fuel pump, pressure regulator), fuel tank, lines, EVAP system.
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, exhaust pipes, oxygen sensors.
Body And Frame:
Body panel removal/installation, door mechanisms, glass, interior trim, chassis diagnostics, rust repair.
Safety Systems:
Airbag system diagnosis and service, seat belt mechanisms.
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt replacement, brake fluid flush, coolant flush.
Troubleshooting:
Diagnostic charts, symptom-to-cause analysis, common problem identification and solutions.
Repair:
Component replacement and repair for all major vehicle systems.
Rebuild:
Detailed instructions for engine, transmission, and differential rebuilds.
Diagnostics:
On-board diagnostics (OBD-II) procedures, reading and clearing DTCs, sensor testing.
Specifications:
Torque specifications, fluid capacities, tolerances, diagnostic values, alignment settings.
Technical Depth
Depth:
Comprehensive, from basic preventative maintenance to advanced engine and transmission rebuilds. Suitable for professional mechanics and advanced DIY enthusiasts.
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Searchability:
Searchable text for quick information retrieval.
Print Quality
Quality:
High-resolution images, diagrams, and text, suitable for printing.
Binding Type
Binding:
N/A (Digital PDF Download)
Paper Type
Paper:
N/A (Digital PDF Download)
⚙️ Engine Specifications
Primary Engine
Engine Code Common 1:
6G72 (3.0L V6 SOHC MPI)
Engine Code Common 2:
6G75 (3.8L V6 SOHC MPI)
Engine Code Diesel:
4M41 (3.2L DI-D DOHC Intercooled Turbo Diesel)
Performance 3 0L V6
Displacement Hp:
177 hp @ 5000 rpm (approx.)
Displacement Torque:
255 Nm @ 4000 rpm (approx.)
Performance 3 8L V6
Displacement Hp:
215 hp @ 5000 rpm (approx.)
Displacement Torque:
333 Nm @ 3750 rpm (approx.)
Performance 3 2L Di-D
Displacement Hp:
165 hp @ 4000 rpm (approx.)
Displacement Torque:
373 Nm @ 2000 rpm (approx.)
Fuel System
Fuel Type Gasoline:
Unleaded gasoline
Fuel Type Diesel:
Diesel fuel
Injection Type:
Multi-point Fuel Injection (MPI) for gasoline, Direct Injection (DI) for diesel.
🔧 Transmission
Standard
Transmission Type Common:
4-speed Automatic Transmission
Optional
Transmission Type Manual:
5-speed Manual Transmission
Features
4Wd System:
Super Select 4WD II (SS4-II) system with electronic control and differential lock capability.
Fluid Specifications
Automatic Transmission Fluid:
Refer to manual for specific ATF type (e.g., SPIII or equivalent).
Manual Transmission Fluid:
Refer to manual for specific MTF type (e.g., 75W-90 GL-4/GL-5).
📐 Dimensions
Exterior Lwb
Length:
Approx. 4,700 - 4,850 mm (depending on market/body style)
Width:
Approx. 1,850 - 1,885 mm
Height:
Approx. 1,850 - 1,895 mm
Exterior Swb
Length:
Approx. 4,300 - 4,370 mm
Wheelbase:
Approx. 2,780 mm (LWB) / 2,450 mm (SWB)
Weights
Curb Weight:
Approx. 1,800 - 2,200 kg (depending on configuration)
Towing Capacity:
Refer to vehicle placard/manual, typically around 2,500 kg (braked).
🛡️ Safety Features
Ratings
Crash Test Results:
Varied by region and testing organization. Generally performed well for its era, though specific ratings should be verified.
Active Features
ABS:
Anti-lock Braking System (ABS) standard on most models.
Traction Control:
Traction Control System (TCS) available on higher trims/later models.
Passive Features
Airbags:
Front airbags standard, side airbags available on select models.
Seat Belts:
Three-point seat belts with pre-tensioners for front occupants.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD stereo system, optional premium audio by Rockford Fosgate on some trims.
Navigation:
Optional factory GPS navigation system available on higher-end models.
Driver Assistance
Cruise Control:
Standard cruise control on most models.
Connectivity
Auxiliary Input:
Rarely standard, typically requires aftermarket installation for audio input.
🔧 Maintenance
Service Intervals Oil
Engine Oil Change:
Every 5,000 miles (8,000 km) or 6 months, whichever comes first (or refer to manual for specific oil type/conditions).
Service Intervals Filters
Oil Filter Replacement:
With every oil change.
Air Filter Replacement:
Every 15,000 miles (24,000 km) or as needed based on inspection.
Service Intervals Fluids
Coolant Flush:
Every 30,000 miles (48,000 km) or 2 years.
Brake Fluid Flush:
Every 24,000 miles (38,000 km) or 2 years.
Fluid Specifications
Engine Oil Spec:
API SJ/SL or ACEA A2/A3, SAE 10W-30 or 5W-30 (check manual for exact requirements based on climate).
Coolant Spec:
Ethylene glycol based coolant, typically a 50/50 mix with distilled water (e.g., Mitsubishi DiaQueen Super Long Life Coolant).
Known Issues
Common Issue 1:
Rear differential whine or bearing noise, especially on higher mileage vehicles.
Common Issue 2:
Suspension component wear (bushings, ball joints) due to off-road use or age.
Common Issue 3:
Power steering leaks or pump noise.
Common Issue 4:
Cracked exhaust manifolds or catalytic converter issues on diesel models.
Common Issue 5:
Interior trim rattles and wear.
📚 Vehicle History
Brand Heritage
Mitsubishi SUV Legacy:
Mitsubishi has a long history of producing capable off-road vehicles, dating back to models like the J-series Jeeps (licensed production) and the original Pajero (1970s).
Model Evolution
Third Generation Debut:
Introduced in 1999 (for the 2000 model year), featuring a monocoque body-on-frame construction, a significant departure from previous generations, enhancing on-road manners and safety.
Production
Manufacturing Locations:
Primarily Japan (Okazaki Plant), with some assembly in other international locations.
Production Years For This Gen:
1999-2006
🏆 Awards & Recognition
Recognitions
Off Road Awards:
Pajero consistently ranked highly in off-road capability tests and received accolades in various international markets for its ruggedness.
Ratings
Reliability Rankings:
Generally considered reliable, though specific model year reliability can vary. This manual helps address any potential issues.
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