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Mitsubishi Pajero 2002-2006 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero Generation: Third Generation (V60/V70 Series) Codes Chassis Codes: V63W, V64W, V65W, V68W, V73W, V74W, V75W, V78W 👋 Introduction Market Position Vehicle Segment:...
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Mitsubishi Pajero 2002-2006 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Pajero
Generation:
Third Generation (V60/V70 Series)
Codes
Chassis Codes:
V63W, V64W, V65W, V68W, V73W, V74W, V75W, V78W
👋 Introduction
Market Position
Vehicle Segment:
Full-size SUV, Body-on-frame, Off-road focused
Competitive Analysis
Key Competitors:
Toyota Land Cruiser Prado, Nissan Patrol, Ford Explorer, Jeep Grand Cherokee
Key Features
Vehicle Attributes:
Robust construction, excellent off-road capability, comfortable ride, spacious interior, reliable powertrains
📋 Manual Details
Coverage Areas
Model Years Covered:
2002, 2003, 2004, 2005, 2006
Page Count
Estimated Pages:
Approximately 1500+
Manual Type
Manual Type:
Service and Repair Workshop Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, lubrication, cooling, fuel delivery, ignition, emissions control, engine management (ECU)
Transmission Drivetrain:
Manual transmission, Automatic transmission (INVECS-II), Transfer case, Front and rear differentials, Driveshafts, Axles
Chassis Suspension Steering:
Front suspension (independent multi-link), Rear suspension (independent multi-link), Power steering system, Steering gear, Wheel alignment
Brakes:
Front disc brakes, Rear disc brakes, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), Brake fluid specifications, Bleeding procedures
Electrical:
Battery, Charging system (alternator), Starting system (starter motor), Lighting system (headlights, taillights), Horn, Wipers and washers, Power windows, Power mirrors, Central locking, Fuse box diagrams, Relay functions, Wiring diagrams
Body Interior:
Body panels, Doors, Hood, Tailgate, Bumpers, Interior trim, Seats, HVAC (Heating, Ventilation, and Air Conditioning) system, SRS (Supplemental Restraint System) airbags
Procedures Included
Maintenance Procedures:
Oil and filter change, Air filter replacement, Spark plug replacement, Coolant flush and refill, Brake pad/shoe replacement, Tire rotation
Diagnostic Procedures:
Troubleshooting charts, DTC (Diagnostic Trouble Code) retrieval and interpretation, Component testing methods
Repair Procedures:
Engine overhaul, Transmission repair/rebuild, Suspension component replacement, Brake system overhaul, Electrical component repair, Body panel repair
Technical Specifications:
Torque specifications for all fasteners, Fluid capacities and types, Lubricant specifications, Diagnostic trouble codes (DTCs), Wiring schematics
Technical Depth
Depth Of Coverage:
Comprehensive (from basic maintenance to full engine/transmission rebuilds, including detailed electrical diagnostics)
📊 Manual Specifications
File Format
File Quality:
High-resolution, searchable PDF
Printable:
Yes, printable pages
Binding Type
Binding Type:
Not Applicable (Digital PDF)
Paper Type
Paper Type:
Not Applicable (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code Gasoline:
6G72 (3.0L SOHC V6), 6G74 (3.5L SOHC V6)
Engine Code Diesel:
4M41 (3.2L DI-D DOHC Intercooled Turbo Diesel)
Performance
3.0L V6 (6G72) Horsepower:
Approx. 175-185 HP @ 5000-5500 RPM
3.5L V6 (6G74) Horsepower:
Approx. 197-202 HP @ 5000-5500 RPM
3.2L Di-D Turbo Diesel (4M41) Horsepower:
Approx. 175 HP @ 4000 RPM
3.5L V6 (6G74) Torque:
Approx. 220-228 lb-ft @ 3500-4000 RPM
3.2L Di-D Turbo Diesel (4M41) Torque:
Approx. 282-295 lb-ft @ 2000 RPM
Fuel System
Gasoline Fuel System:
Multi-point Fuel Injection (MPI)
Diesel Fuel System:
Common Rail Direct Injection (CRDI) with Turbocharger and Intercooler
🔧 Transmission
Standard
Standard Transmission Type:
5-speed Manual (some markets/trims)
Optional
Optional Transmission Type:
4-speed Automatic (INVECS-II with Adaptive Shift Control), 5-speed Automatic (later models/some markets)
Features
Drivetrain:
Part-time 4WD (Super Select 4WD-II on many models), optional Full-time 4WD
Transfer Case:
2-speed transfer case with locking center differential
📐 Dimensions
Exterior
Wheelbase:
Approx. 2780 mm (109.4 in)
Length:
Approx. 4745 mm (186.8 in)
Width:
Approx. 1870 mm (73.6 in)
Height:
Approx. 1855 mm (73.0 in) (without roof rails)
Weights
Curb Weight Gasoline:
Approx. 1900-2100 kg (4189-4630 lbs)
Curb Weight Diesel:
Approx. 2000-2200 kg (4409-4850 lbs)
🛡️ Safety Features
Ratings
NHTSA Front Impact Rating:
4-star (driver), 4-star (passenger) for 2002-2005 models
Active Features
Active Safety Features:
ABS, EBD, Traction Control (optional/standard on higher trims), Active Stability Control (ASC) (optional/standard on higher trims)
Passive Features
Passive Safety Features:
Front airbags, Side airbags (optional), Side curtain airbags (optional), Three-point seatbelts with pretensioners, Anti-whiplash head restraints
💡 Technology Features
Infotainment
Infotainment Systems:
Factory-installed AM/FM/CD audio systems, optional premium sound systems, optional navigation (market dependent).
Driver Assistance
Driver Assistance Features:
Cruise control, parking sensors (optional on later models).
Connectivity
Connectivity Features:
Limited by era; typically analog systems, auxiliary inputs on some premium audio units.
🔧 Maintenance
Service Intervals
Engine Oil And Filter Change:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first (under normal driving conditions).
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months.
Spark Plug Replacement Gasoline:
Every 60,000 miles (96,000 km) for standard plugs, 100,000 miles (160,000 km) for iridium plugs.
Timing Belt Replacement:
Check manual for specific interval, often around 90,000-105,000 miles (145,000-170,000 km). Crucial for 6G7 series V6 engines.
Fluid Specifications
Engine Oil Type Gasoline:
API SN or higher, SAE 5W-30 or 10W-30 (check owner's manual for specific viscosity based on climate).
Engine Oil Type Diesel:
API CJ-4 or higher, SAE 15W-40 or 5W-40 (check owner's manual for specific viscosity).
Coolant Type:
Ethylene glycol-based coolant, typically a green or pink long-life type (e.g., DIA QUEEN SUPER LONG LIFE COOLANT).
Transmission Fluid Automatic:
DIA QUEEN ATF SP-III or equivalent (check manual for specific application).
Transmission Fluid Manual:
API GL-4 or GL-5, SAE 75W-90 gear oil.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Issues Diesel:
Potential for injector pump failure (4M41 early models), turbocharger issues, EGR valve clogging.
Common Issues Gasoline V6:
Intake manifold gaskets can leak, spark plug blow-out (early models), potential for radiator leaks, transmission control issues on some automatics.
Common Issues Suspension:
Wear in bushings and ball joints due to off-road use and age, potential for front hub bearing noise.
Common Issues Electrical:
Window regulator failures, central locking actuator issues, minor sensor failures (e.g., ABS sensors).
Common Issues HVAC:
Blend door actuator failure, AC compressor issues, heater core leaks.
📚 Vehicle History
Brand Heritage
Mitsubishi Off Road Legacy:
Mitsubishi has a long history of producing capable off-road vehicles, notably with the Pajero's success in the Dakar Rally.
Model Evolution
Third Generation Introduction:
Introduced in 1999, the third generation marked a significant shift with a monocoque chassis (unibody) construction, replacing the traditional body-on-frame, offering improved ride comfort and handling.
Production
Production Period:
1999-2006 (for the third generation)
Manufacturing Locations:
Japan (Okazaki Plant), and assembly plants in various countries worldwide.
🏆 Awards & Recognition
Recognitions
Dakar Rally Heritage:
The Pajero lineage has a storied history of success in the Dakar Rally, underscoring its off-road credentials.
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