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Mitsubishi Pajero 2002-2006 Service Repair Workshop Manual

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The Mitsubishi Pajero, specifically the Third Generation (V60/V70 Series) produced from 2002 to 2006, is a full-size, body-on-frame SUV renowned for its robust construction and exceptional off-road capability. Building on...
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SKU: 58173
Mitsubishi Pajero 2002-2006 Service Repair Workshop ManualMitsubishi Pajero 2002-2006 Service Repair Workshop ManualMitsubishi Pajero 2002-2006 Service Repair Workshop Manual
The Mitsubishi Pajero, specifically the Third Generation (V60/V70 Series) produced from 2002 to 2006, is a full-size, body-on-frame SUV renowned for its robust construction and exceptional off-road capability. Building on an extensive off-road legacy, this generation features a monocoque chassis for improved ride comfort and handling. Available with powerful gasoline V6 engines (3.0L and 3.5L) and a 3.2L turbo-diesel, the Pajero offers versatile performance with advanced drivetrain options like the Super Select 4WD-II system and a 2-speed transfer case. Its spacious interior, comfortable ride, and strong safety features, including multiple airbags and available stability control, make it a highly reliable choice for both daily driving and challenging terrains. This comprehensive Service and Repair Workshop Manual, approximately 1500+ pages in English, covers all essential aspects of maintaining and repairing your Mitsubishi Pajero. It details procedures for engine systems, transmission and drivetrain, chassis, suspension, steering, brakes, and electrical systems. You will find step-by-step instructions for routine maintenance, troubleshooting common issues, and in-depth repair procedures for major components. Technical specifications, including torque values, fluid capacities, and wiring diagrams, are also provided to ensure accurate and effective service. This manual is an indispensable resource for owners, mechanics, and technicians seeking to preserve the performance and longevity of their vehicle.
🏷️ 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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