🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero

Generation Code:

NP

Year:

2002-2006

👋 Introduction

Segment:

Mid-size to large SUV, known for its off-road capability and robust construction.

Key Competitors:

Toyota Land Cruiser Prado, Nissan Patrol, Land Rover Discovery, Ford Explorer, Jeep Grand Cherokee.

Strengths:

Renowned off-road prowess, strong chassis, reliable engines (especially diesel variants), durable drivetrain, comfortable ride for an SUV of its era.

Weaknesses:

Fuel economy (particularly petrol engines), some interior plastics could feel less premium than competitors, aging technology by the end of the model run.

Off Road Systems:

Super Select II 4WD system (on many models) offering full-time 4WD, 2WD, 4WD high and low range, and locking center differential. Independent front suspension for better on-road manners, while many retained solid rear axles for durability.

Body On Frame Construction:

Robust body-on-frame construction contributing to off-road durability and towing capacity.

📋 Manual Details

Countries Of Origin:

Japan, Australia

Global Markets Covered:

Likely includes specifications relevant to markets where the NP Pajero was sold, such as Australia, parts of Asia, and potentially some Middle Eastern countries. Specific regional variations may be present within the manual.

Total Pages:

4000

Type:

Workshop Service Manual

Purpose:

Primarily published for use by dealership technicians, independent repair shops, and advanced DIY enthusiasts.

Language:

English (Assumed, typical for workshop manuals of this era and origin for global markets)

Format:

PDF

📖 Manual Coverage

Powertrain:

Engine mechanicals, fuel system, ignition system, exhaust system, cooling system, lubrication system.

Drivetrain:

Transmission (manual and automatic), transfer case, differentials (front, center, rear), driveshafts, CV joints, axles.

Chassis:

Suspension systems (front and rear independent, coil springs, shocks, control arms), steering system (power steering), braking system (ABS, disc/drum configurations), wheels and tires.

Electrical:

Wiring diagrams, starting and charging system, lighting, instrument cluster, body electricals (power windows, locks, mirrors), audio system, climate control electricals, basic diagnostic codes.

Body:

Exterior body panels, doors, hood, tailgate, interior trim, glass, seals, chassis structural components.

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and top-offs, lubrication points.

Diagnostics:

Troubleshooting guides for common drivability issues, electrical faults, and mechanical problems. Symptom-based diagnosis procedures.

Repair:

Detailed step-by-step repair procedures for all major mechanical and electrical components. Includes disassembly, inspection, repair, and reassembly instructions.

Overhaul:

Engine, transmission, and transfer case overhaul procedures, including specifications for critical wear tolerances.

Specifications:

Torque specifications, clearances, fluid capacities, electrical specifications, and diagnostic parameters.

Depth:

Comprehensive, covering everything from basic fluid changes to complete engine and transmission rebuilds. Includes detailed technical explanations of how systems function.

📊 Manual Specifications

File Type:

PDF

Searchability:

Likely text-searchable if the PDF was generated from a digital source or properly OCR'd, greatly enhancing usability for finding specific information.

Printability:

PDF format allows for easy printing of individual pages or sections as needed for workshop use.

Quality:

Variable, depending on the source. Original manufacturer manuals are typically high quality with clear diagrams and text. Scanned PDFs can vary.

Type:

N/A (Digital PDF format)

Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Petrol Engine Option 1:

3.5L V6 (6G74 MIVEC) SOHC/DOHC

Petrol Engine Option 2:

3.8L V6 (6G75) SOHC MIVEC

Diesel Engine Option 1:

3.2L Direct Injection Turbo Diesel (4M41)

3.5L V6 Petrol (Approx.):

147 kW (197 hp) @ 5000 rpm, 308 Nm (227 lb-ft) @ 3000 rpm

3.8L V6 Petrol (Approx.):

177 kW (237 hp) @ 5250 rpm, 353 Nm (260 lb-ft) @ 3750 rpm

3.2L Di-Turbo Diesel (Approx.):

116 kW (155 hp) @ 3800 rpm, 373 Nm (275 lb-ft) @ 2000 rpm (for early models, later ones might have slightly more power/torque)

Petrol Engines:

Multi-point Fuel Injection (MPI)

Diesel Engine:

Common Rail Direct Injection (CRDI)

Type:

Catalytic converters, EGR (Exhaust Gas Recirculation) on diesel.

🔧 Transmission

Manual:

5-speed manual transmission (often found on lower trim levels or specific markets).

Automatic:

4-speed automatic transmission (common across many variants), later models or higher trims might have offered a 5-speed automatic.

Drivetrain Options:

All Wheel Drive (AWD) with lockable center differential (Super Select II system).

Automatic Transmission Fluid:

Diamond SP-III or equivalent ATF (refer to specific manual for exact spec and capacity).

Manual Transmission Fluid:

API GL-4 or GL-5, viscosity typically SAE 75W-90 or 80W-90 (refer to specific manual).

Transfer Case Fluid:

Diamond SP-III or equivalent ATF (refer to specific manual for exact spec and capacity).

📐 Dimensions

Length:

Approx. 4750-4850 mm (short-wheelbase SWB and long-wheelbase LWB variants exist).

Width:

Approx. 1830-1875 mm

Height:

Approx. 1850-1900 mm

Wheelbase:

Approx. 2780 mm (LWB)

Seating Capacity:

5 or 7 seats (depending on configuration and trim).

Cargo Volume:

Variable depending on seat configuration; substantial rear cargo space when rear seats are folded or removed.

Curb Weight:

Approx. 2000-2300 kg (depending on engine and specification).

Gross Vehicle Weight Rating Gvw:

Typically around 2700-2900 kg.

Towing Capacity:

Often rated up to 2500 kg (braked trailer) in markets like Australia.

🛡️ Safety Features

Ancap Rating:

Likely received a 4-star ANCAP rating for models sold in Australia during this period, but verification for specific year/variant is recommended.

ABS:

Standard on most models from 2002 onwards.

Electronic Brakeforce Distribution Ebd:

Often included with ABS.

Traction Control System TCS:

Available on higher trim levels or optional.

Airbags:

Front airbags standard. Side airbags and curtain airbags may be available on higher trims.

Seatbelts:

Three-point seatbelts with pretensioners for front seats. Three-point or lap belts for rear seats depending on position.

Body Structure:

Reinforced safety cell and crumple zones designed for impact absorption.

💡 Technology Features

Audio System:

Factory-fitted radio/cassette/CD players. Higher trims may have upgraded sound systems, possibly with amplifiers and subwoofers. Later models might have optional satellite navigation systems.

Climate Control:

Manual air conditioning is standard, with optional automatic climate control available on higher-spec models.

Cruise Control:

Available on most models, especially those with automatic transmissions.

Parking Sensors:

May be an optional factory-fit or dealer-fit accessory on some later models.

Auxiliary Inputs:

Likely limited to standard radio features; auxiliary audio inputs or USB ports were not common in factory systems of this era.

🔧 Maintenance

Oil Change Interval Petrol:

Typically 5,000-10,000 km or 6-12 months, depending on driving conditions and oil type used. Check manual for precise recommendation.

Oil Change Interval Diesel:

Typically 5,000-7,500 km or 6 months for diesel engines, especially under severe conditions. Check manual for precise recommendation.

Air Filter Replacement:

Every 20,000-40,000 km, or more frequently if driving in dusty conditions.

Fuel Filter Replacement Diesel:

Typically every 20,000-40,000 km for diesel models to ensure fuel system health.

Timing Belt Replacement Petrol V6:

Crucial maintenance item, usually around 90,000-100,000 km. Failure can cause catastrophic engine damage.

Timing Chain Diesel 4M41:

The 4M41 diesel engine uses a timing chain, generally requiring less frequent replacement than a belt, but still requires inspection for wear and tension.

Engine Oil Petrol:

Typically SAE 10W-30 or 10W-40 API SG or higher. Check manual for exact viscosity and API rating.

Engine Oil Diesel:

Typically SAE 15W-40 API CH-4 or higher. Check manual for exact viscosity and API rating.

Coolant:

Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Mitsubishi Super Long Life Coolant (SLLC) or equivalent. Check manual for specific type and capacity.

Brake Fluid:

DOT 3 or DOT 4, refer to manual for exact specification.

Diesel Particulate Filter Dpf Issues:

While the 4M41 is generally robust, some models may experience issues related to carbon buildup in intake manifolds or turbochargers if not maintained diligently, or potential EGR valve issues.

Automatic Transmission Reliability:

Some automatic transmissions in high-mileage vehicles might exhibit signs of wear, particularly if not serviced regularly. The manual will cover diagnostic procedures.

Suspension Component Wear:

As with any SUV of this age and off-road capability, suspension components (bushings, ball joints, tie rod ends) can wear over time and mileage, especially if subjected to heavy off-road use. The manual details inspection and replacement.

Radiator And Cooling System:

Overheating can be an issue if the cooling system is neglected. Radiators, hoses, and thermostats should be inspected and replaced as needed. The manual provides full cooling system diagnostics.

📚 Vehicle History

Mitsubishi Off Road Legacy:

Mitsubishi has a long and storied history in off-road vehicles, dating back to the 1970s with models like the original Pajero (also known as Montero or Shogun in different markets).

Pajero Generations:

The NP Pajero represents the third generation (1999-2006) of the Pajero. It marked a significant shift from previous generations with its introduction of an independent front suspension (IFS) for improved on-road comfort and handling, moving away from solid front axles.

Manufacturing Locations:

Primarily manufactured in Japan, with significant assembly also occurring in other countries for various markets (e.g., Australia).

Years:

The NP Pajero generation spanned approximately from late 2000/early 2001 to late 2006, covering the model years 2002-2006 as indicated.

🏆 Awards & Recognition

Off Road Awards:

The Pajero platform, in general, has a strong rally heritage, winning the Dakar Rally multiple times, which bolsters its off-road credentials, though specific NP generation awards are less commonly highlighted than earlier rally victories.

Consumer Reviews General:

Generally well-regarded by owners for its reliability, off-road capability, and durability. Critical reviews often focused on fuel consumption for petrol models and perceived interior quality compared to some European rivals.

Emissions Compliance:

Meets emissions standards applicable to the years of manufacture in the regions where it was sold. The manual would contain specific emissions-related data for diagnosis and repair.