🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero

Generation:

Third Generation

Chassis Codes:

V63W, V64W, V65W, V68W, V73W, V74W, V75W, V78W

👋 Introduction

Segment:

Mid-size SUV / Off-road Vehicle

Competitors 1996-2001:

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

Powertrain Options:

Robust 4WD systems (Super Select 4WD-i), durable engine options, comfortable ride for its class

Vehicle Design:

Body-on-frame construction for off-road durability, spacious interior, available in short-wheelbase (3-door) and long-wheelbase (5-door) configurations

📋 Manual Details

Models Covered:

Mitsubishi Pajero (also known as Montero in North America and Shogun in the UK)

Years Covered:

1996, 1997, 1998, 1999, 2000, 2001

Estimated Pages:

~3000-5000+ (typical for comprehensive workshop manuals covering multiple engine variants and chassis codes)

Type:

Complete Service and Repair Workshop Manual

Language:

English (typically; may include other languages depending on the source)

Format:

Downloadable Digital Format (PDF)

📖 Manual Coverage

Powertrain:

Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine control systems (ECU, sensors, actuators)

Transmission Drivetrain:

Manual transmission, automatic transmission, transfer case (Super Select 4WD-i, mechanical 4WD), differentials, driveshafts, axles, clutch system

Chassis Suspension:

Front suspension (independent double wishbone, multi-link), rear suspension (independent multi-link), shock absorbers, springs, steering system, power steering, wheel alignment specifications

Brakes:

Front disc brakes (ventilated), rear disc brakes, anti-lock braking system (ABS), brake hydraulics, parking brake

Electrical Electronics:

Battery, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior lights), instrument cluster, power windows, power locks, central locking, mirrors, wipers, horn, fuse box diagrams, relay locations, wiring diagrams

Body Interior:

Body panels, doors, hood, tailgate, bumpers, interior trim, seats, dashboard, climate control system (HVAC), audio system, security system

Routine Maintenance:

Oil change, filter replacement, coolant flush, brake fluid change, spark plug replacement, air filter replacement, battery maintenance, tire rotation

Engine Repair:

Engine overhaul, cylinder head removal/installation, piston ring replacement, bearing replacement, camshaft timing, valve adjustment, component diagnostics

Transmission Drivetrain Repair:

Clutch replacement, transmission overhaul (manual and automatic), transfer case repair, differential repair, axle shaft replacement

Suspension Steering Repair:

Shock absorber replacement, spring replacement, ball joint replacement, tie rod end replacement, power steering pump repair/replacement, steering rack repair

Brake System Repair:

Brake pad/shoe replacement, caliper overhaul, master cylinder replacement, brake line replacement, ABS sensor replacement, bleeding procedure

Electrical Diagnostics:

Troubleshooting electrical faults, component testing, wiring harness repair, sensor calibration, diagnostic trouble codes (DTCs) retrieval and interpretation

Depth:

Comprehensive diagnostic procedures, detailed step-by-step repair instructions, torque specifications, electrical schematics, component testing values, exploded diagrams, overhaul procedures for major assemblies

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchability:

Text-searchable (typically, allowing for quick keyword lookups)

Printability:

Printable on standard office printers

Binding:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Codes Variants:

6G72 (3.0L V6 SOHC/DOHC), 6G74 (3.5L V6 SOHC/DOHC), 4D56 (2.5L L4 Diesel Turbo), 4M40 (2.8L L4 Diesel Turbo)

3.0L V6 (6G72) Estimated Hp:

133 hp (SOHC) to 200 hp (DOHC MIVEC)

3.0L V6 (6G72) Estimated Torque:

176 lb-ft (SOHC) to 217 lb-ft (DOHC MIVEC)

3.5L V6 (6G74) Estimated Hp:

197 hp (SOHC) to 240 hp (DOHC MIVEC)

3.5L V6 (6G74) Estimated Torque:

237 lb-ft (SOHC) to 247 lb-ft (DOHC MIVEC)

2.8L Diesel Turbo (4M40) Estimated Hp:

125 hp

2.8L Diesel Turbo (4M40) Estimated Torque:

201 lb-ft

Fuel Delivery Gasoline:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded gasoline (for V6 engines), Diesel (for diesel engines)

🔧 Transmission

Transmission Types Available:

5-speed manual, 4-speed automatic (INVECS-II)

Optional Transmission:

5-speed automatic (later models, dependent on market/engine)

Drivetrain System:

Super Select 4WD-i (most models, allowing on-the-fly switching between 2WD, 4WD High, 4WD Low, and locking center differential in 4WD High)

Transfer Case:

Electronically controlled or manually operated transfer case depending on trim and market

📐 Dimensions

Wheelbase Short Wb:

~2,500 mm (98.4 in)

Wheelbase Long Wb:

~2,725 mm (107.3 in)

Length Overall Short Wb:

~4,395 mm (173.0 in)

Length Overall Long Wb:

~4,745 mm (186.8 in)

Cargo Volume:

Varies significantly by configuration (5-door with rear seats folded offers substantial capacity)

Curb Weight Range:

~1,800 kg to 2,200 kg (3,968 lbs to 4,850 lbs) depending on engine, drivetrain, and body style

🛡️ Safety Features

NHTSA Rating Early Models:

Likely 3-star or 4-star frontal impact (based on contemporary SUVs, specific data may vary by test year and region)

Driver Assistance Features:

Anti-lock Braking System (ABS) standard on most models, Traction Control System (TCS) available on higher trims

Airbags:

Driver and front passenger airbags standard, side airbags available on higher trims

Body Construction:

Reinforced body-on-frame construction for structural integrity and off-road durability

💡 Technology Features

Audio System:

Factory AM/FM/Cassette/CD player with varying numbers of speakers depending on trim level.

Cruise Control:

Available on higher trim levels.

Navigation:

Rarely factory-equipped on models within this year range; aftermarket units were common.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions and oil type (refer to manual for specifics)

Timing Belt Replacement:

On 6G7 engines, typically every 60,000-100,000 miles (96,000-160,000 km). Critical component for preventing catastrophic engine damage.

Engine Oil Type:

API SG/SH/SJ or higher, SAE 10W-30 or 10W-40 recommended for most climates (check manual for exact viscosity and capacity per engine)

Coolant Type:

Ethylene glycol-based coolant, typically a green or red OAT/HOAT coolant. Capacity around 9-11 liters.

Transmission Fluid Type Auto:

Dexron III or equivalent automatic transmission fluid (ATF). Capacity around 3-4 liters for a drain and fill.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid

Common Problems 1:

Head gasket leaks (especially on earlier 6G74 engines), transfer case actuator failures (Super Select 4WD-i), radiator leaks, catalytic converter issues, ignition coil failures.

Common Problems 2:

Rust in common areas (wheel arches, rocker panels, chassis frame), suspension component wear (bushings, ball joints), intermittent electrical gremlins due to age.

📚 Vehicle History

Mitsubishi Offroad Legacy:

Mitsubishi has a long history of producing capable off-road vehicles, including the predecessor Pajero which dominated the Paris-Dakar Rally.

Third Gen Launch:

Introduced in 1991 globally, the third generation (1996-2001 update) featured significant updates to styling, interior, and powertrain options, including the introduction of independent rear suspension on many models.

Manufacturing Locations:

Japan (Okazaki Plant), Australia, Brazil, Egypt, South Africa, Philippines

🏆 Awards & Recognition

Paris Dakar Heritage:

The Pajero nameplate is synonymous with success in the Paris-Dakar Rally, with multiple outright wins reinforcing its off-road credentials.

Offroad Capability Reviews:

Consistently praised by automotive journalists and off-road enthusiasts for its robust chassis, effective 4WD system, and suspension articulation.