Positioning:
The Mitsubishi Pajero (also known as Montero in some markets) of this era was a highly capable and popular SUV, renowned for its off-road prowess and rugged durability. It competed with vehicles like the Toyota Land Cruiser, Nissan Patrol, and Jeep Cherokee.
Competitors:
Toyota Land Cruiser (80 Series), Nissan Patrol (Y60), Jeep Grand Cherokee (ZJ), Land Rover Discovery.
Vehicle Highlights:
Robust body-on-frame construction, advanced Super Select II 4WD system (or similar), powerful V6 engine options, comfortable interior for its class, excellent off-road articulation and capability.
Value:
This comprehensive service manual provides dealership-level technical information, enabling owners and mechanics to perform all necessary maintenance, diagnostics, and repairs, saving significant costs compared to authorized service centers.
Engine:
Comprehensive engine mechanicals, fuel system, ignition system, cooling system, lubrication system, emission control systems, engine control systems (ECU/ECM), forced induction (if applicable)
Transmission:
Manual and Automatic Transmissions, including torque converter clutch, valve body, control systems, fluid specifications, and overhaul procedures
Drivetrain:
Front and Rear Drive Shafts, Front and Rear Axle Hubs, Differential Cases, Transfer Case, Wheel Hubs, Drive Belts, Drive Axles
Suspension Steering:
Front and Rear Suspension Systems (including independent front suspension on many models), Suspension Arms, Stabilizer Bars, Shock Absorbers, Springs, Steering System, Power Steering, Steering Columns, Steering Sensors
Brakes:
Brake System diagnostics and repair, Brake Master Cylinder, Brake Booster, Brake Actuators, Brake Fluids, Brake Pads/Shoes, Disc/Drum Brakes, Parking Brake System, Skid Control System (ABS)
Electrical Electronics:
Complete Wiring Diagrams, Wire Harness Repair, Lighting System, Combination Meter, Instrument Panel, Charging System, Starting System, Ignition System, Power Mirror Control, Power Window Control, Power Door Lock Control, Audio & Visual Systems, Antenna Systems, Horn, Wiper & Washer System, Defogger Systems
Body Chassis:
Body Repair, Exterior Moldings, Bumpers, Doors, Hood, Tailgate/Back Door, Glass Systems (Windshield, Side Windows, Rear Window), Sun Roof System, Interior Trim, Seats, Seat Belts, Airbag Systems (SRS, Supplemental Restraint System)
Wheels Tires:
Wheel and Tire System, including wheel alignment specifications, tire pressure recommendations, and procedures for tire and wheel replacement.
Lighting System:
Headlamps, tail lamps, combination lamps, interior lighting, and related switches and wiring.
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication, tune-ups, belt replacements, ignition system maintenance
Diagnostics Troubleshooting:
Extensive troubleshooting guides, diagnostic procedures for all major systems, electrical circuit diagnosis, engine performance issues, transmission problems, brake system faults
Repair Rebuild:
Detailed step-by-step repair instructions for component removal, installation, and overhaul (e.g., engine rebuild, transmission overhaul, suspension component replacement, brake caliper repair, body panel replacement)
Specifications:
Torque specifications, clearances, fluid capacities, electrical specifications, emissions data, dimensional data
Bodywork Repair:
Procedures for body panel removal and installation, glass replacement, interior trim repair, and basic bodywork diagnosis.
Air Conditioning HVAC:
Service and repair for the air conditioning system, heater, and ventilation components, including refrigerant handling procedures and wiring diagrams for climate control modules.
Fuel System Diagnostics:
Diagnosis and repair of fuel injectors, fuel pump, fuel filter, fuel pressure regulator, and emission control systems related to fuel delivery.
Exhaust System Repair:
Information on exhaust pipe, muffler, and catalytic converter inspection, removal, and replacement.
Seat Belt Airbag System:
Maintenance and diagnostics for seat belt assemblies, seat belt warning systems, and Supplemental Restraint System (SRS) components, including airbag sensor replacement and module diagnosis.
Depth:
Expert level, covering everything from routine maintenance to complete engine and transmission rebuilds, including detailed wiring diagrams and diagnostic fault codes (DTCs)
Engine Code Common:
6G72 (3.0L SOHC V6), 6G74 (3.5L SOHC/DOHC V6), 4D56 (2.5L I4 Diesel Turbo), 4M40 (2.8L I4 Diesel Turbo)
Displacement Common:
2972 cc (3.0L), 3497 cc (3.5L), 2477 cc (2.5L Diesel), 2835 cc (2.8L Diesel)
Horsepower Range:
Approximately 145-180 hp for 3.0L gasoline, 190-230 hp for 3.5L gasoline, 95-125 hp for diesel variants (figures vary by specific engine variant and market)
Torque Range:
Approximately 170-200 lb-ft for 3.0L gasoline, 220-250 lb-ft for 3.5L gasoline, 175-200 lb-ft for diesel variants (figures vary by specific engine variant and market)
Fuel Delivery:
Multi-point Fuel Injection (MPI) for gasoline engines, Direct Injection (DI) for some diesel engines, Diesel Injection Pump for others
Coolant Type:
Typically a 50/50 mixture of ethylene glycol antifreeze and deionized water. Specific Mitsubishi coolant recommendations may vary.
Oil Type Common Gasoline:
API SG or higher, SAE 10W-30 or 10W-40 (check manual for precise viscosity based on ambient temperature)
Oil Capacity Common 3.0L:
Approximately 4.5 liters (4.8 US quarts) with filter change
Manual Transmission:
Available on many models, typically 5-speed manual transmission (e.g., KM145, V5M31)
Automatic Transmission:
Available on many models, typically 4-speed automatic transmission (e.g., V4A51, W4A51)
Transfer Case:
Super Select II 4WD system (on higher trims/models), allowing on-the-fly switching between 2WD, 4WD Full-Time, 4WD Part-Time with Locked Center Differential, and Low Range. Older models might have simpler part-time 4WD systems.
Automatic Transmission Fluid Atf:
Diamond SP-II, SP-III or equivalent (check manual for exact specification)
Manual Transmission Fluid Mtf:
API GL-3 or GL-4, SAE 75W-90 gear oil (check manual for exact specification)
Oil Change Interval:
Typically every 5,000 miles (8,000 km) or 6 months, whichever comes first. Always consult the manual for specific intervals.
Air Filter Replacement:
Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).
Spark Plug Replacement Gasoline:
Approximately every 30,000-60,000 miles (48,000-96,000 km), depending on plug type (copper vs. iridium/platinum).
Timing Belt Replacement V6 Engines:
Crucial: Many 6G7x V6 engines use a timing belt. Replacement intervals are typically around 60,000 miles (96,000 km) or 4-5 years. Failure can cause catastrophic engine damage. The manual will specify exact intervals and procedures.
Coolant Capacity:
Approx. 7.0-8.5 liters (7.4-9.0 US quarts), depending on engine and radiator size.
Brake Fluid:
DOT 3 or DOT 4 brake fluid (check manual for specific recommendation)
Common Wear Items:
CV joints, suspension bushings, exhaust systems, cooling system components (radiator, hoses), timing belts (on V6 engines), certain electrical components can be prone to wear with age.
Body Corrosion:
As with many vehicles of this age, rust and corrosion can be an issue, particularly in regions with harsh winters or coastal environments. Frame and body mounts should be inspected.
