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Mitsubishi Pajero 2000-2002 Workshop Service Manual Repair

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The Mitsubishi Pajero, specifically the Third Generation (V60/V70) models produced between 2000 and 2002, represents a robust and capable mid-size SUV renowned for its exceptional off-road prowess and durable construction....
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Mitsubishi Pajero 2000-2002 Workshop Service Manual RepairMitsubishi Pajero 2000-2002 Workshop Service Manual RepairMitsubishi Pajero 2000-2002 Workshop Service Manual RepairMitsubishi Pajero 2000-2002 Workshop Service Manual Repair
The Mitsubishi Pajero, specifically the Third Generation (V60/V70) models produced between 2000 and 2002, represents a robust and capable mid-size SUV renowned for its exceptional off-road prowess and durable construction. Building on Mitsubishi's extensive legacy in off-road competition, this generation introduced an integrated body-frame chassis, enhancing on-road comfort and handling without compromising its legendary all-terrain performance. Available with a choice of potent gasoline V6 engines or an efficient turbo-diesel, and featuring the advanced Super Select 4WD II system, the Pajero was engineered for versatility, catering to both demanding off-road expeditions and comfortable daily driving. This comprehensive workshop service manual provides essential guidance for the maintenance, diagnosis, and repair of the Mitsubishi Pajero from 2000-2002. It covers all major systems, including the powertrain, transmission, drivetrain, suspension, brakes, steering, and electrical systems, offering detailed procedures for routine maintenance, component replacement, and complex overhauls. With step-by-step instructions, diagnostic flowcharts, and technical specifications, this manual serves as an indispensable resource for owners, technicians, and mechanics aiming to preserve the integrity and performance of their Pajero.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Pajero
Generation:
Third Generation (V60/V70)
Codes
Chassis Codes:
V63W, V64W, V65W, V68W, V73W, V74W, V75W, V78W
👋 Introduction
Market Position
Segment:
Mid-size SUV / Off-Road Vehicle
Competitive Analysis
Key Competitors:
Toyota Land Cruiser Prado, Nissan Patrol, Ford Explorer, Jeep Grand Cherokee, Land Rover Discovery.
Key Features
Vehicle Strengths:
Renowned off-road capability, robust chassis, versatile interior, comfortable ride for its class, strong durability reputation.
Manual Value:
Essential for maintaining and repairing the vehicle's complex systems, including the advanced 4WD and drivetrain components.
📋 Manual Details
Coverage Areas
Covered Years:
2000, 2001, 2002
Page Count
Estimated Page Count:
Over 1500 pages (typical for comprehensive workshop manuals of this era)
Manual Type
Type:
Workshop Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (including disassembly, assembly, diagnosis, timing), Fuel System, Exhaust System, Cooling System, Lubrication System, Emission Control Systems.
Transmission:
Automatic Transmission (AT), Manual Transmission (MT) - Diagnosis, Repair, Overhaul, Clutch System.
Drivetrain:
4WD System (Super Select 4WD II), Differentials (Front, Rear, Center), Drive Shafts, Axles, Hubs.
Suspension:
Front Suspension (Independent), Rear Suspension (Multi-link), Shock Absorbers, Springs, Bushings, Control Arms, Sway Bars.
Brakes:
Front & Rear Brakes (Disc), ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution), Brake Lines, Master Cylinder, Calipers, Rotors, Pads.
Steering:
Power Steering System, Steering Gearbox, Tie Rods, Power Steering Pump, Fluid.
Electrical System:
Battery, Alternator, Starter Motor, Ignition System, Lighting System (Headlights, Taillights, Interior), Fuses, Relays, Wiring Diagrams, Power Windows, Power Locks, Sunroof.
Climate Control:
Air Conditioning (AC) System, Heater Core, Blower Motor, Refrigerant, Diagnosis, Repair.
Body & Chassis:
Body Panels, Doors, Hood, Tailgate, Bumpers, Glass, Interior Trim, Frame Repair (if applicable), Rust Prevention.
Diagnostics & Troubleshooting:
Fault codes, diagnostic procedures, symptom-based troubleshooting guides.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement.
Component Replacement:
Detailed instructions for replacing specific parts like alternators, starters, water pumps, fuel pumps, sensors, brake pads, etc.
Engine Overhaul:
Complete engine rebuild procedures, including piston ring replacement, bearing replacement, cylinder head gasket replacement, timing belt/chain service.
Transmission Repair:
Internal transmission repairs, clutch replacement, torque converter service.
Brake System Service:
Brake pad and rotor replacement, caliper service, bleeding brake lines, ABS component diagnosis.
Electrical Diagnosis:
Troubleshooting electrical issues using wiring diagrams, component testing procedures.
Suspension & Steering Repair:
Replacement of ball joints, tie rod ends, bushings, shock absorbers, power steering pump.
Body & Interior Repair:
Panel alignment, door mechanism repair, glass replacement, interior trim removal and installation.
Technical Depth
Depth:
Comprehensive: Covers everything from basic preventative maintenance to complex component overhauls and advanced diagnostics.
Detail Level:
Includes step-by-step instructions, torque specifications, diagnostic flowcharts, and exploded diagrams.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Likely text-searchable (depending on original scan quality).
Print Quality
Quality:
Varies with original source, but digital PDFs typically offer clear text and diagrams.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code Gasoline:
6G72 (3.0L V6 SOHC/DOHC), 6G74 (3.5L V6 SOHC/DOHC)
Engine Code Diesel:
4M41 (3.2L Intercooled Turbo Diesel DI-D)
Performance
3.0L V6 (6G72) Horsepower:
Approx. 177-189 HP (depending on DOHC vs SOHC and market)
3.5L V6 (6G74) Horsepower:
Approx. 194-217 HP (depending on DOHC vs SOHC and market)
3.2L Turbo Diesel (4M41) Horsepower:
Approx. 175 HP
3.0L V6 Torque:
Approx. 245-260 Nm
3.5L V6 Torque:
Approx. 302-333 Nm
3.2L Turbo Diesel Torque:
Approx. 370 Nm
Fuel System
Gasoline Fuel Delivery:
Multi-Point Fuel Injection (MPI)
Diesel Fuel Delivery:
Direct Injection (DI) with Common Rail (CR) and Turbocharging
🔧 Transmission
Standard
Standard Transmission:
Manual Transmission (5-speed)
Optional
Optional Transmission:
Automatic Transmission (4-speed INVECS-II)
Features
Drivetrain Control:
Super Select 4WD II system allowing on-the-fly selection between 2WD, 4WD Full-time, 4WD High-lock, and 4WD Low-lock.
📐 Dimensions
Exterior
Wheelbase:
2780 mm (109.4 inches)
Length:
4730 mm (186.2 inches)
Width:
1865 mm (73.4 inches)
Height:
1870 mm (73.6 inches) (may vary slightly with roof rails)
Weights
Curb Weight:
Approx. 2000-2200 kg (depending on engine and trim)
🛡️ Safety Features
Ratings
Crash Test Ratings:
NHTSA: Typically 4-star frontal impact (varies by specific year and configuration, often with side airbags).
Active Features
Active Safety:
ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution), Traction Control System (TCL) on some models.
Passive Features
Passive Safety:
Front Airbags, Optional Side Airbags, Seatbelt Pretensioners, Reinforced Body Structure.
💡 Technology Features
Infotainment
Infotainment System:
Factory fitted audio systems typically included AM/FM radio, CD player, and cassette player. Speaker configurations varied by trim level. Navigation systems were rare and aftermarket additions were common.
Driver Assistance
Driver Assistance:
Limited by modern standards. ABS and EBD were the primary active safety systems. Cruise control was often standard or optional on higher trims.
Connectivity
Connectivity:
No integrated Bluetooth or USB connectivity from the factory. Auxiliary input for audio devices was sometimes available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles or 6 months (whichever comes first) for gasoline engines; 5,000 miles or 6 months for diesel engines, or as specified in the owner's manual.
Timing Belt Replacement:
For gasoline 6G7 series engines, typically every 90,000 - 105,000 miles or 7 years. The 4M41 diesel engine uses a timing chain. (Crucial check in the manual).
Fluid Specifications
Engine Oil Gasoline:
API SG or higher, SAE 10W-30 or 10W-40 (check manual for exact viscosity based on climate).
Engine Oil Diesel:
API CF-4 or CI-4, SAE 15W-40 (check manual for exact viscosity).
Coolant:
Mitsubishi Genuine Long Life Antifreeze Coolant (or equivalent ethylene glycol-based coolant, typically red or green).
Transmission Fluid At:
Mitsubishi Genuine DiaQueen ATF-SP II M or equivalent Dexron III/Mercon compatible ATF.
Transmission Fluid Mt:
API GL-4, SAE 75W-85 or 75W-90.
Brake Fluid:
DOT 3 or DOT 4.
Power Steering Fluid:
Dexron II or III compatible ATF.
Known Issues
Common Problems Gasoline:
Rear main seal leaks, EGR valve issues, ignition coil failures, minor cooling system leaks, potential for oil consumption in higher mileage engines.
Common Problems Diesel:
Turbocharger issues (wear on wastegate actuator), injector pump calibration, glow plug system faults, potential for carbon build-up if not maintained.
Common Problems General:
desgaste de rodamientos de rueda (wheel bearing wear), suspension bushings deterioration, minor electrical gremlins, fuel pump reliability can be a concern on older units, tailgate struts weakening.
📚 Vehicle History
Brand Heritage
Mitsubishi 4X4 Legacy:
Mitsubishi has a long and storied history in off-road vehicles, dating back to the original Pajero's introduction in 1982. The Pajero (also known as Montero in North America and Pajero Sport in some markets) is synonymous with ruggedness and off-road prowess.
Model Evolution
Third Generation Debut:
The third generation, introduced for the 1999/2000 model year, marked a significant departure with a new unibody construction (integrated body frame) replacing the traditional body-on-frame chassis. This improved on-road handling and ride comfort while retaining excellent off-road capability.
Production
Production Period:
2000-2002 falls within the initial production run of the third generation.
Manufacturing Locations:
Primarily Japan (Mizushima Plant).
🏆 Awards & Recognition
Recognitions
Off Road Awards:
The Pajero platform consistently received accolades and proven performance in major off-road rallies like the Dakar Rally, reinforcing its off-road credibility.
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