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Mitsubishi Pajero 2000-2002 Full Service Repair Manual

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This manual covers the Pajero, specifically the Third Generation (V60/V70 Series) produced for the 2000, 2001, and 2002 model years. Renowned for its robust off-road capabilities and comfortable ride, the...
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Mitsubishi Pajero 2000-2002 Full Service Repair ManualMitsubishi Pajero 2000-2002 Full Service Repair ManualMitsubishi Pajero 2000-2002 Full Service Repair ManualMitsubishi Pajero 2000-2002 Full Service Repair Manual
This manual covers the Pajero, specifically the Third Generation (V60/V70 Series) produced for the 2000, 2001, and 2002 model years. Renowned for its robust off-road capabilities and comfortable ride, the Pajero is a full-size SUV that excels in challenging terrains thanks to its advanced four-wheel-drive systems, including the Super Select 4WD II. Available in various configurations, including short and long-wheelbase options, this generation of Pajero is powered by a range of engines, from efficient V6 gasoline units to capable turbo-diesel variants. Its strong chassis, reliable performance, and a legacy of off-road prowess make it a respected choice in its segment. This comprehensive service repair manual, written in English, provides over 1000 pages of detailed information for maintaining and repairing your Pajero. It covers all essential systems, including engine, transmission, drivetrain, suspension, brakes, steering, and electrical systems, with specific attention to the Super Select 4WD II system. The manual includes in-depth procedures for routine maintenance, troubleshooting common issues, component repair, and even full rebuilds for major mechanical assemblies. Technical specifications, torque values, fluid requirements, and wiring diagrams are also provided, making this an indispensable resource for owners, mechanics, and technicians to ensure the optimal performance and longevity of their vehicle.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Pajero
Generation Code:
Third Generation (V60/V70 Series)
Codes
Platform Code:
V60/V70
👋 Introduction
Market Position
Segment:
Full-size SUV, known for off-road capability and ruggedness.
Key Competitors:
Toyota Land Cruiser, Nissan Patrol, Land Rover Discovery, Jeep Grand Cherokee.
Competitive Analysis
Strengths:
Renowned off-road prowess, robust chassis, comfortable ride, strong engine options, good value proposition.
Key Features
Off Road Systems:
Advanced four-wheel-drive systems (Super Select 4WD II), available locking differentials, robust suspension, high ground clearance.
Body Styles:
Available in short-wheelbase (2-door) and long-wheelbase (3-door or 5-door) configurations.
📋 Manual Details
Coverage Areas
Covered Years:
2000, 2001, 2002
Regions Covered:
Global markets, with specific attention to common configurations
Page Count
Estimated Pages:
1000+
Manual Type
Type:
Full Service Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnosis, repair, and overhaul procedures for all applicable engine variants (e.g., 3.0L V6 SOHC, 3.5L V6 SOHC/DOHC, 2.8L Diesel).
Transmission:
Automatic and Manual transmission repair, overhaul, clutch service, fluid specifications, and diagnosis.
Drivetrain:
Four-Wheel Drive (4WD) system operation, Super Select 4WD II (SS4-II) system, differential overhaul, driveshafts, CV joints, and transfer case service.
Suspension:
Independent front suspension (double wishbone), multi-link rear suspension, shock absorbers, springs, bushings, wheel alignment specifications.
Brakes:
Front and rear brake systems (disc/drum configurations), ABS operation, brake fluid specifications, caliper and rotor service, parking brake.
Steering:
Power steering system diagnosis and repair, steering rack and pump service, steering column.
Electrical System:
Full wiring diagrams, fuse and relay locations, battery, charging system (alternator), starting system, lighting, accessories, ECUs, and diagnostic trouble codes (DTCs).
Climate Control:
Air conditioning system (HVAC) service, refrigerant handling, heater core, blower motor, climate control module diagnosis.
Fuel System:
Fuel injection system components (injectors, fuel pump, pressure regulator), fuel tank, lines, EVAP system.
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, exhaust pipes, oxygen sensors.
Body And Frame:
Body panel removal/installation, door mechanisms, glass, interior trim, chassis diagnostics, rust repair.
Safety Systems:
Airbag system diagnosis and service, seat belt mechanisms.
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt replacement, brake fluid flush, coolant flush.
Troubleshooting:
Diagnostic charts, symptom-to-cause analysis, common problem identification and solutions.
Repair:
Component replacement and repair for all major vehicle systems.
Rebuild:
Detailed instructions for engine, transmission, and differential rebuilds.
Diagnostics:
On-board diagnostics (OBD-II) procedures, reading and clearing DTCs, sensor testing.
Specifications:
Torque specifications, fluid capacities, tolerances, diagnostic values, alignment settings.
Technical Depth
Depth:
Comprehensive, from basic preventative maintenance to advanced engine and transmission rebuilds. Suitable for professional mechanics and advanced DIY enthusiasts.
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Searchability:
Searchable text for quick information retrieval.
Print Quality
Quality:
High-resolution images, diagrams, and text, suitable for printing.
Binding Type
Binding:
N/A (Digital PDF Download)
Paper Type
Paper:
N/A (Digital PDF Download)
⚙️ Engine Specifications
Primary Engine
Engine Code Common 1:
6G72 (3.0L V6 SOHC MPI)
Engine Code Common 2:
6G75 (3.8L V6 SOHC MPI)
Engine Code Diesel:
4M41 (3.2L DI-D DOHC Intercooled Turbo Diesel)
Performance 3 0L V6
Displacement Hp:
177 hp @ 5000 rpm (approx.)
Displacement Torque:
255 Nm @ 4000 rpm (approx.)
Performance 3 8L V6
Displacement Hp:
215 hp @ 5000 rpm (approx.)
Displacement Torque:
333 Nm @ 3750 rpm (approx.)
Performance 3 2L Di-D
Displacement Hp:
165 hp @ 4000 rpm (approx.)
Displacement Torque:
373 Nm @ 2000 rpm (approx.)
Fuel System
Fuel Type Gasoline:
Unleaded gasoline
Fuel Type Diesel:
Diesel fuel
Injection Type:
Multi-point Fuel Injection (MPI) for gasoline, Direct Injection (DI) for diesel.
🔧 Transmission
Standard
Transmission Type Common:
4-speed Automatic Transmission
Optional
Transmission Type Manual:
5-speed Manual Transmission
Features
4Wd System:
Super Select 4WD II (SS4-II) system with electronic control and differential lock capability.
Fluid Specifications
Automatic Transmission Fluid:
Refer to manual for specific ATF type (e.g., SPIII or equivalent).
Manual Transmission Fluid:
Refer to manual for specific MTF type (e.g., 75W-90 GL-4/GL-5).
📐 Dimensions
Exterior Lwb
Length:
Approx. 4,700 - 4,850 mm (depending on market/body style)
Width:
Approx. 1,850 - 1,885 mm
Height:
Approx. 1,850 - 1,895 mm
Exterior Swb
Length:
Approx. 4,300 - 4,370 mm
Wheelbase:
Approx. 2,780 mm (LWB) / 2,450 mm (SWB)
Weights
Curb Weight:
Approx. 1,800 - 2,200 kg (depending on configuration)
Towing Capacity:
Refer to vehicle placard/manual, typically around 2,500 kg (braked).
🛡️ Safety Features
Ratings
Crash Test Results:
Varied by region and testing organization. Generally performed well for its era, though specific ratings should be verified.
Active Features
ABS:
Anti-lock Braking System (ABS) standard on most models.
Traction Control:
Traction Control System (TCS) available on higher trims/later models.
Passive Features
Airbags:
Front airbags standard, side airbags available on select models.
Seat Belts:
Three-point seat belts with pre-tensioners for front occupants.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD stereo system, optional premium audio by Rockford Fosgate on some trims.
Navigation:
Optional factory GPS navigation system available on higher-end models.
Driver Assistance
Cruise Control:
Standard cruise control on most models.
Connectivity
Auxiliary Input:
Rarely standard, typically requires aftermarket installation for audio input.
🔧 Maintenance
Service Intervals Oil
Engine Oil Change:
Every 5,000 miles (8,000 km) or 6 months, whichever comes first (or refer to manual for specific oil type/conditions).
Service Intervals Filters
Oil Filter Replacement:
With every oil change.
Air Filter Replacement:
Every 15,000 miles (24,000 km) or as needed based on inspection.
Service Intervals Fluids
Coolant Flush:
Every 30,000 miles (48,000 km) or 2 years.
Brake Fluid Flush:
Every 24,000 miles (38,000 km) or 2 years.
Fluid Specifications
Engine Oil Spec:
API SJ/SL or ACEA A2/A3, SAE 10W-30 or 5W-30 (check manual for exact requirements based on climate).
Coolant Spec:
Ethylene glycol based coolant, typically a 50/50 mix with distilled water (e.g., Mitsubishi DiaQueen Super Long Life Coolant).
Known Issues
Common Issue 1:
Rear differential whine or bearing noise, especially on higher mileage vehicles.
Common Issue 2:
Suspension component wear (bushings, ball joints) due to off-road use or age.
Common Issue 3:
Power steering leaks or pump noise.
Common Issue 4:
Cracked exhaust manifolds or catalytic converter issues on diesel models.
Common Issue 5:
Interior trim rattles and wear.
📚 Vehicle History
Brand Heritage
Mitsubishi SUV Legacy:
Mitsubishi has a long history of producing capable off-road vehicles, dating back to models like the J-series Jeeps (licensed production) and the original Pajero (1970s).
Model Evolution
Third Generation Debut:
Introduced in 1999 (for the 2000 model year), featuring a monocoque body-on-frame construction, a significant departure from previous generations, enhancing on-road manners and safety.
Production
Manufacturing Locations:
Primarily Japan (Okazaki Plant), with some assembly in other international locations.
Production Years For This Gen:
1999-2006
🏆 Awards & Recognition
Recognitions
Off Road Awards:
Pajero consistently ranked highly in off-road capability tests and received accolades in various international markets for its ruggedness.
Ratings
Reliability Rankings:
Generally considered reliable, though specific model year reliability can vary. This manual helps address any potential issues.
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