🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero

Generation:

Third Generation (1999-2006)

Production Years Covered By Manual:

2000, 2001, 2002

Chassis Codes:

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

👋 Introduction

Market Position:

The Mitsubishi Pajero (also known as Montero in some markets) is a well-established, robust, and capable full-size SUV, renowned for its off-road prowess and durability. This generation represented a significant evolution with a more modern design and improved on-road manners while retaining its legendary go-anywhere capability.

Competitive Analysis:

Competed against vehicles like the Toyota Land Cruiser Prado, Nissan Patrol, Land Rover Discovery, and Jeep Grand Cherokee. The Pajero often distinguished itself with its Super Select II 4WD system and a balance of comfort, capability, and value.

Key Features Of The Generation:

Integrated body-on-frame construction, independent front suspension (double wishbone), coil-sprung multi-link rear suspension, advanced 4WD systems (Super Select II), potent V6 engine options, available electronic features, improved interior refinement.

📋 Manual Details

Coverage Areas:

North America, Europe, Asia, Australia

Page Count:

Estimated 2000+ pages (typical for a comprehensive workshop manual)

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Systems Covered:

Engine Mechanical, Engine Management (ECU), Fuel System, Ignition System, Cooling System, Exhaust System, Lubrication System, Intake System, Transmission (Automatic & Manual), Drivetrain (4WD System, Differentials), Brakes (ABS, EBD), Steering, Suspension (Front & Rear), Electrical System (Wiring Diagrams, Components), Body & Trim, HVAC (Heating, Ventilation, Air Conditioning), SRS (Airbag) System, Cruise Control, Emission Control Systems, Diagnostic Trouble Codes (DTCs)

Procedures Included:

Routine Maintenance, Scheduled Service, Engine Overhaul, Transmission Rebuild, Brake System Repair, Suspension Overhaul, Steering System Repair, Electrical Diagnostics and Repair, HVAC System Servicing, Body Panel Replacement, Interior Trim Removal and Installation, Drivetrain Component Servicing, Diagnostic Procedures, Troubleshooting Guides, Component Removal and Installation (detailed step-by-step), Torque Specifications, Lubricant and Fluid Specifications

Technical Depth:

Comprehensive: Covers everything from basic fluid changes and inspections to complete engine and transmission rebuilds, advanced electrical diagnostics, and chassis component overhauls. Includes detailed explanations of system operation and troubleshooting techniques.

Diagnostic Trouble Codes:

Includes sections detailing common Diagnostic Trouble Codes (DTCs) and their meanings, along with troubleshooting procedures to identify and resolve issues based on these codes.

Wiring Diagrams:

Extensive and detailed electrical wiring diagrams for all major systems, including engine control, lighting, power windows, audio, HVAC, airbags, and more. Essential for electrical fault finding.

Torque Specifications:

Precise torque values for all critical fasteners throughout the vehicle, ensuring correct assembly and preventing damage or component failure.

Troubleshooting Guides:

Systematic troubleshooting flowcharts and diagnostic procedures for common and uncommon problems, aiding technicians in efficient problem resolution.

Body And Trim Details:

Includes procedures for interior panel removal, exterior trim, bumpers, doors, windows, sunroofs, and associated hardware. Also covers body repair techniques and common rust prevention/treatment areas.

Climate Control HVAC:

Detailed diagnostics and repair procedures for the heating, ventilation, and air conditioning (HVAC) system, including refrigerant handling, compressor, condenser, evaporator, blower motor, and climate control modules.

Suspension Alignment:

Specifications and procedures for wheel alignment (camber, caster, toe) for both front and rear suspension systems.

Brake System Components:

Covers disc brake systems (front and rear), including caliper overhaul, pad and rotor replacement, brake fluid service, parking brake mechanism, and ABS/EBD system components.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High-resolution, searchable text and clear, legible diagrams/illustrations.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Completeness:

This is a comprehensive workshop manual, designed to cover all repair and maintenance aspects for the specified model years and variants. It is not a condensed or simplified guide.

Searchable Text:

Yes, the PDF format is expected to have searchable text, allowing users to quickly find specific information by keyword.

⚙️ Engine Specifications

Primary Engine Options:

3.5L V6 SOHC (6G74), 3.8L V6 SOHC (6G75 - later in the generation), 3.2L 4-cylinder Intercooled Turbo Diesel (4M41)

Performance 3.5L V6:

Approx. 195-215 horsepower, Approx. 220-240 lb-ft torque (specifications vary slightly by market and year)

Performance 3.2L Diesel:

Approx. 163-175 horsepower, Approx. 270-295 lb-ft torque (specifications vary slightly by market and year)

Fuel System:

Multi-Point Fuel Injection (MPI) for gasoline engines; Direct Injection, Common Rail for diesel engine.

Engine Management:

Electronic engine control unit (ECU) with integrated ignition and fuel management.

Engine Cooling:

Pressurized liquid cooling system with thermostatically controlled fan.

Displacement 3.5L:

3497 cc

Displacement 3.2L Diesel:

3200 cc

Engine Code Gasoline:

6G74 (3.5L)

Engine Code Diesel:

4M41 (3.2L DI-D)

🔧 Transmission

Standard Transmission:

4-speed Automatic Transmission (likely INVECS-II)

Optional Transmission:

5-speed Manual Transmission (less common in some markets for this generation)

Transmission Features:

Electronic control for automatic, 'Sport' mode, 'Winter' mode, full-time 4WD with locking center differential (Super Select II).

Transmission Fluid Type:

Likely DiaQueen ATF SP-II or equivalent (refer to specific model year/engine for exact spec)

Transfer Case System:

Super Select II 4WD: Offers selectable 2H, 4H, 4HLC (4WD High with Locked Center Diff), 4LLC (4WD Low with Locked Center Diff). This is a highly capable and versatile system.

📐 Dimensions

Exterior Dimensions Approx:

Length: 4700-4810 mm, Width: 1870-1890 mm, Height: 1850-1875 mm (short/long wheelbase variants exist)

Wheelbase Approx:

2780 mm (long wheelbase)

Ground Clearance Approx:

210-220 mm

Curb Weight Approx:

1900-2100 kg (depending on engine and configuration)

Cargo Volume Approx:

Variable depending on seating configuration, but substantial for its class.

Wheel Bolt Pattern:

6 x 139.7 mm (common for Pajero/Montero)

Wheel Offset Typical:

+35 to +45 mm

🛡️ Safety Features

Ratings:

Variable by market and testing body; often performed well in its class for its era.

Active Features:

ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution), Traction Control (often optional/standard on higher trims), Active Stability Control (ASC - often optional/standard on higher trims).

Passive Features:

Front airbags (driver and passenger), side airbags (optional), seatbelt pretensioners, reinforced body structure, crumple zones.

Child Seat Anchors:

ISOFIX/LATCH compatible points typically present in rear seats.

Rollover Protection:

Enhanced chassis rigidity and designed safety structures to mitigate risks associated with an SUV's higher center of gravity. Specific rollover mitigation systems were less common in this era.

💡 Technology Features

Infotainment:

Factory-installed premium audio systems, CD players, cassette players (early models). Navigation systems available on higher trims. Basic climate control or automatic climate control systems.

Driver Assistance:

ABS, EBD, Traction Control, Active Stability Control (ASC). Cruise control.

Connectivity:

Limited by era; primarily analog connectivity for audio. Pre-wiring for accessories might be present.

Lighting:

Halogen headlights, fog lamps (optional), rear fog lamps, various interior lighting.

🔧 Maintenance

Service Intervals Typical:

Oil and filter change: every 7,500 - 10,000 miles or 6-12 months. Air filter: every 30,000 miles. Spark plugs: every 60,000-100,000 miles (depending on type). Coolant flush: every 30,000-50,000 miles. Transmission fluid: every 30,000-60,000 miles. Timing belt (if applicable for specific engine): every 60,000-90,000 miles (critical for 6G7x engines).

Fluid Specifications Engine Oil:

SAE 10W-30 or 5W-30 API SJ or higher for gasoline engines. SAE 5W-30 or 5W-40 Low SAPS for diesel engines (refer to manual for exact spec).

Fluid Specifications Coolant:

Ethylene glycol-based coolant with anti-corrosion inhibitors. Typically pink or red dyed. Capacity around 8-10 liters.

Fluid Specifications Brake Fluid:

DOT 3 or DOT 4.

Known Issues Common:

Rear differential whine (especially on earlier models), potential for ABS sensor failures, occasional issues with the multi-mode 4WD selector switch, exhaust manifold cracks (less common), timing belt replacement criticality on V6 engines, intake manifold gasket leaks, glow plug issues on diesel models.

Filter Part Numbers Oil:

Examples: MD135730, MR552956 (exact number varies by engine and supplier; manual will list correct OEM or equivalent).

Tire Size Typical:

265/70R16, 265/65R17, 275/60R18 (depending on trim and wheel size).

Fluid Capacities Engine Oil:

Approx. 4.5 - 5.5 liters (V6 gasoline engines) depending on filter size. Diesel capacity may vary slightly. Consult manual for precise figures.

Fluid Capacities Transmission Auto:

Approx. 7.5 - 8.5 liters (for a drain and fill, total capacity higher). Consult manual.

Fluid Capacities Transfer Case:

Approx. 1.5 - 2.0 liters. Consult manual.

Fluid Capacities Front Differential:

Approx. 1.3 - 1.5 liters. Consult manual.

Fluid Capacities Rear Differential:

Approx. 1.3 - 1.5 liters. Consult manual.

📚 Vehicle History

Brand Heritage:

Mitsubishi has a long history of producing robust off-road vehicles, dating back to models like the original Pajero (1982) which helped define the modern SUV segment. The brand is associated with durability and capability.

Model Evolution:

The third generation (1999-2006) moved from a body-on-frame construction (with integrated ladder frame) to a monocoque body with a built-in ladder frame, offering improved rigidity, ride comfort, and safety. It also featured a significant redesign, more advanced suspension, and updated powertrains.

Production Locations:

Primarily manufactured in Japan (Okazaki Plant), with some assembly occurring in other global locations depending on market.

Notable Variants:

Short-wheelbase (2-door) and Long-wheelbase (5-door) versions, various trim levels (e.g., GLS, Exceed, VR-X) with differing features and engine options.

🏆 Awards & Recognition

Recognitions:

The Pajero range has a history of awards, often recognized for its off-road capability and durability in various international tests and publications, though specific awards for the 2000-2002 models would need detailed research by year and market.

Ratings:

Generally well-regarded for its ruggedness and off-road performance. Consumer satisfaction ratings often focused on its utility and longevity.