🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero (Montero)

Production Years Covered:

2001, 2002, 2003

Chassis Codes Covered:

V63W, V65W, V68W, V73W, V75W, V78W

Generation:

Third Generation (1999/2000-2006)

👋 Introduction

Segment:

Full-size body-on-frame SUV, known for off-road capability and durability

Competitors 2001-2003:

Toyota Land Cruiser, Land Rover Discovery, Jeep Grand Cherokee, Ford Explorer, Nissan Pathfinder

Off Road Capability:

Renowned for its Super Select II 4WD system, robust chassis, and generous ground clearance

Durability:

Built with robust components designed for demanding use, both on-road and off-road

Versatility:

Suitable for family transportation, towing, and serious off-road expeditions

📋 Manual Details

Languages Included:

English, French, German, Spanish

Total Pages:

20000+

Manual Type:

Workshop Service Repair Manual

File Format:

PDF

Searchability:

Fully Searchable

Indexing:

Fully Indexed

Readability:

iPad-ready

Printability:

Printable

File Size Mb:

315

📖 Manual Coverage

Engine:

All engine types, including 3.0L 6G72 V6 SOHC, 3.5L 6G74 V6 SOHC MPI, 3.5L 6G74 V6 SOHC GDI (Direct Injection), 3.2L 4M41 Diesel Turbocharged

Transmission:

4-speed Automatic (V4A51, W4A51), 5-speed Manual (R5M42, W5M42)

Drivetrain:

Super Select II 4WD System (mechanical and electronic components), front and rear differentials, driveshafts, transfer case

Suspension:

Front Independent Suspension (double wishbone), Rear Independent Suspension (multi-link), coil springs, shock absorbers, sway bars

Brakes:

Front ventilated discs, rear discs, ABS system, brake booster, hydraulic lines, parking brake

Steering:

Power assisted rack and pinion, steering column, intermediate shaft

Fuel System:

Fuel pump, fuel tank, fuel injectors, fuel pressure regulator, fuel filter

Cooling System:

Radiator, water pump, thermostat, cooling fans, coolant hoses

Electrical System:

Battery, alternator, starter motor, ignition system, lighting, horns, power windows, power locks, mirrors

HVAC:

Air conditioning system, heater core, blower motor, climate control unit, refrigerant, diagnostics

Body And Chassis:

Frame construction, body panels, doors, hoods, tailgates, interior trim, glass, seals

Safety Systems:

Airbags (SRS), seatbelt pretensioners, ABS diagnostics

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, brake pad/rotor replacement, spark plug replacement

Diagnostics:

Troubleshooting guides, diagnostic trouble codes (DTCs), testing procedures for all major systems

Repair:

Step-by-step repair instructions for all major components and systems, including engine rebuilds, transmission overhauls, suspension component replacement

Overhaul:

Complete overhaul procedures for engines and transmissions

Adjustment:

Adjustment procedures for parking brake, clutch, wheel bearings

Installation:

Installation procedures for new parts, accessories, and sensors

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all vehicle systems

Depth:

Comprehensive: Covers everything from basic scheduled maintenance to complete engine and transmission rebuilds, including in-depth electrical diagnostics and chassis repairs.

📊 Manual Specifications

Format:

Digital PDF

Resolution:

High-resolution, suitable for printing detailed diagrams and text

Binding:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Gasoline Engine 1:

3.0L (2972cc) 6G72 V6 SOHC MPI

Gasoline Engine 2:

3.5L (3497cc) 6G74 V6 SOHC MPI

Gasoline Engine 3:

3.5L (3497cc) 6G74 V6 SOHC GDI (Gasoline Direct Injection)

Diesel Engine 1:

3.2L (3200cc) 4M41 Turbocharged Direct Injection Diesel

Horsepower 6G72:

Approx. 175-185 hp (varies by market and tune)

Torque 6G72:

Approx. 190-200 lb-ft (varies by market and tune)

Horsepower 6G74 Mpi:

Approx. 200-215 hp

Torque 6G74 Mpi:

Approx. 220-230 lb-ft

Horsepower 6G74 Gdi:

Approx. 215-230 hp

Torque 6G74 Gdi:

Approx. 230-240 lb-ft

Horsepower 4M41:

Approx. 160-175 hp

Torque 4M41:

Approx. 260-280 lb-ft

Fuel Type:

Unleaded Gasoline (for V6 engines), Diesel Fuel (for 4M41)

Injection Type:

Multi-Point Fuel Injection (MPI) or Gasoline Direct Injection (GDI) for petrol; Direct Injection for diesel

🔧 Transmission

Standard Transmission:

Varies by region and trim. Often a 5-speed manual was standard on lower trims, or automatic on higher trims.

Optional Transmission 1:

4-speed INVECS-II Automatic Transmission (e.g., V4A51/W4A51)

Optional Transmission 2:

5-speed Manual Transmission (e.g., R5M42/W5M42)

4Wd System:

Super Select II electronically controlled 4WD system with selectable 2WD, 4WD High, 4WD Low, and locking center differential.

📐 Dimensions

Wheelbase:

Approx. 2780 mm (109.4 inches)

Length:

Approx. 4735 mm (186.4 inches) for SWB, 4900 mm (192.9 inches) for LWB

Width:

Approx. 1855 mm (73.0 inches)

Height:

Approx. 1855-1890 mm (73.0-74.4 inches) depending on roof rails and suspension

Curb Weight Kg:

Approx. 1900-2100 kg (4189-4630 lbs) depending on configuration

Gross Vehicle Weight Rating Kg:

Approx. 2500-2700 kg (5512-5952 lbs) depending on configuration

🛡️ Safety Features

NHTSA Front Impact:

Not readily available for all specific configurations, but generally considered a robust vehicle for its era. Some markets received higher ratings.

ABS:

Standard on most models, often with EBD (Electronic Brake-force Distribution)

Airbags:

Driver and front passenger airbags standard. Side airbags available on some higher trims.

Seatbelts:

3-point seatbelts with pretensioners for front occupants, 3-point or lap belts for rear occupants

💡 Technology Features

Audio System:

Factory AM/FM/CD player, often with premium Rockford Fosgate audio systems on higher trims. Tape deck also common.

Climate Control:

Manual or automatic climate control systems

Cruise Control:

Standard on most models

Connectivity Features:

Limited by era; typically focused on audio input. No Bluetooth or integrated navigation as standard on most trims.

🔧 Maintenance

Oil Change Interval:

Typically every 7,500 miles (12,000 km) or 6-12 months, depending on driving conditions.

Air Filter Replacement:

Every 15,000 miles (24,000 km) or as needed based on inspection.

Spark Plug Replacement:

Platinum tipped: 60,000-100,000 miles (96,000-160,000 km); Iridium tipped: 100,000+ miles (160,000+ km). Refer to manual for specific engine type.

Coolant Replacement:

Initial change at 60,000 miles (96,000 km), then every 30,000 miles (48,000 km) or 2 years thereafter.

Engine Oil Specification:

API SG or higher, SAE 10W-30 or 5W-30 (depending on temperature range). Check manual for precise viscosity for specific engines.

Transmission Fluid Automatic:

DIA QUEEN ATF-SP III or equivalent

Transmission Fluid Manual:

API GL-4 or GL-5, SAE 75W-90 (check manual for specific requirements)

Coolant Type:

Ethylene glycol based antifreeze, 50/50 mix with distilled water

Brake Fluid Type:

DOT 3 or DOT 4

Common Issues Gasoline V6:

Idling issues due to throttle body or EGR valve, potential for intake manifold gasket leaks, timing belt replacement (on non-interference engines, though some are interference - check specific engine code), occasional catalytic converter failure.

Common Issues Diesel 4M41:

Potential for injector seal leaks, glow plug issues, turbocharger wear over time. Early models had some issues with cylinder head cracking if overheated, though less common on later revisions within this range.

Common Issues 4Wd System:

Actuator failures for transfer case and differentials, sensor issues related to the Super Select system.

Common Issues Suspension:

Worn ball joints, tie rod ends, and bushings due to the vehicle's weight and off-road use.

📚 Vehicle History

Mitsubishi SUV Legacy:

The Pajero lineage began in 1982, establishing Mitsubishi as a key player in the SUV market with a reputation for off-road prowess.

Third Generation Introduction:

Introduced in 1999 (for model year 2000), this generation marked a significant shift with a monocoque (unibody) chassis integrated with a 'CSI' (Chassis Integrated Frame) structure, offering improved on-road manners and safety.

Key Changes 2001-2003:

Minor updates in styling, features, and engine refinements across these model years. Introduction of GDI engines in some markets.

Manufacturing Locations:

Primarily manufactured in Japan by Mitsubishi Motors. Also assembled in other locations globally through CKD kits or joint ventures.

🏆 Awards & Recognition

Off Road Awards:

The Pajero/Montero platform has a distinguished record in off-road endurance events like the Dakar Rally.

Consumer Ratings Era:

Generally well-regarded for capability and durability, though fuel economy and certain interior materials received mixed reviews in some consumer reports.