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Introduction
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Market Position
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Positioning:
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The Mitsubishi Pajero (also known as Montero in North America and Shogun in the UK) is a renowned and capable off-road focused SUV, known for its robust construction and versatility. The 2002 model represents the third generation, which transitioned to a unibody construction while retaining its off-road prowess.
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Competitive Analysis
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Competitors:
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Competes with other capable SUVs of its era, such as the Toyota Land Cruiser Prado, Nissan Patrol, Land Rover Discovery, Jeep Grand Cherokee, and Ford Explorer.
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Key Features
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Distinctive Features:
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Super Select II 4WD system (on many models), independent suspension, spacious interior, high ground clearance, durable construction.
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Manual Value Proposition
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Value:
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This comprehensive manual empowers owners and technicians to perform all necessary maintenance, diagnostics, and repairs, ensuring the longevity and optimal performance of the Pajero.
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Manual Coverage
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Systems Covered
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Engine:
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All engine types, including internal components, cooling, lubrication, fuel delivery, ignition, emissions, and engine management systems.
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Transmission:
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Manual and automatic transmissions, clutch systems, transfer case, and drivetrain components.
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Suspension:
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Independent front and rear suspension, shock absorbers, springs, control arms, bushings, and steering linkages.
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Brakes:
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Front and rear disc brakes, ABS (Anti-lock Braking System), parking brake, hydraulic system, and brake components.
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Electrical:
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Complete electrical system, including battery, charging system, starter, lighting, instruments, power accessories, and wiring diagrams.
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Body And Chassis:
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Body construction, panels, doors, glass, interior trim, and chassis frame components.
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HVAC:
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Heating, Ventilation, and Air Conditioning (HVAC) system components, operation, and service.
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Safety Systems:
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Airbag systems, seat belt mechanisms, and related sensors.
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Procedures Included
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Maintenance:
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Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, belt inspections, and general upkeep.
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Troubleshooting:
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Diagnostic procedures for common and uncommon issues, fault code interpretation, and step-by-step troubleshooting guides.
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Repair:
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Detailed instructions for component removal, disassembly, inspection, repair, reassembly, and installation for all major vehicle systems.
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Rebuilding:
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Comprehensive instructions for rebuilding engines, transmissions, differentials, and other major mechanical components.
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Restoration:
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Guidance on restoring and refurbishing various aspects of the vehicle to original specifications.
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Wiring Diagrams:
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Detailed electrical wiring diagrams for all vehicle circuits, crucial for electrical troubleshooting and repairs.
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Technical Depth
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Depth:
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Comprehensive, covering everything from basic fluid checks and filter changes to complex engine and transmission rebuilds, electronic diagnostics, and bodywork.
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Engine Specifications
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Primary Engine
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Engine Options 2002:
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3.0L V6 (6G72), 3.5L V6 (6G74), 3.2L DI-D Turbo Diesel (4M41). Specific availability varied by market.
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Performance
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3.5L V6 (6G74) Estimated Power:
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Approximately 200-220 hp (149-164 kW) depending on market and tuning.
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3.5L V6 (6G74) Estimated Torque:
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Approximately 220-230 lb-ft (298-312 Nm) depending on market and tuning.
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Fuel System
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Fuel Injection Type:
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Multi-point Fuel Injection (MPI) for petrol engines, Common Rail Direct Injection (CRDI) for diesel engines.
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Engine Management
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Engine Control Unit Type:
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ECU/ECM controlled, often with OBD-II (On-Board Diagnostics II) compliance.
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Cooling System
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Cooling Type:
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Pressurized liquid cooling system with thermostat and radiator fan.
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Technology Features
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Infotainment
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Infotainment System Features:
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Factory fitted radio/cassette or CD player, with optional premium sound systems. Some models may have a basic navigation system or climate control displays.
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Driver Assistance
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Driver Assistance Features:
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ABS, optional Traction Control (TCS), optional Electronic Stability Control (ESC) on some later models or higher trims.
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Connectivity
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Connectivity Options:
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Limited by modern standards. Features typically include power windows, power locks, and cruise control. Aftermarket upgrades for Bluetooth or auxiliary inputs are common.
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Off Road Tech
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4Wd System Technology:
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The signature Super Select II 4WD system is a key technological feature, allowing seamless switching between 2WD and 4WD modes, including a locked center differential for maximum traction.
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Maintenance
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Service Intervals
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Oil Change Interval Km:
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Typically every 10,000-15,000 km or 6-12 months, depending on driving conditions and oil type. Refer to manual for precise intervals.
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Transmission Fluid Change Interval Km:
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Automatic transmission fluid: approximately 60,000-100,000 km, Manual transmission fluid: 80,000-100,000 km. Refer to manual for exact intervals and procedures.
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Timing Belt Replacement Km:
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For 6G7 engines (V6 petrol), timing belt replacement is critical, typically around 90,000-100,000 km. Failure can cause severe engine damage. Consult manual for specific interval and procedure.
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Fluid Specifications
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Engine Oil Type Petrol:
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API SG/SH/SJ or ACEA A2/A3, viscosity SAE 10W-30 or 10W-40 (check manual for specific grade and capacity).
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Engine Oil Type Diesel:
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API CG-4 or CF-4, viscosity SAE 10W-30 or 15W-40 (check manual for specific grade and capacity).
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Coolant Type:
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Ethylene glycol-based coolant with corrosion inhibitors (typically a pink or red coolant). Mopar OAT or HOAT compatible coolant often acceptable, but verify with manual. Capacity approx. 9.5-10.5 liters.
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Brake Fluid Type:
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DOT 3 or DOT 4 brake fluid.
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Known Issues
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Common Wear Items:
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Suspension bushings, ball joints, tie rod ends, wheel bearings, and exhaust components can be subject to wear, especially with off-road use. Check for leaks from coolant hoses and radiator.
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Diesel Specific Issues:
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Early 4M41 engines may have had injector seal issues or EGR valve problems. Turbocharger health is critical.
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Electrical Gremlins:
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While generally reliable, aging wiring harnesses or corroded grounds can sometimes lead to minor electrical issues. The manual's wiring diagrams are essential here.
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Maintenance Schedule Summary
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Key Maintenance Items:
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Regular oil and filter changes, air filter replacement, cabin air filter replacement, spark plug inspection/replacement (petrol), fuel filter replacement (diesel), coolant flush, transmission fluid and filter service, differential and transfer case fluid changes, brake system inspection, suspension and steering component checks.
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