🏷️ Basic Information

Make:

Mitsubishi

Model:

Montero

Model Nickname:

Montero (North America), Pajero (Rest of World)

Chassis Code:

V63, V64, V65, V66, V68, V73, V74, V75, V76, V77, V78

👋 Introduction

Segment:

Mid-size SUV (body-on-frame)

Target Audience:

Families, off-road enthusiasts, those seeking rugged utility and towing capability

Key Competitors:

Toyota 4Runner, Ford Explorer, Jeep Grand Cherokee, Nissan Pathfinder, Chevrolet TrailBlazer

Off Road Capability:

Body-on-frame construction, available Super Select II 4WD system with locking center differential, low-range gearing

Powertrain Options:

Robust V6 engines, durable automatic transmissions

Utility:

Spacious interior, available third-row seating, good towing capacity

📋 Manual Details

Years Covered:

2003, 2004, 2005, 2006

Regions Covered:

Primarily North American specifications, but general procedures apply globally

Estimated Page Count:

1500+

Type:

Factory Service Repair Manual (FSM)

Language:

English

Format:

Digital Download (PDF)

📖 Manual Coverage

Powertrain:

Engine mechanical, lubrication, cooling, fuel, ignition, exhaust, emissions control, engine management, powertrain control module (PCM)

Transmission Drivetrain:

Automatic transmission (INVECS-II), manual transmission (if applicable), transfer case (Super Select II), front axle, rear axle, driveshafts, differentials

Suspension Steering:

Front independent suspension (double wishbone), rear multi-link suspension, power steering system, steering gear, steering column

Brakes:

Front ventilated discs, rear solid discs, anti-lock braking system (ABS), electronic brake-force distribution (EBD), parking brake

Body Chassis:

Body structure, exterior trim, interior trim, doors, windows, sunroof, bumpers, frame

Electrical Electronics:

Battery, charging system, starting system, lighting, instrumentation, wipers, horn, power windows, power locks, mirrors, HVAC controls, audio system, airbags, body control module (BCM), fuse boxes, wiring diagrams

Comfort Convenience:

Climate control system (HVAC), seats, upholstery, interior lighting

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection/replacement, brake service, tire rotation

Diagnostics Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting, component testing, electrical system diagnostics

Repair Overhaul:

Engine removal/installation, cylinder head service, transmission overhaul, brake caliper rebuild, suspension component replacement, electrical component repair

Inspection:

Component wear inspection, safety system checks, fluid level verification

Alignment Balancing:

Wheel alignment specifications and procedures, wheel balancing

Depth:

Comprehensive, from basic maintenance to complete engine and transmission overhauls, including detailed electrical schematics and diagnostic procedures

Diagnostic Tools:

Information on Mitsubishi proprietary diagnostic tools (e.g., MUT-III) and generic OBD-II scanners

📊 Manual Specifications

File Type:

PDF

Searchable Text:

Yes (typically)

Quality:

High-resolution scans, clear illustrations and diagrams

Binding:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Code:

6G74

Engine Type:

3.5L SOHC V6 (24-valve)

Bore X Stroke:

93.0 mm x 85.8 mm

Compression Ratio:

8.8:1 (typical)

Horsepower Hp:

200-215 hp @ 5000-5500 rpm (depending on year and emissions calibration)

Torque Lb-Ft:

225-235 lb-ft @ 3500-4000 rpm (depending on year)

Fuel Delivery:

Multi-Point Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline (87 octane recommended)

Engine Block Material:

Aluminum alloy

Cylinder Head Material:

Aluminum alloy

🔧 Transmission

Type:

4-speed Automatic (INVECS-II)

Type:

5-speed Manual (less common in North America for these years)

Drivetrain:

Available part-time 4WD (Easy Select) and full-time 4WD (Super Select II)

Transfer Case:

Two-speed transfer case with locking center differential (Super Select II)

Automatic Transmission Fluid:

DIAQueen ATF SP-III or equivalent

📐 Dimensions

Length:

187.4 - 192.5 inches (4760 - 4890 mm) depending on configuration

Width:

73.4 inches (1865 mm)

Height:

70.1 - 73.2 inches (1780 - 1860 mm) depending on roof rails and suspension

Wheelbase:

109.7 inches (2785 mm)

Curb Weight:

4400 - 4800 lbs (2000 - 2180 kg) depending on configuration

Towing Capacity:

Up to 5000 lbs (2268 kg) (check specific year/configuration)

Gross Vehicle Weight Rating:

6200 - 6500 lbs (2812 - 2948 kg)

🛡️ Safety Features

NHTSA Front Crash Test:

4-star driver, 5-star passenger (for models with side airbags)

IIHS Side Impact Rating:

Good (for models equipped with side airbags)

ABS:

Standard on all models

Ebd:

Standard on all models

Traction Control:

Available on some models

Airbags:

Front airbags standard; available side curtain airbags for front and second rows

Seatbelts:

3-point seatbelts with pretensioners and load limiters in front

💡 Technology Features

Audio System:

Factory AM/FM/CD player with 6 or 8 speakers, optional premium Rockford Fosgate audio system.

Navigation:

Optional factory GPS navigation system available on higher trims.

Cruise Control:

Standard on most trims.

Power Accessories:

Power windows, power locks, power mirrors, remote keyless entry.

🔧 Maintenance

Oil Change Interval:

Every 3,750 miles (6,000 km) or 6 months, whichever comes first (under severe driving conditions), or 7,500 miles (12,000 km) or 12 months (under normal driving conditions). Consult manual for specific driving condition definitions.

Engine Coolant Replacement:

Initial change at 60,000 miles (96,000 km) or 48 months, then every 30,000 miles (48,000 km) or 24 months thereafter.

Transmission Fluid Change:

Every 30,000 miles (48,000 km) or 24 months for severe use, 60,000 miles (96,000 km) or 48 months for normal use.

Spark Plug Replacement:

Platinum tipped plugs typically rated for 60,000-100,000 miles. Consult manual for exact interval and plug type (e.g., NGK Platinum PFR5N-11).

Timing Belt:

This engine uses a timing *chain*, not a belt, which typically does not require periodic replacement but should be inspected.

Engine Oil:

SAE 5W-30 viscosity grade, API Service SG, SH, or SJ certified. Capacity approx. 4.5 US quarts (4.3 liters) with filter.

Coolant:

Mitsubishi Super Long Life Coolant (SLLC) or equivalent Asian vehicle specific silicate-free OAT coolant. Mix 50/50 with distilled water. Capacity approx. 10.0 US quarts (9.5 liters).

Power Steering Fluid:

Dexron II or Dexron III ATF (or equivalent).

Brake Fluid:

SAE J1703 or FMVSS No. 116 DOT 3.

Common Issues:

Exhaust manifold cracks, rear differential whine, SRS warning light due to seat occupancy sensor or clock spring, transfer case actuator issues (on some models), rust on body and frame (especially in salt-belt regions), occasional transmission shift quality issues.

Common Issues Engine:

Minor oil leaks from valve cover gaskets, spark plug tube seals.

📚 Vehicle History

Heritage:

Mitsubishi Motors has a long history of producing rugged, capable off-road vehicles and SUVs, exemplified by the Pajero/Montero lineage.

Generation:

This generation (2000-2006) is the third generation of the Montero/Pajero, featuring a unibody construction with a reinforced chassis, unlike its body-on-frame predecessors.

Facelift:

A significant facelift occurred for the 2003 model year, introducing revised styling, updated interior features, and improved powertrain.

Production Location:

Pajeros were primarily produced in Japan at Mitsubishi's factories. North American models (Montero) were also assembled in Japan and sometimes in other locations like the USA for specific markets.

Production Years Third Gen:

2000-2006

🏆 Awards & Recognition

Off Road Awards:

While specific awards for the 2003-2006 model year are not widely publicized, the Montero/Pajero platform consistently received praise for its off-road prowess and durability in automotive reviews of its era.

Consumer Satisfaction:

Consumer satisfaction varied, with many owners praising its ruggedness and capability, while others noted potential reliability concerns common to some models of this era.