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Mitsubishi Montero 2000-2002 Service Repair Workshop Manual

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This manual covers the Montero, also known as the Pajero in export markets, specifically focusing on the V70 Series, second generation facelifted models produced for the 2000, 2001, and 2002...
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类型: Car
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Mitsubishi Montero 2000-2002 Service Repair Workshop ManualMitsubishi Montero 2000-2002 Service Repair Workshop ManualMitsubishi Montero 2000-2002 Service Repair Workshop Manual
This manual covers the Montero, also known as the Pajero in export markets, specifically focusing on the V70 Series, second generation facelifted models produced for the 2000, 2001, and 2002 model years. This full-size, body-on-frame SUV is renowned for its robust off-road capability, featuring the advanced Super Select 4WD II system, powerful V6 engines (3.0L and 3.5L), and durable construction. It was positioned as a capable family and adventure vehicle, competing with other prominent SUVs of its era. Its strengths lie in its versatile drivetrain, spacious interior, and overall reliability, making it a dependable choice for diverse driving conditions and a popular vehicle for outdoor enthusiasts. This comprehensive Factory Service Manual, over 1500 pages in English, provides in-depth guidance for the maintenance, repair, and diagnostics of your Montero. It covers all major systems, including engine mechanical and management, manual and automatic transmissions, drivetrain, suspension, brakes, steering, electrical systems, and body/interior components. Detailed procedures for preventive maintenance, engine and transmission servicing, brake and suspension repairs, electrical diagnostics, and HVAC service are included, along with critical technical specifications and torque values. This manual is an essential resource for owners and technicians aiming to ensure the longevity, performance, and proper functioning of the vehicle.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Montero
Model Alias:
Pajero (export markets)
Codes
Platform Code:
V70 Series
Generation Codes:
Second Generation (1990-2006), with specific focus on facelifted V70 models
👋 Introduction
Market Position
Segment:
Full-size, body-on-frame SUV, positioned as a capable off-road and family vehicle.
Competitive Analysis
Key Competitors:
Ford Explorer, Chevrolet TrailBlazer/Blazer, Jeep Grand Cherokee, Toyota 4Runner, Nissan Pathfinder.
Key Features
Strengths:
Robust off-road capability (Super Select 4WD II), powerful V6 engines, spacious interior, durable construction.
Target Audience:
Families, outdoor enthusiasts, individuals seeking a reliable and capable SUV for diverse driving conditions.
Manual Value
Usefulness:
Essential for owners and independent mechanics looking to perform accurate repairs, maintenance, and diagnostics, ensuring longevity and optimal performance.
📋 Manual Details
Coverage Areas
Applicable Years:
2000, 2001, 2002
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication, cooling.
Engine Management:
Fuel injection (MPI/GDI), ignition system, emissions control, sensors, actuators, ECU diagnostics.
Transmission Manual:
Manual transmission operation, disassembly, assembly, troubleshooting, fluid specifications.
Transmission Automatic:
Automatic transmission operation, hydraulics, electronic controls, disassembly, assembly, troubleshooting, fluid specifications.
Drivetrain 4Wd:
Super Select 4WD II system, transfer case operation, front and rear differentials, driveshafts, CV joints.
Suspension Front:
Independent front suspension, coil springs, shock absorbers, control arms, ball joints, steering linkage.
Brakes:
Front disc brakes, rear disc brakes, anti-lock braking system (ABS), brake fluid, hydraulic components, parking brake.
Steering:
Power steering system, steering gear, steering column, wheel alignment specifications.
Electrical System:
Battery, charging system (alternator), starting system, lighting, wipers, horn, power accessories.
Body And Interior:
Body panels, doors, windows, glass, interior trim, seats, HVAC system, body repair.
Diagnostics And Troubleshooting:
Diagnostic trouble codes (DTCs), troubleshooting flowcharts, common fault diagnosis.
Suspension Rear
Suspension Rear:
Multi-link coil spring rear suspension, shock absorbers, trailing arms, panhard rod.
Procedures Included
Preventive Maintenance:
Oil changes, filter replacements, spark plug service, brake fluid flush, coolant replacement, drive belt inspection/replacement.
Engine Repair:
Head gasket replacement, piston ring installation, bearing replacement, complete engine overhaul procedures.
Transmission Service:
Transmission fluid and filter change, clutch replacement (manual), torque converter replacement (automatic).
Brake Service:
Brake pad and rotor replacement, caliper overhaul, bleeding brake system, ABS component replacement.
Suspension And Steering Repair:
Component replacement (shocks, struts, ball joints, tie rods), steering rack repair/replacement, wheel alignment procedures.
Electrical Diagnostics:
Wiring diagrams, component testing, troubleshooting electrical circuits, starter and alternator testing.
HVAC Service:
Refrigerant handling, component replacement (compressor, condenser, evaporator), system flushing.
Body Repair:
Panel replacement, dent repair, glass replacement, door and latch adjustment.
Technical Depth
Depth:
Comprehensive, covering all aspects from basic maintenance to complex component overhaul and diagnostics. Includes detailed specifications and torque values.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Typically searchable text within PDF for easy keyword lookup.
Print Quality
Quality:
High-resolution digital reproduction of original factory documentation.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code Gasoline:
6G72 (3.0L SOHC V6), 6G74 (3.5L SOHC/DOHC V6)
Engine Description 3.0L:
3.0-liter SOHC V6 (SOHC 12-valve)
Engine Description 3.5L:
3.5-liter SOHC V6 (SOHC 24-valve) - Common for 2001-2002 models in North America
Performance 3.0L
Horsepower 3.0L:
Approximately 177-180 hp @ 5000-5500 rpm
Torque 3.0L:
Approximately 245-250 lb-ft @ 3500-4000 rpm
Performance 3.5L
Horsepower 3.5L:
Approximately 200-215 hp @ 5000-5500 rpm
Torque 3.5L:
Approximately 260-275 lb-ft @ 3500-4000 rpm
Fuel System
Fuel Delivery:
Multi-Point Fuel Injection (MPI) or Gasoline Direct Injection (GDI) for some 3.5L variants.
Fuel Type
Fuel:
Unleaded Gasoline (87 Octane recommended, higher octane may be specified for certain engines/conditions)
Cooling System
Coolant Type:
Ethylene Glycol based coolant (e.g., Mitsubishi DiaQueen Super Long Life Coolant or equivalent green/yellow coolant)
Lubrication System
Oil Type:
SAE 5W-30 or 10W-30 (API Service SG, SH, or SJ)
Oil Capacity Approx:
Approx. 4.5-5.0 US quarts (4.3-4.7 liters) with filter change
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission (V5M31)
Optional
Transmission Type Optional:
4-speed Automatic Transmission (V4A51)
Features
Drivetrain Options:
Part-time 4WD or Full-time 4WD (Super Select 4WD II system)
Fluid Specs Manual
Manual Transmission Fluid:
API GL-4 SAE 75W-90 or 80W-90 Gear Oil
Fluid Specs Automatic
Automatic Transmission Fluid:
Mitsubishi DiaQueen ATF SP-II M or SP-III (or equivalent Dexron III/Mercon compatible)
📐 Dimensions
Exterior
Length:
Approximately 187.4 inches (4760 mm)
Width:
Approximately 70.1 inches (1780 mm)
Height:
Approximately 70.1 inches (1780 mm)
Wheelbase
Wheelbase:
Approximately 109.7 inches (2785 mm)
Weights
Curb Weight Approx:
Approximately 4200 - 4600 lbs (1905 - 2087 kg), depending on configuration
Cargo
Cargo Volume Behind 3Rd Row:
Limited (often removed or folded)
Cargo Volume Behind 2Nd Row:
Approximately 40-50 cu ft
Towing
Towing Capacity Approx:
Up to 5000 lbs (2268 kg) (may vary by market and configuration)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
4-star (2000-2001 models, specific tests varied by year)
NHTSA Front Impact Passenger:
4-star (2000-2001 models, specific tests varied by year)
IIHS Side Impact:
Good (for models equipped with side airbags, if applicable)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Optional Active Skid Control (ASC) on some models
Passive Features
Airbags Front:
Driver and front passenger airbags
Airbags Side:
Optional side-impact airbags available on some trims/years
Rollover Protection:
Reinforced chassis and body structure designed for SUV application.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, often with cassette tape. Premium audio systems available on higher trims.
Navigation:
Optional factory navigation system (less common and dated by modern standards).
Driver Assistance
Cruise Control:
Standard or optional cruise control.
Connectivity
Auxiliary Input:
Typically no factory auxiliary input; aftermarket solutions are common.
Convenience
Power Features:
Power windows, power door locks, power mirrors, optional power sunroof, optional power adjustable front seats.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 - 7,500 miles (6,000 - 12,000 km) or 6-12 months, depending on driving conditions (refer to manual for specifics).
Air Filter Replacement:
Every 15,000 - 30,000 miles (24,000 - 48,000 km)
Spark Plug Replacement:
Every 30,000 - 60,000 miles (48,000 - 96,000 km) depending on plug type (copper vs. platinum/iridium)
Timing Belt Replacement:
Critical: Every 60,000 - 90,000 miles (96,000 - 144,000 km) or 5-7 years for interference engines (V6 engines are typically interference).
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4
Power Steering Fluid Type:
ATF Dexron II/III compatible
Transfer Case Fluid Type:
API GL-4 SAE 75W-90 or 80W-90 Gear Oil
Differential Fluid Type:
API GL-5 SAE 80W-90 Gear Oil
Known Issues
Common Problem 1:
Timing belt failure if not replaced at recommended intervals (interference engine).
Common Problem 2:
Oil leaks from valve covers or oil pan gaskets.
Common Problem 3:
Automatic transmission shifting issues or failure to engage drive gears (often related to fluid degradation or solenoid issues).
Common Problem 4:
Cracked exhaust manifolds on V6 engines due to heat cycles.
Common Problem 5:
Wear in front suspension components (ball joints, tie rods) due to off-road use or age.
📚 Vehicle History
Brand Heritage
Mitsubishi SUV Legacy:
Mitsubishi has a long history of producing robust off-road vehicles, starting with the Pajero/Montero in 1976.
Model Evolution
Generation Context:
This period (2000-2002) represents the latter part of the second generation (NH/NJ/NK Series in some markets), which received significant updates for the 1997 model year including styling and powertrain enhancements.
Facelift Details:
Facelifts during the second generation often included updated front/rear styling, interior trim, and powertrain refinements, such as the introduction of the 3.5L V6.
Production
Manufacturing Location:
Primarily manufactured in Japan (Pajero) and some units assembled in other locations globally.
Production Years Full:
Second Generation: 1990-2006 (with various facelifts and updates)
🏆 Awards & Recognition
Recognitions
Off Road Reputation:
Consistently recognized for its excellent off-road capabilities, often compared favorably to more specialized off-road vehicles.
Durability Awards:
While specific awards may vary, the Montero/Pajero line is generally regarded as a durable and reliable platform, particularly in its body-on-frame construction.
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