Product Name:
Mitsubishi Montero Pajero Complete Workshop Service Repair Manual 2003 2004
Model Generation:
Third Generation (1999-2006, Chassis code V60)
Chassis Codes:
V63W, V65W, V68W, V73W, V75W, V78W
Segment:
Full-size SUV, body-on-frame construction, known for off-road capability and ruggedness.
Competitors:
Toyota Land Cruiser, Nissan Pathfinder, Ford Explorer, Jeep Grand Cherokee, Land Rover Discovery
Vehicle Attributes:
Available Super Select II 4WD system, independent front suspension, robust chassis, comfortable ride for an SUV of its class, spacious interior.
Purpose:
Empowers owners and technicians to perform all necessary maintenance, repairs, and diagnostics, saving time and money compared to dealership service.
Powertrain:
Engine mechanicals, fuel injection, ignition, cooling, exhaust, lubrication, automatic transmission, manual transmission, transfer case, differentials (front and rear)
Chassis:
Suspension (front independent, rear multi-link), steering system (power assisted rack and pinion), braking system (ABS, EBD, disc brakes front/rear), wheels and tires
Electrical:
Engine control module (ECM), body control module (BCM), lighting, instrumentation, audio systems, power accessories (windows, locks, mirrors), HVAC controls, airbags, anti-theft system, wiring diagrams
Body:
Body panels, doors, windows, interior trim, seats, glass, bumpers, sunroof (if equipped)
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, drive belt inspection and replacement
Diagnostics Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical system diagnostics, engine performance issues
Repair Rebuild:
Engine overhaul, transmission overhaul, brake caliper rebuild, suspension component replacement, steering gear replacement, exhaust system repair
Installation Adjustment:
Component installation (e.g., alternator, starter, fuel pump), alignment procedures, brake pad replacement, timing belt installation
Specification Tables:
Includes detailed tables for all specifications: torque values, clearances, capacities, electrical resistance, etc.
Depth:
Comprehensive; covers basic maintenance to complete engine and transmission overhauls, detailed electrical troubleshooting, and bodywork repairs.
Quality:
High-resolution scans of original factory service manuals, ensuring clarity of text and diagrams.
Binding:
N/A (Downloadable Digital Format)
Paper:
N/A (Digital Format)
Text Search:
Fully searchable PDF text, allowing quick access to specific information via keywords.
Coverage Scope:
Covers all major mechanical, electrical, and body systems for the specified model years and engine variants.
Engine Code And Type:
6G72 (3.0L V6 SOHC MPI), 6G74 (3.5L V6 SOHC MPI), 6G75 (3.8L V6 SOHC MPI - less common for these specific years, but potential engine variant)
3.5L V6 (6G74) Horsepower:
Approx. 200-215 hp (depending on market and specific tune)
3.5L V6 (6G74) Torque:
Approx. 225-235 lb-ft (depending on market and specific tune)
Injection System:
Multi-Point Fuel Injection (MPI), Electronic Control Unit (ECU) managed
Timing Belt:
Yes (Interference engine; critical replacement interval)
Idle Speed Control:
Electronically controlled
Ignition System Type:
Distributorless Ignition System (DIS) with coil-on-plug or coil packs.
Transmission Type:
4-speed Automatic (4WD) / 5-speed Manual (2WD/4WD, less common in North America for this generation)
Transfer Case:
Super Select II 4WD system (selectable 2WD High, 4WD High, 4WD High with center differential lock, 4WD Low with center differential lock)
Automatic Transmission Control:
Electronic control with adaptive shift logic
Transfer Case Engagement:
Electronically actuated for 4WD modes (on most models), manual shifter for 4WD Low.
Automatic Transmission Fluid Type:
DIA QUEEN ATF SP-III (or equivalent)
Manual Transmission Fluid Type:
API GL-4 or GL-5 (SAE 75W-90 recommended)
NHTSA Rollover Rating:
4-star (for 2003 model year)
Antilock Brakes:
Standard (ABS)
Electronic Brakeforce Distribution:
Standard (EBD)
Limited Slip Differential:
Optional rear limited-slip differential (LSD) on some models.
Airbags:
Driver and front passenger airbags standard, optional side-impact airbags
Seatbelts:
Three-point seatbelts with pretensioners and load limiters for front occupants
Oil Change Interval:
Every 3,750 miles or 3 months (severe duty), or 7,500 miles or 6 months (normal duty) - consult manual for exact recommendation.
Timing Belt Replacement:
Critical: Recommended every 60,000 - 70,000 miles or 5 years. Failure can cause catastrophic engine damage.
Engine Oil Type:
API SJ or SL, SAE 5W-30 or 10W-30 (refer to manual for viscosity based on temperature)
Coolant Type:
Mitsubishi Super Long Life Coolant (SLLC) or equivalent HOAT (Hybrid Organic Acid Technology) - typically a pink or red coolant.
Engine Oil Capacity Quarts:
Approx. 4.8 quarts (with filter) for 3.5L V6
Coolant Capacity Quarts:
Approx. 8.6 quarts for 3.5L V6
Common Problems:
Timing belt failure (if not replaced on schedule), front axle shaft seal leaks, power steering pump noise, rear differential pinion seal leaks, occasional HVAC blower motor issues.
Catalytic Converter:
Can be prone to clogging if engine misfires or oil consumption issues are present, impacting performance and fuel economy.
OBD Ii Access:
OBD-II compliant, diagnostic port located under the dashboard on the driver's side.
Mitsubishi SUV Legacy:
Mitsubishi has a long history of producing capable off-road vehicles, dating back to models like the J-Series trucks and the original Pajero/Montero.
Third Generation Design:
This generation introduced a more modern, unibody construction (though with a reinforced integrated chassis structure) and a fully independent suspension, transitioning from its predecessor's more utilitarian roots to a more comfortable and refined SUV.
Production Locations:
Japan (primarily), some assembly in other regions
Model Years Covered By Manual:
2003, 2004
