🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero

Generation:

Third Generation (NM/NP)

Chassis Codes:

K80, K90 series (NM/NP Pajero/Montero)

👋 Introduction

Segment:

Mid-size SUV, Off-road capable

Reputation:

Renowned for ruggedness, off-road capability, and reliability.

Key Competitors:

Toyota Land Cruiser Prado, Nissan Patrol, Jeep Grand Cherokee, Ford Explorer, Land Rover Discovery.

Off Road System:

Super Select II 4WD system with locking center and rear differentials (on some variants), excellent ground clearance, robust suspension.

Body On Frame:

Traditional body-on-frame construction for superior durability and off-road resilience.

Interior Versatility:

Spacious interiors, available third-row seating (5-door models), flexible cargo configurations.

📋 Manual Details

Applicable Years:

2000, 2001, 2002, 2003

Engine Variants Covered:

V6 3.0L 6G72 SOHC, V6 3.5L 6G74 SOHC/DOHC, 2.8L 4M41 Turbo-Diesel (Region Dependent)

Transmission Types Covered:

4-Speed Automatic (INVECS-II), 5-Speed Manual

Body Styles Covered:

3-door (Short Wheelbase), 5-door (Long Wheelbase)

Estimated Pages:

1500+

Type:

Workshop Service Repair Manual

Language:

English

Format:

Digital Download (PDF)

📖 Manual Coverage

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of all engine components including cylinder head, block, crankshaft, pistons, connecting rods, valves, camshafts, timing system, lubrication system, cooling system.

Engine Management:

Fuel injection system (MPI), ignition system, emission control systems, sensors, actuators, ECU diagnosis and troubleshooting, diagnostic trouble codes (DTCs).

Transmission Manual:

Clutch system, gearbox disassembly, repair, and adjustment, shift mechanism.

Transmission Automatic:

INVECS-II automatic transmission operation, disassembly, repair, torque converter, valve body, electronic control unit (TCU) diagnosis.

Drivetrain Transfer Case:

Super Select II 4WD system operation, service, repair, front and rear differentials, drive shafts, CV joints.

Suspension:

Independent front suspension (double wishbone), multi-link rear suspension, shock absorbers, springs, control arms, bushings, alignment specifications.

Steering:

Power steering system, pump, rack and pinion, steering column, linkage, troubleshooting.

Brakes:

Front disc brakes, rear disc brakes (some models with drum), ABS system (Anti-lock Braking System), hydraulic system, brake fluid specifications, bleeding procedures, parking brake.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting system, wipers, horn, power windows, central locking, fuses, relays, wiring diagrams.

Body And Chassis:

Body construction, door mechanisms, glass, seals, bumpers, underbody protection, chassis components, corrosion protection.

HVAC:

Air conditioning system operation, diagnosis, refrigerant, compressor, condenser, evaporator, heater core, climate control unit.

Safety Systems:

Airbag system diagnosis and components, seatbelt mechanisms.

Routine Maintenance:

Oil and filter changes, air filter replacement, spark plug replacement, fluid level checks and top-offs, tire rotation, brake inspection.

Troubleshooting:

Diagnostic procedures for common and uncommon problems across all major systems, symptom-based troubleshooting guides, diagnostic trouble code (DTC) interpretation.

Component Replacement:

Detailed step-by-step instructions for replacing virtually every component on the vehicle, from minor bulbs to major engine and transmission assemblies.

Engine Rebuilding:

Comprehensive instructions for engine overhaul, including torque specifications, clearances, and assembly procedures.

Transmission Overhaul:

Step-by-step guides for rebuilding both manual and automatic transmissions.

Brake System Service:

Pad and rotor replacement, caliper service, brake line bleeding, ABS component diagnosis and replacement.

Electrical Diagnostics:

Detailed wiring diagrams, troubleshooting flowcharts for electrical issues, component testing procedures.

Alignment And Suspension Service:

Ride height adjustments, suspension component replacement, wheel alignment procedures and specifications.

Body And Trim Repair:

Panel replacement, door and window adjustment, interior trim removal and installation.

Depth:

Comprehensive: Covers everything from basic fluid changes and checks to complete engine and transmission rebuilds, complex electrical diagnostics, and bodywork repairs.

Diagnostic Tools:

Includes information on diagnostic trouble codes (DTCs) and the use of scan tools for advanced diagnostics.

Specifications:

Provides detailed technical specifications for all major components, including torque values, clearances, fluid capacities, and electrical resistance.

📊 Manual Specifications

Format:

PDF

Searchable:

Yes (text-based PDF)

Printable:

Yes

Image Resolution:

High (clear diagrams and photos)

Type:

N/A (Digital Download)

Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Code Gasoline 1:

6G72

Engine Description Gasoline 1:

3.0L SOHC V6

Displacement Gasoline 1:

2972 cc (181.4 cu in)

Horsepower Gasoline 1:

Approx. 173-181 hp @ 5500 rpm (varies by market/spec)

Torque Gasoline 1:

Approx. 184-186 lb-ft @ 4000 rpm (varies by market/spec)

Engine Code Gasoline 2:

6G74

Engine Description Gasoline 2:

3.5L SOHC/DOHC V6

Displacement Gasoline 2:

3497 cc (213.4 cu in)

Horsepower Gasoline 2:

Approx. 195-215 hp (SOHC), 240-275 hp (DOHC MIVEC) @ 5500-6750 rpm

Torque Gasoline 2:

Approx. 217-230 lb-ft (SOHC), 250-273 lb-ft (DOHC MIVEC) @ 3500-4500 rpm

Engine Code Diesel:

4M41

Engine Description Diesel:

2.8L Turbo-Diesel 4-cylinder

Displacement Diesel:

2835 cc (173.0 cu in)

Horsepower Diesel:

Approx. 123-145 hp @ 4000 rpm

Torque Diesel:

Approx. 215-236 lb-ft @ 2000 rpm

Fuel Type Gasoline:

Unleaded gasoline (87 octane or higher recommended)

Fuel Type Diesel:

Diesel fuel

Fuel Injection Gasoline:

Multi-Point Fuel Injection (MPI)

Fuel Injection Diesel:

Direct Injection, Common Rail Diesel (CRD) with turbocharger and intercooler

Ignition System:

Distributorless ignition system (DIS) with coil-on-plug or distributor-based for some older configurations.

🔧 Transmission

Transmission Type Standard:

5-Speed Manual (typically on lower trims/certain markets)

Transmission Type Optional:

4-Speed Automatic (INVECS-II)

Gear Ratios:

Detailed ratios provided within manual for both manual and automatic transmissions.

Transmission Fluid Manual:

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

Transmission Fluid Automatic:

Mitsubishi DiaQueen SPII or equivalent ATF (Dexron III/Mercon compatible variants often suitable, but consult manual)

Transfer Case:

Super Select II 4WD system with center differential lock and electronic control for on-the-fly 2WD/4WD selection and 4WD high/low range.

📐 Dimensions

Length Swb:

Approx. 4305 mm (169.5 in)

Length Lwb:

Approx. 4670 mm (183.9 in)

Width:

Approx. 1815 mm (71.5 in)

Height:

Approx. 1870 mm (73.6 in)

Wheelbase Swb:

Approx. 2525 mm (99.4 in)

Wheelbase Lwb:

Approx. 2780 mm (109.4 in)

Ground Clearance:

Approx. 210-225 mm (8.3-8.9 in) (varies by tire size and suspension)

Cargo Volume Lwb Seats Up:

Significant cargo space, often exceeding 1000 liters behind the second row.

Curb Weight:

Approx. 1800-2100 kg (3968-4630 lbs) depending on configuration.

Towing Capacity:

Typically rated around 2500 kg (5511 lbs) for braked trailers (market dependent).

🛡️ Safety Features

NHTSA Rating:

Varies by market and specific year/configuration. Generally considered a robust vehicle. Specific crash test data should be researched independently for the exact model year and region.

ABS:

Standard Anti-lock Braking System (ABS) on most models.

Traction Control:

Traction Control System (TCL) available on some higher trims.

Electronic Stability:

Electronic Stability Control (ESC) or Active Stability Control (ASC) may be available on later models within this range or as an option.

Airbags:

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

Seatbelts:

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

Child Anchors:

ISOFIX child seat anchor points (availability varies by region and specific model year).

💡 Technology Features

Audio System:

Factory-fitted radio/cassette player or CD player with AM/FM tuner. Speaker configurations vary by trim level.

Navigation:

Optional GPS navigation system available on higher trim levels, often integrated into the dashboard.

Climate Control:

Manual or automatic climate control systems depending on trim. Available rear climate controls on some LWB models.

Cruise Control:

Standard on most models.

Parking Sensors:

Rear parking sensors may be available as an option on some later models.

Power Accessories:

Power windows, power door locks, power mirrors standard on most trims.

Keyless Entry:

Available on higher trim levels.

🔧 Maintenance

Oil Change Interval:

Every 5,000-10,000 km (3,000-6,000 miles) or 6-12 months, depending on driving conditions and oil type. Manual specifies detailed intervals.

Air Filter Replacement:

Every 20,000-40,000 km (12,000-25,000 miles) or as needed based on dusty conditions.

Spark Plug Replacement Gasoline:

Platinum-tipped plugs typically 90,000-100,000 km (55,000-60,000 miles). Iridium plugs can last longer. Refer to manual for specific type and interval.

Timing Belt Replacement:

Critical maintenance item for 6G7 series engines. Typically 80,000-100,000 km (50,000-60,000 miles). Failure can cause severe engine damage. Manual will specify exact interval and recommended replacement parts (belt, tensioner, idler pulleys, water pump).

Engine Oil Spec:

SAE 10W-30 or 10W-40 API SG, SH, SJ, SL classification for gasoline engines. Diesel oil specifications vary, consult manual. Oil capacity typically 4.5-5.5 liters.

Coolant Spec:

Ethylene glycol-based antifreeze. Mitsubishi Super Long Life Coolant (LLC) or equivalent. A 50/50 mix with distilled water is standard. Capacity around 8-10 liters.

Brake Fluid Spec:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid Spec:

DEXRON II or III ATF or equivalent power steering fluid.

Engine Oil Leaks:

Common areas for oil leaks include valve cover gaskets, oil pan gaskets, and crankshaft seals, particularly with higher mileage vehicles.

Timing Belt Failure:

As mentioned, crucial to adhere to replacement intervals. Some model years may have issues with tensioners or idler pulleys. Manual will detail inspection and replacement procedures.

Automatic Transmission Shifts:

Intermittent or harsh shifting can sometimes be related to TCU programming, solenoid issues, or fluid degradation. Manual covers diagnostic steps.

Suspension Wear:

Bushings, ball joints, and tie rod ends can wear over time, leading to noise and steering looseness. Regular inspection recommended.

Exhaust Manifold Cracks:

Some V6 engines can develop cracks in the exhaust manifolds, leading to exhaust leaks and ticking noises.

Air Conditioning Leaks:

Leaking refrigerant lines or seals can affect AC performance.

📚 Vehicle History

Mitsubishi Off Road:

Mitsubishi has a long and distinguished history in off-road motorsport, including numerous Dakar Rally victories, which heavily influenced the Pajero's design and engineering.

Third Gen Launch:

The third generation Pajero (NM in Australia/Japan, NP in North America) launched in late 1999 for the 2000 model year, introducing a significant redesign with a unibody chassis and independent front suspension for improved on-road manners while retaining strong off-road capabilities.

Nm To Np Updates:

The NP Pajero (2003 model year in North America) received updates including revised styling, enhanced interior features, and powertrain improvements, notably the introduction of the 3.8L V6 engine in some markets.

Manufacturing Locations:

Primarily manufactured in Japan, with production also occurring in Australia (for the Australian market) and potentially other global locations depending on market.

🏆 Awards & Recognition

Off Road Awards:

The Pajero/Montero has consistently received high praise and awards for its off-road capabilities from various automotive publications and organizations globally.

Reliability Ratings:

Generally regarded as a reliable vehicle, though specific year and engine variants may have individual performance histories. The manual aids in maintaining this reliability.

Emission Standards:

Meets various regional emission standards depending on the market of sale. Manual provides diagnostic and repair procedures related to emission control systems.