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2009 Mitsubishi Pajero (Montero) Workshop Repair Service Manual (MUT-III)-556MB

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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero (Montero) Year: 2009 Codes Chassis Code: V80/V90 Series (3rd Generation Facelift / 4th Generation depending on market interpretation) Platform: Pajero V Series...
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2009 Mitsubishi Pajero (Montero) Workshop Repair Service Manual (MUT-III)-556MB
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Pajero (Montero)
Year:
2009
Codes
Chassis Code:
V80/V90 Series (3rd Generation Facelift / 4th Generation depending on market interpretation)
Platform:
Pajero V Series
👋 Introduction
Market Position
Vehicle Segment:
Full-size body-on-frame SUV, known for off-road capability and ruggedness.
Brand Perception:
Mitsubishi's reputation for durable and capable off-road vehicles is carried by the Pajero/Montero.
Competitive Analysis
Key Competitors:
Toyota Land Cruiser Prado, Nissan Patrol, Land Rover Discovery, Jeep Grand Cherokee, Chevrolet TrailBlazer (depending on market).
Key Features
Vehicle Strengths:
Renowned Super Select 4WD system (on many variants), robust chassis, comfortable ride for its class, good off-road articulation.
Manual Value Proposition:
Provides owners and technicians with the essential, accurate information needed to maintain and repair the 2009 Pajero/Montero, ensuring longevity and optimal performance.
📋 Manual Details
Coverage Areas
Region Coverage:
Global (applicable to models sold worldwide)
Market Specific Variants:
Includes information relevant to North American (Montero) and international (Pajero) specifications where applicable.
Page Count
Estimated Page Count:
Detailed and extensive, typical for a full workshop manual. Exact page count not specified in product data but file size (556MB) indicates comprehensive coverage.
Manual Type
Type:
Workshop Repair Service Manual
Tool Integration:
MUT-III (Mitsubishi Under Car Diagnosis System) compatible information, referencing diagnostic procedures and data.
Language
Language:
English
Format
Digital Format:
Likely PDF, given the file size and 'printable' description.
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system.
Drivetrain:
Transmission (Automatic & Manual), Transfer Case, Driveshafts, Differentials (Front, Center, Rear), Axles.
Chassis:
Suspension (Front & Rear), Steering System, Brake System (Hydraulic & ABS), Wheels & Tires.
Electrical:
Engine Control Module (ECM), Powertrain Control Module (PCM), Body Control Module (BCM), Lighting, Instrumentation, Audio System, HVAC Controls, Power Accessories (Windows, Locks, Mirrors), SRS Airbag System, Anti-theft System, Diagnostic System.
Body And Frame:
Body Panels, Doors, Hood, Tailgate, Interior Trim, Seating, Exterior Trim, Frame/Unibody Structure.
Procedures Included
Maintenance:
Routine inspections, fluid changes (oil, coolant, brake fluid, transmission fluid, differential fluid), filter replacements, lubrication.
Repair And Rebuild:
Engine overhaul, transmission overhaul, suspension component replacement, brake caliper/rotor replacement, steering rack repair, electrical component diagnosis and replacement.
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, wiring diagrams, diagnostic trouble codes (DTCs) with explanations and P-codes, freeze frame data analysis.
Specifications And Tolerances:
Torque specifications, clearances, fluid capacities, component measurements, alignment data.
Special Tools:
Lists and descriptions of special tools required for specific repair and diagnostic procedures.
Technical Depth
Depth:
Comprehensive. Covers everything from basic maintenance to in-depth diagnostics and full component rebuilds.
Diagnostic Focus:
Detailed diagnostic flowcharts and electrical schematics for troubleshooting complex issues.
📊 Manual Specifications
File Format
Format:
Digital (most likely PDF), with 556MB file size indicating high detail and potentially images/diagrams.
Print Quality
Printability:
Explicitly stated as 'Printable!', allowing for physical copy creation.
Binding Type
Binding For Print:
If printed, typically comb-bound or spiral-bound for lay-flat usability in a workshop environment.
Paper Type
Paper Quality For Print:
Recommended: Heavyweight, durable paper to withstand workshop conditions.
Searchability
Text Searchability:
Assuming PDF, text should be searchable for quick access to specific information.
⚙️ Engine Specifications
Primary Engine
Engine Code Common:
3.8L V6 (6G75) is a prevalent option for 2009 in many markets. 3.2L Di-D Diesel (4M41) also common.
Engine Displacement 3.8L V6:
3.8 Liters (3828 cc)
Engine Displacement 3.2L Diesel:
3.2 Liters (3200 cc)
Performance
Horsepower 3.8L V6:
Approximately 235-250 hp @ 5250-5500 rpm (varies by market and tune).
Torque 3.8L V6:
Approximately 260-270 lb-ft @ 4000-4500 rpm (varies by market and tune).
Horsepower 3.2L Di-D:
Approximately 175-180 hp @ 3800 rpm (varies by market and tune).
Torque 3.2L Di-D:
Approximately 280-295 lb-ft @ 2000-2750 rpm (varies by market and tune).
Fuel System
Fuel System V6:
Electronic Fuel Injection (MPI - Multi-Point Injection)
Fuel System Diesel:
Common Rail Direct Injection (CRDI)
Engine Management
Engine Control:
ECU (Engine Control Unit) with OBD-II/EOBD diagnostics.
Engine Construction
Block Material V6:
Aluminum Alloy
Head Material V6:
Aluminum Alloy
🔧 Transmission
Standard
Transmission Type V6 Common:
5-speed Automatic
Optional
Transmission Type Manual:
5-speed Manual (less common in some markets for 2009).
Transmission Type Diesel:
5-speed Automatic or 5-speed Manual
Features
Transfer Case:
Mitsubishi's renowned 'Super Select II' or 'Easy Select' 4WD system, offering 2WD, 4WD High, 4WD Low, and often a locking center differential.
Fluid Specifications
Automatic Transmission Fluid:
Specific to Mitsubishi ATF SP-III or equivalent. Consult manual for exact specification and capacity.
Manual Transmission Fluid:
GL-4 or GL-5 gear oil. Consult manual for viscosity grade (e.g., 75W-90) and capacity.
Transfer Case Fluid
Transfer Case Oil:
GL-5 gear oil. Consult manual for viscosity grade and capacity.
📐 Dimensions
Exterior
Length:
Approx. 4850 - 4900 mm (varies slightly by body style - short/long wheelbase).
Width:
Approx. 1875 - 1900 mm.
Height:
Approx. 1850 - 1900 mm.
Wheelbase:
Approx. 2780 mm (long wheelbase).
Weights
Curb Weight:
Approx. 2100 - 2300 kg (varies significantly by engine, drivetrain, and trim).
Gross Vehicle Weight Rating Gvwr:
Approx. 2800 - 3000 kg.
Towing Capacity:
Varies by market and configuration, typically around 2500-3500 kg.
🛡️ Safety Features
Ratings
NHTSA Crash Test Results:
Refer to specific market's NHTSA or equivalent agency ratings. Generally performed well for its class and era, but specific scores may vary.
Active Features
ABS:
Standard Anti-lock Braking System.
E Bd:
Electronic Brakeforce Distribution.
Traction Control:
Active Traction Control (ATC) or Traction Control System (TCS).
Electronic Stability:
Electronic Stability Control (ESC) or Active Stability Control (ASC) may be available on certain trims/markets.
Passive Features
Airbags:
Front airbags for driver and passenger, side curtain airbags, and potentially front side-impact airbags depending on trim.
Seatbelts:
Three-point seatbelts with pre-tensioners and load limiters for front seats. Three-point rear seatbelts.
Rollover Protection:
Reinforced body structure, designed to mitigate rollover impact. Roll stability control may also be featured.
💡 Technology Features
Infotainment
Audio System:
Factory-fitted audio system with CD player, AM/FM radio, and potentially auxiliary input or Rockford Fosgate premium sound system on higher trims. Satellite radio may be an option.
Navigation:
Optional GPS navigation system available on select trims, likely a DVD-based or early hard-drive-based system.
Climate Control:
Manual or automatic climate control (ECC - Electronic Climate Control) with multi-zone capability on higher trims.
Driver Assistance
Cruise Control:
Standard cruise control system.
Parking Assist:
Rear parking sensors or rearview camera may be available on higher trims.
Connectivity
Bluetooth:
Bluetooth hands-free calling and audio streaming may be an option on higher trims or as an aftermarket addition.
Usb Aux:
Auxiliary audio input jack is common. USB ports may be present on later models or higher trims.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first. Consult manual for specific mileage/time based on driving conditions.
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km), or as needed based on driving environment.
Cabin Air Filter:
Every 12,000-15,000 miles (19,000-24,000 km) or annually.
Spark Plugs V6:
Iridium-tipped spark plugs typically have a long service life, often 60,000-100,000 miles (96,000-160,000 km). Consult manual for specific type and interval.
Timing Belt Or Chain:
The 6G75 V6 uses a timing belt. Replacement interval is critical, typically around 60,000-100,000 miles (96,000-160,000 km) or 7-10 years. The 4M41 diesel uses a timing chain, generally maintenance-free for the life of the engine.
Fluid Specifications
Engine Oil Type:
API SN/SP or ILSAC GF-5/GF-6 certified. Viscosity grade typically 5W-30 or 5W-20 for V6, and specific diesel oil for 4M41. Consult manual for exact grade and capacity.
Coolant Type:
Long-life (often pink or red) ethylene glycol-based coolant. Consult manual for specific Mitsubishi specification (e.g., DIA-QUEEN SUPER LONG LIFE COOLANT) and capacity.
Brake Fluid Type:
DOT 3 or DOT 4 hydraulic brake fluid.
Known Issues
Common Wear Items:
Suspension components (bushings, ball joints, tie rods) due to off-road use and vehicle weight, brake wear, exhaust system corrosion in certain climates.
Potential Powertrain Concerns:
Spark plug fouling on early V6 models, potential EGR issues on diesel engines, transmission shifting issues if fluid maintenance is neglected. Timing belt service is critical for the V6.
Electrical Quirks:
Occasional issues with window regulators, central locking actuators, or infotainment system glitches, typical for vehicles of this age.
📚 Vehicle History
Brand Heritage
Mitsubishi SUV Legacy:
Mitsubishi has a long history of producing capable off-road vehicles, dating back to the original Pajero in 1982, which cemented the brand's reputation.
Model Evolution
Fourth Generation:
The 2009 model belongs to the fourth generation (NW/NX series for some markets, often referred to as the facelifted third generation in others), introduced in 2006. This generation saw significant updates in styling, chassis, and technology.
Production
Manufacturing Location:
Primarily manufactured in Japan (Mizushima Plant, Kurashiki, Okayama Prefecture), with some regional assembly plants.
Production Period:
Fourth generation produced from 2006 to 2021 (with various facelifts), with the 2009 model being a mid-cycle example.
🏆 Awards & Recognition
Recognitions
Off Road Awards:
The Pajero/Montero lineage has received numerous accolades for off-road performance and durability in various international publications and rally events (e.g., Dakar Rally success for earlier generations).
Consumer Ratings:
Often praised for its capability and value in the large SUV segment, though reliability ratings from some consumer organizations can be mixed compared to segment leaders.
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