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Mitsubishi Pajero NP 2002-2006 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero Generation Code: NP Model Years Covered: 2002, 2003, 2004, 2005, 2006 Codes Platform Code: Third Generation Pajero (V60/V70 Series) 👋 Introduction Market...
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🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Pajero
Generation Code:
NP
Model Years Covered:
2002, 2003, 2004, 2005, 2006
Codes
Platform Code:
Third Generation Pajero (V60/V70 Series)
👋 Introduction
Market Position
Segment:
Large SUV / Off-Road Vehicle
Reputation:
Known for robust off-road capability and durability
Competitive Analysis
Competitors:
Toyota Land Cruiser Prado, Nissan Patrol, Ford Explorer, Jeep Grand Cherokee
Key Features
Platform Advantage:
Body-on-frame construction for ruggedness and towing capacity
Powertrain Highlight:
Available V6 and V8 gasoline engines, plus efficient diesel options (market dependent)
Drivetrain Highlight:
Legendary Super Select 4WD II system offering exceptional off-road performance and on-road versatility
Manual Value Proposition
Benefit To Owner:
Empowers owners with the knowledge to perform maintenance and repairs, saving time and money.
Benefit To Technician:
Provides authoritative, detailed procedures and specifications for efficient and accurate servicing.
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Service Repair
Scope:
Comprehensive repair and maintenance
Page Count
Total Pages:
4000
Manual Type
Type:
Digital Service Manual
Format:
PDF
Language
Language:
English
Availability
Delivery Method:
Instant Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system
Drivetrain:
Manual and Automatic Transmissions, Transfer Case (Super Select 4WD), Front and Rear Axles, Driveshafts, Differentials
Chassis:
Suspension (Front & Rear), Steering System, Braking System (ABS, Hydraulic)
Electrical:
Engine Control Unit (ECU), Body Control Module (BCM), Lighting, Instrumentation, Audio System, Power Accessories, Charging System, Starting System, Wiring Diagrams
Body And Interior:
Body Panels, Doors, Windows, Seats, HVAC System, Trim Components, Exterior Lighting
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication points, inspection procedures
Diagnostics:
Troubleshooting guides, fault code interpretation, symptom-based diagnostics, diagnostic tool usage
Repair:
Component removal and installation, major overhauls, system repairs, bodywork procedures
Specifications:
Torque specifications, clearances, fluid capacities, electrical specifications, diagnostic parameters
Technical Depth
Depth:
Comprehensive from basic fluid checks to complete engine and transmission rebuilds, including detailed electrical schematics.
Target Audience:
Professional Technicians and Enthusiast DIYers
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Searchable text for quick information retrieval
Print Quality
Quality:
High-resolution, clear diagrams and text for easy reading and printing
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code Gasoline:
6G72 (3.0L V6 SOHC)
Engine Code Gasoline Optional:
6G74 (3.5L V6 SOHC/DOHC MIVEC)
Engine Code Diesel:
4M41 (3.2L DOHC DI-D Turbo Diesel)
Performance 3.0L V6
Horsepower 3.0L V6:
Approx. 173-186 hp (129-139 kW)
Torque 3.0L V6:
Approx. 245-255 Nm (181-188 lb-ft)
Performance 3.5L V6
Horsepower 3.5L V6:
Approx. 202-235 hp (151-175 kW), depending on DOHC/MIVEC
Torque 3.5L V6:
Approx. 314-343 Nm (232-253 lb-ft), depending on DOHC/MIVEC
Performance 3.2L Di-D
Horsepower 3.2L Di-D:
Approx. 163 hp (122 kW)
Torque 3.2L Di-D:
Approx. 373 Nm (275 lb-ft)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI) for gasoline, Direct Injection (DI) for diesel
Fuel Type:
Unleaded Gasoline (91 RON minimum), Diesel Fuel
Cooling System
Coolant Type:
Ethylene Glycol based coolant (e.g., Mitsubishi Super Long Life Coolant)
Lubrication System
Oil Type 3.0L V6:
API SG or higher, SAE 10W-30 or 10W-40
Oil Capacity 3.0L V6:
Approx. 4.5 Liters (4.8 US Quarts)
Oil Type 3.5L V6:
API SG or higher, SAE 10W-30 or 10W-40
Oil Capacity 3.5L V6:
Approx. 4.5 Liters (4.8 US Quarts)
Oil Type 3.2L Di-D:
API CF-4 or API CG-4, SAE 5W-30 or 5W-40 (Synthetic recommended)
Oil Capacity 3.2L Di-D:
Approx. 7.8 Liters (8.2 US Quarts)
🔧 Transmission
Standard
Transmission Type Gasoline:
5-Speed Manual (W5M51-2 or similar)
Optional
Transmission Type Gasoline Automatic:
4-Speed Automatic (V4A51 or similar)
Transmission Type Diesel:
5-Speed Automatic (W5A51 or similar)
Features
Transfer Case:
Super Select 4WD II system with electronic engagement
Transfer Case Modes:
2H, 4H, 4HLC (Locked Center Diff), 4LLC (Locked Center & Low Range)
Fluid Specifications Automatic
Automatic Transmission Fluid:
DIA QUEEN ATF-SP II M or equivalent
Fluid Capacities
Automatic Transmission Capacity:
Approx. 8.5 - 9.5 Liters (8.9 - 10.0 US Quarts)
📐 Dimensions
Exterior
Length:
Approx. 4795 mm (188.8 in) for GLS LWB
Width:
Approx. 1875 mm (73.8 in)
Height:
Approx. 1855 mm (73.0 in) for GLS LWB
Wheelbase:
Approx. 2780 mm (109.4 in) for LWB
Weights
Curb Weight:
Approx. 1950 - 2150 kg (4300 - 4740 lbs), depending on configuration
Gvw:
Approx. 2700 - 2900 kg (5952 - 6393 lbs)
🛡️ Safety Features
Ratings
Ancap Rating:
4 Stars (for models tested circa early 2000s, specific results vary)
Active Features
ABS:
Standard on most models
Traction Control:
Optional or standard on higher trims
Electronic Stability Control:
Rarely equipped on this generation
Passive Features
Airbags:
Front airbags (driver & passenger) standard, side airbags optional on some trims
Seatbelts:
Three-point inertia-reel seatbelts with pretensioners
Chassis Design:
Reinforced body-on-frame construction
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM CD Player with optional Cassette, typically 6-speaker system.
Navigation:
Optional factory-fitted GPS navigation system on higher trim levels.
Driver Assistance
Cruise Control:
Standard on most models
Parking Sensors:
Rarely equipped
Connectivity
Auxiliary Input:
Typically not standard; aftermarket solutions common.
Climate Control
HVAC System:
Manual or automatic climate control with rear ventilation.
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first.
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months.
Fuel Filter Replacement Diesel:
Every 30,000 miles (48,000 km)
Spark Plug Replacement 3.0L V6:
Every 60,000 miles (96,000 km)
Timing Belt Replacement:
Every 60,000 miles (96,000 km) - Crucial for 6G72/6G74 engines.
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4
Power Steering Fluid:
DIA QUEEN PSF or equivalent (ATF Dexron II)
Transfer Case Fluid:
DIA QUEEN SUPER HYPOID GEAR OIL 80W-90 or equivalent
Differential Fluid Front Rear:
DIA QUEEN SUPER HYPOID GEAR OIL 80W-90 or equivalent
Known Issues
Engine:
Timing belt failure (if not replaced on schedule), oil leaks from valve covers and oil pan, potential for head gasket issues on higher mileage units.
Transmission:
Occasional automatic transmission shifting issues, potential for transfer case actuator problems.
Suspension And Steering:
Worn ball joints and tie rod ends, suspension bushings degrading over time, potential for power steering pump noise.
Electrical:
Corroded electrical connectors, issues with window regulators, potential alternator or starter motor failure.
Diesel Specific:
Glow plug issues, turbocharger problems, injector seal leaks (common on common rail diesels).
📚 Vehicle History
Brand Heritage
Mitsubishi Motors:
Established Japanese manufacturer with a long history in automotive production and motorsport.
Model Evolution
Pajero Lineage:
The Pajero (Montero in some markets) is Mitsubishi's flagship SUV, renowned for its off-road prowess since its debut in 1982.
Np Generation Introduction:
The NP Pajero (NP Pajero) represented a significant update to the third generation, incorporating styling revisions and updated powertrains.
Production
Manufacturing Locations:
Primarily Japan, with assembly in other global locations depending on market.
🏆 Awards & Recognition
Recognitions
Off Road Awards:
Consistently recognized for its off-road capabilities in various publications and competitions.
Ratings
Consumer Reports:
Mixed reviews, often praised for capability but criticized for fuel economy and some reliability concerns in specific areas compared to some competitors.
Certifications
Emissions Standards:
Compliant with prevailing emissions standards for its model years in respective markets.