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Mitsubishi

Mitsubishi Pajero Montero Workshop Manual 2002

Mitsubishi Pajero Montero Workshop Manual 2002

$16.99
$16.99
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Vehicle data plateRef 298485
Brand
Mitsubishi
Vehicle
Cars
Models covered
Highlander, Montero, Pajero, Toyota
Years
2002
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

What happens after you pay

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  • The same link is emailed to you โ€” re-download any time
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๐Ÿท๏ธ Basic Information
Identification
Make:
Mitsubishi
Model:
Pajero / Montero
Year:
2002
Codes
Chassis Codes:
V60, V70 Series (e.g., V73W, V75W, V77W, V78W)
Engine Codes:
6G72 (3.0L V6), 6G74 (3.5L V6), 4M41 (3.2L DI-D Diesel)
Generation
Generation:
Third Generation (1999-2006)
๐Ÿ‘‹ Introduction
Market Position
Market Position:
The Mitsubishi Pajero/Montero of this era was a highly regarded mid-size SUV, known for its off-road capability, durability, and comfortable ride. It competed against vehicles like the Toyota Land Cruiser Prado, Nissan Pathfinder, and Jeep Grand Cherokee.
Competitive Analysis
Competitive Analysis:
The 2002 model year represented a mature third generation, offering advanced features for its time, including independent front suspension for better on-road manners and robust 4WD systems (Super Select II). This manual provides the essential technical data to maintain and repair these advanced systems.
Key Features
Key Features:
Iconic off-road SUV, monocoque chassis with body-on-frame construction (hybrid), advanced Super Select II 4WD system with locking center and rear differentials (on some models), comfortable interior, robust powertrain options.
๐Ÿ“‹ Manual Details
Coverage Areas
Coverage Areas:
Global (covers variations for different markets)
Page Count
Page Count:
Extensive (Full FSM, likely over 2000 pages)
Manual Type
Manual Type:
Factory Service Manual (FSM) / Workshop Manual
Language
Language:
English, Espanol, Francais, Deutsch
Format
Format:
Software Database Download (RAR archive containing PDF files)
๐Ÿ“– Manual Coverage
Systems Covered
Systems Covered:
General Information, Maintenance, Engine Mechanical, Engine Lubrication & Cooling Systems, Engine Fuel & Emission Control System, Accelerator Control, Fuel and Exhaust Systems, Clutch, Manual Transmission, Automatic Transmission, Propeller Shaft & Differential Carrier, Front Axle, Rear Axle, Front Suspension, Rear Suspension, Brake System, Steering System, Restraint System, Body and Trim, Heater, Air Conditioner, Electrical System, ETC (referring to a comprehensive list of vehicle systems)
Electrical System Details:
Comprehensive wiring diagrams, component testing, diagnostic procedures for all electrical systems including lighting, ignition, charging, fuel injection, body electronics, and HVAC controls.
Procedures Included
Procedures Included:
All service and repair procedures, maintenance schedules, diagnostic procedures, component removal and installation, electrical wiring diagrams, troubleshooting guides, specifications.
Engine Repair Procedures:
Engine assembly/disassembly, cylinder head service, piston and connecting rod installation, crankshaft and bearing replacement, valve timing, component torque specifications, diagnostic trouble codes (DTCs) and troubleshooting.
Transmission Repair Procedures:
Automatic and manual transmission overhaul, torque converter replacement, clutch service, gear inspection, transmission fluid and filter changes, electronic control unit (ECU) diagnostics.
Suspension And Steering Repair:
Front and rear suspension component replacement (shocks, struts, springs, control arms, bushings), wheel alignment specifications, power steering system service and repair, steering rack and linkage replacement.
Brake System Repair:
Brake pad and rotor replacement, caliper overhaul, brake line and hose replacement, master cylinder and brake booster service, ABS system diagnostics and repair.
Technical Depth
Technical Depth:
Comprehensive, technician-level detail suitable for dealership use. Includes in-depth diagnostics, component-level repair, and full rebuild procedures.
Diagnostic Capabilities:
Detailed diagnostic flowcharts for common problems, specific electrical diagnostic procedures, explanation of sensor inputs and outputs, and guidance on using diagnostic tools.
Component Specifications:
Includes critical specifications such as torque values for fasteners, piston ring end gap, bearing clearances, valve seat recession, and cylinder head flatness tolerances.
๐Ÿ“Š Manual Specifications
File Format
File Format:
RAR archive containing PDF files. Requires WinRAR or compatible software for extraction.
Print Quality
Print Quality:
Likely high-resolution scans of original factory documents, suitable for printing clear diagrams and text.
Binding Type
Binding Type:
Digital Download (Not applicable to physical binding)
Paper Type
Paper Type:
Digital PDF (Not applicable to physical paper type)
โš™๏ธ Engine Specifications
Primary Engine
Primary Engine:
3.5L V6 SOHC/DOHC (6G74). Also common are the 3.0L V6 (6G72) and 3.2L DI-D Turbo Diesel (4M41).
Performance
3.5L V6 Horsepower:
Approximately 200-215 hp (depending on DOHC/SOHC and market)
3.5L V6 Torque:
Approximately 230-245 lb-ft (depending on DOHC/SOHC and market)
Fuel System
Fuel System:
Multi-point Fuel Injection (MPI)
Engine Mechanical
Engine Block Material:
Aluminum Alloy (for V6 gasoline engines)
Cylinder Head Design:
DOHC (Double Overhead Camshaft) or SOHC (Single Overhead Camshaft) depending on specific engine variant.
Valvetrain:
Timing belt driven DOHC/SOHC. Hydraulic lash adjusters (on some models) or shims for valve clearance adjustment.
Cooling System
Coolant Type:
Mitsubishi DiaQueen Super Long Life Coolant (Green) or equivalent ethylene glycol-based coolant with corrosion inhibitors. Capacity: Approx. 8.7-9.5 liters.
๐Ÿ”ง Transmission
Standard
Standard Transmission:
4-speed Automatic Transmission (INVECS-II)
Optional
Optional Transmission:
5-speed Manual Transmission (on some models/markets)
Features
4 Speed Automatic Features:
INVECS-II (Intelligent & Innovative Vehicle Electronic Control System) with adaptive shift control.
Fluid Specs
Automatic Transmission Fluid:
DiaQueen SPII-ATF or equivalent Dexron III/Mercon ATF. Capacity: Approx. 8.0-9.5 liters (depending on model).
๐Ÿ“ Dimensions
Exterior
Wheelbase:
Approx. 2780 mm (109.4 inches)
Length:
Approx. 4750-4860 mm (187.0-191.3 inches)
Width:
Approx. 1815-1855 mm (71.5-73.0 inches)
Height:
Approx. 1860-1910 mm (73.2-75.2 inches)
Weights
Curb Weight:
Approx. 1950-2150 kg (4300-4740 lbs)
Gross Vehicle Weight Rating:
Approx. 2700-2800 kg (5950-6170 lbs)
Interior
Seating Capacity:
7 passengers (with third-row seating)
๐Ÿ›ก๏ธ Safety Features
Ratings
NHTSA Crash Test Results:
Results vary by year and specific test. Generally received good ratings for its class at the time, with some models offering advanced safety features.
Active Features
Active Features:
ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), Traction Control System (TCS), Active Stability Control (ASC) on some higher trims.
Passive Features
Passive Features:
Front airbags, optional side airbags, front and rear crumple zones, reinforced passenger cabin.
๐Ÿ’ก Technology Features
Infotainment
Infotainment Features:
Basic audio systems with cassette and CD players, optional premium sound systems. Climate control systems can be manual or automatic.
Driver Assistance
Driver Assistance Features:
Cruise control, park assist sensors (on some later models/trims), advanced 4WD system with electronic controls.
Connectivity
Connectivity Features:
Limited by 2002 standards. May include power outlets and basic antenna systems for radio.
Electrical System
Battery:
Typically a 12V system. Battery size and CCA depend on engine and market (e.g., Group 34R or similar).
Alternator:
Capacity varies by model and equipment, typically 90-110 Amps.
๐Ÿ”ง Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first, depending on driving conditions. Consult manual for specific recommendations.
Timing Belt Replacement:
For 6G72 and 6G74 V6 gasoline engines, typically every 60,000-100,000 miles (96,000-160,000 km). Crucial to follow the manual's interval as failure is catastrophic.
Fluid Specifications
Engine Oil Specification:
API SG, SH, or SJ certified. Viscosity typically SAE 10W-30 or 5W-30 (check manual for temperature-dependent recommendations). Capacity: Approx. 4.5-5.0 liters.
Brake Fluid Specification:
DOT 3 or DOT 4.
Power Steering Fluid:
Use genuine Mitsubishi power steering fluid or Dexron II/III ATF.
Differential Oil Specification:
Front and Rear Differential: Hypoid gear oil API GL-5, viscosity SAE 80W-90. Capacity: Front approx. 1.2-1.3L, Rear approx. 1.6-1.8L (depending on differential type).
Transfer Case Oil:
Mitsubishi DiaQueen SS II or equivalent. Viscosity SAE 75W-90. Capacity: Approx. 1.4-1.6L.
Grease Points:
Includes lubrication points for suspension, steering linkage, and driveshaft U-joints, specifying NLGI #2 multi-purpose grease.
Known Issues
Common Issues:
Timing belt failure if not replaced on schedule, radiator leaks, front CV joint wear, differential seal leaks, potential for transmission issues on high-mileage vehicles. Interior trim can be prone to wear.
๐Ÿ“š Vehicle History
Brand Heritage
Brand Heritage:
Mitsubishi has a long history in off-road vehicles, with the Pajero nameplate dating back to 1982. The Pajero is renowned for its Dakar Rally success, cementing its off-road credentials.
Model Evolution
Model Evolution:
The third generation (1999-2006) marked a significant shift with a monocoque chassis incorporating a 'space frame' for improved rigidity and on-road comfort compared to traditional body-on-frame designs. It introduced more sophisticated electronics and amenities.
4Wd System:
Super Select II 4WD system, offering 2WD High, 4WD High (with center differential unlocked or locked), and 4WD Low (with center differential locked). Features a planetary gear center differential.
Production
Production Locations:
Japan (primarily Mizushima Plant), and assembly plants in other countries like Brazil, China, and Iran.
๐Ÿ† Awards & Recognition
Recognitions
Recognitions:
The Pajero line has a storied history of winning the Dakar Rally, which significantly boosted its image as a capable off-road vehicle. Specific awards for the 2002 model year would vary by publication and region.

Delivery & file format

This is a digital PDF download, not a printed book. After payment the download link appears on your order confirmation page and is emailed to the address you entered. Files open in any PDF reader on phone, tablet or computer and can be printed.

Check the model year and engine before you buy

Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.

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