1. Introduction
This manual provides detailed service and repair information for Mitsubishi Pajero vehicles produced from 1997 to 2014. It is designed for both professional technicians and experienced do-it-yourself mechanics. The content covers various aspects of vehicle maintenance, diagnosis, and repair, including engine, transmission, chassis, electrical systems, and bodywork. Adherence to the procedures outlined in this manual is crucial for safe and effective vehicle servicing.
Image 1.1: Front cover of the Mitsubishi Pajero Automotive Repair Manual, illustrating the scope of the publication for models from 1997 to 2014.
2. Vehicle Identification
Accurate identification of your Mitsubishi Pajero model is essential before commencing any repair or maintenance work. Key identification points include:
- Vehicle Identification Number (VIN): Located on the dashboard (visible through the windshield) and on the driver's side door jamb.
- Engine Code: Stamped on the engine block. Refer to the manual's specifications section for specific engine code locations.
- Model Year: Typically part of the VIN or found on the vehicle's compliance plate.
Ensure that the information in this manual corresponds to your specific vehicle's year, engine type, and transmission configuration.
3. Safety Precautions
Always prioritize safety when working on any vehicle. Failure to follow proper safety procedures can result in serious injury or damage to the vehicle. Key safety guidelines include:
- Wear appropriate personal protective equipment (PPE), such as safety glasses, gloves, and sturdy footwear.
- Ensure the vehicle is securely supported on jack stands before working underneath it. Never rely solely on a jack.
- Disconnect the battery's negative terminal before working on electrical components.
- Allow hot engine components to cool before handling.
- Work in a well-ventilated area, especially when dealing with fuel, exhaust fumes, or cleaning solvents.
- Keep a fire extinguisher readily accessible.
4. General Maintenance
Regular maintenance is crucial for the longevity and reliable operation of your Mitsubishi Pajero. This section details routine service procedures, including:
- Oil and filter changes (engine, transmission, differential)
- Air filter and fuel filter replacement
- Spark plug inspection and replacement
- Brake system inspection and fluid replacement
- Coolant system flush and refill
- Tire rotation and pressure checks
- Belt and hose inspection
Refer to the maintenance schedule provided in this manual for recommended service intervals based on mileage or time.
5. Engine Repair and Overhaul
This section covers detailed procedures for diagnosing, repairing, and overhauling the various engine types found in the 1997-2014 Mitsubishi Pajero models. Topics include:
- Cylinder head removal and installation
- Piston and connecting rod service
- Crankshaft and main bearing replacement
- Timing belt/chain replacement procedures
- Fuel injection system diagnosis and repair
- Turbocharger inspection and replacement (where applicable)
Specific instructions are provided for both petrol and diesel engine variants.
6. Transmission and Drivetrain
Detailed instructions for servicing and repairing the manual and automatic transmissions, transfer cases, and differential units are provided. This includes:
- Transmission removal and installation
- Clutch replacement (manual transmission)
- Automatic transmission fluid and filter service
- Transfer case and differential fluid changes
- Driveshaft and axle shaft service
7. Braking System
This section covers all components of the braking system, ensuring safe and effective stopping power. Procedures include:
- Brake pad and rotor replacement (front and rear)
- Brake caliper service
- Brake fluid flushing and bleeding
- Anti-lock Braking System (ABS) component testing and replacement
- Parking brake adjustment and repair
8. Suspension and Steering
Guidance on maintaining and repairing the vehicle's suspension and steering components for optimal handling and ride comfort:
- Shock absorber and strut replacement
- Coil spring and leaf spring service
- Ball joint and control arm replacement
- Steering rack/box service
- Power steering pump and hose replacement
- Wheel alignment procedures
9. Electrical System
This section provides comprehensive information for diagnosing and repairing electrical issues, including detailed wiring diagrams. Topics covered:
- Battery testing and replacement
- Alternator and starter motor service
- Lighting system diagnosis and repair
- Wiper and washer system service
- Fuse box and relay identification
- Sensor testing and replacement
10. Bodywork and Interior
Instructions for minor body repairs, trim removal, and interior component service:
- Door panel removal and window regulator service
- Seat removal and installation
- Exterior trim and molding replacement
- Minor dent and scratch repair techniques
11. Troubleshooting Guides
This section offers systematic troubleshooting charts to help diagnose common problems based on symptoms. It includes:
- Engine starting issues
- Poor engine performance
- Brake system malfunctions
- Suspension noises
- Electrical component failures
Follow the diagnostic steps carefully to identify the root cause of the issue.
12. Technical Specifications
A comprehensive list of technical data, including:
- Engine torque specifications
- Fluid capacities and types (engine oil, coolant, transmission fluid, brake fluid)
- Tire pressure recommendations
- Electrical component resistance values
- Vehicle dimensions and weights
Always refer to these specifications for accurate adjustments and component selection.
13. Important Regional Information
Note for USA Buyers: This repair manual primarily covers international Mitsubishi Pajero models (e.g., NL, NM/NP, NS, NT, NW Petrol, NW Diesel). While some information may be applicable, it may not fully cover specific variants or components found in Mitsubishi Montero models sold in the USA. Users in the USA seeking in-depth repair information for their specific Montero model may need to consult resources tailored to the USA market.
14. Support
For any questions regarding the content or specific procedures within this manual, please contact the publisher, Haynes Manuals Inc. Ensure you have the manual's ISBN or product details ready when making an inquiry.
Publisher: Haynes Manuals Inc
