2001 Mitsubishi Pajero GLS, XLS, Limited, Exceed Workshop Manual (P/N PWJE0001)

• 2001-2002 Pajero/Montero coverage: Matches V64W, V65W, V68W, V74W, V75W, and V78W model codes in the V60/V70 chassis family, including short- and long-wheelbase bodies, 3-door and 5-door layouts, and European LHD and RHD specifications.
• Engine and fuel-system procedures: Separates the 6G74 GDI gasoline, 4M41 DOHC intercooler-turbo diesel, and 4D56 diesel systems, with timing-belt or timing-chain service, cylinder-head-gasket work, engine removal and installation, injection diagnosis, pump service, injector checks, and ECU testing.
• Transmission and 4WD diagnosis: Details V5MT1/V5M31 manual and V5A51 automatic applications, including A/T and Super Select 4WD II troubleshooting, torque-converter stall and fluid-pressure testing, shift-lock/key-interlock diagnosis, transmission controls, transfer-ECU checks, and assembly removal and installation.
• Axles, brakes, and steering: Documents front and rear differential repair, freewheel clutch and rear differential lock service, propeller shafts, suspension, steering gear and pump work, hydraulic brake booster diagnosis, ABS fault tracing, brake bleeding, and wheel-speed/G-sensor checks.
• Electrical, SRS, body, and HVAC systems: Includes post-collision SRS diagnosis, airbag and clock-spring service, seat-belt pretensioner updates, SWS and immobilizer troubleshooting, combination-meter and body-electrical testing, plus manual and automatic A/C repair procedures.
• Document identity and size: 1,874 PDF pages in 39 files - the PWJE0001 chassis workshop set contains 1,848 pages, plus a 26-page Mitsubishi Stability Control supplement with separate 6G7 and 4M4 circuit diagrams for LHD and RHD vehicles.

V60/V70 Model Codes and Revision Structure

The vehicle-identification tables decode the exact configuration before repair information is selected. V6 denotes the short-wheelbase chassis and V7 the long-wheelbase chassis; M identifies a 3-door body and L a 5-door body. Engine and transmission combinations include the 4D56 with a V5MT1 or V5M31 manual transmission, the 4M41 with a V5M31 manual or V5A51 automatic, and the 6G74 GDI with a V5M31 manual or V5A51 automatic. Buyers using the Montero name should match the model code, engine, transmission, steering side, and market specification rather than relying on the badge alone.

This file set combines the 2001 base workshop sections with Mitsubishi-issued service bulletins, a 2001 model-year supplement, and group-specific 2002 change pages. The 2002 material builds on the 2001 procedures instead of repeating the entire manual. Important additions include the electronically controlled 4D56 Step III fuel and emissions system, revised SRS coverage for seat-belt pretensioners, and updates affecting cooling, intake/exhaust, automatic transmission, trim, mirrors, and electrical equipment.

Integrated bulletins correct or expand 4M41 timing-chain replacement, bearing-block removal and installation, valve-clearance inspection, GDI idle learning, transmission removal, rear-suspension alignment, side-step installation, and headlamp aiming information.

Powertrain, 4WD, and Chassis Procedures

The engine chapters are organized around work performed in the vehicle or during major-component removal. They cover 6G74 timing-belt replacement, 4D56 timing-belt and balance-belt service, 4M41 timing-chain work, oil-pan and oil-seal procedures, camshaft service, cylinder-head-gasket replacement, and engine-assembly removal and installation.

The fuel groups go considerably deeper into system diagnosis. The 6G74 GDI section separates manual- and automatic-transmission troubleshooting and provides diagnosis-code charts, freeze-frame data where applicable, MUT-II data and actuator tests, ECU-terminal checks, fuel-pressure testing, injector and high-pressure-pump service, throttle-body adjustment, and injector-driver checks. The 4M41 and 4D56 Step III chapters add injection-timing checks, pump and nozzle procedures, sensor testing, fail-safe logic, and ECU diagnosis.

The automatic-transmission group includes road-test logic, solenoid and sensor diagnosis, hydraulic-circuit references, line-pressure adjustment, control-cable setup, transfer operation checks, and A/T-ECU and transfer-ECU inspection. Axle groups document hub and knuckle work, drive-shaft service, differential-carrier disassembly and setup, pinion-height and preload checks, freewheel-clutch operation, and rear differential-lock testing.

Brake sections cover both non-ABS and ABS configurations, including the hydraulic brake booster, warning-buzzer circuits, MUT-II diagnosis, system bleeding, disc-brake service, load-sensing proportioning valve checks, wheel-speed sensors, and G sensor. Across these groups, the reference tables provide component-specific tightening torques, lubricants and capacities, service limits, clearances, pressure-test data, and electrical inspection values.

Electrical References, Tools, and Repair Cautions

Named visual references include the Gasoline Direct Injection System Diagram, Mitsubishi Stability Control System Diagram and System Circuit Diagram, the centralized-junction circuit, floor-console wiring-harness configuration diagrams, SC-ECU/G-sensor installation-position views, and SRS-ECU harness-terminal routing.

The procedures identify factory tools such as MUT-II MB991502, SRS harness probe MB991222, belt-tension meter set MB991668, fuel-pressure gauge set MB991637, and the specified differential pinion-height and preload fixtures.

Several cautions are easy to miss in a generic repair guide. Before SRS work, the negative battery cable must be disconnected and insulated, followed by the required 60-second discharge period. The clock spring must be centered on its mating marks or its flat cable can be severed when the steering wheel turns; front-probing the plated SRS terminals can also damage the connector contact surface. The axle chapters warn against placing vehicle weight on a wheel bearing before the drive-shaft nut is fully tightened, while the GDI section prohibits altering the factory-set throttle stop because the ECU can learn an incorrect closed-throttle position.

What PWJE0001 Does Not Replace

PWJE0001 is the chassis workshop manual, not the separate engine-overhaul, technical-information, full electrical-wiring, or collision body-repair publication. Mitsubishi states that detailed internal inspection, adjustment, disassembly, and reassembly of an engine or transmission after it has been removed requires the separate engine or transmission manual.

The included body chapters cover glass, doors, latches, sunroof, trim, seats, and exterior equipment, but not the separate PBJE0001 body-repair book. Likewise, this set contains system-specific electrical diagnosis and a Mitsubishi Stability Control wiring supplement, not the complete PHJE0001 electrical-wiring manual.