Mitsubishi Pajero Sport 1999 2000 2001 2002 Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero Sport Model Years Covered: 1999, 2000, 2001, 2002 Codes Platform Code: K90 Series (Second Generation) 👋 Introduction Market Position Segment: Mid-size SUV, often positioned as a capable off-road vehicle with rugged construction. Competitive Analysis Key Competitors: Toyota 4Runner, Nissan Pathfinder, Jeep Cherokee (XJ/WJ), Ford Explorer, Isuzu Rodeo. Key Features Off Road Capability: Body-on-frame construction, available 4WD system (Super Select 4WD or similar), robust suspension designed for off-road use. Durability: Known for its sturdy build and reliable mechanical components, suitable for demanding conditions. Practicality: Spacious interior for its class, good towing capacity, versatile for family use and outdoor adventures. 📋 Manual Details Coverage Areas Region Covered: Global (based on factory specifications, may vary by market) Market Focus: Service and Repair Page Count Estimated Page Count: Likely extensive, typical for factory service manuals of this era (estimated 1500-2500+ pages, actual count not provided but implied by detail level) Manual Type Type: Official Factory Service Repair Shop Manual Language Language: English Format Digital Format: PDF Accessibility: Downloadable via email link, accessible on various devices (PC, tablet, smartphone) with PDF reader. 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, lubrication system, cooling system, exhaust system, engine management, transmission (automatic and manual), drivetrain (4WD system, differentials, driveshafts). Chassis: Suspension (front and rear), steering system, braking system, wheels and tires, frame and body mounting. Electrical: Wiring diagrams, charging system, starting system, lighting, ignition system, instrumentation, power accessories, HVAC controls, body electrical components. Body: Body construction, interior trim, exterior trim, doors, windows, sunroof (if applicable), bumpers, glass replacement. Engine Management System: Includes engine control unit (ECU) operation, sensor data interpretation, and diagnostic trouble codes (DTCs). Intake And Exhaust System: Covers air intake components, exhaust manifold, catalytic converter, mufflers, and pipes. Lubrication And Cooling System: Includes oil pump, oil filter, oil passages, radiator, water pump, thermostat, hoses, and fan operation. Procedures Included Maintenance: Routine maintenance checks, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, lubrication points. Repair: Component disassembly and reassembly, component repair, troubleshooting common issues, diagnostic procedures, engine rebuild, transmission overhaul. Diagnostics: Detailed diagnostic flowcharts, symptom-based troubleshooting, electrical circuit testing, on-board diagnostics (OBD-II if applicable). Troubleshooting Charts: Extensive charts linking symptoms to potential causes and diagnostic steps, aiding in efficient problem diagnosis. Tune Ups: Detailed instructions for performing tune-ups, including spark plug replacement, ignition timing checks, and fuel system adjustments. Assembly And Disassembly: Step-by-step instructions with exploded diagrams for virtually every component of the vehicle. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls, including detailed torque specifications, tolerances, and OEM procedures. Oem Specifications: Provides precise OEM specifications for torque values, clearances, compression ratios, fluid pressures, electrical resistance, and more. Wiring Diagrams: Comprehensive and detailed electrical wiring diagrams for all vehicle systems, crucial for electrical troubleshooting. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely searchable text content due to PDF format (depends on OCR quality of the original scan). Print Quality Printability: Printable (user can print sections or entire manual). Binding Type Binding: Digital (No physical binding). Paper Type Paper Type: Not Applicable (Digital file). ⚙️ Engine Specifications Primary Engine Engine Type: V6 SOHC MPI (Multi-Point Injection) Engine Code: 6G72 (3.0L) or 6G74 (3.5L) depending on specific market and trim. Displacement: 2972 cc (3.0L) or 3497 cc (3.5L) Bore X Stroke: Refer to manual for specific engine code Performance Horsepower: Approx. 175-185 hp (3.0L) or 195-210 hp (3.5L) - exact figures vary by market and tune. Torque: Approx. 245-270 Nm (3.0L) or 300-330 Nm (3.5L) - exact figures vary by market and tune. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) / Multi-Point Fuel Injection (MPI) Fuel Type: Unleaded gasoline (Octane rating to be confirmed in manual) 🔧 Transmission Standard Transmission Type: 4-speed automatic (INVECS-II) or 5-speed manual transmission. Optional Optional Transmission: Availability of 5-speed manual on certain trims, or different automatic variants. Features Drive System: Part-time 4WD with selectable 2WD, 4WD High, and 4WD Low (Super Select 4WD-II on some models). Transfer Case: Robust transfer case with locking center differential on some 4WD systems. 📐 Dimensions Exterior Wheelbase: Approx. 2725 mm (107.3 inches) Length: Approx. 4610 mm (181.5 inches) Width: Approx. 1775 mm (69.9 inches) Height: Approx. 1785 mm (70.3 inches) (without roof rails) Weights Curb Weight: Approx. 1850-2000 kg (4078-4409 lbs) depending on configuration. Gross Vehicle Weight Rating: Refer to vehicle compliance plate or manual. Towing Capacity: Refer to manual and local regulations, typically around 2500 kg (5500 lbs) braked. 🛡️ Safety Features Ratings NHTSA Rating: Not specifically rated by NHTSA for these years in all markets; designed to meet contemporary safety standards. Active Features ABS: Anti-lock Braking System (ABS) often standard or available on higher trims. Traction Control: Traction Control System (TCS) available on some models. Passive Features Airbags: Driver and front passenger airbags....
Extensive charts linking symptoms to potential causes and diagnostic steps, aiding in efficient problem diagnosis.
Tune Ups:
Detailed instructions for performing tune-ups, including spark plug replacement, ignition timing checks, and fuel system adjustments.
Assembly And Disassembly:
Step-by-step instructions with exploded diagrams for virtually every component of the vehicle.
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls, including detailed torque specifications, tolerances, and OEM procedures.
Oem Specifications:
Provides precise OEM specifications for torque values, clearances, compression ratios, fluid pressures, electrical resistance, and more.
Wiring Diagrams:
Comprehensive and detailed electrical wiring diagrams for all vehicle systems, crucial for electrical troubleshooting.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely searchable text content due to PDF format (depends on OCR quality of the original scan).
Print Quality
Printability:
Printable (user can print sections or entire manual).
Binding Type
Binding:
Digital (No physical binding).
Paper Type
Paper Type:
Not Applicable (Digital file).
⚙️ Engine Specifications
Primary Engine
Engine Type:
V6 SOHC MPI (Multi-Point Injection)
Engine Code:
6G72 (3.0L) or 6G74 (3.5L) depending on specific market and trim.
Displacement:
2972 cc (3.0L) or 3497 cc (3.5L)
Bore X Stroke:
Refer to manual for specific engine code
Performance
Horsepower:
Approx. 175-185 hp (3.0L) or 195-210 hp (3.5L) - exact figures vary by market and tune.
Torque:
Approx. 245-270 Nm (3.0L) or 300-330 Nm (3.5L) - exact figures vary by market and tune.
Unleaded gasoline (Octane rating to be confirmed in manual)
🔧 Transmission
Standard
Transmission Type:
4-speed automatic (INVECS-II) or 5-speed manual transmission.
Optional
Optional Transmission:
Availability of 5-speed manual on certain trims, or different automatic variants.
Features
Drive System:
Part-time 4WD with selectable 2WD, 4WD High, and 4WD Low (Super Select 4WD-II on some models).
Transfer Case:
Robust transfer case with locking center differential on some 4WD systems.
📐 Dimensions
Exterior
Wheelbase:
Approx. 2725 mm (107.3 inches)
Length:
Approx. 4610 mm (181.5 inches)
Width:
Approx. 1775 mm (69.9 inches)
Height:
Approx. 1785 mm (70.3 inches) (without roof rails)
Weights
Curb Weight:
Approx. 1850-2000 kg (4078-4409 lbs) depending on configuration.
Gross Vehicle Weight Rating:
Refer to vehicle compliance plate or manual.
Towing Capacity:
Refer to manual and local regulations, typically around 2500 kg (5500 lbs) braked.
🛡️ Safety Features
Ratings
NHTSA Rating:
Not specifically rated by NHTSA for these years in all markets; designed to meet contemporary safety standards.
Active Features
ABS:
Anti-lock Braking System (ABS) often standard or available on higher trims.
Traction Control:
Traction Control System (TCS) available on some models.
Passive Features
Airbags:
Driver and front passenger airbags.
Seatbelts:
Three-point seatbelts with pretensioners.
Body Structure:
Reinforced safety cell and crumple zones for crash energy absorption.
💡 Technology Features
Infotainment
Audio System:
Factory fitted AM/FM radio with cassette player, CD player optional on higher trims. Limited digital integration by modern standards.
Driver Assistance
Cruise Control:
Available on most models.
Power Accessories:
Power windows, power door locks, power mirrors common features.
Connectivity
Connectivity Features:
No integrated Bluetooth or USB connectivity; aftermarket solutions are typically required for modern smartphone integration.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions (refer to manual for exact intervals).
Timing Belt Replacement:
Crucial for 6G7 series V6 engines. Typically recommended every 60,000-90,000 miles (100,000-150,000 km). Failure can cause catastrophic engine damage. Manual will specify interval and procedure.
Fluid Specifications
Engine Oil:
API SJ or SL, SAE 10W-30 or 10W-40, capacity approx. 4.5-5.0 liters (refer to manual for exact specification and capacity).
Coolant:
Ethylene glycol-based antifreeze/coolant, typically a 50/50 mix with distilled water. Specific type and capacity in manual.
API GL-4 or GL-5 gear oil, SAE 75W-90. Capacity approx. 2.5-3.0 liters.
Differential Fluid:
API GL-5 gear oil, SAE 80W-90 or 90. Capacity for front and rear differentials typically around 1.5-2.0 liters each.
Known Issues
Automatic Transmission:
Some models may experience occasional harsh shifting or delayed engagement, potentially related to valve body or transmission control module issues. Regular fluid changes are critical.
Transfer Case Actuator:
Issues with the electronic actuator for the 4WD system can occur, leading to failure to engage 4WD. The manual will detail diagnostic and repair procedures.
Engine Cooling System:
Radiator leaks, thermostat failures, or fan clutch issues can lead to overheating if not addressed promptly. Timing belt service is paramount.
Suspension Bushings:
Wear in suspension bushings can lead to clunking noises, poor handling, and premature tire wear. Replacement is a common maintenance item.
📚 Vehicle History
Brand Heritage
Mitsubishi Offroad Legacy:
Mitsubishi has a long history in off-road vehicles and rallying, notably with the Pajero/Montero lineage.
Model Evolution
Pajero Sport Introduction:
The Pajero Sport (also known as Montero Sport in North America) was introduced as a more affordable, often less luxurious, but equally capable off-road oriented SUV based on the Pajero platform.
Second Generation K90:
The K90 series Pajero Sport, covered by this manual, represented the second generation, featuring updated styling and mechanicals over the original.
Production
Production Period:
1996-2008 for the second generation (K90 series), with these specific years falling within that range.
🏆 Awards & Recognition
Recognitions
Offroad Awards:
While specific awards for the Pajero Sport of this era might be market-specific, Mitsubishi's overall Pajero/Montero line has a strong reputation in off-road competitions and enthusiast circles.
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