Mitsubishi Pajero Montero Sport Nativa Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero Sport / Montero Sport / Nativa Codes Chassis Codes: K90, K80 series (typical for generation covered) Engine Codes: Likely includes 4M4x (Diesel) and 6G7x (Petrol) series engines. 👋 Introduction Market Position Vehicle Segment: Mid-size SUV, often positioned as a capable off-roader with comfortable on-road manners. Competitive Analysis Key Competitors: Toyota 4Runner, Ford Explorer, Nissan Pathfinder, Jeep Grand Cherokee, Chevrolet Trailblazer (depending on specific model year and market). Key Features Powertrain Options: Likely offered with robust diesel engines (e.g., 4M41) and capable gasoline V6 engines (e.g., 6G7x series) known for durability and towing capacity. Drivetrain: Typically features a Super Select 4WD system or similar, offering selectable 2WD and 4WD modes, including low-range gearing for off-road capability. 📋 Manual Details Coverage Areas Systems Covered: Engine Mechanical, Engine Control System, Fuel System, Exhaust, Cooling System, Air Conditioning System, Starting System, Charging System, Ignition System, Manual Transaxle, Automatic Transaxle, Transfer Case, Front Differential, Rear Differential, Drive Shafts, Front Suspension, Rear Suspension, Steering System, Front Brakes, Rear Brakes, Parking Brake, Wheels and Tires, Body Repair, Exterior Trim, Interior Trim, Electrical Systems, Wiring Diagrams, Emission Control Systems. Page Count Estimated Page Count: Likely 1000+ pages (typical for comprehensive factory service manuals). Manual Type Manual Type: Factory Service Repair Workshop Manual Language Language: English Format File Format: Zip / PDF Compatibility Operating Systems: Windows, Mac 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine teardown, inspection, assembly, torque specifications, component identification, timing belt/chain replacement, piston and ring installation, cylinder head service, crankshaft and bearing installation, oil pump and water pump service. Engine Control System: ECU identification, sensor testing and diagnosis (e.g., Crankshaft Position Sensor, Camshaft Position Sensor, MAP sensor, MAF sensor, O2 sensors, TPS), actuator testing (e.g., Idle Air Control Valve, EGR valve), fuel injector testing, diagnostic trouble codes (DTCs) and troubleshooting flowcharts. Fuel System: Fuel pump testing and replacement, fuel filter replacement, fuel injector cleaning and testing, fuel pressure regulation, fuel tank service, fuel lines and vapor emission control (EVAP) system diagnosis. Cooling System: Radiator service, water pump replacement, thermostat operation and replacement, coolant specifications and capacities, fan clutch/electric fan operation, heater core service, pressure testing the cooling system. Air Conditioning System: Refrigerant types and capacities, compressor operation and service, receiver/drier replacement, expansion valve or orifice tube service, leak detection, diagnostic procedures for cooling performance. Starting System: Starter motor testing, replacement, solenoid operation, battery testing and specifications, wiring and connection checks. Charging System: Alternator testing, output specifications, regulator function, battery charging system diagnosis, belt tension adjustment. Ignition System: Spark plug specifications and replacement, ignition coil testing, ignition module function, crankshaft and camshaft sensor roles in ignition timing. Manual Transaxle: Gearbox disassembly, inspection, assembly, gear ratio information, clutch system integration, shift mechanism service, fluid types and capacities, common wear points. Automatic Transaxle: Transmission fluid type and capacity, valve body operation, torque converter service, transmission control module (TCM) diagnosis, solenoids and sensors, clutch pack specifications, rebuilding procedures (if applicable). Transfer Case: Operation of 4WD systems, transfer case disassembly and assembly, fluid type and capacity, engagement mechanisms, shift control systems. Front Differential: Differential fluid type and capacity, ring and pinion gear setup, bearing preloads, seal replacement, CV joint inspection and replacement. Rear Differential: Differential fluid type and capacity, ring and pinion gear setup, bearing preloads, seal replacement, limited-slip differential (LSD) service (if applicable). Drive Shafts: U-joint inspection and replacement, driveshaft balancing, CV axle inspection and replacement. Front Suspension: Ball joint inspection and replacement, control arm bushings, shock absorber/strut replacement, spring replacement, wheel bearing service, alignment specifications. Rear Suspension: Shock absorber replacement, coil spring replacement, trailing arm bushings, Panhard rod inspection, alignment specifications. Steering System: Power steering pump service, steering rack or gearbox diagnosis and repair, tie rod end inspection, steering column components, power steering fluid type and capacity. Front Brakes: Brake pad replacement, rotor machining or replacement, caliper service, brake fluid type and bleeding procedures, anti-lock braking system (ABS) components and diagnosis. Rear Brakes: Brake shoe/pad replacement, drum or rotor service, caliper or wheel cylinder service, brake fluid type and bleeding procedures, ABS component diagnosis. Parking Brake: Parking brake cable adjustment and replacement, parking brake mechanism service (drum-in-hat or caliper integrated). Wheels And Tires: Tire pressure recommendations, rotation schedules, wheel alignment procedures and specifications, lug nut torque values, wheel bearing adjustment. Body Repair: Frame straightening procedures, panel replacement, welding specifications, rust repair techniques, body panel alignment. Exterior Trim: Bumper removal and installation, grille, headlight and taillight replacement, door handle and mirror assembly service, trim molding installation. Interior Trim: Dashboard removal, door panel access, seat removal and installation, headliner service, center console disassembly. Electrical Systems: Fuse box diagrams, relay functions, component testing using multimeters, power distribution, grounding points, common electrical gremlins. Wiring Diagrams: Comprehensive circuit diagrams for all major systems (engine, transmission, lights, accessories, safety systems), color coding, connector pinouts, troubleshooting pathways....

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Tipo: Car

Proveedor:

SKU: 193195

Colecciones: ALL Mitsubishi

Disponibilidad: En stock

Etiquetas: Car Cars Mitsubishi Montero Sport Nativa Pajero

Variantes de producto

Descripción

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Pajero Sport / Montero Sport / Nativa

Codes

Chassis Codes:

K90, K80 series (typical for generation covered)

Engine Codes:

Likely includes 4M4x (Diesel) and 6G7x (Petrol) series engines.

👋 Introduction

Market Position

Vehicle Segment:

Mid-size SUV, often positioned as a capable off-roader with comfortable on-road manners.

Competitive Analysis

Key Competitors:

Toyota 4Runner, Ford Explorer, Nissan Pathfinder, Jeep Grand Cherokee, Chevrolet Trailblazer (depending on specific model year and market).

Key Features

Powertrain Options:

Likely offered with robust diesel engines (e.g., 4M41) and capable gasoline V6 engines (e.g., 6G7x series) known for durability and towing capacity.

Drivetrain:

Typically features a Super Select 4WD system or similar, offering selectable 2WD and 4WD modes, including low-range gearing for off-road capability.

📋 Manual Details

Coverage Areas

Systems Covered:

Engine Mechanical, Engine Control System, Fuel System, Exhaust, Cooling System, Air Conditioning System, Starting System, Charging System, Ignition System, Manual Transaxle, Automatic Transaxle, Transfer Case, Front Differential, Rear Differential, Drive Shafts, Front Suspension, Rear Suspension, Steering System, Front Brakes, Rear Brakes, Parking Brake, Wheels and Tires, Body Repair, Exterior Trim, Interior Trim, Electrical Systems, Wiring Diagrams, Emission Control Systems.

Page Count

Estimated Page Count:

Likely 1000+ pages (typical for comprehensive factory service manuals).

Manual Type

Manual Type:

Factory Service Repair Workshop Manual

Language

Language:

English

Format

File Format:

Zip / PDF

Compatibility

Operating Systems:

Windows, Mac

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine teardown, inspection, assembly, torque specifications, component identification, timing belt/chain replacement, piston and ring installation, cylinder head service, crankshaft and bearing installation, oil pump and water pump service.

Engine Control System:

ECU identification, sensor testing and diagnosis (e.g., Crankshaft Position Sensor, Camshaft Position Sensor, MAP sensor, MAF sensor, O2 sensors, TPS), actuator testing (e.g., Idle Air Control Valve, EGR valve), fuel injector testing, diagnostic trouble codes (DTCs) and troubleshooting flowcharts.

Fuel System:

Fuel pump testing and replacement, fuel filter replacement, fuel injector cleaning and testing, fuel pressure regulation, fuel tank service, fuel lines and vapor emission control (EVAP) system diagnosis.

Cooling System:

Radiator service, water pump replacement, thermostat operation and replacement, coolant specifications and capacities, fan clutch/electric fan operation, heater core service, pressure testing the cooling system.

Air Conditioning System:

Refrigerant types and capacities, compressor operation and service, receiver/drier replacement, expansion valve or orifice tube service, leak detection, diagnostic procedures for cooling performance.

Starting System:

Starter motor testing, replacement, solenoid operation, battery testing and specifications, wiring and connection checks.

Charging System:

Alternator testing, output specifications, regulator function, battery charging system diagnosis, belt tension adjustment.

Ignition System:

Spark plug specifications and replacement, ignition coil testing, ignition module function, crankshaft and camshaft sensor roles in ignition timing.

Manual Transaxle:

Gearbox disassembly, inspection, assembly, gear ratio information, clutch system integration, shift mechanism service, fluid types and capacities, common wear points.

Automatic Transaxle:

Transmission fluid type and capacity, valve body operation, torque converter service, transmission control module (TCM) diagnosis, solenoids and sensors, clutch pack specifications, rebuilding procedures (if applicable).

Transfer Case:

Operation of 4WD systems, transfer case disassembly and assembly, fluid type and capacity, engagement mechanisms, shift control systems.

Front Differential:

Differential fluid type and capacity, ring and pinion gear setup, bearing preloads, seal replacement, CV joint inspection and replacement.

Rear Differential:

Differential fluid type and capacity, ring and pinion gear setup, bearing preloads, seal replacement, limited-slip differential (LSD) service (if applicable).

Drive Shafts:

U-joint inspection and replacement, driveshaft balancing, CV axle inspection and replacement.

Front Suspension:

Ball joint inspection and replacement, control arm bushings, shock absorber/strut replacement, spring replacement, wheel bearing service, alignment specifications.

Rear Suspension:

Shock absorber replacement, coil spring replacement, trailing arm bushings, Panhard rod inspection, alignment specifications.

Steering System:

Power steering pump service, steering rack or gearbox diagnosis and repair, tie rod end inspection, steering column components, power steering fluid type and capacity.

Front Brakes:

Brake pad replacement, rotor machining or replacement, caliper service, brake fluid type and bleeding procedures, anti-lock braking system (ABS) components and diagnosis.

Rear Brakes:

Brake shoe/pad replacement, drum or rotor service, caliper or wheel cylinder service, brake fluid type and bleeding procedures, ABS component diagnosis.

Parking Brake:

Parking brake cable adjustment and replacement, parking brake mechanism service (drum-in-hat or caliper integrated).

Wheels And Tires:

Tire pressure recommendations, rotation schedules, wheel alignment procedures and specifications, lug nut torque values, wheel bearing adjustment.

Body Repair:

Frame straightening procedures, panel replacement, welding specifications, rust repair techniques, body panel alignment.

Exterior Trim:

Bumper removal and installation, grille, headlight and taillight replacement, door handle and mirror assembly service, trim molding installation.

Interior Trim:

Dashboard removal, door panel access, seat removal and installation, headliner service, center console disassembly.

Electrical Systems:

Fuse box diagrams, relay functions, component testing using multimeters, power distribution, grounding points, common electrical gremlins.

Wiring Diagrams:

Comprehensive circuit diagrams for all major systems (engine, transmission, lights, accessories, safety systems), color coding, connector pinouts, troubleshooting pathways.

Emission Control Systems:

Catalytic converter function, EGR system diagnosis, charcoal canister operation, EVAP system leak detection and repair, PCV system service.

Sun Roof System:

Motor replacement, track lubrication, seal inspection and replacement, switch diagnosis.

Seat Belt System:

Seat belt retractor service, buckle replacement, pre-tensioner system (if applicable) diagnosis and safety precautions.

Power Door Lock Control:

Actuator diagnosis and replacement, switch testing, control module function, keyless entry system integration.

Power Window Control:

Window motor replacement, regulator repair, switch diagnosis, master control switch service.

Window Defogger System:

Grid line repair, defogger switch and relay testing, power supply checks.

Yaw Rate Sensor:

Location, testing procedures, integration with stability control systems (e.g., Active Stability Control - ASC).

Steering Sensor:

Steering angle sensor calibration and replacement, connection to power steering and stability control systems.

Clutch Pedal Sub Assy:

Pedal adjustment, return spring, master cylinder linkage.

Brake Pedal:

Pedal pivot, return spring, connection to brake booster and master cylinder.

Clutch Start Switch Assy:

Function in starting system (ensuring clutch is depressed), testing and replacement.

Parking Brake Lever:

Lever mechanism, cable routing, adjustment procedures.

Clutch Master Cylinder Assy:

Inspection, seal replacement, bleeding procedures, fluid type.

Clutch Release Cylinder Assy:

Inspection, seal replacement, bleeding procedures, fluid type.

Procedures Included

Maintenance:

Routine oil changes, filter replacements, fluid level checks and top-offs, spark plug replacement, brake fluid flushes, coolant flushes, lubrication points, tire rotation and pressure checks, battery terminal cleaning.

Troubleshooting:

Diagnostic flowcharts for common symptoms (e.g., no-start conditions, poor engine performance, braking issues, electrical failures), interpretation of diagnostic trouble codes (DTCs), systematic isolation of faults.

Repair:

Step-by-step instructions for component replacement, rebuilding procedures for major assemblies (engine, transmission, differentials), body panel repair and replacement, interior trim repair, electrical component repair.

Installation:

Installation procedures for aftermarket accessories (if detailed), correct torque specifications for all fasteners, proper routing of lines and wires.

Technical Depth

Diagnostic Capabilities:

Detailed sensor data interpretation, actuating components via scan tool (where applicable), resistance, voltage, and current testing for electrical components.

Rebuild Procedures:

Comprehensive disassembly, cleaning, inspection, measurement, and reassembly of major mechanical components with explicit tolerance specifications.

Wiring Diagram Detail:

High-resolution, color-coded wiring diagrams with component identification, wire gauge, connector pin assignments, and splice locations.

Special Tools:

Identification and usage instructions for any specialized tools required for specific repair or diagnostic procedures.

📊 Manual Specifications

File Format

PDF Quality:

High-resolution, text-searchable PDF files for easy navigation and content retrieval.

Printable:

Designed for easy printing of individual pages or sections.

Binding Type

Binding Type:

Digital Download (Not Applicable)

Paper Type

Paper Type:

Digital Download (Not Applicable)

⚙️ Engine Specifications

Primary Engine

Common Diesel Engine:

3.2L 4M41 I4 Turbo Diesel (example: 160-190 HP, 280-320 lb-ft torque, depending on year and tuning).

Common Petrol Engine:

3.5L 6G74 V6 SOHC/DOHC MPI (example: 175-210 HP, 215-250 lb-ft torque, depending on year).

Performance

Typical Horsepower Range:

160 HP - 215 HP

Typical Torque Range:

280 lb-ft - 250 lb-ft

Fuel System

Diesel Fuel System:

Common Rail Direct Injection (CRDI) or Electronic Fuel Injection (EFI) with turbocharging and intercooler.

Petrol Fuel System:

Multi-Point Fuel Injection (MPI).

🔧 Transmission

Standard

Standard Transmission:

Often a 5-speed Manual Transmission (e.g., W5M51/W5MB1) or a 4-speed Automatic Transmission (e.g., V4A51).

Optional

Optional Transmission:

Later models may feature a 5-speed Automatic Transmission.

Features

Transfer Case Type:

Super Select 4WD system, offering 2H, 4H, 4HLC (Lock), and 4LLC (Low Lock) modes.

📐 Dimensions

Exterior

Length:

Approximately 4,690 - 4,750 mm (varies by generation and specific market).

Width:

Approximately 1,775 - 1,815 mm.

Height:

Approximately 1,700 - 1,750 mm.

Weights

Curb Weight:

Approximately 1,900 - 2,100 kg (depending on engine and equipment).

Towing Capacity:

Typically around 2,500 - 3,000 kg (braked trailer, varies by market and engine).

🛡️ Safety Features

Ratings

Crash Test Results:

Varies by year and testing authority (e.g., ANCAP, NHTSA). Check specific model year for detailed ratings. Often performed well for its class.

Active Features

Active Safety:

ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), ASC (Active Stability Control) or similar traction control systems (depending on trim and year).

Passive Features

Passive Safety:

Front airbags (driver and passenger), side airbags (optional or standard on higher trims), seat belt pre-tensioners, reinforced body structure.

💡 Technology Features

Infotainment

Infotainment Features:

Varies significantly by trim and year. May include CD/MP3 player, radio, navigation systems, Bluetooth connectivity, and touchscreen interfaces in later models.

Driver Assistance

Driver Assistance Features:

Depending on trim and year: Cruise control, parking sensors, rearview camera, and potentially limited advanced driver-assistance systems (ADAS) in newer generations.

Connectivity

Connectivity Options:

Auxiliary input, USB ports, Bluetooth phone and audio streaming in models equipped with compatible head units.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 5,000 - 10,000 km or 6 months, whichever comes first (refer to owner's manual for specific engine and oil type).

Timing Belt Interval:

For petrol engines with timing belts: typically 90,000 - 100,000 km or 5-7 years. Diesel engines may use timing chains or belts with different intervals. Crucial to verify for specific engine.

Fluid Specifications

Engine Oil Type:

Diesel: API CI-4 or higher, SAE 15W-40 or 5W-40. Petrol: API SN/SP, SAE 5W-30 or 10W-30 (check specific viscosity for climate).

Transmission Fluid Manual:

GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90 (specific to transmission).

Transmission Fluid Automatic:

DIA Queen ATF-SP III or equivalent DEXRON III/VI type fluid (specific to transmission).

Coolant Type:

Mitsubishi Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based coolant with organic acid technology (OAT).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Known Issues

Common Diesel Issues:

Potential for injector issues, turbocharger wear, EGR valve clogging, and glow plug problems, especially with high mileage or inconsistent maintenance.

Common Petrol Issues:

Occasional issues with head gaskets (on older V6s), cooling system leaks, and timing belt replacement if neglected.

Suspension Wear:

Bushings, ball joints, and tie rod ends can wear over time, particularly in vehicles used for off-roading or on rough roads.

Automatic Transmission Quirks:

Some models may experience transmission shifting issues or overheating if fluid is not regularly serviced or if subjected to heavy towing.

📚 Vehicle History

Brand Heritage

Mitsubishi Offroad Legacy:

Mitsubishi has a long and successful history in off-road racing (e.g., Dakar Rally) with the Pajero nameplate, which influences the design and capability of the Sport/Montero Sport/Nativa variants.

Model Evolution

First Generation:

Introduced in the mid-1990s as a sportier, more car-like derivative of the original Pajero, targeting a different market segment.

Subsequent Generations:

Each generation has seen updates in styling, technology, safety, and powertrain options, while retaining its core SUV and off-road capabilities.

Production

Manufacturing Locations:

Primarily manufactured in Japan and Thailand, with assembly in other regions depending on market.

🏆 Awards & Recognition

Recognitions

Offroad Capability Recognition:

Consistently recognized for its off-road prowess and robust drivetrain, making it a popular choice for adventure and utility.