Mitsubishi Pajero Sport 1999-2002 Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero Sport Generation: 1st Generation (K90 Series) Production Years Covered: 1999, 2000, 2001, 2002 👋 Introduction Market Position Segment: Compact/Mid-size SUV, often positioned as a capable off-roader and family vehicle Competitive Analysis Competitors: Jeep Cherokee (XJ/Liberty), Toyota 4Runner, Nissan Pathfinder, Ford Explorer, Chevrolet Blazer Key Features Platform Sharing: Based on the Mitsubishi Triton/Pajero pickup truck platform Body Styles: Primarily 5-door SUV, with some markets offering a 3-door variant 📋 Manual Details Coverage Areas Region Of Origin: Likely North America/Global Market (specific regional variations may exist) Vehicle Variants Covered: All Pajero Sport models within the specified year range Page Count Estimated Page Count: N/A (PDF format, variable based on printer settings) Manual Type Type: Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete engine mechanical repair, diagnosis, and overhaul procedures for all gasoline and diesel variants Transmission: Manual and automatic transmission repair, overhaul, diagnosis, and fluid specifications Drivetrain: Four-wheel drive (4WD) system operation, maintenance, and repair, including transfer case and differentials Suspension: Front and rear suspension component diagnosis, replacement, and alignment specifications Steering: Power steering system diagnosis, repair, and component replacement Brakes: Hydraulic brake system diagnosis, repair, including ABS, brake pad and rotor replacement, and bleeding procedures Electrical System: Complete wiring diagrams, component testing, diagnosis of starter, alternator, battery, lighting, and accessories Fuel System: Fuel injection system diagnosis, components (injectors, pump, filter), and fuel pressure specifications Cooling System: Radiator, fan, water pump, thermostat, and coolant specifications Exhaust System: Exhaust manifold, catalytic converter, muffler, and pipe repair and replacement Body And Frame: Body panel repair, door mechanisms, glass replacement, and frame alignment (if applicable) HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks, tire rotations, and spark plug replacement Troubleshooting: Diagnostic charts and symptom-based troubleshooting for common and complex issues Component Replacement: Step-by-step instructions for replacing major and minor vehicle components Rebuild Procedures: Complete overhaul instructions for engines, transmissions, and other major mechanical assemblies Diagnostic Testing: Procedures for testing electrical components, sensors, and actuators Technical Depth Depth: Comprehensive: Covers basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and wiring schematics 📊 Manual Specifications File Format Quality: High-resolution PDF, typically searchable text and clear diagrams Searchability: Yes, usually with a searchable text layer for efficient information retrieval Print Quality Printability: Yes, designed to be printable for in-garage use Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Petrol Engine Code Example: 6G72 (3.0L V6) Displacement 3.0L: 2972 cc Configuration 3.0L: SOHC V6, 12 valves Horsepower 3.0L Approx: 133 - 144 hp @ 4800 - 5000 rpm (market dependent) Torque 3.0L Approx: 175 - 184 lb-ft @ 3500 - 4000 rpm (market dependent) Primary Engine Diesel Engine Code Example: 4D56 (2.5L Turbo Diesel) Displacement 2.5L Diesel: 2477 cc Configuration 2.5L Diesel: OHC, 8 valves, Turbocharged, Intercooled Horsepower 2.5L Diesel Approx: 103 - 114 hp @ 4000 rpm (market dependent) Torque 2.5L Diesel Approx: 177 - 192 lb-ft @ 2000 - 2500 rpm (market dependent) Fuel System Petrol Type: Multi-point Fuel Injection (MPI) Diesel Type: Indirect Injection (IDI) with Turbocharging and Intercooling 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission Optional Transmission Type: 4-speed Automatic Transmission (INVECS-II) Features 4Wd System: Super Select II 4WD system (shift-on-the-fly 2WD/4WD, 4WD High with locked center diff, 4WD Low) 📐 Dimensions Exterior Length Approx Mm: 4610 - 4725 mm (depending on market and specific model) Exterior Width Approx Mm: 1775 - 1800 mm Exterior Height Approx Mm: 1730 - 1770 mm (with roof rails) Wheelbase Mm: 2725 mm Weights Curb Weight Approx Kg: 1800 - 2000 kg (depending on engine and equipment) 🛡️ Safety Features Ratings NHTSA Ratings: N/A (Pre-dates widespread standardized ratings for this model) Active Features ABS: Available (Anti-lock Braking System) Passive Features Airbags: Driver and Passenger airbags (market dependent) Seatbelts: 3-point front and rear seatbelts with pretensioners 💡 Technology Features Infotainment Audio System: Factory fitted radio/cassette or CD player, with basic speaker system. Aftermarket upgrades are common. Driver Assistance Cruise Control: Available on higher trim levels 4Wd Control: Manual engagement for 2WD/4WD High/Low via lever or electronic button depending on specific variant. 🔧 Maintenance Service Intervals Oil Change Interval Km: 5,000 - 7,500 km (depending on driving conditions and oil type) Interval Months: 6 months Service Intervals Air Filter Interval Km: 15,000 - 20,000 km Service Intervals Fuel Filter Interval Km: 20,000 - 30,000 km (especially for diesel) Fluid Specifications Engine Oil Type: API SG/SH or higher, SAE 10W-30 or 5W-30 (check manual for climate-specific recommendations) Capacity 3.0L V6 Approx L: 4.7 L (with filter) Fluid Specifications Transmission Auto Type: Diamond SP-III or equivalent ATF Fluid Specifications Transmission Manual Type: API GL-4 SAE 75W-90 or 80W-90...
Indirect Injection (IDI) with Turbocharging and Intercooling
🔧 Transmission
Standard Transmission
Type:
5-speed Manual Transmission
Optional Transmission
Type:
4-speed Automatic Transmission (INVECS-II)
Features
4Wd System:
Super Select II 4WD system (shift-on-the-fly 2WD/4WD, 4WD High with locked center diff, 4WD Low)
📐 Dimensions
Exterior Length
Approx Mm:
4610 - 4725 mm (depending on market and specific model)
Exterior Width
Approx Mm:
1775 - 1800 mm
Exterior Height
Approx Mm:
1730 - 1770 mm (with roof rails)
Wheelbase
Mm:
2725 mm
Weights
Curb Weight Approx Kg:
1800 - 2000 kg (depending on engine and equipment)
🛡️ Safety Features
Ratings
NHTSA Ratings:
N/A (Pre-dates widespread standardized ratings for this model)
Active Features
ABS:
Available (Anti-lock Braking System)
Passive Features
Airbags:
Driver and Passenger airbags (market dependent)
Seatbelts:
3-point front and rear seatbelts with pretensioners
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette or CD player, with basic speaker system. Aftermarket upgrades are common.
Driver Assistance
Cruise Control:
Available on higher trim levels
4Wd Control:
Manual engagement for 2WD/4WD High/Low via lever or electronic button depending on specific variant.
🔧 Maintenance
Service Intervals Oil Change
Interval Km:
5,000 - 7,500 km (depending on driving conditions and oil type)
Interval Months:
6 months
Service Intervals Air Filter
Interval Km:
15,000 - 20,000 km
Service Intervals Fuel Filter
Interval Km:
20,000 - 30,000 km (especially for diesel)
Fluid Specifications Engine Oil
Type:
API SG/SH or higher, SAE 10W-30 or 5W-30 (check manual for climate-specific recommendations)
Capacity 3.0L V6 Approx L:
4.7 L (with filter)
Fluid Specifications Transmission Auto
Type:
Diamond SP-III or equivalent ATF
Fluid Specifications Transmission Manual
Type:
API GL-4 SAE 75W-90 or 80W-90 Gear Oil
Fluid Specifications Coolant
Type:
Ethylene Glycol based coolant, 50/50 mix with distilled water
Fluid Specifications Brake Fluid
Type:
DOT 3 or DOT 4
Known Issues
Common Wear Items:
Ball joints, tie rod ends, wheel bearings, exhaust components, clutch wear (manual transmission)
Diesel Specific:
Glow plug issues, potential for turbocharger wear if maintenance is neglected
Electrical Gremlins:
Can occur with age, particularly around door switches, window regulators, and corrosion in connectors.
📚 Vehicle History
Brand Heritage
Mitsubishi Offroad Legacy:
Mitsubishi has a strong heritage in off-road vehicles, dating back to the original Pajero (Montero) and its numerous Dakar Rally victories.
Model Evolution
Pajero Sport Introduction:
The Pajero Sport (also known as Montero Sport in North America and Mitsubishi Challenger in Australia) was introduced in 1996 as a more affordable, body-on-frame SUV based on the second-generation Pajero/Montero platform, but utilizing the mechanicals of the Triton/Pajero Sport pickup truck.
Production
Assembly Locations:
Primarily Japan, with significant production in Thailand and other global locations.
🏆 Awards & Recognition
Recognitions
Segment Awards:
Often praised in its time for its off-road capability and ruggedness, though not typically a recipient of major 'car of the year' type awards.
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