Mitsubishi Sportero 2005-2014 Service Repair Workshop Manual
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Basic Information Identification Make: Mitsubishi Model: Sportero Generation: First Generation (2005-2014) Chassis Code: Likely based on the Mitsubishi Triton platform (e.g., KB4T) Codes Model Years Covered: 2005, 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014 Introduction Market Position Vehicle Segment: Compact Pickup Truck / Utility Vehicle. Competitors: Likely competed with vehicles such as the Toyota Hilux/Tacoma, Ford Ranger, Nissan Navara/Frontier, Chevrolet Colorado/S-10. Key Features Primary Purpose: Workhorse utility vehicle, capable of light to moderate off-road use and hauling. Target Demographic: Tradespeople, outdoor enthusiasts, those seeking a rugged and versatile vehicle. Manual Benefit: Empowers owners and independent shops with factory-level repair knowledge, saving on labor costs and ensuring proper maintenance. Manual Details Coverage Areas Primary Coverage: Full service, repair, maintenance, diagnostics, and troubleshooting for the Mitsubishi Sportero (2005-2014). Secondary Coverage: Wiring diagrams, specifications, step-by-step instructions, illustrations, and diagrams. Page Count Estimated Page Count: Estimated 1500-3000+ pages (typical for comprehensive workshop manuals of this era and scope). Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine Mechanical: Complete disassembly, assembly, overhaul, and troubleshooting of all engine components. Engine Electrical: Ignition system, starting system, charging system, fuel injection system, engine control module (ECM) diagnostics. Emission Control: Catalytic converter, oxygen sensors, EVAP system, EGR system, emissions diagnostics and repair. Fuel System: Fuel pump, fuel injectors, fuel filter, fuel pressure regulator, fuel tank service, fuel system diagnostics. Clutch System: Clutch disc, pressure plate, release bearing, clutch hydraulics, clutch pedal adjustment, troubleshooting. Manual Transaxle: Gearbox disassembly, assembly, overhaul, fluid specifications, shift mechanism repair, troubleshooting. Automatic Transaxle: Transmission disassembly, assembly, valve body, torque converter, transmission fluid, shift control, diagnostics, reprogramming. Driveshaft Axle: CV joints, drive shafts, differentials, propeller shafts, universal joints, lubrication, repair. Suspension System: Front and rear suspension components, shock absorbers, struts, control arms, ball joints, bushings, alignment specifications. Steering System: Power steering pump, steering rack/gearbox, tie rods, steering column, power steering fluid, steering angle sensor. Restraint System: Airbag system components, seat belts, SRS module diagnostics and replacement. Brake System: Brake pads, rotors, calipers, brake fluid, ABS system, parking brake, brake system bleeding, diagnostics. Body Interior Exterior: Body panel removal/installation, door mechanisms, interior trim, glass replacement, body repair techniques. Body Electrical: Lighting systems, power windows, power locks, mirrors, wipers, horn, interior electronics, body control module (BCM). HVAC: Air conditioning system, heater core, blower motor, refrigerant, climate control module, system diagnostics. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, spark plug replacement, fluid checks and changes. Diagnostics: Troubleshooting guides, fault code interpretation, diagnostic tool usage, symptom-based diagnostics. Repair: Step-by-step repair procedures for all covered systems, including component replacement and adjustment. Rebuilding: Detailed instructions for engine, transmission, and differential rebuilds. Wiring Schematics: Comprehensive electrical wiring diagrams for all vehicle systems. Technical Depth Depth: Advanced diagnostics, complete component overhaul, electrical troubleshooting, and factory-level repair procedures. Target Audience: Professional automotive technicians and experienced DIY mechanics. Manual Specifications File Format File Type: PDF Searchability: Likely searchable text within the PDF for quick information retrieval. Print Quality Printability: Yes, all pages are printable. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Quality: N/A (Digital PDF format - user to print on desired paper) Engine Specifications Primary Engine Engine Type: Likely to include naturally aspirated gasoline and diesel engines. Common Engine Options: 2.4L (4G64), 2.5L (4D56 - Diesel), 3.0L V6 (6G72), 2.8L (4M40 - Diesel). Performance Horsepower Range: Approximately 100 HP (diesel) to 180 HP (petrol/V6), depending on engine and market. Torque Range: Approximately 200 Nm (diesel) to 280 Nm (petrol/V6), depending on engine and market. Fuel System Fuel Delivery: Multi-point fuel injection (MPI) for gasoline, Common Rail Direct Injection (CRDI) for diesel. Fuel Type: Unleaded Gasoline, Diesel. Transmission Standard Transmission Type: 5-speed Manual Transmission (R5M42/R5M41). Optional Transmission Type: 4-speed or 5-speed Automatic Transmission (V4A51, W4A5A). Features Drivetrain: Rear-Wheel Drive (RWD) and Four-Wheel Drive (4WD) options available. Dimensions Exterior Body Styles: Single Cab, Extended Cab, Double Cab. Typical Length: Approximately 4,800 mm to 5,300 mm (depending on cab configuration). Weights Curb Weight: Approximately 1,700 kg to 2,000 kg (depending on configuration and engine). Safety Features Ratings Crash Test Results: Varies by region and specific testing authority; generally designed to meet safety standards of the early 2000s. Active Features Braking Aids: Anti-lock Braking System (ABS) available on higher trims or as an option. Passive Features Airbags: Driver and front passenger airbags standard on most models. Seat Belts: Three-point seat belts with pretensioners. Technology Features Infotainment Audio System: Basic AM/FM/CD player, optional premium audio systems with additional speakers available in higher trims. Driver Assistance Stability Control: Electronic Stability Control (ESC) may be available on later models or specific markets. Connectivity Auxiliary Input: Auxiliary input jack for external audio devices may be present on some later models. Maintenance Service Intervals Oil Change Interval: Typically every 5,000-10,000 km or 6 months, whichever comes...
Approximately 100 HP (diesel) to 180 HP (petrol/V6), depending on engine and market.
Torque Range:
Approximately 200 Nm (diesel) to 280 Nm (petrol/V6), depending on engine and market.
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI) for gasoline, Common Rail Direct Injection (CRDI) for diesel.
Fuel Type:
Unleaded Gasoline, Diesel.
Transmission
Standard
Transmission Type:
5-speed Manual Transmission (R5M42/R5M41).
Optional
Transmission Type:
4-speed or 5-speed Automatic Transmission (V4A51, W4A5A).
Features
Drivetrain:
Rear-Wheel Drive (RWD) and Four-Wheel Drive (4WD) options available.
Dimensions
Exterior
Body Styles:
Single Cab, Extended Cab, Double Cab.
Typical Length:
Approximately 4,800 mm to 5,300 mm (depending on cab configuration).
Weights
Curb Weight:
Approximately 1,700 kg to 2,000 kg (depending on configuration and engine).
Safety Features
Ratings
Crash Test Results:
Varies by region and specific testing authority; generally designed to meet safety standards of the early 2000s.
Active Features
Braking Aids:
Anti-lock Braking System (ABS) available on higher trims or as an option.
Passive Features
Airbags:
Driver and front passenger airbags standard on most models.
Seat Belts:
Three-point seat belts with pretensioners.
Technology Features
Infotainment
Audio System:
Basic AM/FM/CD player, optional premium audio systems with additional speakers available in higher trims.
Driver Assistance
Stability Control:
Electronic Stability Control (ESC) may be available on later models or specific markets.
Connectivity
Auxiliary Input:
Auxiliary input jack for external audio devices may be present on some later models.
Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-10,000 km or 6 months, whichever comes first (refer to manual for specific engine).
Timing Belt Replacement:
For gasoline engines, typically around 100,000 km or 5-7 years. Diesel engines may use timing chains.
Fluid Specifications
Engine Oil Spec:
API SN/SM or ACEA A3/B4, viscosity typically 5W-30 or 10W-40 (check manual for exact specification).
Transmission Fluid Manual:
Gear oil GL-4 or GL-5, viscosity typically 75W-90.
Transmission Fluid Auto:
Mitsubishi DiaQueen ATF SP-III or equivalent.
Coolant Type:
Long-life ethylene glycol coolant, typically a mix of 50% coolant and 50% distilled water.
Known Issues
Common Wear Items:
Ball joints, tie rod ends, bushings, clutch wear, exhaust system corrosion (depending on climate).
Diesel Engine Considerations:
Glow plug performance, injector maintenance, turbocharger health (if equipped).
Vehicle History
Brand Heritage
Brand Legacy:
Mitsubishi has a long history of producing robust and reliable utility vehicles and trucks, often with a focus on durability and off-road capability.
Model Evolution
Platform Basis:
The Sportero is largely based on the Mitsubishi Triton (L200) pickup truck platform, shared globally with minor regional variations.
Trim Levels:
Likely offered in various trim levels such as GL, GLS, Exceed, and specific regional packages.
Production
Manufacturing Locations:
Primarily manufactured in Thailand, with assembly in other countries depending on market.
Awards & Recognition
Recognitions
Truck Awards:
Specific awards would be market-dependent, but the Triton platform on which the Sportero is based has received various 'truck of the year' accolades in different regions for its utility and value.