🏷️ Basic Information Identification Make: Mitsubishi Model: Montero iO Model Nickname: Pajero iO (Japan) Generation Generation: First Generation (H60/H70) Codes Chassis Code Range: H61W, H62W, H66W, H67W, H76W, H77W 👋 Introduction Market Position Segment: Compact SUV / Sport Utility Vehicle Target Audience: Enthusiasts and owners seeking to perform maintenance, repairs, and diagnostics on their Mitsubishi Montero iO. Competitive Analysis Competitors: Suzuki Vitara, Honda CR-V, Toyota RAV4, Nissan X-Trail (first generation), Daihatsu Terios Key Features Vehicle Strengths: Compact size, often available with excellent 4WD (Super Select 4WD-i or similar) for its class, capable off-road for its size, good fuel economy for an SUV. Manual Value Proposition: Provides in-depth technical information essential for maintaining and repairing the vehicle, saving on labor costs and ensuring correct procedures are followed. 📋 Manual Details Coverage Areas Covered Years: 2000, 2001, 2002 Page Count Total Pages: 1000 Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, Engine control, Fuel system, Ignition system, Exhaust system, Transmission (manual and automatic), Transfer case, Drive axles Chassis: Suspension (front and rear), Steering system, Brake system (including ABS), Wheels and tires Electrical: Body electrical, Lighting, Instruments, Audio system, HVAC controls, SRS (Airbag) system, Power windows, Locks, Mirrors Body: Body panels, Doors, Hood, Liftgate, Interior trim, Glass, Bumpers, Seats, Safety restraint systems Procedures Included Maintenance: Scheduled maintenance, Fluid changes (oil, coolant, brake, transmission, differential), Filter replacements, Lubrication points, Spark plug replacement, Belt inspection/replacement Repair: Engine overhaul, Cylinder head removal/installation, Piston/ring replacement, Crankshaft/bearing service, Valve train service, Fuel injector testing/replacement, Ignition coil replacement, Catalytic converter replacement, Transmission overhaul/rebuild, Clutch replacement, Drive shaft repair, Suspension component replacement (shocks, struts, bushings, ball joints), Brake pad/rotor replacement, Caliper overhaul, Power steering pump/rack replacement, Electrical component diagnosis and replacement, Body panel repair, Glass replacement Diagnostics: Troubleshooting charts, Symptom-based diagnostics, Diagnostic Trouble Codes (DTCs) interpretation and clearing, Electrical circuit testing, Sensor testing, Actuator testing Technical Depth Depth: Comprehensive, covering routine maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures. 📊 Manual Specifications File Format File Type: PDF Print Quality Quality: High-resolution scans, ensuring clear diagrams, text, and images. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: 4G13, 4G14, 4G15, 4G93 Engine Type: Inline 4-cylinder, SOHC or DOHC, multi-point fuel injection Performance Displacement Liters: 1.3L (4G13), 1.6L (4G18), 1.8L (4G93) Horsepower Range: Approx. 80 HP (4G13) to 130 HP (4G93 DOHC Turbocharged variant in some markets, though not typically for iO models in core markets). Torque Range: Approx. 115 Nm (4G13) to 170 Nm (4G93). Fuel System Fuel Delivery: Electronic Multi-Point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Cooling System Coolant Type: Ethylene Glycol based coolant (e.g., Mitsubishi DiaQueen Super Long Life Coolant or equivalent) Lubrication System Engine Oil Type: API SG/SH/SJ or ILSAC GF-2/GF-3 classification. Viscosity SAE 10W-30 or 10W-40 is common, check manual for specific temperature range recommendations. Oil Capacity Liters: Approx. 3.5 - 4.0 Liters with filter change, depending on engine variant. 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission (F5M33 or similar) and 4-speed Automatic Transmission (F4A42 or similar) were common. Optional Transmission Type Optional: Some markets may have offered different gear ratios or specialized off-road transmissions. Features Drivetrain: Part-time 4WD (4H, 4L) and potentially Full-time 4WD (Super Select 4WD-i) depending on trim and market. Available in 2WD (Rear-Wheel Drive). Fluid Specs Automatic Transmission Fluid Type: Dexron III or equivalent. Specific Mitsubishi specification may be DiaQueen ATF-SP II M or similar. Manual Transmission Fluid Type: API GL-4 Gear Oil, SAE 75W-90 is a common recommendation. Manual recommends GL-4 specified oil. 📐 Dimensions Exterior Length Mm: Approx. 3,700 - 3,900 mm (depending on bumper design and body style - short wheelbase) Width Mm: Approx. 1,600 - 1,700 mm Height Mm: Approx. 1,600 - 1,700 mm Weights Curb Weight Kg: Approx. 1100 - 1300 kg Gross Vehicle Weight Rating Kg: Approx. 1600 - 1750 kg 🛡️ Safety Features Ratings Crash Test Ratings: Specific independent crash test data for this generation may be limited for all markets. Generally designed to meet Japanese safety standards of the era. Active Features ABS: Available on higher trims or as an option. Traction Control: Less common on base models, potentially available on higher trims with advanced 4WD systems. Passive Features Airbags: Driver and front passenger airbags typically standard on most models for these years. Side airbags were rare or optional. Seat Belts: 3-point seat belts with pretensioners for front occupants, 3-point or 2-point for rear occupants depending on seating position. 💡 Technology Features Infotainment Audio System: Factory fitted AM/FM radio with CD player or cassette player. Speaker configuration typically 4 or 6 speakers. Aftermarket head unit upgrades are common. Navigation: Navigation systems were not commonly offered or were very basic, often as a...