🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Sport / Pajero Sport Codes Platform Code: K90 Series (Second Generation) Generation Identifier: Second Generation 👋 Introduction Market Position Segment: Mid-size SUV / Off-road focused vehicle Key Competitors: Toyota 4Runner, Nissan Pathfinder, Ford Explorer, Jeep Grand Cherokee, Chevrolet Blazer (during its respective production years). Competitive Analysis Strengths: Renowned off-road capability (especially with Super Select 4WD-II), robust construction, reliable powertrains (particularly the V6), relatively affordable maintenance compared to some European counterparts. Weaknesses: Interior ergonomics and material quality can be dated, fuel economy is not a strong suit, third-row seating (where equipped) is often cramped. Key Features Off Road Systems: Available Super Select II 4WD system offering 2H, 4H, 4HLC (4WD High-Lock), 4LLC (4WD Low-Lock) modes; available rear differential lock. Body Style: Body-on-frame construction, offering superior durability and off-road articulation compared to unibody SUVs. 📋 Manual Details Coverage Areas Applicable Years: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004 Regions Covered: Global (models designated Montero Sport and Pajero Sport are generally identical in this generation) Page Count Estimated Pages: ~1500-2000+ (typical for a comprehensive workshop manual covering multiple model years and engine options) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical (including disassembly, inspection, assembly), engine electrical, fuel system, cooling system, exhaust system, ignition system, lubrication system, intake system, emission control systems. Transmission: Manual transmission (clutch, gearbox, transfer case), Automatic transmission (hydraulic control, torque converter, planetary gearsets, valve body, solenoids), differentials (front, rear, center if applicable). Chassis: Suspension (front independent, rear solid axle), steering system (power steering pump, rack and pinion/steering box), brake system (front discs, rear drums/discs, ABS), driveline components (propeller shafts, CV joints, universal joints). Body & Electrical: Body construction, exterior trim, interior trim, seats, HVAC system, body electrical systems (lighting, wipers, power windows, locks), wiring diagrams, fuses, relays, body control modules. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection/replacement, brake pad/shoe inspection. Component Repair: Engine overhaul, cylinder head reconditioning, piston and ring replacement, crankshaft bearing replacement, transmission rebuild (manual and automatic), clutch replacement, brake caliper/master cylinder rebuild, suspension component replacement, steering rack/box overhaul. Diagnostics & Troubleshooting: Step-by-step troubleshooting guides for common problems, diagnostic trouble codes (DTCs) interpretation, electrical circuit testing, fuel system pressure testing, ignition system testing. Specifications & Data: Torque specifications for all fasteners, clearances and tolerances for engine and transmission components, fluid capacities, electrical specifications, wheel alignment parameters. Technical Depth Depth: Comprehensive: Covers from basic preventative maintenance and fluid changes to full engine and transmission rebuilds, complex electrical diagnostics, and chassis component overhauls. Includes detailed exploded views and diagrams. 📊 Manual Specifications File Format Format Details: Searchable PDF, allowing for quick navigation to specific topics. High-resolution scanned pages for clarity. Print Quality Quality: Excellent (assuming a professionally produced manual). Diagrams are clear, text is legible. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine 1 Engine Code: 6G72 (SOHC V6), 6G74 (DOHC V6) Displacement: 3.0L (6G72), 3.5L (6G74) Configuration: V6, SOHC or DOHC Horsepower Range: Approx. 175-200 hp (3.0L), 200-240 hp (3.5L) Torque Range: Approx. 180-190 lb-ft (3.0L), 220-240 lb-ft (3.5L) Fuel System: Electronic Fuel Injection (EFI), Multi-point fuel injection Fuel Type: Unleaded Gasoline Engine Alternatives Engine Code 2: 4G64 (4-Cylinder) Displacement 2: 2.4L Configuration 2: Inline 4-Cylinder, SOHC Horsepower 2: Approx. 135-140 hp Torque 2: Approx. 145-150 lb-ft 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission (V5M21, V5M31) Optional Transmission Type: 4-speed Automatic Transmission (V4A51) Features Drivetrain Options: Part-time 4WD, Full-time 4WD (Super Select II system) Transfer Case Type: Two-speed transfer case with locking center differential (Super Select II) 📐 Dimensions Exterior Length: Approx. 179.3 inches (4555 mm) Width: Approx. 69.5 inches (1765 mm) Height: Approx. 66.1 inches (1680 mm) (without roof rails) Wheelbase: Approx. 103.7 inches (2635 mm) Weights Curb Weight Range: Approx. 4000-4500 lbs (1814-2041 kg), depending on configuration and engine. Gross Vehicle Weight Rating Range: Approx. 5500-6000 lbs (2495-2721 kg) 🛡️ Safety Features Ratings NHTSA Front Impact: Likely rated 'Good' or 'Acceptable' in frontal crash tests by IIHS/NHTSA for its era, but specific data for all years/trims may vary. Body-on-frame construction offers inherent structural integrity. Active Features ABS: Available Anti-lock Braking System (ABS) Traction Control: Limited availability or basic form in some later models, not a prevalent feature across the entire range. Passive Features Airbags: Driver and front passenger airbags standard. Seatbelts: Three-point seatbelts with pretensioners for front occupants, lap belts for rear passengers (depending on seating configuration). 💡 Technology Features Infotainment Audio System: Factory-installed AM/FM/Cassette/CD players, with varying speaker configurations. Optional premium sound systems available on higher trims. Navigation: Very limited or no factory navigation available for most of this generation. Aftermarket installations were common. Driver Assistance Cruise Control:...