Mitsubishi Pajero iO 2000-2002 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero iO Model Nickname: Pajero Pinin, Pajero Mini (some markets) Codes Chassis Codes: H76W, H77W, H71W, H72W Engine Codes: 4G93 (1.8L), 4G94 (2.0L), 4A30 (0.7L Turbo - Kei car) 👋 Introduction Market Position Segment: Compact SUV / Crossover, Light Off-Roader Target Audience: Individuals and families seeking a versatile, compact, and capable vehicle for urban and light off-road use Competitive Analysis Competitors: Honda CR-V, Toyota RAV4, Suzuki Vitara, Nissan X-Trail (first generation), Daihatsu Terios Key Features Body Styles: 3-door (short wheelbase), 5-door (long wheelbase) Drivetrain Options: 2WD (FWD), 4WD (Super Select II or Easy Select 4WD) Off Road Capability: Relatively high ground clearance, available 4WD with low-range gearing (on some models), good approach/departure angles for its class 📋 Manual Details Coverage Areas Markets Covered: Global (with regional variations noted) Trim Levels Covered: All factory trim levels for the specified years Page Count Estimated Page Count: 800+ Manual Type Manual Type: Service and Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, assembly, inspection, overhaul for 4G93, 4G94, and 4A30 variants Engine Electrical: Ignition system, fuel injection system (MPI), starting and charging systems, engine control unit (ECU) diagnosis Transmission Manual: Disassembly, assembly, inspection, and repair of manual transmissions (e.g., KM132, KM145) Transmission Automatic: Disassembly, assembly, inspection, and repair of automatic transmissions (e.g., V4A51, F4A42) Drivetrain: Front and rear differentials, transfer case (4WD), driveshafts, CV joints, wheel bearings Suspension: Front independent suspension (MacPherson strut), rear multi-link or coil spring suspension, shock absorbers, springs, control arms Steering: Power steering system, steering column, steering rack/gearbox Brakes: Front disc brakes, rear drum or disc brakes, ABS system components and diagnosis, parking brake Fuel System: Fuel tank, fuel pump, fuel lines, fuel filter, evaporative emission control (EVAP) system Cooling System: Radiator, thermostat, water pump, cooling fan, hoses, coolant specifications Exhaust System: Exhaust manifold, catalytic converter, muffler, exhaust pipes, emissions control HVAC: Air conditioning system, heater core, blower motor, controls, refrigerant handling Body And Frame: Body panel removal and installation, door mechanisms, glass, bumpers, chassis structure Electrical System General: Wiring diagrams, fuses, relays, lighting system, wipers, horns, power windows, central locking Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs Troubleshooting: Diagnostic charts and procedures for common problems across all systems Engine Rebuild: Step-by-step instructions for complete engine disassembly and reassembly Transmission Repair: Detailed guides for transmission component replacement and adjustment Brake Service: Brake pad/shoe replacement, caliper/wheel cylinder service, brake fluid bleeding, ABS component replacement Suspension Component Replacement: Replacement of ball joints, tie rod ends, control arms, shock absorbers, springs Electrical Component Testing: Testing of sensors, actuators, switches, and ECUs using multimeters and diagnostic tools Body Repair: Procedures for dent removal, panel replacement, door alignment HVAC Service: Refrigerant system servicing, component replacement (compressor, condenser, evaporator) Technical Depth Depth: Comprehensive: Covers everything from basic maintenance to complete component overhaul and diagnostics Diagnostic Charts: Includes detailed diagnostic flowcharts for engine, transmission, and electrical faults Torque Specifications: Extensive listing of all critical torque specifications for fasteners Alignment Specifications: Wheel alignment specifications for front and rear suspensions Wiring Diagrams: Full-color, detailed electrical wiring diagrams for all vehicle systems 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval Printability: Printable pages for in-garage use Print Quality Image Resolution: High-resolution images and diagrams Binding Type Binding: Not Applicable (Digital PDF) Paper Type Paper Type: Not Applicable (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine 1 Code: 4G93 Engine 1 Displacement: 1.8 Liters (1834 cc) Engine 1 Configuration: Inline-4, SOHC (or DOHC on some variants), MPI (Multi-Point Injection) Engine 1 Power: Approx. 115-125 PS (85-92 kW) Engine 1 Torque: Approx. 160-170 Nm Optional Engine Engine 2 Code: 4G94 Engine 2 Displacement: 2.0 Liters (1997 cc) Engine 2 Configuration: Inline-4, DOHC, GDI (Gasoline Direct Injection) on some variants Engine 2 Power: Approx. 130-136 PS (96-100 kW) Engine 2 Torque: Approx. 175-185 Nm Optional Engine Kei Engine 3 Code: 4A30 Engine 3 Displacement: 0.7 Liters (659 cc) Engine 3 Configuration: Inline-4, DOHC, Turbocharged, Intercooled Engine 3 Power: Approx. 64 PS (47 kW) - limited by Kei car regulations Fuel System Fuel Delivery: Electronic Multi-Point Fuel Injection (MPI) or Gasoline Direct Injection (GDI) Fuel Type: Unleaded Gasoline 🔧 Transmission Standard Transmission Type 1: 5-Speed Manual Optional Transmission Type 2: 4-Speed Automatic (INVECS-II system on some models) Features 4Wd System: Available 'Easy Select 4WD' or 'Super Select 4WD II' with modes like 2H, 4H, 4HLC, 4LLC Transmission Fluid 1 Manual: API GL-4, SAE 75W-90 (manual transmission) Transmission Fluid 2 Automatic: DIAQUEEN SP-III or equivalent (automatic transmission) 📐 Dimensions Exterior Wheelbase 3 Door: Approx. 2,280 mm (89.8 in) Wheelbase 5 Door: Approx. 2,420 mm (95.3 in) Length 3 Door: Approx. 3,735 mm (147.0 in) Length 5 Door: Approx. 4,055 mm (159.6 in)...

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Type: Car

Vendor:

Sku: 500509

Collections: ALL Mitsubishi

Availability: In stock

Tags: 2000 2001 2002 Car Cars Misc Mitsubishi Pajero iO

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Pajero iO

Model Nickname:

Pajero Pinin, Pajero Mini (some markets)

Codes

Chassis Codes:

H76W, H77W, H71W, H72W

Engine Codes:

4G93 (1.8L), 4G94 (2.0L), 4A30 (0.7L Turbo - Kei car)

👋 Introduction

Market Position

Segment:

Compact SUV / Crossover, Light Off-Roader

Target Audience:

Individuals and families seeking a versatile, compact, and capable vehicle for urban and light off-road use

Competitive Analysis

Competitors:

Honda CR-V, Toyota RAV4, Suzuki Vitara, Nissan X-Trail (first generation), Daihatsu Terios

Key Features

Body Styles:

3-door (short wheelbase), 5-door (long wheelbase)

Drivetrain Options:

2WD (FWD), 4WD (Super Select II or Easy Select 4WD)

Off Road Capability:

Relatively high ground clearance, available 4WD with low-range gearing (on some models), good approach/departure angles for its class

📋 Manual Details

Coverage Areas

Markets Covered:

Global (with regional variations noted)

Trim Levels Covered:

All factory trim levels for the specified years

Page Count

Estimated Page Count:

Manual Type

Manual Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine disassembly, assembly, inspection, overhaul for 4G93, 4G94, and 4A30 variants

Engine Electrical:

Ignition system, fuel injection system (MPI), starting and charging systems, engine control unit (ECU) diagnosis

Transmission Manual:

Disassembly, assembly, inspection, and repair of manual transmissions (e.g., KM132, KM145)

Transmission Automatic:

Disassembly, assembly, inspection, and repair of automatic transmissions (e.g., V4A51, F4A42)

Drivetrain:

Front and rear differentials, transfer case (4WD), driveshafts, CV joints, wheel bearings

Suspension:

Front independent suspension (MacPherson strut), rear multi-link or coil spring suspension, shock absorbers, springs, control arms

Steering:

Power steering system, steering column, steering rack/gearbox

Brakes:

Front disc brakes, rear drum or disc brakes, ABS system components and diagnosis, parking brake

Fuel System:

Fuel tank, fuel pump, fuel lines, fuel filter, evaporative emission control (EVAP) system

Cooling System:

Radiator, thermostat, water pump, cooling fan, hoses, coolant specifications

Exhaust System:

Exhaust manifold, catalytic converter, muffler, exhaust pipes, emissions control

HVAC:

Air conditioning system, heater core, blower motor, controls, refrigerant handling

Body And Frame:

Body panel removal and installation, door mechanisms, glass, bumpers, chassis structure

Electrical System General:

Wiring diagrams, fuses, relays, lighting system, wipers, horns, power windows, central locking

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs

Troubleshooting:

Diagnostic charts and procedures for common problems across all systems

Engine Rebuild:

Step-by-step instructions for complete engine disassembly and reassembly

Transmission Repair:

Detailed guides for transmission component replacement and adjustment

Brake Service:

Brake pad/shoe replacement, caliper/wheel cylinder service, brake fluid bleeding, ABS component replacement

Suspension Component Replacement:

Replacement of ball joints, tie rod ends, control arms, shock absorbers, springs

Electrical Component Testing:

Testing of sensors, actuators, switches, and ECUs using multimeters and diagnostic tools

Body Repair:

Procedures for dent removal, panel replacement, door alignment

HVAC Service:

Refrigerant system servicing, component replacement (compressor, condenser, evaporator)

Technical Depth

Depth:

Comprehensive: Covers everything from basic maintenance to complete component overhaul and diagnostics

Diagnostic Charts:

Includes detailed diagnostic flowcharts for engine, transmission, and electrical faults

Torque Specifications:

Extensive listing of all critical torque specifications for fasteners

Alignment Specifications:

Wheel alignment specifications for front and rear suspensions

Wiring Diagrams:

Full-color, detailed electrical wiring diagrams for all vehicle systems

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content for quick information retrieval

Printability:

Printable pages for in-garage use

Print Quality

Image Resolution:

High-resolution images and diagrams

Binding Type

Binding:

Not Applicable (Digital PDF)

Paper Type

Paper Type:

Not Applicable (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine 1 Code:

Engine 1 Displacement:

1.8 Liters (1834 cc)

Engine 1 Configuration:

Inline-4, SOHC (or DOHC on some variants), MPI (Multi-Point Injection)

Engine 1 Power:

Approx. 115-125 PS (85-92 kW)

Engine 1 Torque:

Approx. 160-170 Nm

Optional Engine

Engine 2 Code:

Engine 2 Displacement:

2.0 Liters (1997 cc)

Engine 2 Configuration:

Inline-4, DOHC, GDI (Gasoline Direct Injection) on some variants

Engine 2 Power:

Approx. 130-136 PS (96-100 kW)

Engine 2 Torque:

Approx. 175-185 Nm

Optional Engine Kei

Engine 3 Code:

Engine 3 Displacement:

0.7 Liters (659 cc)

Engine 3 Configuration:

Inline-4, DOHC, Turbocharged, Intercooled

Engine 3 Power:

Approx. 64 PS (47 kW) - limited by Kei car regulations

Fuel System

Fuel Delivery:

Electronic Multi-Point Fuel Injection (MPI) or Gasoline Direct Injection (GDI)

Fuel Type:

Unleaded Gasoline

🔧 Transmission

Standard

Transmission Type 1:

5-Speed Manual

Optional

Transmission Type 2:

4-Speed Automatic (INVECS-II system on some models)

Features

4Wd System:

Available 'Easy Select 4WD' or 'Super Select 4WD II' with modes like 2H, 4H, 4HLC, 4LLC

Transmission Fluid 1 Manual:

API GL-4, SAE 75W-90 (manual transmission)

Transmission Fluid 2 Automatic:

DIAQUEEN SP-III or equivalent (automatic transmission)

📐 Dimensions

Exterior

Wheelbase 3 Door:

Approx. 2,280 mm (89.8 in)

Wheelbase 5 Door:

Approx. 2,420 mm (95.3 in)

Length 3 Door:

Approx. 3,735 mm (147.0 in)

Length 5 Door:

Approx. 4,055 mm (159.6 in)

Width:

Approx. 1,690 mm (66.5 in)

Height:

Approx. 1,620-1,700 mm (63.8-66.9 in) depending on roof rails

Weights

Curb Weight:

Approx. 1,100 - 1,350 kg (2,425 - 2,976 lbs)

Gross Vehicle Weight Rating:

Varies by model and configuration

🛡️ Safety Features

Ratings

NHTSA Rating:

Not extensively rated by NHTSA in North America due to limited market presence during that era

Euro Ncap Rating:

Likely participated in European testing, but specific scores for this generation are not widely published

Active Features

Anti-lock Braking System (ABS) standard on many models, optional on base trims

Traction Control:

Traction control system (TCS) available on higher trims or as an option

Passive Features

Airbags:

Driver and front passenger airbags standard on most models

Seatbelts:

3-point front seatbelts with pretensioners, 3-point rear seatbelts

Child Anchors:

ISOFIX/LATCH child seat mounting points

💡 Technology Features

Infotainment

Audio System:

Factory-installed AM/FM stereo with CD player, optional cassette tape deck. Speaker configuration varied by trim.

Display:

Basic digital or analog climate controls and radio display. No advanced touchscreen infotainment in this era.

Driver Assistance

Cruise Control:

Available on higher trim levels and often optional.

Anti Theft:

Factory immobilizer system on some models, central locking with keyless entry optional.

Connectivity

Auxiliary Inputs:

No standard auxiliary audio inputs (e.g., 3.5mm jack or USB) common in this model's production run.

🔧 Maintenance

Service Intervals Engine Oil

Oil Change Interval:

Every 7,500 - 10,000 miles (12,000 - 15,000 km) or 6-12 months, whichever comes first (depending on driving conditions)

Oil Filter Replacement:

Replace with oil change

Service Intervals Spark Plugs

Spark Plug Replacement:

Approx. 60,000 - 100,000 miles (100,000 - 160,000 km) depending on plug type (e.g., platinum, iridium)

Service Intervals Filters

Air Filter Replacement:

Every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed

Fuel Filter Replacement:

Every 30,000 - 50,000 miles (48,000 - 80,000 km)

Fluid Specifications

Engine Oil Specification:

API SL or higher, SAE 5W-30 or 5W-40 (check owner's manual for exact viscosity based on climate)

Coolant Specification:

Mitsubishi Super Long Life Coolant (MS-97641) or equivalent ethylene glycol-based coolant with demineralized water (50/50 mix)

Brake Fluid Specification:

DOT 3 or DOT 4 brake fluid

Power Steering Fluid:

Dexron II or III ATF, or specified power steering fluid

Known Issues

Idle Air Control Valve:

Can become dirty or faulty, leading to rough idling or stalling.

Oxygen Sensors:

Wear out over time, affecting fuel economy and emissions.

Cv Joint Boots:

Can split, leading to grease loss and premature wear of CV joints, especially in off-road use.

Automatic Transmission Issues:

Some models may experience delayed engagement or slipping if fluid is not changed regularly. The INVECS-II system requires correct fluid.

Rear Main Seal Leaks:

Reported on some high-mileage examples, requiring transmission removal for repair.

📚 Vehicle History

Brand Heritage

Mitsubishi SUV Legacy:

Mitsubishi has a long history of producing capable SUVs, starting with the original Pajero (Montero in North America), known for its off-road prowess and durability.

Model Evolution

Pajero Io Introduction:

Introduced in 1998 as a smaller, more city-friendly alternative to the larger Pajero. It was designed to compete in the growing compact SUV segment.

Generation Focus:

This manual covers the first generation of the Pajero iO, produced from 1998 to 2007. The 2000-2002 model years represent an early phase of this generation.

Regional Naming:

Known as the Mitsubishi Pajero Pinin in Europe and other markets. In Japan, a smaller Kei car version was also sold as the Pajero Mini (which had different engine options).

Production

Production Period:

1998 - 2007 (First Generation)

Manufacturing Locations:

Japan (primarily), potentially assembled in other locations for specific markets.

🏆 Awards & Recognition

Recognitions

Off Road Awards:

While not a Dakar Rally winner like its larger sibling, its compact size and capable 4WD system earned it a reputation among enthusiasts for trail capability.

Ratings

Reliability Perception:

Generally considered reliable with proper maintenance, reflecting Mitsubishi's reputation for robust powertrains.