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Mitsubishi Pajero Sport 2001 Repair Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero Sport Year: 2001 Codes Chassis Code: K90 Series Platform: Second Generation Pajero Sport (Pajero Sport II / Challenger) 👋 Introduction Market Position Segment: Mid-size SUV / Sports Utility Wagon Target Audience: Off-road enthusiasts, families, individuals seeking rugged and versatile transportation Competitive Analysis Key Competitors: Toyota Land Cruiser Prado, Nissan Pathfinder, Ford Explorer, Jeep Cherokee (XJ/WJ) Key Features Off Road Capability: Body-on-frame construction, available Super Select 4WD system, good ground clearance Versatility: Practicality for daily use combined with off-road prowess Durability: Reputation for robust construction and reliability 📋 Manual Details Coverage Areas Primary Coverage: Full vehicle repair and service Secondary Coverage: Maintenance, troubleshooting, diagnostics, component repair, wiring diagrams, specifications Page Count Estimated Pages: 1500+ Manual Type Type: Factory Service Manual (FSM) / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system Drivetrain: Manual transmission, automatic transmission, transfer case, front axle, rear axle, drivelines, differentials Suspension Steering: Front suspension (independent), rear suspension (multi-link beam axle), steering system, power steering Brakes: Front disc brakes, rear drum brakes (or disc depending on specification), ABS system, parking brake Electrical: 12V electrical system, battery, charging system, starting system, lighting, instruments, gauges, horns, wipers, washers, power accessories Body Chassis: Body construction, exterior panels, interior trim, doors, windows, glass, seats, body hardware, frame construction HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system Safety Restraints: Airbag system (if equipped), seat belts Emission Control: Emission control systems and components Procedures Included Maintenance: Scheduled maintenance (oil changes, filter replacements, fluid checks), component inspections Diagnostics: Troubleshooting guides, diagnostic trouble codes (DTCs) interpretation, symptom-based troubleshooting Repair: Detailed step-by-step repair procedures for all major vehicle components and systems Overhaul: Engine and transmission overhaul procedures, component disassembly and reassembly Adjustment: Adjustment procedures for brakes, clutch, engine timing, etc. Installation: Installation procedures for replacement parts and accessories Torque Specifications: Detailed torque specifications for critical fasteners Wiring Diagrams: Comprehensive electrical wiring diagrams for all systems Technical Depth Depth: Comprehensive: Covers everything from basic fluid checks and filter changes to complete engine and transmission rebuilds, including advanced electrical diagnostics and body repair. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Readability: High resolution, clear text and diagrams, optimized for digital viewing and printing. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) Searchability Text Search: Fully searchable PDF text for quick access to information Compatibility Software Requirements: Any PDF reader (e.g., Adobe Acrobat Reader) ⚙️ Engine Specifications Primary Engine Engine Code Gasoline: 6G72 (3.0L V6 SOHC) Engine Code Diesel: 4D56 (2.5L I4 Turbo Diesel) Performance 3.0L V6 Horsepower: Approx. 175-180 PS (173-178 hp) depending on market 3.0L V6 Torque: Approx. 245-250 Nm (181-184 lb-ft) depending on market 2.5L Diesel Horsepower: Approx. 105-130 PS (104-128 hp) depending on variant and market 2.5L Diesel Torque: Approx. 240-280 Nm (177-207 lb-ft) depending on variant and market Fuel System 3.0L V6 Fuel Delivery: Multi-point Fuel Injection (MPI) 2.5L Diesel Fuel Delivery: Indirect Injection (IDI) or Direct Injection (DI) with Turbocharger, depending on specific model variant Emission Control Emission Standards: Compliant with prevailing emission standards for the respective market (e.g., Euro 2/3) 🔧 Transmission Standard Transmission Type Gasoline: 5-speed Manual Transmission Transmission Type Diesel: 5-speed Manual Transmission Optional Transmission Type Gasoline Optional: 4-speed Automatic Transmission Transmission Type Diesel Optional: 4-speed Automatic Transmission Features 4Wd System: Mitsubishi's Super Select 4WD II system (optional, with rear differential lock) Transfer Case Gearing: High range (2H, 4H) and Low range (4LLc) 📐 Dimensions Exterior Length: Approx. 4610 mm (181.5 in) Width: Approx. 1775 mm (69.9 in) Height: Approx. 1730 mm (68.1 in) Wheelbase: Approx. 2725 mm (107.3 in) Ground Clearance: Approx. 205 mm (8.1 in) Weights Curb Weight: Approx. 1800-1950 kg (3968-4300 lbs), varies by engine and trim Gross Vehicle Weight: Approx. 2500-2600 kg (5511-5732 lbs) Cargo Cargo Volume: Subject to configuration (5-seater vs 7-seater), typically significant cargo space behind the second row. 🛡️ Safety Features Ratings NHTSA Rating: Not specifically rated by NHTSA in many markets for this specific year/model; generally considered robust for its class. Active Features ABS: Anti-lock Braking System (ABS) - Available or standard depending on trim and market Traction Control: Traction Control System (TCS) - Less common for this model year, potentially available on higher trims/specific markets. Passive Features Airbags: Driver and front passenger airbags (standard or optional depending on market/trim) Seat Belts: 3-point seat belts with pretensioners for front occupants, 3-point or lap belts for rear occupants Rollover Protection: Reinforced chassis and body structure designed for SUV use 💡 Technology Features Infotainment Audio System: Factory fitted radio/cassette or CD player, often with 4-6 speakers. Aftermarket upgrades common. Navigation: Optional, typically aftermarket or early integrated systems, not as advanced as modern units. Driver Assistance Cruise Control: Available...
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Mitsubishi Pajero Sport 2001 Repair Service Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Pajero Sport
Year:
2001
Codes
Chassis Code:
K90 Series
Platform:
Second Generation Pajero Sport (Pajero Sport II / Challenger)
👋 Introduction
Market Position
Segment:
Mid-size SUV / Sports Utility Wagon
Target Audience:
Off-road enthusiasts, families, individuals seeking rugged and versatile transportation
Competitive Analysis
Key Competitors:
Toyota Land Cruiser Prado, Nissan Pathfinder, Ford Explorer, Jeep Cherokee (XJ/WJ)
Key Features
Off Road Capability:
Body-on-frame construction, available Super Select 4WD system, good ground clearance
Versatility:
Practicality for daily use combined with off-road prowess
Durability:
Reputation for robust construction and reliability
📋 Manual Details
Coverage Areas
Primary Coverage:
Full vehicle repair and service
Secondary Coverage:
Maintenance, troubleshooting, diagnostics, component repair, wiring diagrams, specifications
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Factory Service Manual (FSM) / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system
Drivetrain:
Manual transmission, automatic transmission, transfer case, front axle, rear axle, drivelines, differentials
Suspension Steering:
Front suspension (independent), rear suspension (multi-link beam axle), steering system, power steering
Brakes:
Front disc brakes, rear drum brakes (or disc depending on specification), ABS system, parking brake
Electrical:
12V electrical system, battery, charging system, starting system, lighting, instruments, gauges, horns, wipers, washers, power accessories
Body Chassis:
Body construction, exterior panels, interior trim, doors, windows, glass, seats, body hardware, frame construction
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system
Safety Restraints:
Airbag system (if equipped), seat belts
Emission Control:
Emission control systems and components
Procedures Included
Maintenance:
Scheduled maintenance (oil changes, filter replacements, fluid checks), component inspections
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs) interpretation, symptom-based troubleshooting
Repair:
Detailed step-by-step repair procedures for all major vehicle components and systems
Overhaul:
Engine and transmission overhaul procedures, component disassembly and reassembly
Adjustment:
Adjustment procedures for brakes, clutch, engine timing, etc.
Installation:
Installation procedures for replacement parts and accessories
Torque Specifications:
Detailed torque specifications for critical fasteners
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all systems
Technical Depth
Depth:
Comprehensive: Covers everything from basic fluid checks and filter changes to complete engine and transmission rebuilds, including advanced electrical diagnostics and body repair.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Print Quality
Readability:
High resolution, clear text and diagrams, optimized for digital viewing and printing.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
Searchability
Text Search:
Fully searchable PDF text for quick access to information
Compatibility
Software Requirements:
Any PDF reader (e.g., Adobe Acrobat Reader)
⚙️ Engine Specifications
Primary Engine
Engine Code Gasoline:
6G72 (3.0L V6 SOHC)
Engine Code Diesel:
4D56 (2.5L I4 Turbo Diesel)
Performance
3.0L V6 Horsepower:
Approx. 175-180 PS (173-178 hp) depending on market
3.0L V6 Torque:
Approx. 245-250 Nm (181-184 lb-ft) depending on market
2.5L Diesel Horsepower:
Approx. 105-130 PS (104-128 hp) depending on variant and market
2.5L Diesel Torque:
Approx. 240-280 Nm (177-207 lb-ft) depending on variant and market
Fuel System
3.0L V6 Fuel Delivery:
Multi-point Fuel Injection (MPI)
2.5L Diesel Fuel Delivery:
Indirect Injection (IDI) or Direct Injection (DI) with Turbocharger, depending on specific model variant
Emission Control
Emission Standards:
Compliant with prevailing emission standards for the respective market (e.g., Euro 2/3)
🔧 Transmission
Standard
Transmission Type Gasoline:
5-speed Manual Transmission
Transmission Type Diesel:
5-speed Manual Transmission
Optional
Transmission Type Gasoline Optional:
4-speed Automatic Transmission
Transmission Type Diesel Optional:
4-speed Automatic Transmission
Features
4Wd System:
Mitsubishi's Super Select 4WD II system (optional, with rear differential lock)
Transfer Case Gearing:
High range (2H, 4H) and Low range (4LLc)
📐 Dimensions
Exterior
Length:
Approx. 4610 mm (181.5 in)
Width:
Approx. 1775 mm (69.9 in)
Height:
Approx. 1730 mm (68.1 in)
Wheelbase:
Approx. 2725 mm (107.3 in)
Ground Clearance:
Approx. 205 mm (8.1 in)
Weights
Curb Weight:
Approx. 1800-1950 kg (3968-4300 lbs), varies by engine and trim
Gross Vehicle Weight:
Approx. 2500-2600 kg (5511-5732 lbs)
Cargo
Cargo Volume:
Subject to configuration (5-seater vs 7-seater), typically significant cargo space behind the second row.
🛡️ Safety Features
Ratings
NHTSA Rating:
Not specifically rated by NHTSA in many markets for this specific year/model; generally considered robust for its class.
Active Features
ABS:
Anti-lock Braking System (ABS) - Available or standard depending on trim and market
Traction Control:
Traction Control System (TCS) - Less common for this model year, potentially available on higher trims/specific markets.
Passive Features
Airbags:
Driver and front passenger airbags (standard or optional depending on market/trim)
Seat Belts:
3-point seat belts with pretensioners for front occupants, 3-point or lap belts for rear occupants
Rollover Protection:
Reinforced chassis and body structure designed for SUV use
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette or CD player, often with 4-6 speakers. Aftermarket upgrades common.
Navigation:
Optional, typically aftermarket or early integrated systems, not as advanced as modern units.
Driver Assistance
Cruise Control:
Available on higher trim levels.
Parking Sensors:
Not typically factory fitted for this model year.
Connectivity
Bluetooth:
Not factory fitted for this model year. Aftermarket solutions available.
Usb Ports:
Not factory fitted for this model year.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-10,000 km (3,000-6,000 miles) or 6 months, depending on driving conditions and oil type.
Air Filter Replacement:
Every 20,000-40,000 km (12,000-24,000 miles) or as needed based on dusty conditions.
Coolant Replacement:
Every 40,000-80,000 km (24,000-48,000 miles) or 2-4 years.
Transmission Fluid Change Manual:
Every 60,000-80,000 km (36,000-48,000 miles) or 3-4 years.
Transmission Fluid Change Auto:
Every 40,000-60,000 km (24,000-36,000 miles) or 2-3 years, especially under heavy use.
Fluid Specifications
Engine Oil Type Gasoline:
API SJ/SL, SAE 10W-30 or 10W-40 (check owner's manual for specific viscosity recommendation)
Engine Oil Type Diesel:
API CF/CG-4, SAE 10W-30 or 15W-40 (check owner's manual for specific viscosity recommendation)
Transmission Fluid Manual:
GL-4 Gear Oil (e.g., Mitsubishi Genuine Gear Oil or equivalent)
Transmission Fluid Automatic:
Mitsubishi DIA-Queen ATF-II E or equivalent DEXRON II/III
Coolant:
Ethylene Glycol based coolant (e.g., Mitsubishi Super Long Life Coolant or equivalent)
Brake Fluid:
DOT 3 or DOT 4
Known Issues
Common Wear Items:
Brake pads and rotors, suspension bushings, ball joints, tie rod ends, exhaust system components, fuel injectors (especially diesel)
Potential Diesel Issues:
Glow plug issues, turbocharger wear, injection pump seals on older diesel variants
Potential Gasoline Issues:
Spark plug fouling, oxygen sensor failure, ignition coil issues on some V6 variants
4Wd System Maintenance:
Regular inspection and lubrication of driveline components, transfer case, and differentials are crucial for longevity.
📚 Vehicle History
Brand Heritage
Mitsubishi 4X4 Legacy:
Mitsubishi has a long and storied history in off-road vehicles, beginning with the iconic Mitsubishi Jeep in the 1950s, leading to the Pajero lineage which includes the Pajero Sport.
Model Evolution
Generation Context:
The 2001 Pajero Sport belongs to the second generation (1996-2006) of the Pajero Sport, known internationally as Mitsubishi Challenger. It was built on the same platform as the second-generation Pajero (Montero Sport in North America).
Production
Manufacturing Plants:
Primarily manufactured in Japan, with some production occurring in other Mitsubishi overseas facilities depending on the market.
Sales Regions:
Widely sold globally, including Asia, Oceania, Europe, Africa, and South America. Less common in North America where the Montero Sport was the primary offering.
🏆 Awards & Recognition
Recognitions
Off Road Awards:
While not a dedicated race vehicle, the Pajero Sport lineage has consistently performed well in various off-road competitions and expeditions globally, earning it a reputation for capability.
Ratings
Reliability Surveys:
Generally considered reliable for its era, though specific model year reliability can vary. Consumer satisfaction surveys often place Mitsubishi vehicles in the mid-to-high range.
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