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...
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)
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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