1999-2002 Mitsubishi Pajero Sport Service & Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero Sport Years Covered: 1999, 2000, 2001, 2002 Other Names: Challenger, Montero Sport, Nativa, Shogun Sport, G-WAGON Codes Chassis Codes: K90 Series (e.g., K94W, K96W, K97W) 👋 Introduction Market Position Vehicle Segment: Compact/Mid-size SUV, Body-on-frame construction Target Audience: Off-road enthusiasts, families, individuals seeking a rugged and capable SUV Competitive Analysis Key Competitors: Toyota 4Runner, Nissan Pathfinder, Jeep Cherokee (XJ/WJ), Ford Explorer, Chevrolet Blazer Key Features Off Road Capability: Renowned for its robust chassis, effective four-wheel-drive system (Super Select II), and good ground clearance. Powertrain Options: Offered with reliable V6 gasoline engines and efficient diesel engines in various markets. Durability: Known for its durable construction and ability to withstand demanding use, both on-road and off-road. Diy Advantage Diy Value Proposition: Empowers owners to perform their own maintenance and repairs, saving costs and fostering a deeper understanding of their vehicle. 📋 Manual Details Coverage Areas Manual Coverage Scope: Comprehensive service and repair for all workshop procedures Page Count Estimated Page Count: Likely over 1000 pages (typical for comprehensive service manuals) Manual Type Manual Type: Service and Repair Manual Language Language: English Format Digital Format: PDF Download Compatibility Operating Systems: All Versions of Windows & Mac Requirements Software Requirement: Adobe PDF Reader 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine overhaul, component diagnostics, timing belt/chain, lubrication system, cooling system Engine Management: Fuel injection system, ignition system, emission control systems, ECU diagnostics, sensor testing Transmission Manual: Clutch system, manual gearbox overhaul, shift linkage, troubleshooting Transmission Automatic: Automatic transmission overhaul, hydraulic control, torque converter, electronic controls, fluid service Drivetrain: Four-wheel drive system (Super Select II), transfer case, differentials (front/rear), driveshafts, CV joints Suspension: Front suspension (independent torsion bar or coil spring), rear suspension (multi-link coil spring), shock absorbers, springs, bushings Steering: Power steering system, steering rack/box, tie rod ends, wheel alignment specifications Brakes: Front disc brakes, rear drum or disc brakes, ABS system diagnostics, brake fluid specifications, caliper and cylinder overhaul Electrical System: Battery, charging system, starter motor, lighting system, horn, power windows, mirrors, wipers, central locking Body And Chassis: Body panel removal and installation, interior trim, glass, seals, frame repair (if applicable), rust prevention Heating And Air Conditioning: HVAC system diagnosis, refrigerant, blower motor, evaporator, condenser, controls Safety Systems: Airbag system (SRS) diagnostics and replacement, seatbelt mechanisms Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, air filter service Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting for various systems Repair And Rebuild: Detailed step-by-step instructions for component removal, repair, and reassembly Diagnostics: On-board diagnostics (OBD-I/OBD-II) interpretation, wiring diagrams, diagnostic connector locations Specifications And Data: Torque specifications, clearances, tolerances, fluid capacities, electrical data Technical Depth Depth Of Coverage: Comprehensive: Covers everything from basic fluid changes to major engine and transmission rebuilds, including electrical system diagnostics and bodywork. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF for quick information retrieval Print Quality Print Readability: High quality, designed for clear viewing of diagrams and text when printed Binding Type Binding Format: Digital Download (PDF), not physically bound Paper Type Digital Paper Simulation: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Gas Engine Code Gas: 6G72 (3.0L V6), 6G74 (3.5L V6) Displacement Gas: 2,972 cc (3.0L) or 3,497 cc (3.5L) Configuration Gas: SOHC or DOHC V6 Horsepower Gas: Approx. 175-200 HP (depending on exact engine and market) Torque Gas: Approx. 230-260 lb-ft (depending on exact engine and market) Primary Engine Diesel Engine Code Diesel: 4D56 (2.5L I4 Turbo Diesel), 4M40 (2.8L I4 Turbo Diesel) Displacement Diesel: 2,477 cc (2.5L) or 2,835 cc (2.8L) Configuration Diesel: Inline 4-cylinder, Turbocharged Horsepower Diesel: Approx. 105-130 HP (depending on exact engine and market) Torque Diesel: Approx. 200-250 lb-ft (depending on exact engine and market) Fuel System Fuel Delivery Gas: Multi-point fuel injection (MPI) Fuel Delivery Diesel: Direct injection, Turbocharged, Intercooled (common for later models) 🔧 Transmission Standard Standard Transmission Type: 5-speed manual transmission Optional Optional Transmission Type: 4-speed automatic transmission (with electronic control) Features Drivetrain System: Part-time or Full-time 4WD with Super Select II system (lever or electronic control depending on trim/market) Transfer Case Gear Ratios: High range (1.000:1), Low range (1.900:1 to 2.100:1, approximate) 📐 Dimensions Exterior Wheelbase: Approx. 2,725 mm (107.3 in) Length: Approx. 4,620 - 4,740 mm (181.9 - 186.6 in) Width: Approx. 1,775 - 1,815 mm (69.9 - 71.5 in) Height: Approx. 1,755 - 1,800 mm (69.1 - 70.9 in) Weights Curb Weight: Approx. 1,800 - 2,000 kg (3,968 - 4,409 lbs), varies by engine and trim Towing Capacity: Varies by market and configuration, typically around 2,000-2,500 kg (4,400-5,500 lbs) 🛡️ Safety Features Ratings Crash Test Ratings: Information not consistently available for all markets; likely met or exceeded regional safety standards of the era. Active Features ABS: Available on many models, especially higher trims and later years. Traction Control: Less common on...
Torque specifications, clearances, tolerances, fluid capacities, electrical data
Technical Depth
Depth Of Coverage:
Comprehensive: Covers everything from basic fluid changes to major engine and transmission rebuilds, including electrical system diagnostics and bodywork.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable PDF for quick information retrieval
Print Quality
Print Readability:
High quality, designed for clear viewing of diagrams and text when printed
Binding Type
Binding Format:
Digital Download (PDF), not physically bound
Paper Type
Digital Paper Simulation:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine Gas
Engine Code Gas:
6G72 (3.0L V6), 6G74 (3.5L V6)
Displacement Gas:
2,972 cc (3.0L) or 3,497 cc (3.5L)
Configuration Gas:
SOHC or DOHC V6
Horsepower Gas:
Approx. 175-200 HP (depending on exact engine and market)
Torque Gas:
Approx. 230-260 lb-ft (depending on exact engine and market)
Part-time or Full-time 4WD with Super Select II system (lever or electronic control depending on trim/market)
Transfer Case Gear Ratios:
High range (1.000:1), Low range (1.900:1 to 2.100:1, approximate)
📐 Dimensions
Exterior
Wheelbase:
Approx. 2,725 mm (107.3 in)
Length:
Approx. 4,620 - 4,740 mm (181.9 - 186.6 in)
Width:
Approx. 1,775 - 1,815 mm (69.9 - 71.5 in)
Height:
Approx. 1,755 - 1,800 mm (69.1 - 70.9 in)
Weights
Curb Weight:
Approx. 1,800 - 2,000 kg (3,968 - 4,409 lbs), varies by engine and trim
Towing Capacity:
Varies by market and configuration, typically around 2,000-2,500 kg (4,400-5,500 lbs)
🛡️ Safety Features
Ratings
Crash Test Ratings:
Information not consistently available for all markets; likely met or exceeded regional safety standards of the era.
Active Features
ABS:
Available on many models, especially higher trims and later years.
Traction Control:
Less common on this generation, primarily found on very high-end trims or specific markets.
Passive Features
Airbags:
Driver and front passenger airbags standard on many models, side airbags less common.
Seatbelts:
Three-point seatbelts for all occupants, pretensioners for front seats.
💡 Technology Features
Infotainment
Audio System:
Factory-fitted radio/cassette player or CD player, often with basic speaker systems. Aftermarket upgrades are common.
Driver Assistance
Cruise Control:
Available on higher trim levels.
Connectivity
Connectivity Features:
Limited by the era; primarily focused on basic vehicle functions and entertainment. No advanced Bluetooth or smartphone integration from factory.
🔧 Maintenance
Service Intervals
Engine Oil And Filter Change:
Every 5,000 - 10,000 km (3,000 - 6,000 miles) or 6-12 months, depending on driving conditions and oil type.
Timing Belt Replacement:
Typically every 90,000 - 120,000 km (56,000 - 75,000 miles) for gasoline engines. Diesel engines often use timing chains, requiring inspection rather than scheduled replacement.
Transmission Fluid Change:
Manual: Inspect regularly, change every 60,000 - 100,000 km (36,000 - 60,000 miles). Automatic: Change fluid and filter every 40,000 - 80,000 km (25,000 - 50,000 miles).
Fluid Specifications
Engine Oil Gasoline:
API SJ or higher, SAE 10W-30 or 5W-30 (check owner's manual for specific viscosity based on climate).
Engine Oil Diesel:
API CF or higher, SAE 15W-40 or 10W-40 (check owner's manual for specific viscosity).
Transmission Fluid Automatic:
Mitsubishi DiaQueen ATF SP-III or equivalent.
Transmission Fluid Manual:
GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90.
Coolant:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Mitsubishi Super Long Life Coolant (LLC) is recommended.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Automatic Transmission Slippage:
Some early models may exhibit slippage or harsh shifting, often related to fluid degradation or worn clutch packs. Requires professional diagnosis.
Diesel Engine Glow Plugs:
Glow plugs can fail, leading to hard starting in cold weather. Requires testing and replacement.
Rust Corrosion:
As with many vehicles of this era, particularly in rust-prone climates, frame and body panel rust can be an issue. Regular inspection and rust prevention are recommended.
Suspension Bushings:
Worn suspension bushings can lead to clunking noises, poor handling, and premature tire wear. Inspection and replacement are part of regular maintenance.
Electrical Connector Corrosion:
Corrosion in electrical connectors, especially in areas exposed to moisture, can cause intermittent faults in various systems.
📚 Vehicle History
Brand Heritage
Mitsubishi Off Road Legacy:
Builds upon Mitsubishi's strong reputation in off-road vehicles, exemplified by the Pajero/Montero lineage and Dakar Rally success.
Model Evolution
Pajero Sport Introduction:
Introduced as a sportier, more personal alternative to the full-size Pajero, utilizing a chassis derived from the Mitsubishi Triton/L200 pickup truck.
Production
Production Start Year:
1996
Production Location:
Japan
🏆 Awards & Recognition
Recognitions
Off Road Reputation:
While not typically garnering specific 'awards' in the consumer sense, the Pajero Sport (and its global variants) are widely recognized for their off-road prowess and durability in enthusiast circles.
Ratings
Consumer Satisfaction:
Varies by market and specific year, but generally considered a reliable and capable SUV, especially for its intended purpose.