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Mitsubishi Pajero Sport 1999 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero Sport Year: 1999 Codes Chassis Code: K50, K60, K70 Series 👋 Introduction Market Position Positioning: Rugged, capable SUV with strong off-road heritage, competing with vehicles like Toyota 4Runner, Nissan Pathfinder, and Jeep Cherokee of the era. Competitive Analysis Advantages: Known for its robust chassis, reliable engines, and effective Super Select 4WD system. Key Features Features: Body-on-frame construction, available diesel and gasoline engines, multiple transmission options, advanced 4WD systems. Manual Value Proposition Value: Provides essential factory-level information for maintenance, repair, and troubleshooting, enabling cost savings and extending vehicle lifespan. Target Audience Audience: DIY enthusiasts, independent repair shops, and owners seeking in-depth knowledge of their vehicle. 📋 Manual Details Coverage Areas Regions Covered: Global (specifications may vary slightly by market) Page Count Estimated Page Count: 1000+ Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul, cylinder head, block assembly, pistons, crankshaft, camshafts, timing system, lubrication system Engine Performance: Fuel injection, ignition system, emission control systems, turbocharger (if applicable) Transmission: Manual and Automatic transmission overhaul, clutch, gearbox, transfer case, propeller shafts Driveline: Front and Rear axles, differentials, drive shafts, constant velocity (CV) joints Suspension: Front and Rear suspension systems, shock absorbers, springs, control arms, ball joints, bushings Steering: Steering gear, power steering system, steering column, tie rods Brakes: Front and Rear brake systems (disc/drum), parking brake, ABS (Anti-lock Braking System) Electrical System: Starting system, charging system (alternator, battery), lighting system, ignition system, ECU (Engine Control Unit), sensors Body Interior Exterior: Body panels, doors, windows, seats, trim, bumpers, exterior trim, paint specifications (general) HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair Instrumentation Warning Systems: Instrument cluster, gauges, warning lights, diagnostic trouble codes (DTCs) Procedures Included Maintenance: Scheduled maintenance, fluid checks and changes, filter replacements, tune-ups Troubleshooting: Diagnostic procedures for common problems, symptom-based troubleshooting charts Repair: Step-by-step repair procedures for all major components and systems Disassembly Assembly: Detailed instructions for component removal, disassembly, cleaning, inspection, and reassembly Electrical Diagnostics: Wiring diagrams, component testing, diagnostic connector locations, troubleshooting electrical faults Technical Depth Depth: Comprehensive factory-level diagnostics, repair, and overhaul procedures suitable for professional mechanics and experienced DIYers 📊 Manual Specifications File Format File Type: PDF Requirements: PDF Reader (e.g., Adobe Acrobat Reader) Print Quality Printability: All pages printable Binding Type Binding: Digital Download (no physical binding) Paper Type Paper Type: N/A (Digital format) Usability Searchability: Likely searchable text within PDF (depending on OCR quality) ⚙️ Engine Specifications Primary Engine Engine Code Gasoline: 6G72 (3.0L V6 SOHC) Engine Displacement Gasoline: 3.0 Liters (2972 cc) Engine Configuration Gasoline: V6, 24-valve, SOHC Engine Code Diesel: 4D56 (2.5L I4 SOHC Turbo Diesel) Engine Displacement Diesel Displacement Diesel: 2.5 Liters (2477 cc) Engine Configuration Diesel Configuration Diesel: Inline 4-cylinder, 8-valve, SOHC, Turbocharged Performance Gasoline Horsepower Gasoline: ~160-180 HP (varies by market and specific tune) Torque Gasoline: ~230-250 Nm (varies by market and specific tune) Performance Diesel Horsepower Diesel: ~95-115 HP (varies by market and specific tune) Torque Diesel: ~200-230 Nm (varies by market and specific tune) Fuel System Fuel Injection Gasoline: Multi-point Fuel Injection (MPI) Fuel Injection Diesel: Indirect Injection (IDI) or Direct Injection (DI) with Turbocharger Ignition System Ignition Type: Electronic Ignition (Distributor-based or Distributorless Ignition System - DIS) Cooling System Cooling Type: Water-cooled 🔧 Transmission Standard Type Standard: 5-speed Manual Transmission Optional Type Optional: 4-speed Automatic Transmission Features 4Wd System: Mitsubishi Super Select 4WD (SS4) or Easy Select 4WD system with locking center differential and low-range gearing Fluid Specifications Atf Type: Dexron III or equivalent for Automatic Transmission (refer to manual for exact specification) Manual Gear Oil Type: API GL-4 or GL-5, SAE 75W-90 or 80W-90 (refer to manual for exact specification) 📐 Dimensions Exterior Length: ~4.6 - 4.7 meters (varies by body style) Width: ~1.7 - 1.8 meters Height: ~1.7 - 1.8 meters (varies by roof rack configuration) Weights Curb Weight: ~1800 - 2000 kg (varies by engine and configuration) Gross Vehicle Weight Rating Gvw: ~2400 - 2600 kg (varies by configuration) Towing Towing Capacity: ~2000 - 2500 kg (braked trailer, varies by market) 🛡️ Safety Features Ratings Crash Test Results: No standardized global ratings readily available for this specific model year; refer to individual market safety regulations. Active Features ABS: Optional on many models, standard on higher trims Passive Features Airbags: Driver and Passenger airbags optional or standard depending on market and trim level Seatbelts: 3-point seatbelts with pretensioners for front occupants, 3-point or lap belts for rear occupants 💡 Technology Features Infotainment Audio System: Basic AM/FM/Cassette or CD player, optional premium sound system depending on trim level. Navigation: Not commonly available or was a very basic aftermarket option for this era. Driver Assistance Cruise Control: Available on higher trim levels. Traction Control: Rarely available on this generation. 🔧 Maintenance...
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Mitsubishi Pajero Sport 1999 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Pajero Sport
Year:
1999
Codes
Chassis Code:
K50, K60, K70 Series
👋 Introduction
Market Position
Positioning:
Rugged, capable SUV with strong off-road heritage, competing with vehicles like Toyota 4Runner, Nissan Pathfinder, and Jeep Cherokee of the era.
Competitive Analysis
Advantages:
Known for its robust chassis, reliable engines, and effective Super Select 4WD system.
Key Features
Features:
Body-on-frame construction, available diesel and gasoline engines, multiple transmission options, advanced 4WD systems.
Manual Value Proposition
Value:
Provides essential factory-level information for maintenance, repair, and troubleshooting, enabling cost savings and extending vehicle lifespan.
Target Audience
Audience:
DIY enthusiasts, independent repair shops, and owners seeking in-depth knowledge of their vehicle.
📋 Manual Details
Coverage Areas
Regions Covered:
Global (specifications may vary slightly by market)
Page Count
Estimated Page Count:
1000+
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine overhaul, cylinder head, block assembly, pistons, crankshaft, camshafts, timing system, lubrication system
Engine Performance:
Fuel injection, ignition system, emission control systems, turbocharger (if applicable)
Transmission:
Manual and Automatic transmission overhaul, clutch, gearbox, transfer case, propeller shafts
Driveline:
Front and Rear axles, differentials, drive shafts, constant velocity (CV) joints
Suspension:
Front and Rear suspension systems, shock absorbers, springs, control arms, ball joints, bushings
Steering:
Steering gear, power steering system, steering column, tie rods
Brakes:
Front and Rear brake systems (disc/drum), parking brake, ABS (Anti-lock Braking System)
Electrical System:
Starting system, charging system (alternator, battery), lighting system, ignition system, ECU (Engine Control Unit), sensors
Body Interior Exterior:
Body panels, doors, windows, seats, trim, bumpers, exterior trim, paint specifications (general)
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair
Instrumentation Warning Systems:
Instrument cluster, gauges, warning lights, diagnostic trouble codes (DTCs)
Procedures Included
Maintenance:
Scheduled maintenance, fluid checks and changes, filter replacements, tune-ups
Troubleshooting:
Diagnostic procedures for common problems, symptom-based troubleshooting charts
Repair:
Step-by-step repair procedures for all major components and systems
Disassembly Assembly:
Detailed instructions for component removal, disassembly, cleaning, inspection, and reassembly
Electrical Diagnostics:
Wiring diagrams, component testing, diagnostic connector locations, troubleshooting electrical faults
Technical Depth
Depth:
Comprehensive factory-level diagnostics, repair, and overhaul procedures suitable for professional mechanics and experienced DIYers
📊 Manual Specifications
File Format
File Type:
PDF
Requirements:
PDF Reader (e.g., Adobe Acrobat Reader)
Print Quality
Printability:
All pages printable
Binding Type
Binding:
Digital Download (no physical binding)
Paper Type
Paper Type:
N/A (Digital format)
Usability
Searchability:
Likely searchable text within PDF (depending on OCR quality)
⚙️ Engine Specifications
Primary Engine
Engine Code Gasoline:
6G72 (3.0L V6 SOHC)
Engine Displacement Gasoline:
3.0 Liters (2972 cc)
Engine Configuration Gasoline:
V6, 24-valve, SOHC
Engine Code Diesel:
4D56 (2.5L I4 SOHC Turbo Diesel)
Engine Displacement Diesel
Displacement Diesel:
2.5 Liters (2477 cc)
Engine Configuration Diesel
Configuration Diesel:
Inline 4-cylinder, 8-valve, SOHC, Turbocharged
Performance Gasoline
Horsepower Gasoline:
~160-180 HP (varies by market and specific tune)
Torque Gasoline:
~230-250 Nm (varies by market and specific tune)
Performance Diesel
Horsepower Diesel:
~95-115 HP (varies by market and specific tune)
Torque Diesel:
~200-230 Nm (varies by market and specific tune)
Fuel System
Fuel Injection Gasoline:
Multi-point Fuel Injection (MPI)
Fuel Injection Diesel:
Indirect Injection (IDI) or Direct Injection (DI) with Turbocharger
Ignition System
Ignition Type:
Electronic Ignition (Distributor-based or Distributorless Ignition System - DIS)
Cooling System
Cooling Type:
Water-cooled
🔧 Transmission
Standard
Type Standard:
5-speed Manual Transmission
Optional
Type Optional:
4-speed Automatic Transmission
Features
4Wd System:
Mitsubishi Super Select 4WD (SS4) or Easy Select 4WD system with locking center differential and low-range gearing
Fluid Specifications
Atf Type:
Dexron III or equivalent for Automatic Transmission (refer to manual for exact specification)
Manual Gear Oil Type:
API GL-4 or GL-5, SAE 75W-90 or 80W-90 (refer to manual for exact specification)
📐 Dimensions
Exterior
Length:
~4.6 - 4.7 meters (varies by body style)
Width:
~1.7 - 1.8 meters
Height:
~1.7 - 1.8 meters (varies by roof rack configuration)
Weights
Curb Weight:
~1800 - 2000 kg (varies by engine and configuration)
Gross Vehicle Weight Rating Gvw:
~2400 - 2600 kg (varies by configuration)
Towing
Towing Capacity:
~2000 - 2500 kg (braked trailer, varies by market)
🛡️ Safety Features
Ratings
Crash Test Results:
No standardized global ratings readily available for this specific model year; refer to individual market safety regulations.
Active Features
ABS:
Optional on many models, standard on higher trims
Passive Features
Airbags:
Driver and Passenger airbags optional or standard depending on market and trim level
Seatbelts:
3-point seatbelts with pretensioners for front occupants, 3-point or lap belts for rear occupants
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM/Cassette or CD player, optional premium sound system depending on trim level.
Navigation:
Not commonly available or was a very basic aftermarket option for this era.
Driver Assistance
Cruise Control:
Available on higher trim levels.
Traction Control:
Rarely available on this generation.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000 - 10,000 km or 6 months (refer to manual for specific recommendation)
Timing Belt Replacement:
For 6G72 V6 engine: Typically 90,000 - 100,000 km (critical item, refer to manual)
Fluid Specifications
Engine Oil Type Gasoline:
API SG/SH/SJ, SAE 10W-30 or 10W-40 (refer to manual for exact specification)
Engine Oil Type Diesel:
API CD/CE/CF, SAE 15W-40 (refer to manual for exact specification)
Coolant Type:
Ethylene glycol based, long-life coolant (e.g., Mitsubishi Super Long Life Coolant or equivalent)
Known Issues
Common Wear Items:
Suspension bushings, ball joints, CV boots, exhaust components due to age and off-road use.
Diesel Engine Considerations:
Glow plug issues, turbocharger maintenance, potential for injector pump wear.
📚 Vehicle History
Brand Heritage
Mitsubishi Off Road:
Mitsubishi has a long and storied history in off-road vehicles, notably with the Pajero (Montero) lineage, known for its Dakar Rally successes.
Model Evolution
First Generation:
The Pajero Sport (also known as Montero Sport or Challenger in some markets) was introduced in 1996 as a sportier, more road-biased sibling to the more utilitarian Pajero. It shared chassis components with the Triton/L200 pickup.
Production
Manufacturing Locations:
Primarily manufactured in Japan and Thailand, with other assembly plants globally.
🏆 Awards & Recognition
Recognitions
Off Road Capability:
Widely recognized for its robust off-road prowess and the effectiveness of its 4WD system, a hallmark of Mitsubishi SUVs.
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