The Mitsubishi Pajero Sport, produced in 2002, is a capable mid-size SUV built on a robust body-on-frame chassis, designed for both family use and off-road adventures. Available with various engine options, including a 2.5L Turbo Diesel (4D56), a 3.0L V6 Petrol (6G72), and a 3.5L V6 Petrol (6G74), it offers a blend of power and utility. Its renowned off-road capability is enhanced by the optional Super Select II 4WD system, providing exceptional traction and control in diverse conditions. The Pajero Sport's engineering emphasizes durability and reliability, building on a heritage in producing rugged utility vehicles. This comprehensive service and repair manual provides extensive coverage for the 2002 Mitsubishi Pajero Sport, detailing all major systems including the powertrain, drivetrain, chassis, suspension, and electrical components. It includes step-by-step procedures for routine maintenance, detailed engine and transmission repair instructions, troubleshooting guides, and essential technical specifications such as torque values and fluid capacities. The manual is designed to assist owners, mechanics, and technicians in accurately diagnosing issues, performing repairs, and maintaining the vehicle to ensure optimal performance and longevity. 🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero Sport Year: 2002 Codes Chassis Code: K90 Series (K94W, K96W, K97W, K99W) Engine Codes General: 4D56 (2.5L Diesel), 6G72 (3.0L V6 Petrol), 6G74 (3.5L V6 Petrol) 👋 Introduction Market Position Vehicle Segment: Mid-size SUV (Sport Utility Vehicle), Body-on-frame construction. Target Audience: Families, off-road enthusiasts, those seeking robust and capable utility vehicles. Competitive Analysis Key Competitors 2002: Toyota 4Runner, Nissan Pathfinder, Ford Explorer, Jeep Grand Cherokee, Isuzu Trooper. Key Features Body Styles: 5-door SUV. Drivetrain Options: Rear-Wheel Drive (RWD) and Super Select II 4WD system (optional). Off Road Capability: Renowned for its robust chassis, capable 4WD system, and good ground clearance. 📋 Manual Details Coverage Areas Market Coverage: Global (specific to 2002 model year variants) Page Count Estimated Page Count: 1000+ Manual Type Manual Type: Full Service & Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical (all variants), Fuel system, Ignition system, Exhaust system, Cooling system, Lubrication system, Turbocharger system (if applicable) Drivetrain: Manual Transmission, Automatic Transmission, Transfer Case (4WD Systems), Front Axle, Rear Axle, Driveshafts, CV Joints Chassis & Suspension: Front Suspension (Double Wishbone), Rear Suspension (Multi-link), Steering System (Hydraulic Power Steering), Brakes (ABS, ventilated discs front, solid discs rear), Wheels & Tires Electrical: Battery, Starting System, Charging System, Lighting System, Instrument Cluster, Gauges, Switches, Fuses & Relays, Engine Control Unit (ECU) Wiring Diagrams, Body Control Module (BCM) Systems Body & Interior: Body Panels, Doors, Hood, Tailgate, Glass, Interior Trim, Seats, HVAC (Heating, Ventilation, and Air Conditioning), Seats, Seatbelts, SRS Airbag System Procedures Included Routine Maintenance: Oil Changes, Filter Replacements (oil, air, fuel), Spark Plug Replacement, Coolant Flushes, Brake Fluid Replacement, Gearbox Oil Changes Engine Repair: Engine Rebuilds, Cylinder Head Overhaul, Piston & Ring Replacement, Valve Adjustment, Timing Belt/Chain Service, Fuel Injector Servicing, Turbocharger Rebuild Transmission & Drivetrain Repair: Clutch Replacement, Transmission Overhaul (Manual & Automatic), Transfer Case Repair, Differential Servicing, CV Joint Boot Replacement Brake System Repair: Brake Pad & Rotor Replacement, Brake Caliper Overhaul, ABS System Diagnostics & Repair, Brake Line Replacement Suspension & Steering Repair: Shock Absorber/Strut Replacement, Bushing Replacement, Ball Joint Replacement, Tie Rod End Replacement, Power Steering Pump & Rack Repair Electrical System Troubleshooting: Wiring Diagram Interpretation, Fault Code Diagnosis, Sensor Testing, Component Replacement (alternator, starter, sensors), ECU Diagnosis HVAC System Service: Refrigerant Charging, Component Replacement (compressor, condenser, evaporator), Blower Motor Replacement, Blend Door Actuator Repair Technical Depth Diagnostic Procedures: Step-by-step diagnostic routines for common and rare faults, including OBD-II diagnostics and component-specific testing. Troubleshooting Guides: Comprehensive fault finding charts based on symptoms, directing technicians to specific causes and repair procedures. Rebuild Procedures: Detailed instructions for complete engine, transmission, and differential rebuilds, including torque specifications and clearances. Technical Data: Includes precise specifications for clearances, torque values, fluid capacities, electrical resistance, pressures, and more. 📊 Manual Specifications File Format File Format: PDF Print Quality Searchability: Text-searchable PDF for quick information retrieval. Image Quality: High-resolution diagrams, illustrations, and photographs. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Completeness Completeness: Full service, repair, and maintenance coverage. ⚙️ Engine Specifications Primary Engine 4D56 2.5L Turbo Diesel: Displacement: 2.5 Liters (2477 cc), Configuration: Inline 4-cylinder, DOHC, Turbocharged, Power: Approx. 115-134 hp (depending on market/tune), Torque: Approx. 240-280 Nm, Fuel System: Direct Injection, Common Rail (later variants) or Indirect Injection. 6G72 3.0L V6 Petrol: Displacement: 3.0 Liters (2972 cc), Configuration: V6, SOHC, Power: Approx. 175-181 hp, Torque: Approx. 250-260 Nm, Fuel System: Multi-Point Fuel Injection (MPI). 6G74 3.5L V6 Petrol: Displacement: 3.5 Liters (3497 cc), Configuration: V6, SOHC/DOHC (depending on specific variant), Power: Approx. 197-220 hp, Torque: Approx. 300-330 Nm, Fuel System: Multi-Point Fuel Injection (MPI). Performance 0-60 Mph Estimate: Varies significantly by engine and drivetrain, typically 9-12 seconds for petrol V6 models....