🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero Sport / Montero Sport

Production Years:

2000, 2001, 2002

Body Style:

SUV / Truck

Chassis Codes:

K94, K96, K97, K99 (specific variants may apply)

Engine Codes:

6G72 (3.0L V6), 6G74 (3.5L V6), 4D56 (2.5L Diesel) - Confirmation of specific engine availability for model years is advised.

👋 Introduction

Segment:

Mid-size SUV / Body-on-frame SUV, often positioned as a capable off-road and family vehicle.

Competitors:

Jeep Cherokee (XJ/WJ), Ford Explorer, Toyota 4Runner, Nissan Pathfinder, Chevrolet TrailBlazer/Blazer, Isuzu Rodeo.

Vehicle Strengths:

Robust chassis, capable 4WD system (Super Select 4WD often available), strong V6 engines, practical interior, good towing capacity, relatively reliable for its class.

Target Audience:

Families, outdoor enthusiasts, individuals seeking a versatile and durable SUV with off-road capability.

Usefulness:

Essential for owners and mechanics to maintain, diagnose, and repair the vehicle effectively, ensuring longevity and optimal performance. Crucial for identifying specific part numbers and procedures.

📋 Manual Details

Coverage:

Covers all models and all repairs A-Z for the specified production years.

Page Count:

Estimated 2000+ pages (typical for comprehensive workshop manuals of this era, specific count not provided in product info).

Type:

Factory Service Manual (FSM) / Workshop / Repair Manual

Language:

English (standard for most international markets, confirmation may be needed).

Format:

Digital Download (PDF implied by 'Download!!')

📖 Manual Coverage

Engine Mechanical:

Engine assembly, disassembly, cylinder head, block, crankshaft, pistons, connecting rods, lubrication system, cooling system, fuel injection system.

Engine Electrical:

Ignition system, starting system, charging system, engine control module (ECM), sensors, actuators.

Transmission Manual:

Manual transmission, clutch system, driveline components.

Transmission Automatic:

Automatic transmission (if applicable), hydraulic control system, torque converter, transmission control module (TCM).

Drivetrain:

Transfer case, front and rear differentials, axle shafts, CV joints, driveshafts.

Suspension:

Front suspension (independent, typically double wishbone), rear suspension (typically multi-link solid axle), springs, shock absorbers, control arms, bushings.

Steering:

Power steering system, steering gear, steering column, tie rods.

Brakes:

Front and rear brake systems (disc brakes), ABS (Anti-lock Braking System), hydraulic lines, master cylinder, brake boosters, calipers, pads, rotors.

Electrical System:

Wiring diagrams, lighting system (headlights, taillights, interior), fuses, relays, battery, starter, alternator, power windows, power locks, mirrors.

Body And Interior:

Body panel removal and installation, door mechanisms, seats, dashboard, trim panels, glass, sunroof (if equipped).

HVAC:

Heating, ventilation, and air conditioning (HVAC) system, climate control, refrigerant handling.

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel lines, fuel injectors, EVAP system.

Scheduled Maintenance:

Oil changes, filter replacements, spark plug replacement, coolant flushes, brake fluid changes, transmission fluid changes, differential fluid changes, timing belt replacement (if applicable).

Diagnostic Procedures:

Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnostics, electrical system diagnostics.

Repair Procedures:

Step-by-step instructions for component removal, installation, and repair for all major systems.

Adjustment Procedures:

Wheel alignment specifications, brake adjustments, clutch adjustments (if applicable).

Specification Data:

Torque specifications, clearances, fluid capacities, diagnostic readings, emission control data.

Wiring Diagrams:

Detailed electrical wiring schematics for all vehicle systems.

Depth:

Comprehensive, from basic maintenance and fluid checks to complete engine rebuilds, transmission overhauls, and advanced electrical diagnostics. Suitable for professional technicians and advanced DIYers.

📊 Manual Specifications

Digital Format:

Likely PDF, enabling searchability and easy navigation. Assumed to be high resolution for clear diagrams.

Print Readability:

High resolution, ensuring clarity of diagrams, schematics, and text when printed. Assumed to be optimized for readability.

Binding:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

3.0L V6 Mpi Sohc:

Engine Code: 6G72. Displacement: 2972cc. Bore x Stroke: 86.1mm x 85.0mm. Horsepower: Approx. 175-180 hp @ 5000-5200 rpm. Torque: Approx. 245-250 Nm @ 3500-4000 rpm.

3.5L V6 Mpi Sohc:

Engine Code: 6G74. Displacement: 3497cc. Bore x Stroke: 93.0mm x 85.0mm. Horsepower: Approx. 195-200 hp @ 5000 rpm. Torque: Approx. 300-310 Nm @ 3500-4000 rpm.

2.5L Diesel Turbo Intercooled:

Engine Code: 4D56. Displacement: 2477cc. Bore x Stroke: 91.1mm x 95.0mm. Horsepower: Approx. 114-132 hp (depending on variant). Torque: Approx. 250-295 Nm.

Fuel Type:

Unleaded Gasoline (for V6 models), Diesel Fuel (for diesel models).

Injection Type:

Multi-Point Fuel Injection (MPI) for V6 gasoline engines. Direct Injection or Indirect Injection for diesel engines (confirm specific variant).

ECM Type:

Engine Control Module (ECM) with diagnostic capabilities, likely OBD-II compliant.

🔧 Transmission

Transmission Options:

Typically offered with a 5-speed manual transmission or a 4-speed automatic transmission. Specific availability varied by trim and market.

Automatic Transmission:

4-speed automatic transmission, often with electronically controlled gear selection.

Drivetrain Options:

Part-time 4WD, Full-time 4WD (Super Select 4WD on some models), RWD (Rear-Wheel Drive) on base models. The manual will detail operation and maintenance of these systems.

Atf Type:

Likely ATF-SP II M or equivalent for automatic transmissions. Manual transmission fluid specification will be detailed in the manual.

📐 Dimensions

Wheelbase:

Approximately 2,725 mm (107.3 inches). Specific wheelbase may vary slightly by configuration.

Length:

Approximately 4,620 mm (181.9 inches). Specific length may vary slightly by configuration.

Width:

Approximately 1,775 mm (69.9 inches). Specific width may vary slightly by configuration.

Height:

Approximately 1,700 mm to 1,750 mm (66.9 to 68.9 inches), depending on roof rack and suspension. Specific height may vary.

Curb Weight:

Ranging from approximately 1,800 kg to 2,000 kg (3,968 lbs to 4,409 lbs), depending on engine, drivetrain, and equipment.

Towing Capacity:

Typically rated around 2,500 kg to 3,000 kg (5,500 lbs to 6,600 lbs) when properly equipped, subject to local regulations and specific model configuration.

Cargo Volume:

Ample cargo space behind the second row, with further expansion possible by folding seats. Specific volume figures are detailed in the manual.

🛡️ Safety Features

Crash Test Results:

Likely received varying safety ratings depending on the testing agency and the specific year/market. Frontal and side impact protection details will be in the manual. No definitive widely published ratings for all configurations from this era readily available without specific research.

ABS:

Anti-lock Braking System (ABS) typically standard or optional on higher trims.

Traction Control:

Traction Control System (TCS) may be available on some models, particularly those with advanced 4WD systems.

Airbags:

Front airbags for driver and passenger. Side airbags may have been optional on higher trims.

Seatbelts:

Three-point seatbelts with pretensioners for front occupants, three-point or lap belts for rear occupants.

Chassis Construction:

Body-on-frame construction, known for durability and off-road robustness. Manual will detail chassis reinforcement and repair.

💡 Technology Features

Audio System:

Factory radio with AM/FM, CD player. Speaker configuration varies by trim. Manual will cover basic audio system diagnostics.

Cruise Control:

Cruise control system likely available on higher trim levels.

Power Accessories:

Power windows, power door locks, power mirrors are common features. Manual will detail their operation and troubleshooting.

🔧 Maintenance

Oil Change:

Typically every 7,500 km (4,500 miles) or 6 months, whichever comes first. Specific recommendation based on driving conditions should be in the manual.

Air Filter Replacement:

Recommended at 15,000 km (9,000 miles) or annually, or more frequently in dusty conditions. Manual will provide specific intervals.

Coolant Flush:

Typically every 40,000 km (24,000 miles) or 2 years. Always use recommended coolant type.

Timing Belt:

Crucial for 6G72 and 6G74 engines (interference engines). Replacement typically recommended every 90,000 km to 105,000 km (55,000 to 65,000 miles) or 5-7 years. The manual will specify exact interval and procedure, including idler pulleys and tensioners.

Engine Oil Type:

API SG or higher. Viscosity typically 10W-30 or 5W-30 for gasoline engines. Diesel engines may require specific diesel engine oil. Manual will provide precise specifications and capacities.

Coolant Type:

Ethylene glycol-based antifreeze, typically a green or pink color. Manual will specify Mitsubishi Genuine Super Long Life Coolant or compatible equivalent.

Brake Fluid Type:

DOT 3 or DOT 4. Manual will specify.

Common Wear Items:

CV joints, ball joints, tie rod ends, brake components (rotors, pads), wheel bearings, exhaust system components, radiator, thermostat, fuel pump. Maintenance of the 4WD system (fluid changes, U-joints) is important.

Engine Specifics:

Potential for head gasket issues on some V6 engines if overheated. Timing belt replacement is critical. Diesel engines can be robust but require proper maintenance.

Transmission Specifics:

Automatic transmissions can develop shifting issues or solenoid problems with age. Manual transmissions are generally robust.

📚 Vehicle History

Mitsubishi SUVs:

Mitsubishi has a long history of producing capable off-road vehicles, with the Pajero (Montero in many markets) lineage dating back to the early 1980s. The Pajero Sport / Montero Sport is a derivative of the larger Pajero/Montero, often built on a more specialized platform or adapted for different market needs.

First Generation:

The Pajero Sport/Montero Sport was first introduced in 1996. The models covered by this manual represent the early production years of the first generation (often designated as KG/KH chassis).

Trim Levels:

Various trim levels existed, often differentiated by engine, drivetrain, interior features, and exterior styling. Common trims included LS, XLS, ES (names vary by market).

Manufacturing Locations:

Primarily manufactured in Japan, with potential production in other Mitsubishi global facilities.

🏆 Awards & Recognition

Vehicle Awards:

Specific awards for the Pajero Sport/Montero Sport from this era are not widely publicized. However, Mitsubishi SUVs generally earned a reputation for off-road capability and durability.

Consumer Reports:

Consumer Reports ratings varied during these years, with some praise for capability but occasional notes on reliability for specific components. Manual provides the owner/mechanic with the tools to address these potential areas.