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Mitsubishi Pajero iO 2000-2002 Repair Service Manual

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The Mitsubishi Pajero iO, produced for the 2000, 2001, and 2002 model years, represents a compact SUV designed for versatility and capable off-road performance within its class. This model, part...
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Mitsubishi Pajero iO 2000-2002 Repair Service ManualMitsubishi Pajero iO 2000-2002 Repair Service ManualMitsubishi Pajero iO 2000-2002 Repair Service ManualMitsubishi Pajero iO 2000-2002 Repair Service Manual
The Mitsubishi Pajero iO, produced for the 2000, 2001, and 2002 model years, represents a compact SUV designed for versatility and capable off-road performance within its class. This model, part of the H60/H70 Series, offers a blend of maneuverability suitable for urban environments with the ruggedness expected from the Pajero lineage. Key features include available advanced 4WD systems, practical interior space, and engines ranging from 1.8L to 2.0L, delivering a balanced driving experience for individuals and small families seeking adventure. This comprehensive workshop repair and service manual provides in-depth guidance for all Mitsubishi Pajero iO models and configurations from 2000 to 2002. Covering a vast array of systems including the powertrain, transmission, chassis, electrical components, and body, this manual details essential maintenance procedures, diagnostic strategies, and repair techniques. It is an indispensable resource for owners, technicians, and mechanics aiming to ensure the optimal performance, reliability, and longevity of their Pajero iO, offering clear instructions and technical specifications.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Pajero iO
Years Covered:
2000, 2001, 2002
Codes
Internal Project Code:
H60/H70 Series (Specific to iO variant of the Pajero family)
👋 Introduction
Market Position
Segment:
Compact SUV / Crossover
Target Audience:
Individuals seeking a capable, yet compact and fuel-efficient off-road oriented vehicle.
Competitive Analysis
Key Competitors:
Honda CR-V, Toyota RAV4, Suzuki Vitara, Daihatsu Terios, Ford EcoSport (depending on region)
Key Features
Off Road Capability:
Available with Mitsubishi's Super Select II 4WD system (depending on market/trim), offering genuine off-road prowess for its class.
Compact Size:
Easier maneuverability and parking in urban environments, appealing to city dwellers.
Practicality:
Versatile interior, suitable for small families or individuals requiring cargo space.
📋 Manual Details
Coverage Areas
Global Regions:
Worldwide (with specific regional variations noted within)
Model Variants:
All Pajero iO models and configurations for the specified years
Page Count
Estimated Page Count:
Over 1000 pages (typical for comprehensive workshop manuals)
Manual Type
Type:
Workshop Repair and Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, engine management (ECU), fuel system, ignition system, exhaust system, cooling system
Transmission:
Manual transmission (5-speed), Automatic transmission (4-speed INVECS-II), transfer case, drivetrain components (axles, driveshafts, differentials)
Chassis:
Suspension (front MacPherson strut, rear Multi-link Beam), steering system, braking system (front vented discs, rear drums/discs), wheels and tires
Electrical:
12V electrical system, charging system (alternator, battery), starting system, lighting (headlights, taillights, interior), instruments and gauges, power accessories (windows, locks, mirrors), audio system, immobilizer system
Body And Interior:
Body construction, exterior panels, doors, hood, tailgate, interior trim, seats, HVAC system (heating, ventilation, air conditioning)
Procedures Included
Maintenance:
Scheduled maintenance (oil changes, filter replacements, fluid checks), lubrication, belt replacement, spark plug replacement, brake pad/shoe replacement, tire rotation
Troubleshooting:
Diagnostic procedures for engine performance issues, starting problems, electrical faults, transmission issues, brake problems
Repair:
Engine rebuild procedures, transmission overhaul, brake caliper/master cylinder replacement, suspension component replacement, electrical component repair/replacement, body panel repair
Diagnostics:
OBD-II (On-Board Diagnostics) system explanation, diagnostic trouble codes (DTCs), sensor testing procedures, wiring diagrams for electrical systems
Technical Depth
Depth:
Comprehensive coverage from basic maintenance to complete engine and transmission overhauls, including detailed diagnostics and electrical troubleshooting.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable, allowing for quick navigation to specific topics.
Print Quality
Quality:
High-resolution scans suitable for printing, with clear diagrams and illustrations.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code And Type:
4G93 (1.8L SOHC/DOHC Inline-4) and 4G94 (2.0L DOHC Inline-4)
Performance
Horsepower Range:
Approximately 110-135 HP (varies by engine variant and market)
Torque Range:
Approximately 160-175 Nm (varies by engine variant and market)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Technical Details
Bore X Stroke:
Varies by engine (e.g., 4G93: 81.0 mm x 89.0 mm; 4G94: 86.0 mm x 86.0 mm)
Compression Ratio:
Varies by engine (e.g., 4G93: 9.5:1, 4G94: 9.7:1)
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission (5MT)
Optional
Transmission Type Optional:
4-speed Automatic Transmission with INVECS-II (4AT)
Features
Drivetrain Options:
2WD (Rear-Wheel Drive) or 4WD (Full-Time or Part-Time, often with Super Select II system)
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90
Automatic Transmission Fluid:
DIA QUEEN ATF-J2 or equivalent
📐 Dimensions
Exterior
Length:
Approx. 3,745 mm - 3,850 mm (varies slightly by model year/variant)
Width:
Approx. 1,690 mm
Height:
Approx. 1,645 mm - 1,705 mm (varies by roof rail/suspension)
Wheelbase:
Approx. 2,280 mm
Weights
Curb Weight:
Approx. 1,200 kg - 1,350 kg (depending on drivetrain and options)
Gross Vehicle Weight Rating:
Typically around 1,700 kg - 1,800 kg
🛡️ Safety Features
Ratings
Crash Test Results:
Varies by region and testing agency (e.g., Euro NCAP, JNCAP). Specific ratings for this model may be limited.
Active Features
Braking System:
Anti-lock Braking System (ABS) available on higher trims or as an option.
Traction Control:
Active Stability Control (ASC) or Traction Control (TCL) may be available on specific models/markets.
Passive Features
Airbags:
Driver and front passenger airbags standard on most models; side airbags may be optional.
Seatbelts:
Three-point seatbelts with pretensioners for front occupants.
Body Structure:
Reinforced impact-absorbing body structure.
💡 Technology Features
Infotainment
Audio System:
Factory fitted AM/FM stereo with CD player, and sometimes cassette player. Speaker configurations vary by trim.
Navigation:
Factory navigation systems were rare on this model and typically aftermarket additions.
Driver Assistance
Cruise Control:
Available on higher trim levels, often integrated with the throttle body.
Connectivity
Auxiliary Inputs:
Unlikely to have standard AUX or USB inputs; aftermarket solutions are common.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 - 10,000 miles (12,000 - 15,000 km) or 6-12 months, whichever comes first (refer to specific market recommendations).
Air Filter Replacement:
Every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed based on conditions.
Spark Plug Replacement:
Typically around 60,000 - 100,000 miles (96,000 - 160,000 km) for iridium or platinum plugs, depending on type.
Fluid Specifications
Engine Oil Capacity And Type:
Approximately 4.0 - 4.5 liters of API SN/SP, ILSAC GF-5/GF-6, SAE 0W-20 or 5W-30 (check manual for precise specification).
Coolant Type:
Mitsubishi Super Long Life Coolant (SLLC) or equivalent (Ethylene Glycol-based, Pink color)
Brake Fluid Type:
DOT 3 or DOT 4 (check manual)
Known Issues
Engine Performance Minor:
Occasional minor oil leaks from valve cover gasket or oil pan seal. Carbon buildup in engines with frequent short trips.
Transmission Issues:
Some reports of automatic transmission shifting issues or solenoid failures, particularly with higher mileage. Clutch wear in manual transmissions.
Suspension Wear:
Wear in ball joints, tie rod ends, and bushings due to its off-road capability and age.
Electrical Minor:
Power window motor failures, issues with dashboard warning lights, or minor sensor faults.
📚 Vehicle History
Brand Heritage
Mitsubishi Offroad:
Mitsubishi has a strong heritage in off-road vehicles, dating back to the original Pajero (Montero in some markets) introduced in 1982, known for its durability and rally success (e.g., Paris-Dakar).
Model Evolution
Pajero Io Concept:
The Pajero iO (also known as Pajero Pinin in Europe, and Mitsubishi Pajero TR4 in Brazil) was developed as a smaller, more affordable, and city-friendly alternative to the larger Pajero models, while retaining some off-road capability.
Production
Production Period:
First generation: 1998-2007. This manual covers the early facelifted models of the first generation.
Manufacturing Locations:
Primarily manufactured in Japan, with significant production also in Brazil for the South American market.
🏆 Awards & Recognition
Recognitions
Model Specific Awards:
While the larger Pajero line has numerous accolades, specific awards for the iO model are less prominent. Its recognition often comes from its niche as a capable compact SUV.
Ratings
Consumer Reports Ratings:
Availability of ratings in contemporary consumer reports may be limited due to market variations and age.
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