1999-2002 Mitsubishi Pajero Sport Service Repair Workshop Manual Download PDF

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The Mitsubishi Pajero Sport, also known as the Montero Sport in North America and Challenger in Japan and Australia, is a rugged, body-on-frame SUV built on the robust Mitsubishi Triton...

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Tipo: Car

Proveedor:

SKU: 52665

Etiquetas: 1999 2000 2001 2002 Car Cars Misc Mitsubishi Pajero Sport

Variantes de producto

Descripción

The Mitsubishi Pajero Sport, also known as the Montero Sport in North America and Challenger in Japan and Australia, is a rugged, body-on-frame SUV built on the robust Mitsubishi Triton pickup truck platform. Produced from 1996 through 2008 for its first generation, this capable vehicle was engineered as a versatile off-roader and family transporter, often positioned as an economical alternative to competitors like the Toyota 4Runner. Available in 2WD and 4WD configurations, many models featured the advanced Super Select 4WD system, offering multiple modes for various terrains. The Pajero Sport was offered primarily as a 5-door SUV, though a 3-door variant was also available in select markets, showcasing Mitsubishi's strong heritage in off-road performance derived from its motorsport success. This comprehensive Factory Service Repair Workshop Manual covers the 1st Generation Pajero Sport models from 1999 to 2002. With over 1500 pages, it provides in-depth information on all major vehicle systems, including engine mechanicals, fuel, exhaust, cooling, lubrication, ignition, manual and automatic transmissions, transfer case, axles, suspension, brakes, steering, wheels, tires, body, interior, HVAC, and electrical systems. The manual details routine maintenance, component diagnosis and repair, wiring diagrams, torque specifications, and special tools, making it an essential resource for owners, mechanics, and technicians to ensure the proper upkeep and repair of their vehicle.

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Pajero Sport

Model Alias:

Montero Sport (North America), Challenger (Japan, Australia)

Generation

Generation:

1st Generation

Codes

Chassis Codes:

K90 series

👋 Introduction

Market Position

Positioning:

Mid-size, body-on-frame SUV positioned as a capable off-roader and family vehicle, often seen as a more affordable alternative to the Toyota Land Cruiser Prado or Nissan Pathfinder of the era.

Competitive Analysis

Key Competitors:

Toyota 4Runner/Land Cruiser Prado, Nissan Pathfinder, Jeep Cherokee (XJ/WJ), Ford Explorer, Chevrolet Blazer.

Key Features

Platform Sharing:

Based on the Mitsubishi Triton (L200) pickup truck platform, offering robust construction and off-road capability.

Drivetrain Options:

Available in 2WD and 4WD configurations, with the highly regarded Super Select 4WD system in many markets.

Body Styles:

Primarily offered as a 5-door SUV, with some markets receiving a 3-door variant.

📋 Manual Details

Coverage Areas

Applicable Years:

1999, 2000, 2001, 2002

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Factory Service Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine Control System Efi:

Fuel System:

Exhaust System:

Cooling System:

Lubrication System:

Ignition System:

Manual Transmission Getrag:

Automatic Transmission Invvecs:

Transfer Case Super Select:

Front Axle And Suspension:

Rear Axle And Suspension:

Brake System:

Steering System:

Wheel And Tires:

Body And Frame:

Interior And Exterior Trim:

HVAC System:

Electrical System Lighting:

Electrical System Instruments Gauges:

Electrical System Audio Visual:

Electrical System Power Accessories:

Safety Systems Airbags:

Diagnostics Troubleshooting:

Procedures Included

Routine Maintenance:

Component Diagnosis:

Component Repair And Overhaul:

Wiring Diagrams:

Torque Specifications:

Special Tools:

Technical Depth

Depth:

Comprehensive (from basic maintenance to full engine/transmission rebuilds)

📊 Manual Specifications

File Format

File Type:

Searchable PDF

Print Quality

Image Resolution:

High-resolution, suitable for printing

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code Gas 1:

Engine Name Gas 1:

3.0L V6 SOHC (12-valve)

Displacement Gas 1:

2972 cc

Horsepower Gas 1:

Approx. 177 hp @ 5200 rpm (specific output varied by market and emissions regulations)

Torque Gas 1:

Approx. 245 Nm (181 lb-ft) @ 3500 rpm (specific output varied by market and emissions regulations)

Engine Code Diesel 1:

Engine Name Diesel 1:

2.5L 4-Cylinder SOHC Turbo Diesel

Displacement Diesel 1:

2477 cc

Horsepower Diesel 1:

Approx. 109 hp @ 4000 rpm (specific output varied by market)

Torque Diesel 1:

Approx. 240 Nm (177 lb-ft) @ 2000 rpm (specific output varied by market)

Fuel System

Fuel Delivery Gas:

Electronic Fuel Injection (EFI)

Fuel Type Gas:

Unleaded Gasoline

Fuel Type Diesel:

Diesel

🔧 Transmission

Standard

Transmission Type Common:

4-speed Automatic (INVECS-II)

Optional

Transmission Type Optional:

5-speed Manual (Getrag)

Features

4Wd System Name:

Super Select 4WD

4Wd Modes:

2H, 4H, 4HLC (with locked center differential), 4LLC (with locked center differential and low range gearing).

📐 Dimensions

Exterior

Length:

Approx. 4,520 mm (178.0 in)

Width:

Approx. 1,775 mm (69.9 in)

Height:

Approx. 1,770 mm (69.7 in) (varies slightly with roof rails)

Wheelbase:

Approx. 2,725 mm (107.3 in)

Ground Clearance:

Approx. 205 mm (8.1 in)

Weights

Curb Weight:

Approx. 1,700 - 1,900 kg (3,748 - 4,189 lbs) (varies by configuration)

🛡️ Safety Features

Ratings

Safety Rating Organizations:

NHTSA, Euro NCAP (ratings vary by market and testing year)

Active Features

Available (typically standard on higher trims)

Passive Features

Airbags:

Driver and front passenger airbags standard on many models.

Seatbelts:

Three-point seatbelts with pretensioners for front occupants.

💡 Technology Features

Infotainment

Audio System:

Factory-installed AM/FM cassette or CD players, often with 4-6 speakers. Aftermarket head units are common upgrades.

Driver Assistance

Cruise Control:

Available on most models.

Traction Control:

Less common on this generation, not a widespread feature.

Connectivity

Connectivity Options:

Primarily limited to audio connectivity. No factory Bluetooth or USB ports.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions and oil type.

Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.

Spark Plug Replacement Gas:

Approx. 60,000 miles (96,000 km) for platinum or iridium plugs.

Fluid Specifications

Engine Oil Type Gas:

API SG or higher, SAE 10W-30 or 10W-40 (refer to manual for specific viscosity based on temperature).

Engine Oil Capacity Gas:

Approx. 4.5 - 5.0 liters (4.8 - 5.3 US quarts) with filter change (6G72 V6).

Transmission Fluid Type Auto:

Diamond ATF SP-II M or equivalent.

Transmission Fluid Capacity Auto:

Approx. 7.5 - 9.0 liters (7.9 - 9.5 US quarts) for full refill (INVECS-II).

Transfer Case Fluid Type:

API GL-3 or GL-4 SAE 75W-90 Hypoid Gear Oil.

Differential Fluid Type Front Rear:

API GL-5 SAE 80W-90 Hypoid Gear Oil.

Coolant Type:

Ethylene glycol-based coolant with corrosion inhibitors (e.g., Mitsubishi Super Long Life Coolant).

Known Issues

Common Issue Power Steering Leaks:

Leaking power steering hoses or pumps can be a concern, particularly with age and mileage.

Common Issue Automatic Transmission Harshness:

Some models may experience rough shifting or delayed engagement in the automatic transmission, often related to fluid condition or valve body issues.

Common Issue Radiator Corrosion:

Radiator tank corrosion and leaks can occur, especially if the coolant is not maintained properly.

Common Issue Timing Belt Replacement:

The 6G72 V6 uses a timing belt that requires replacement at recommended intervals (typically 60,000-90,000 miles) to prevent catastrophic engine damage.

Common Issue Super Select 4Wd Actuator:

The vacuum actuator for the front hub lockout or the electronic components controlling the 4WD system can sometimes fail, preventing proper engagement.

📚 Vehicle History

Brand Heritage

Mitsubishi Offroad History:

Mitsubishi has a long and distinguished history in off-road motorsport, notably the Paris-Dakar Rally, which informed the design and engineering of vehicles like the Pajero lineage, including the Pajero Sport.

Model Evolution

Pajero Sport Origin:

Developed as a more affordable, sport-utility variant of the Pajero (Montero) platform, sharing its robust ladder frame and powertrain options but with distinct styling and often a shorter wheelbase.

Production

Manufacturing Locations:

Primarily produced in Japan, with assembly also occurring in various international plants for local markets.

Production Start Year:

Production End Year For Gen1:

2008 (though sales continued in some markets)