🏷️ Basic Information

Make:

Mitsubishi

Model:

Montero iO

Model Nickname:

Pajero iO / Pajero Mini (in some markets)

Product Name:

Mitsubishi Montero iO 2000-2002 Workshop Service Repair Manual PDF

Chassis Code:

H60/H70 series

Engine Codes Covered:

4G93, 4G94

👋 Introduction

Vehicle Segment:

Compact SUV / Crossover Utility Vehicle (CUV), also known as 'Sport Utility Coupe' or 'Kei SUV' in its original Japanese market form.

Target Audience:

Enthusiasts and owners seeking in-depth maintenance and repair knowledge for their compact Mitsubishi SUV.

Competitors 2000S:

Suzuki Vitara/Grand Vitara, Honda CR-V, Toyota RAV4, Ford EcoSport, Nissan X-Trail (depending on market and exact segment placement).

Unique Selling Points:

Compact dimensions, capable 4WD system (Super Select), good fuel efficiency for its class, rugged styling.

Manual Value Proposition:

Provides critical technical information to maintain and repair the Montero iO, enabling cost savings and ensuring longevity.

📋 Manual Details

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF

Estimated Page Count:

Varies by specific edition, typically 800-1500+ pages for a comprehensive workshop manual

📖 Manual Coverage

Engine:

Complete overhaul, diagnostics, lubrication, cooling, fuel, emissions, ignition, engine mechanicals, timing belt/chain

Transmission:

Automatic Transmission (AT) and Manual Transmission (MT) overhaul, diagnostics, fluid service, operation

Drivetrain:

Transfer case, differentials (front and rear), driveshafts, axles, CV joints, Super Select 4WD system

Suspension:

Front and rear suspension systems, shock absorbers, springs, bushings, alignment specifications

Steering:

Power steering system, steering gearbox/rack, steering column, tie rods

Brakes:

Front and rear brake systems (disc/drum), hydraulic system, ABS (if equipped), parking brake

Electrical:

Starting system, charging system, battery, lighting, ignition, instrument cluster, body electricals, wiring diagrams, fuses and relays, power windows, locks, mirrors

HVAC:

Heating, Ventilation, and Air Conditioning system, components, diagnostics, refrigerant service

Body:

Body construction, exterior panels, interior trim, doors, windows, bumpers, chassis adjustments, corrosion protection

Chassis:

Frame and body structure, collision repair information

Maintenance:

Routine checks, fluid changes, filter replacements, belt inspections, tire rotation

Troubleshooting:

System-specific diagnostic procedures, common problems and their solutions, fault codes

Repair:

Step-by-step repair instructions for all major components and systems

Overhaul:

Complete disassembly and reassembly procedures for engines, transmissions, differentials, etc.

Diagnostics:

Detailed diagnostic charts, testing procedures for electrical and mechanical components

Depth:

Comprehensive coverage suitable for professional technicians and advanced DIY mechanics.

Assumptions:

Assumes technician is conversant with general automobile practices and has access to standard tools and equipment.

📊 Manual Specifications

Digital Format:

PDF (Portable Document Format)

Searchability:

Typically includes text-searchable content for easy navigation.

Printability:

Designed for printing, with clear diagrams and text.

Binding:

N/A (Digital PDF)

Paper Quality:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Code Common:

4G93 (GDI and MPI variants)

Engine Layout:

Inline 4-cylinder

Displacement Liters:

1.8L

Fuel Delivery:

Multi-Point Fuel Injection (MPI) or Gasoline Direct Injection (GDI)

Valvetrain:

DOHC (Double Overhead Camshaft) 16-valve

Horsepower Ps Approx:

130-145 PS (approx. 128-143 hp) depending on variant (GDI often slightly higher)

Torque Nm Approx:

170-185 Nm (approx. 125-137 lb-ft) depending on variant

Compression Ratio:

Approx. 9.5:1 to 10.5:1 (varies by GDI/MPI)

Fuel Type:

Unleaded Gasoline

Fuel Pump Type:

Electric, in-tank

🔧 Transmission

Transmission Type Standard:

4-speed Automatic Transmission (INVECS-II)

Transmission Type Optional:

5-speed Manual Transmission

Drivetrain Options:

2WD (Rear-wheel drive) or 4WD (All-wheel drive) with Mitsubishi's Super Select system

Transfer Case:

2-speed transfer case with center differential lock (on 4WD models with Super Select)

📐 Dimensions

Length Mm:

Approx. 3,735 - 3,800 mm (depending on bumper/trim)

Width Mm:

Approx. 1,695 mm

Height Mm:

Approx. 1,700 - 1,800 mm (depending on 4WD vs 2WD and roof rails)

Wheelbase Mm:

Approx. 2,200 mm

Ground Clearance Mm:

Approx. 195 - 205 mm (varies by model/drivetrain)

Curb Weight Kg:

Approx. 1,200 - 1,350 kg

Gross Vehicle Weight Rating Kg:

Approx. 1,700 - 1,800 kg

🛡️ Safety Features

NHTSA Rating:

Not extensively rated by NHTSA for this specific early model/market. Euro NCAP ratings for similar Mitsubishi models of the era can serve as a reference.

ABS:

Available, often standard on higher trims or optional. Anti-lock Braking System.

Traction Control:

Rarely available on this generation, but some advanced systems might have incorporated elements.

Airbags:

Driver and front passenger airbags standard on most models.

Seat Belts:

3-point front seat belts with pre-tensioners, 3-point rear seat belts (except possibly center seat).

Child Seat Anchors:

ISOFIX or LATCH anchor points may be present depending on market and specific configuration.

💡 Technology Features

Head Unit:

Factory fitted AM/FM radio with CD player or cassette deck. Aftermarket head unit compatibility is standard.

Speakers:

Typically 4-6 speaker setup.

Cruise Control:

Available on higher trim levels.

Parking Sensors:

Rarely factory fitted, typically an aftermarket accessory.

Bluetooth:

Not factory fitted. Requires aftermarket adapter or head unit.

Usb Ports:

Not factory fitted. Requires aftermarket adapter or head unit.

🔧 Maintenance

Oil Change Interval Km:

Every 7,500 - 10,000 km or 6-12 months, whichever comes first (refer to manual for precise recommendation).

Engine Coolant Interval Km:

Initial change at 10,000 km or 12 months, then every 40,000 km or 24 months thereafter (using correct coolant).

Transmission Fluid Interval Km:

Automatic: Approx. 40,000-80,000 km (severe use may require more frequent changes). Manual: Approx. 80,000 km.

Timing Belt Replacement Km:

100,000 km or 7 years (for 4G93/4G94 engines, critical interval). Check manual for exact figure.

Engine Oil Type Viscosity:

API SJ/SL, SAE 5W-30 or 10W-30 (depending on climate, check manual for specific GDI/MPI recommendations).

Engine Oil Capacity Liters:

Approx. 4.0 - 4.5 liters (with filter change)

Transmission Fluid Type:

ATF SP-II M or SP-III (for Automatic), API GL-4 SAE 75W-90 (for Manual).

Coolant Type:

Mitsubishi Super Long Life Coolant (LLC) or equivalent ethylene glycol based coolant.

Common Problems:

Timing belt failure (if not replaced at recommended intervals), GDI injector clogging (especially on early GDI engines), front suspension component wear (bushings, ball joints), occasional electrical gremlins.

Maintenance Critical Point:

Strict adherence to the timing belt replacement schedule is paramount to avoid catastrophic engine damage.

📚 Vehicle History

Parent Company:

Mitsubishi Motors Corporation (MMC), part of the wider Mitsubishi Group.

First Generation Start:

1998

Generation Covered:

First Generation (H60/H70)

Facelift Timing:

A minor facelift may have occurred around 2000/2001, introducing minor styling changes and feature updates.

Production Period:

1998 - 2007 (First Generation)

Manufacturing Locations:

Primarily Japan (Mizushima Plant), with potential CKD assembly in other markets.

🏆 Awards & Recognition

Market Reception:

Generally well-regarded for its compact size, 4WD capability, and value proposition in its segment. Specific awards are difficult to pinpoint for this niche model.

Reliability Perception:

Moderate reliability, with common issues often related to age and mileage rather than inherent design flaws, aside from the critical timing belt maintenance.