Mitsubishi Pajero Sport 1999-2002 Repair Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero Sport Years Covered: 1999, 2000, 2001, 2002 Generation Generation Designation: First Generation (K70/K90 Series) Codes Chassis Codes: K74W (Short Wheelbase), K94W (Long...

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Taper: Car

Distributeur:

UGS: 441771

Mots clés: 1999 2000 2001 2002 Car Cars Misc Mitsubishi Pajero Sport

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Pajero Sport

Years Covered:

1999, 2000, 2001, 2002

Generation

Generation Designation:

First Generation (K70/K90 Series)

Codes

Chassis Codes:

K74W (Short Wheelbase), K94W (Long Wheelbase)

Engine Codes:

4D56 (2.5L Diesel), 6G74 (3.5L V6 Petrol)

👋 Introduction

Market Position

Vehicle Segment:

Mid-size SUV / Off-road utility vehicle.

Competitive Analysis

Key Competitors:

Toyota Land Cruiser Prado, Nissan Terrano, Isuzu Trooper, Ford Explorer.

Key Features

Body Styles:

Available in 3-door (short wheelbase) and 5-door (long wheelbase) configurations.

Drivetrain Options:

Robust 4WD systems, including Mitsubishi's renowned Super Select 4WD with locking differentials and various modes (2H, 4H, 4HLc, 4LLc).

Reputation:

Known for its durability, off-road capability, and rugged construction, often considered a capable and reliable workhorse.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive repair and service procedures for all major vehicle systems.

Page Count

Estimated Page Count:

1000+ pages (typical for comprehensive service manuals of this era)

Manual Type

Manual Type:

Repair Service Manual

Language

Language:

English

Format

Format:

PDF (Downloadable)

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnostics, repair, and overhaul for 4D56 (2.5L TDIC) and 6G74 (3.5L V6 MPI) engines, including timing belt replacement, fuel injection system, cooling system, lubrication system.

Transmission:

Repair and service for Manual Transmissions (5-speed) and Automatic Transmissions (4-speed INVECS-II), including fluid changes, torque converter, and gear train overhaul.

Drivetrain:

Front and rear differentials, driveshafts, CV joints, transfer case (including Super Select 4WD system operation and repair), and hub mechanisms.

Suspension:

Front independent suspension (Double Wishbone) and Rear multi-link suspension servicing, including shock absorbers, coil springs, control arms, bushings, and alignment specifications.

Brakes:

Front ventilated disc brakes, rear drum brakes (or optional rear discs), ABS system diagnostics and component replacement, brake fluid specifications and bleeding procedures.

Steering:

Power steering system diagnosis, pump, rack and pinion, steering linkage, and column repair.

Electrical:

Full wiring diagrams, fuse and relay identification, starter, alternator, battery, ignition system, lighting system, power windows, central locking, and instrument cluster diagnostics.

Body And Chassis:

Body panel removal/installation, interior trim, doors, hood, tailgate, glass, body repair, and structural components.

HVAC:

Air conditioning system servicing, refrigerant handling, heater core, blower motor, and control panel diagnostics.

Fuel System:

Fuel tank, fuel pump, fuel lines, injectors, and fuel filter replacement for both petrol and diesel variants.

Procedures Included

Scheduled Maintenance:

Detailed maintenance schedules for oil changes, filter replacements, fluid checks, belt inspections, and spark plug replacement.

Troubleshooting:

Extensive diagnostic flowcharts and symptom-based troubleshooting guides for common mechanical and electrical issues.

Repair And Overhaul:

Step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, assembly, and reinstallation.

Torque Specifications:

Comprehensive list of critical torque values for engine, transmission, chassis, and suspension fasteners.

Special Tools:

Identification of specialized tools required for specific repair procedures.

Wiring Diagrams:

High-quality, detailed electrical wiring schematics for all vehicle systems.

Technical Depth

Depth Of Coverage:

Full factory-level repair information, suitable for professional technicians and experienced DIY enthusiasts.

Diagnostic Capability:

Covers basic visual inspections to advanced electronic diagnostics and component testing.

Rebuild Procedures:

Detailed procedures for engine and transmission rebuilding, including parts specifications and tolerances.

📊 Manual Specifications

File Format

File Format:

Print Quality

Resolution:

High-resolution scans, ensuring clarity of diagrams and text.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Searchability

Searchable Text:

Likely text-searchable PDF, allowing quick information retrieval.

⚙️ Engine Specifications

Primary Engine Diesel

Engine Code:

Displacement:

2.5 Liters (2477 cc)

Configuration:

Inline 4-cylinder, Turbocharged Diesel Intercooled (TDIC)

Horsepower:

Approx. 105-115 hp (depending on market and specific tuning)

Torque:

Approx. 200-240 Nm (depending on market and specific tuning)

Primary Engine Petrol

Engine Code:

Displacement:

3.5 Liters (3497 cc)

Configuration:

V6, SOHC, MPI (Multi-Point Injection)

Horsepower:

Approx. 175-180 hp

Torque:

Approx. 280-300 Nm

Fuel System

Diesel Fuel Type:

Diesel

Petrol Fuel Type:

Unleaded Petrol

Performance

Emissions Standards:

Pre-Euro 4, standards vary by market.

🔧 Transmission

Standard

Manual Transmission:

5-speed manual transmission (e.g., R5M33 or similar)

Optional

Automatic Transmission:

4-speed automatic transmission with INVECS-II (Intelligent and Innovative Control) system.

Features

Transfer Case:

Super Select 4WD system with electronic control or manual lever operation, offering 2H, 4H, 4HLc, and 4LLc modes.

Fluid Specifications Auto

Automatic Transmission Fluid:

DIA Queen ATF-SP II M or equivalent (refer to manual for exact specification).

Fluid Specifications Manual

Manual Transmission Fluid:

API GL-4 or GL-5, SAE 75W-90 (refer to manual for exact specification).

📐 Dimensions

Exterior Short Wheelbase

Length:

Approx. 4320 mm

Width:

Approx. 1775 mm

Height:

Approx. 1740 mm

Exterior Long Wheelbase

Length:

Approx. 4675 mm

Width:

Approx. 1775 mm

Height:

Approx. 1740 mm

Wheelbase

Short Wheelbase:

Approx. 2500 mm

Long Wheelbase:

Approx. 2725 mm

Weights

Curb Weight:

Approx. 1700-1900 kg (varies by configuration and engine)

Gross Vehicle Weight Rating:

Approx. 2400-2600 kg (varies by configuration and engine)

Towing Capacity:

Refer to local regulations and manual; typically around 2000-2500 kg (braked).

🛡️ Safety Features

Ratings

Crash Test Results:

N/A for this specific period in many markets; likely performed to Japanese domestic safety standards.

Active Features

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

Traction Control:

Traction Control System (TCS) sometimes available on V6 models.

Passive Features

Airbags:

Driver and passenger airbags commonly equipped.

Seatbelts:

Three-point seatbelts with pretensioners for front occupants.

Rollover Protection:

Reinforced body structure, though specific rollover ratings are not prominent for this era.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM/Cassette or CD player with 4-6 speakers, depending on trim level.

Navigation:

Rarely equipped; typically aftermarket units were installed.

Driver Assistance

Cruise Control:

Available on higher trim levels and V6 models.

Connectivity

Phone Integration:

No integrated Bluetooth or smartphone connectivity; typically requires aftermarket solutions.

🔧 Maintenance

Service Intervals Diesel

Engine Oil Change:

Every 5,000 km or 6 months (whichever comes first), using mineral or semi-synthetic oil suitable for diesels.

Oil Filter Replacement:

With every oil change.

Fuel Filter Replacement:

Every 20,000-40,000 km (refer to manual for specific interval).

Timing Belt Replacement:

Every 100,000 km or 5 years (critical for 4D56 engine; check manual for exact interval and condition).

Service Intervals Petrol

Engine Oil Change:

Every 7,500 km or 6 months (whichever comes first), using synthetic or semi-synthetic oil.

Oil Filter Replacement:

With every oil change.

Spark Plug Replacement:

Every 50,000-100,000 km depending on plug type (refer to manual).

Timing Belt Replacement:

Every 90,000 km or 6 years (critical for 6G74 V6 engine; check manual for exact interval).

Fluid Specifications

Engine Coolant:

Genuine Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based coolant with anti-corrosion additives).

Brake Fluid:

DOT 3 or DOT 4 brake fluid (refer to manual for exact type).

Power Steering Fluid:

Power steering fluid specified by Mitsubishi (often ATF Dexron II/III compatible).

Known Issues

Diesel Engine Common:

Turbocharger wear, injector pump issues, glow plug failures, and potential head gasket issues if not maintained.

Petrol Engine Common:

Timing belt failure if overdue, intake manifold gasket leaks, and ignition coil issues.

Drivetrain Common:

Front CV joint wear, transfer case actuator issues (on electronic systems), and differential seal leaks.

Suspension Common:

Worn bushings, ball joints, and shock absorbers due to off-road use and age.

Electrical Common:

Corrosion on electrical connectors, faulty window regulators, and alternator bearing noise.

📚 Vehicle History

Brand Heritage

Mitsubishi SUV Legacy:

Builds on Mitsubishi's long history of producing capable off-road vehicles, including the iconic Pajero (Montero).

Model Evolution

Pajero Sport Debut:

Introduced as a more lifestyle-oriented and sportier derivative of the larger Pajero platform, often based on the chassis of the previous generation Pajero.

Production

Manufacturing Locations:

Primarily manufactured in Japan and Thailand, with other assembly plants globally.

Production Years

Model Run:

The first generation ran from 1996 to 2008 (though the years 1999-2002 are specifically covered by this manual).

🏆 Awards & Recognition

Recognitions

Offroad Capability Awards:

While specific awards are not widely publicized for this model's early years, its Pajero lineage consistently earned accolades for off-road prowess, including numerous Dakar Rally victories.

Ratings

Consumer Satisfaction:

Generally well-regarded for its ruggedness and utility, though less so for refined on-road manners or fuel economy compared to modern SUVs.