Mitsubishi Pajero Sport 1999 Full Service Repair Manual

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Mots clés: 1999 Car Cars Misc Mitsubishi Pajero Sport

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Description

The Mitsubishi Pajero Sport, specifically the K90 Series SUV manufactured in 1999, is a mid-size vehicle renowned for its robust engineering and impressive off-road capabilities. Building on an extensive legacy in producing durable and reliable SUVs, this model offered a compelling blend of on-road comfort and rugged utility, making it a competitive choice in its segment against vehicles like the Toyota 4Runner and Nissan Pathfinder. Key features include its body-on-frame construction, available four-wheel-drive systems with a transfer case offering various modes, and a naturally aspirated 3.0-liter V6 engine designed to provide ample power for both daily driving and demanding terrain. Its durable design and strong powertrain options contribute to its reputation for longevity and dependability. This comprehensive service and repair manual in English provides essential information for the maintenance and repair of the 1999 Mitsubishi Pajero Sport. It covers a wide array of vehicle systems, including the powertrain, drivetrain, suspension, steering, brakes, and electrical systems, as well as body and chassis components, and HVAC. The manual details scheduled maintenance procedures, repair and rebuild processes, and diagnostic troubleshooting for common issues. With its in-depth technical specifications and clear guidance, this manual serves as an indispensable resource for owners, mechanics, and technicians aiming to ensure the optimal performance, safety, and longevity of their Pajero Sport.

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Pajero Sport

Year:

Codes

Chassis Code:

K90 Series

Body Style:

👋 Introduction

Market Position

Segment:

Mid-size SUV, often marketed as a more rugged and off-road capable alternative to unibody SUVs.

Competitive Analysis

Competitors 1999:

Toyota 4Runner, Nissan Pathfinder, Jeep Cherokee (XJ), Ford Explorer, Chevrolet Blazer.

Key Features

Off Road Capability:

Body-on-frame construction, available 4WD/AWD systems, good ground clearance, robust suspension contribute to strong off-road performance.

Powertrain Options:

Known for reliable V6 gasoline engines, offering a balance of power and refinement for its class.

Durability:

Designed for durability and longevity, making it a popular choice for those seeking a capable and dependable SUV.

📋 Manual Details

Coverage Areas

Regions Covered:

Global (with potential regional variations noted)

Page Count

Estimated Page Count:

Comprehensive (typically 1000+ pages for full service manuals)

Manual Type

Type:

Full Service & Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine, fuel system, exhaust system, cooling system, lubrication system, ignition system, emissions control.

Drivetrain:

Transmission (manual & automatic), transfer case, driveshafts, differentials, axles, hubs, CV joints.

Suspension Steering:

Front suspension, rear suspension, shock absorbers, springs, control arms, steering gear, power steering system, steering column.

Brakes:

Front brakes (discs), rear brakes (drums/discs), ABS system, parking brake, brake hydraulics, brake lines, master cylinder, calipers, rotors.

Electrical:

Battery, charging system (alternator, starter), ignition switch, lighting system (headlights, taillights, interior), fuses, relays, wiring diagrams, instrument cluster, body control module (BCM).

Body Chassis:

Body panels, doors, hood, tailgate, bumpers, interior trim, glass, chassis frame, rust prevention.

HVAC:

Heating, ventilation, air conditioning (compressor, condenser, evaporator, refrigerant, blower motor, controls).

Safety Features:

Airbags, seat belts, rollover protection (if applicable).

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, tire rotation, brake inspections, battery maintenance.

Repair Rebuild:

Engine overhauls, transmission rebuilds, brake system repairs, suspension component replacement, electrical system troubleshooting and repair.

Troubleshooting:

Diagnostic procedures, symptom-based troubleshooting charts, fault code interpretation.

Diagnostics:

On-board diagnostics (OBD-II), sensor testing, actuator testing.

Technical Depth

Depth:

Comprehensive from basic maintenance to complete engine and transmission overhauls, including detailed electrical schematics and diagnostic procedures.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely searchable text (depending on scan quality of original).

Print Quality

Printability:

Printable (standard PDF format).

Binding Type

Binding:

Not applicable (digital format).

Paper Type

Paper Quality:

Not applicable (digital format).

⚙️ Engine Specifications

Primary Engine

Engine Type:

Naturally Aspirated SOHC V6

Displacement:

3.0 Liters (approx. 2972 cc)

Engine Code:

6G72 (common designation for Mitsubishi 3.0L V6)

Performance

Horsepower:

Approximately 175-185 HP (depending on specific market tune)

Torque:

Approximately 240-250 Nm (depending on specific market tune)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline (Octane rating as per owner's manual recommendations)

🔧 Transmission

Standard

Transmission Type:

5-Speed Manual Transmission

Optional

Transmission Type:

4-Speed Automatic Transmission with Overdrive

Features

Transfer Case:

Super Select 4WD system (or similar, depending on market), offering 2H, 4H, 4HLC (with locked center diff), 4LLC (with locked center diff and low range).

📐 Dimensions

Exterior

Length:

Approximately 4600-4700 mm (depending on body style/bumper variations)

Width:

Approximately 1775-1800 mm

Height:

Approximately 1770-1800 mm

Wheelbase:

Approximately 2725 mm

Weights

Curb Weight:

Approximately 1800-2000 kg (depending on configuration)

Gross Vehicle Weight Rating:

Typically around 2400-2600 kg

🛡️ Safety Features

Ratings

Crash Test Results:

Information specific to 1999 may vary by region; refer to NHTSA/Euro NCAP for comparable era vehicles.

Active Features

Available Anti-lock Braking System (ABS)

Passive Features

Airbags:

Driver and Passenger Airbags

Seatbelts:

Three-point inertia-reel seat belts

💡 Technology Features

Infotainment

Audio System:

Factory-installed radio/cassette player or CD player with basic speaker system. Aftermarket upgrades are common.

Climate Control:

Manual or automatic climate control systems depending on trim level.

Driver Assistance

Cruise Control:

Available cruise control system.

Connectivity

Power Accessories:

Power windows, power door locks, power mirrors.

🔧 Maintenance

Service Intervals

Oil Change:

Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first (refer to manual for exact specification).

Engine Oil Filter:

Replace at every oil change.

Air Filter:

Inspect every 7,500 miles (12,000 km), replace as needed (typically every 15,000-30,000 miles).

Fuel Filter:

Replace approximately every 30,000 miles (48,000 km) or as specified.

Spark Plugs:

Replace based on mileage or time interval (e.g., 60,000-100,000 miles for iridium plugs if equipped, check manual for original spec).

Transmission Fluid Manual:

Inspect fluid level regularly, change interval typically around 30,000-60,000 miles.

Transmission Fluid Automatic:

Inspect fluid level and condition regularly. Change interval typically 30,000-60,000 miles, depending on driving conditions.

Coolant:

Flush and replace every 24-36 months or 30,000-50,000 miles.

Fluid Specifications

Engine Oil:

API SG or higher, SAE 10W-30 or 5W-30 (refer to manual for viscosity based on temperature).

Transmission Fluid Automatic:

Mitsubishi Diaqueen SP-III or equivalent DEXRON-III/MERCON.

Transfer Case Fluid:

API GL-4 SAE 75W-90 Gear Oil (check manual for specific type).

Differential Fluid:

API GL-5 SAE 80W-90 Gear Oil (check manual for front/rear specific).

Coolant:

Ethylene glycol-based coolant, typically a 50/50 mix with distilled water.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Known Issues

Engine Vibration:

Potential for engine vibration due to aging engine mounts or balance shaft issues in some 6G7x series engines.

Transmission Issues:

Automatic transmission shift quality can degrade over time; regular fluid changes are crucial. Manual transmission clutch wear is normal with use.

4Wd System:

Actuators or sensors in the 4WD system can fail, requiring diagnosis and repair. Regular operation is recommended to prevent seizing.

Rust Corrosion:

Like many vehicles of this era, susceptible to rust, especially in areas with harsh winters or coastal environments. Frame, wheel arches, and rocker panels are common areas.

Suspension Components:

Ball joints, bushings, and tie rod ends can wear out over time, affecting steering and ride quality.

📚 Vehicle History

Brand Heritage

Mitsubishi SUV Legacy:

Mitsubishi has a long history of producing capable off-road vehicles, notably the Pajero (Montero in some markets), dating back to the early 1980s. The Pajero Sport is a derivative, often built on a chassis shared with the Triton/L200 pickup truck.

Model Evolution

Pajero Sport Generation:

This 1999 model represents the first generation of the Pajero Sport, introduced globally in 1996 as the 'Challenger' in some markets. It aimed to offer a more affordable and slightly less opulent alternative to the flagship Pajero.

Production

Manufacturing Locations:

Primarily manufactured in Japan, with potential assembly in other regions depending on market.

🏆 Awards & Recognition

Recognitions

Off Road Awards:

While the Pajero Sport itself might not have specific widely publicized awards, the broader Pajero lineage has numerous accolades from off-road publications and events for its capability.