🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero Sport / Montero Sport

Model Variant:

SUV

Chassis Codes:

K90 Series

Generation Codes:

First Generation (1996-2008)

👋 Introduction

Market Segment:

Compact/Mid-size SUV, Body-on-frame construction

Key Competitors:

Toyota 4Runner, Jeep Cherokee (XJ), Ford Explorer, Nissan Pathfinder, Isuzu Rodeo

Vehicle Platform:

Shared platform with Mitsubishi Pajero (Gen 2.5) and L200/Triton pickup trucks.

Body Styles:

Typically offered as a 2-door or 4-door SUV.

Drivetrain Options:

Rear-Wheel Drive (RWD) and Four-Wheel Drive (4WD) available.

📋 Manual Details

Model Years Covered:

1999, 2000, 2001, 2002

Regions Covered:

Global (with potential regional variations noted)

Estimated Page Count:

Over 1500 pages (typical for comprehensive workshop manuals)

Manual Type:

Workshop Repair and Service Manual

Language:

English

Format:

Digital (likely PDF, printable)

📖 Manual Coverage

Systems Covered:

Engine, Transmission (Automatic & Manual), Drivetrain, Suspension, Steering, Brakes, Fuel System, Cooling System, Exhaust System, Electrical System (Wiring Diagrams included), HVAC, Body & Chassis, Interior Components, Diagnostic Procedures, Troubleshooting.

Procedures Included:

Routine Maintenance, Tune-ups, Component Removal & Installation, Major Overhauls, Troubleshooting Guides, Diagnostic Flowcharts, Electrical System Diagnosis, Torque Specifications, Lubrication Procedures, Specifications & Measurements, Repair Procedures.

Technical Depth:

Comprehensive from basic maintenance to in-depth mechanical and electrical repairs, including factory diagnostic procedures and specifications for professional and advanced DIY use.

📊 Manual Specifications

File Format:

PDF (Portable Document Format)

Print Quality:

High-resolution, suitable for printing individual sections or the entire manual.

Binding Type:

N/A (Digital Product)

Paper Type:

N/A (Digital Product)

⚙️ Engine Specifications

Engine Code Common:

6G72 (3.0L SOHC V6), 6G74 (3.5L SOHC/DOHC V6)

Engine Type:

V6 SOHC/DOHC Gasoline

Horsepower 3.0L:

Approx. 175-185 hp @ 5500-6000 rpm

Torque 3.0L:

Approx. 180-188 lb-ft @ 4500-5000 rpm

Horsepower 3.5L:

Approx. 195-200 hp @ 5000-5500 rpm (SOHC), 235 hp @ 6000 rpm (DOHC)

Torque 3.5L:

Approx. 205-210 lb-ft @ 3500-4000 rpm (SOHC), 235 lb-ft @ 4500 rpm (DOHC)

Fuel Delivery:

Electronic Fuel Injection (EFI)

Recommended Fuel:

Unleaded gasoline (Octane rating as per owner's manual/label)

🔧 Transmission

Transmission Type Common:

4-Speed Automatic

Transmission Type Optional:

5-Speed Manual

Transfer Case Type:

Part-time 4WD system (Super Select available on some trims/markets)

Gear Ratios:

Specific gear ratios are detailed within the manual for both transmission types.

Transmission Fluid Spec Auto:

Mitsubishi DiaQueen ATF-SP II M or equivalent.

Transmission Fluid Capacity Auto:

Approx. 7.5 - 8.5 Liters (Dry Fill)

Transmission Fluid Spec Manual:

API GL-4 or GL-5 gear oil, viscosity typically 75W-90 or 80W-90.

📐 Dimensions

Length Approx:

4500-4600 mm (depending on configuration)

Width Approx:

1775-1800 mm

Height Approx:

1750-1800 mm

Wheelbase Approx:

2725 mm

Ground Clearance Approx:

200-215 mm

Curb Weight Approx:

1800-2000 kg

Gross Vehicle Weight Rating Approx:

2400-2500 kg

Towing Capacity Approx:

Up to 2500 kg (braked trailer, check local regulations)

🛡️ Safety Features

Crash Test Availability:

Limited official data for this specific generation in some regions. Owners advised to consult professional resources for safety assessment.

ABS:

Available on higher trims/later models

Traction Control:

Less common on early models, potentially available on select trims.

Airbags:

Driver and Passenger airbags standard on most models within this range.

Seatbelts:

Three-point seatbelts with pretensioners (front seats).

💡 Technology Features

Audio System:

Factory radio/cassette player or CD player, often with 4-6 speakers. Upgrades are common.

Cruise Control:

Available on most models.

Power Features:

Power windows, power door locks, power mirrors.

Auxiliary Ports:

Not standard; aftermarket solutions are common for AUX or USB connectivity.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000 - 10,000 km or 6-12 months, depending on driving conditions and oil type used. Refer to manual for specific intervals.

Timing Belt Replacement:

Critical: 6G72/6G74 engines use a timing belt. Replacement interval is typically 90,000-100,000 km or 5-7 years. Failure can cause catastrophic engine damage.

Engine Oil Type:

API SJ or higher, SAE 10W-30 or 10W-40 recommended (check manual for specific viscosity based on climate).

Engine Oil Capacity:

Approx. 4.5 - 5.0 Liters (with filter) for V6 engines.

Coolant Type:

Ethylene glycol-based coolant, typically a 50/50 mix with deionized water. Check manual for Mitsubishi specified coolant.

Brake Fluid Type:

DOT 3 or DOT 4.

Timing Belt Wear:

As mentioned, critical for engine health. Regular inspection and timely replacement is paramount.

Valve Stem Seals:

Can degrade over time, leading to oil consumption and blue smoke on startup, especially in higher mileage examples.

Rear Main Seal Leaks:

Can develop leaks, often requiring transmission removal for replacement.

Transfer Case Actuator:

Issues with the electronic or vacuum-actuated 4WD system can arise; manual inspection and testing are crucial.

Exhaust Manifold Cracks:

Can occur due to thermal cycling, leading to exhaust leaks and ticking noises.

Tune Up Components:

Spark plugs (typically 6 for V6), ignition wires/coils, air filter, fuel filter, distributor cap/rotor (if applicable).

📚 Vehicle History

Mitsubishi Offroad Legacy:

Mitsubishi has a long-standing reputation for robust off-road vehicles, stemming from the Pajero lineage and their rally racing successes (e.g., Paris-Dakar).

First Generation Launch:

Introduced in 1996 as a more affordable and road-biased alternative to the flagship Pajero, sharing much of its mechanicals with the L200 pickup.

Production Locations:

Primarily Japan, with significant production also occurring in Brazil and other global assembly plants.

Production Period:

1996-2006 (First Generation)

🏆 Awards & Recognition

Offroad Capability Acclaim:

While specific 'awards' might be limited, the Pajero Sport/Montero Sport is widely recognized for its robust chassis and competent off-road performance for its class, inherited from the Pajero lineage.

Consumer Reviews General:

Generally praised for durability, off-road capability, and practicality, but sometimes criticized for fuel economy and ride comfort compared to unibody SUVs.