🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero Sport

Year:

1999

Chassis Code:

K70/K80 Series (Challenger/Montero Sport equivalent)

👋 Introduction

Vehicle Segment:

Mid-size SUV / Sport Utility Truck (based on Pajero platform).

Competitors 1999:

Toyota 4Runner, Nissan Pathfinder, Ford Explorer, Jeep Grand Cherokee.

Off Road Capability:

Renowned for its robust chassis, 4WD systems, and suspension for off-road use.

Body On Frame Construction:

Durable body-on-frame construction suitable for heavy-duty use and towing.

Target Audience:

Professional technicians and skilled DIY mechanics due to its technical depth.

📋 Manual Details

Manual Coverage Scope:

Comprehensive repair and service procedures for all major vehicle systems.

Estimated Page Count:

Likely 1000+ pages (typical for full factory service manuals).

Manual Classification:

Factory Service Manual (FSM) / Repair Manual

Language:

English

Digital Format:

PDF

📖 Manual Coverage

Engine Service:

Engine mechanical, fuel injection, ignition, cooling, lubrication, emissions control.

Transmission Service:

Manual and automatic transmission repair, clutch system, driveline.

Suspension Steering Service:

Front and rear suspension, steering gear, power steering system.

Brake System Service:

Hydraulic brake systems (ABS included), parking brake, brake component overhaul.

Electrical System Service:

Charging system, starting system, lighting, instrument cluster, body electrical, ECUs.

HVAC Service:

Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair.

Body Interior Service:

Body panel repair, interior trim, doors, windows, glass, seats.

Maintenance Procedures:

Routine maintenance tasks, fluid changes, filter replacements, lubrication.

Diagnostics Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, electrical schematics.

Repair Overhaul:

Detailed step-by-step repair and overhaul procedures for all major components.

Specifications Tolerances:

Torque specifications, clearances, measurements, wear limits.

Diagnostic Capability:

Advanced diagnostics, including ECU testing and wiring harness analysis.

Rebuild Procedures:

Complete engine, transmission, and differential rebuild instructions.

📊 Manual Specifications

PDF Quality:

High-resolution scans, typically searchable text for easy navigation and printing.

Printability:

Designed for easy printing of individual pages or sections.

Digital Binding:

N/A (Digital PDF format)

Digital Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Code 1:

4G64 (2.4L SOHC I4)

Engine Displacement 1:

2351 cc

Engine Bore Stroke 1:

86.5 mm x 99.0 mm

Engine Compression Ratio 1:

8.5:1 (approx.)

Engine Horsepower 1:

133 hp @ 5500 rpm (approx.)

Engine Torque 1:

135 lb-ft @ 4500 rpm (approx.)

Engine Code 2:

6G72 (3.0L SOHC V6)

Engine Displacement 2:

2972 cc

Engine Bore Stroke 2:

91.1 mm x 76.0 mm

Engine Compression Ratio 2:

8.5:1 (approx.)

Engine Horsepower 2:

173 hp @ 5500 rpm (approx.)

Engine Torque 2:

184 lb-ft @ 4500 rpm (approx.)

Fuel Injection:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Ignition Type:

Distributorless Ignition System (DIS) with Coil-on-Plug (COP) or Coil-Pack.

Coolant Type:

Ethylene Glycol based coolant (e.g., Mitsubishi Super Long Life Coolant or equivalent).

Engine Oil Capacity 4G64:

4.5 Liters (4.8 US Quarts) with filter change.

Engine Oil Capacity 6G72:

5.0 Liters (5.3 US Quarts) with filter change.

Recommended Oil Viscosity 4G64:

10W-30 or 5W-30 (depending on climate).

Recommended Oil Viscosity 6G72:

10W-30 or 5W-30 (depending on climate).

🔧 Transmission

Transmission Type Standard:

5-speed Manual Transmission (KM200 series for 4cyl, KM201 series for V6).

Transmission Type Optional:

4-speed Automatic Transmission (V4A51 series).

Transfer Case:

Part-time 4WD system (Super Select 4WD on some trims) with transfer case with low-range gearing.

Automatic Transmission Fluid:

Diamond SP-III (or equivalent ATF SP-III spec).

Manual Transmission Fluid:

API GL-4, SAE 75W-85 or 75W-90 gear oil.

Transfer Case Fluid:

API GL-3 or GL-4, SAE 75W-85 or 75W-90 gear oil.

Rear Differential Fluid:

API GL-5, SAE 80W-90 gear oil.

📐 Dimensions

Wheelbase:

2725 mm (107.3 in)

Length:

4610 mm (181.5 in)

Width:

1775 mm (69.9 in)

Height:

1750 mm (68.9 in)

Curb Weight Approx 4Cyl:

1800 - 1950 kg (3970 - 4300 lbs)

Curb Weight Approx V6:

1900 - 2050 kg (4190 - 4520 lbs)

Gross Vehicle Weight Rating Gvwr Approx:

2500 kg (5511 lbs)

Wheel Size Standard:

15 inch (alloy or steel)

Tire Size Standard:

235/75R15

Wheel Bolt Pattern:

6 x 139.7 mm (6 x 5.5 inches)

Wheel Offset Et:

ET +35 to +46 mm (typical)

🛡️ Safety Features

Crash Test Ratings Note:

Vehicle safety standards and ratings from 1999 vary significantly by region. Consult specific regional authorities for detailed ratings.

Antilock Brakes ABS:

Optional on some models, standard on higher trims or specific markets.

Airbags:

Driver and front passenger airbags standard or optional depending on trim and market.

Seatbelts:

3-point seatbelts with pretensioners for front occupants, 3-point rear seatbelts.

Frame Construction:

Reinforced body-on-frame construction for enhanced durability and crash protection.

💡 Technology Features

Audio System:

Factory fitted AM/FM/Cassette player with optional CD changer. Speaker configurations vary by trim level.

Cruise Control:

Optional, typically available on higher trim levels, allowing for set speed cruising.

Trailer Towing Prep:

Often equipped with a tow hitch receiver and trailer wiring harness, indicating towing capability.

🔧 Maintenance

Oil Change Interval:

Every 7,500 miles (12,000 km) or 6 months, whichever comes first (under normal driving conditions). Severe conditions may require more frequent changes.

Air Filter Replacement:

Every 15,000 miles (24,000 km) or 12 months.

Fuel Filter Replacement:

Every 30,000 miles (48,000 km) for gasoline engines.

Timing Belt Replacement 4G64:

Every 60,000 miles (96,000 km) or 4 years. (Crucial item to replace to prevent catastrophic engine damage).

Timing Belt Replacement 6G72:

Every 60,000 miles (96,000 km) or 4 years. (Crucial item to replace to prevent catastrophic engine damage).

Brake Fluid Type:

DOT 3 or DOT 4.

Power Steering Fluid:

Dexron II-E or equivalent ATF.

Coolant Capacity:

Approximately 7.5 Liters (7.9 US Quarts) for the 4G64, 8.5 Liters (9.0 US Quarts) for the 6G72. (Exact capacity may vary).

Common Wear Items:

Suspension bushings, ball joints, sway bar links, exhaust system components, and rear main crankshaft seals (especially on higher mileage V6 engines).

Common Electrical Issues:

Fuel pump failures, ABS sensor issues, and minor electrical gremlins in body control modules or window regulators are not uncommon in older vehicles.

Engine Specific Issues:

Overheating due to radiator blockage or coolant leaks, especially if the cooling system is not properly maintained. The 6G72 V6 can sometimes experience intake manifold gasket leaks.

Tsb Coverage:

A comprehensive service manual should include references to Technical Service Bulletins (TSBs) for known manufacturing defects or common repair procedures.

📚 Vehicle History

Mitsubishi SUV Legacy:

Mitsubishi has a long-standing reputation in the SUV market with models like the Pajero (Montero in North America) and Outlander, known for off-road prowess and durability.

Pajero Sport Lineage:

The Pajero Sport (or Challenger/Montero Sport) is a derivative of the larger Pajero/Montero, often built on a slightly shorter wheelbase and with a focus on a balance of on-road comfort and off-road capability.

Generation 1 Start Year:

1996

Generation 1 End Year:

2007 (first generation across various markets)

Manufacturing Plants:

Primarily manufactured in Japan (Okazaki Plant), and potentially other Mitsubishi assembly plants globally.

🏆 Awards & Recognition

Off Road Awards Note:

While the Pajero Sport itself may not have specific widely publicized awards as a standalone model in 1999, it benefits from the Pajero/Montero's strong reputation for off-road performance and durability, which has historically garnered many accolades.