🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero iO

Model Nickname:

Pajero Junior (earlier generations), Pajero Mini (kei car variant, not covered by this manual)

Platform Code:

H61W, H62W, H66W, H67W, H71W, H72W, H76W, H77W (depending on engine and drivetrain)

Engine Codes:

4G93 (1.8L SOHC/DOHC), 4G94 (2.0L DOHC)

Chassis Codes:

H60/H70 Series

👋 Introduction

Segment:

Compact SUV / Crossover

Target Audience:

Owners seeking to perform their own maintenance and repairs, DIY enthusiasts, independent repair shops.

Key Competitors:

Honda CR-V, Toyota RAV4, Suzuki Vitara, Nissan Xterra (depending on market and exact specification)

Vehicle Usp:

Compact dimensions, capable four-wheel-drive system (Super Select 4WD-i), reliable powertrain options, surprisingly versatile for its size.

Value Proposition:

Empowers owners to maintain and repair their Pajero iO, saving money on dealership service costs and ensuring the longevity of the vehicle.

📋 Manual Details

Years Covered:

2000, 2001, 2002

Regions Covered:

Primarily North America, Europe, and Asia/Oceania (specifications may vary by region)

Total Pages:

1000

Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Powertrain:

Engine mechanical (including cylinder head, block, pistons, crankshaft, camshafts), lubrication system, cooling system, fuel system (including fuel injection, fuel pump, injectors), exhaust system, ignition system, emissions control.

Transmission:

Manual transmission (G5M), Automatic transmission (V4A51/W4A51). Includes clutch system, gear shifting mechanisms, torque converter (for automatic), hydraulic control systems.

Drivetrain:

Four-wheel drive system (Super Select 4WD-i system), propeller shafts, front and rear differentials, drive axles, hub assemblies.

Chassis:

Front and rear suspension systems (independent struts front, multi-link rear), steering system (power steering components), braking system (front discs, rear drums/discs, ABS components), wheel bearings.

Electrical System:

12V electrical system, battery, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior lights), power windows, power mirrors, central locking, horn, fuses, relays, wiring diagrams for all systems.

Body And Interior:

Exterior body panels, doors, hood, tailgate, bumpers, glass, seals, interior trim panels, seats, dashboard, HVAC system (heating, ventilation, air conditioning).

Maintenance:

Scheduled maintenance intervals, oil and filter changes, fluid level checks and top-ups, spark plug replacement, air filter replacement, fuel filter replacement, brake pad replacement, tire rotation and pressure checks.

Repair:

Engine overhaul, transmission overhaul, brake caliper and master cylinder repair, suspension component replacement, steering rack replacement, electrical component diagnostics and replacement, body panel repair and replacement, HVAC system repair.

Troubleshooting:

Diagnostic procedures for common drivability issues, electrical faults, ABS warnings, starting problems, cooling system leaks, HVAC malfunctions. Includes symptom charts and flowcharts.

Specifications:

Torque specifications for all fasteners, engine timing specifications, diagnostic trouble codes (DTCs) and their meanings, fluid capacities and types, electrical resistance values, battery specifications.

Depth:

Comprehensive. Covers everything from basic fluid changes and inspections to full engine and transmission rebuilds, complex electrical diagnostics, and bodywork.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchability:

Text-searchable (allows users to quickly find specific keywords and topics)

Resolution:

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

Binding:

N/A (Digital PDF format)

Paper Quality:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine 1 Displacement:

1.8 Liters

Engine 1 Type:

4G93 (Inline-4 Cylinder)

Engine 1 Valvetrain:

SOHC (16-valve) or DOHC (16-valve)

Engine 1 Fuel System:

Multi-point Fuel Injection (MPI)

Engine 1 Horsepower:

Approx. 115-130 PS (depending on SOHC/DOHC and market)

Engine 1 Torque:

Approx. 160-175 Nm (depending on SOHC/DOHC and market)

Engine 2 Displacement:

2.0 Liters

Engine 2 Type:

4G94 (Inline-4 Cylinder)

Engine 2 Valvetrain:

DOHC (16-valve), GDI (Gasoline Direct Injection) in some variants

Engine 2 Fuel System:

MPI or GDI

Engine 2 Horsepower:

Approx. 135 PS

Engine 2 Torque:

Approx. 177 Nm

Ignition System:

Electronic Ignition (Distributorless Ignition System - DIS in later models)

Fuel Type:

Unleaded Gasoline

Fuel Tank Capacity:

Approx. 50 Liters (13.2 US gallons)

🔧 Transmission

Transmission Type:

5-speed Manual

Transmission Type:

4-speed Automatic with Overdrive (INVECS-II Sport Mode)

Drivetrain Options:

2WD (Rear-Wheel Drive), 4WD (Super Select 4WD-i system)

Transfer Case:

2-speed transfer case with locking center differential (on 4WD models)

📐 Dimensions

Length:

Approx. 3,775 mm (148.6 inches)

Width:

Approx. 1,695 mm (66.7 inches)

Height:

Approx. 1,750 mm (68.9 inches)

Wheelbase:

Approx. 2,280 mm (89.8 inches)

Curb Weight:

Approx. 1,250 - 1,400 kg (2,755 - 3,086 lbs), depending on configuration

Gross Vehicle Weight Rating:

Varies by model, typically around 1,700 kg

Cargo Volume Rear Seats Up:

Moderate, sufficient for daily use and light utility.

Cargo Volume Rear Seats Down:

Significantly increased, allowing for larger items. The rear seats typically fold flat.

🛡️ Safety Features

NHTSA Rating:

Specific NHTSA ratings for this generation and market may vary. Generally, compact SUVs of this era had moderate safety features.

ABS:

Anti-lock Braking System (ABS) was often an optional or standard feature depending on trim level and market.

Traction Control:

Traction control systems were less common in this segment and year, but might be present on higher trims or specific market versions.

Airbags:

Driver and front passenger airbags were typically standard. Side airbags were less common.

Seatbelts:

Three-point seatbelts with pretensioners for front occupants, three-point seatbelts for rear occupants.

Body Structure:

Reinforced body structure for crash energy absorption.

💡 Technology Features

Audio System:

Factory-installed AM/FM radio with CD player or cassette deck. Speaker configurations typically 4 or 6 speakers.

Climate Control:

Manual or automatic climate control systems, depending on trim level. Includes A/C, heater, and ventilation functions.

Cruise Control:

Available on higher trim levels.

Power Accessories:

Power windows, power door locks, power mirrors were common options.

🔧 Maintenance

Oil Change Interval:

Typically every 7,500 - 10,000 miles (12,000 - 16,000 km) or 6-12 months, whichever comes first.

Air Filter Replacement:

Every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed based on driving conditions.

Spark Plug Replacement:

Every 30,000 - 60,000 miles (48,000 - 96,000 km), depending on spark plug type (standard vs. iridium).

Transmission Fluid Change:

Manual: Check fluid level periodically, change fluid every 30,000 - 60,000 miles (48,000 - 96,000 km). Automatic: Change fluid and filter every 30,000 - 45,000 miles (48,000 - 72,000 km) or under severe service.

Engine Oil Type:

API SG or higher, SAE 10W-30 or 10W-40 (refer to manual for exact specifications based on temperature).

Engine Oil Capacity:

Approx. 4.0 - 4.3 Liters (4.2 - 4.5 US quarts) with filter change.

Coolant Type:

Mitsubishi Super Long Life Coolant (MS-90039) or equivalent ethylene glycol-based antifreeze (50/50 mix with distilled water).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid Type:

Dexron II or equivalent ATF (Automatic Transmission Fluid).

Manual Transmission Fluid:

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

Automatic Transmission Fluid:

Diamond ATF-SP II M or SP III, or equivalent DEXRON III.

Common Problems:

Minor oil leaks from gaskets/seals (e.g., valve cover, oil pan), occasional issues with ABS sensors, interior trim creaks, potential for exhaust system rust in certain climates. The 4WD system generally robust but requires periodic checks of U-joints and fluid levels.

📚 Vehicle History

Heritage Overview:

Mitsubishi has a long history of producing rugged and capable off-road vehicles, exemplified by the iconic Pajero (Montero in North America) line. The Pajero iO is a smaller, more urban-focused iteration of this heritage.

Generation Timeline:

The Pajero iO (also known as Pajero Pinin in some markets) was first introduced in the late 1990s as a compact SUV designed for versatility and light off-roading. This manual covers the latter part of its first generation (1998-2007).

Manufacturing Location:

Primarily Japan.

Production Years:

1998 - 2007 (for the first generation covered by this manual).

🏆 Awards & Recognition

Awards List:

While the Pajero iO itself may not have a long list of specific awards, its lineage shares the prestigious 'Off-Road Car of the Year' awards held by its larger Pajero sibling, reflecting Mitsubishi's strength in the SUV market.

Reliability Perception:

Generally perceived as a reliable vehicle, especially the powertrain, with proper maintenance. Durability is a characteristic of the Pajero family.