The Mitsubishi Pajero iO, also known as the Pajero Pinin, is a compact SUV produced from 1998 to 2007, with this manual specifically covering models from 2000 to 2002. This lightweight vehicle is designed for agility and offers respectable off-road capability for its class, making it a versatile choice for both urban driving and recreational activities. Building on a heritage in robust off-road vehicles, the Pajero iO offers a blend of practicality and adventurous spirit, competing with other compact SUVs of its era. It is equipped with various engine options, including 1.3L, 1.5L, and 1.5L MIVEC engines, and offers an optional Super Select II 4WD system for enhanced traction.
This comprehensive factory service repair manual provides detailed information essential for the maintenance, repair, and troubleshooting of the Mitsubishi Pajero iO. It covers all major systems, including the engine, fuel, ignition, cooling, exhaust, transmission (manual and automatic), drivetrain, suspension, steering, braking, and electrical systems. The manual includes step-by-step repair instructions, diagnostic procedures, technical specifications, wiring diagrams, and safety guidelines, making it an invaluable resource for owners, technicians, and mechanics aiming to keep their vehicle in optimal condition.
Common Name:
Pajero iO, Pajero Pinin
Generation Designation:
First Generation (H61W/H71W/H62W/H72W/H66W/H76W/H67W/H77W)
Chassis Codes:
H61W, H71W, H62W, H72W, H66W, H76W, H67W, H77W
Production Years Covered:
2000, 2001, 2002
Segment:
Compact SUV / Recreational Off-Roader
Competitors:
Honda CR-V, Toyota RAV4, Suzuki Vitara, Nissan X-Trail (earlier models), Land Rover Freelander.
Vehicle Type:
Lightweight, compact SUV known for its agile handling and off-road capability relative to its size.
Target Audience:
Individuals seeking a versatile vehicle for urban driving, light off-roading, and recreational activities.
Systems Covered:
Engine mechanical, fuel system, ignition system, cooling system, exhaust system, clutch, manual transmission, automatic transmission, transfer case, driveshafts, differentials, suspension (front and rear), steering system, braking system (front and rear), ABS, body electrical system, interior and exterior trim, HVAC system, SRS (airbag) system, wiring diagrams, diagnostic trouble codes (DTCs), troubleshooting, maintenance procedures, specifications.
Estimated Page Count:
Hundreds of pages (specific count not provided, but described as 'complete official full factory service repair manual')
Type:
Factory Service Repair Manual
Powertrain:
Detailed coverage of all engine variants, transmissions, drivetrain components, and related systems.
Chassis:
Comprehensive information on suspension, steering, brakes (including ABS), wheels, and tires.
Electrical:
Extensive coverage of the body electrical system, engine control module (ECM), SRS (airbag) system, lighting, instrumentation, and detailed wiring diagrams.
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication, inspections.
Repair:
Step-by-step repair instructions for all major components and systems, including engine rebuilds, transmission overhauls, suspension and steering repairs, brake component replacement, and electrical system troubleshooting.
Troubleshooting:
Diagnostic procedures for common and uncommon faults, including symptom-based troubleshooting and fault code interpretation.
Depth:
Factory-level detail, covering everything from basic maintenance to complete engine and transmission rebuilds, including torque specifications, clearances, diagnostic procedures, and specialized tool requirements.
Quality:
High resolution, suitable for printing individual pages or the entire manual.
Binding:
N/A (Digital Download)
Paper:
N/A (Digital Download)
Engine Type:
Inline 4-cylinder, SOHC, 12-valve
Displacement:
1.3 L (1300 cc)
Bore X Stroke:
71.0 mm x 81.4 mm
Fuel Delivery:
Electronic Fuel Injection (EFI)
Horsepower Ps:
82 PS @ 5500 rpm
Torque Kgf M:
10.7 kgf-m @ 3500 rpm
Engine Type:
Inline 4-cylinder, DOHC, 16-valve (MIVEC)
Displacement:
1.5 L (1468 cc)
Bore X Stroke:
75.0 mm x 83.0 mm
Compression Ratio:
10.0:1
Fuel Delivery:
Electronic Fuel Injection (EFI)
Horsepower Ps:
107 PS @ 6000 rpm
Torque Kgf M:
14.0 kgf-m @ 4000 rpm
Recommended Fuel:
Unleaded gasoline (Octane rating varies by market, typically 91 AKI or higher)
Fuel Tank Capacity:
50 Liters
Type:
5-speed Manual Transmission
Type:
4-speed Automatic Transmission with Lock-up Clutch
Drive System:
Optional Super Select II 4WD system with electronically controlled coupling, offering 2H, 4H, 4HLC (4WD High Lock), and 4LLC (4WD Low Lock) modes.
Manual Transmission Fluid:
API GL-3 or GL-4, SAE 75W-90 (check manual for specific viscosity and type)
Automatic Transmission Fluid:
DIA/ATF SP-III (or equivalent specified by Mitsubishi)
Manual Transmission Capacity:
Approx. 2.3 Liters
Automatic Transmission Capacity:
Approx. 6.8 Liters (total fill)
Transfer Case Capacity:
Approx. 0.9 Liters
Rear Differential Capacity:
Approx. 1.2 Liters
Length:
3,780 mm (Short Wheelbase), 4,115 mm (Long Wheelbase)
Height:
1,640 mm (Short Wheelbase), 1,755 mm (Long Wheelbase)
Wheelbase:
2,200 mm (Short Wheelbase), 2,420 mm (Long Wheelbase)
Ground Clearance:
Approx. 195 mm
Curb Weight:
Approx. 1,200 - 1,400 kg (depending on configuration)
Gross Vehicle Weight Rating Gvwr:
Varies by model, consult manual or vehicle placard.
NHTSA Rating:
Not prominently rated in major US crash tests due to its primary market focus, but generally considered robust for its class.
ABS:
Optional Anti-lock Braking System (ABS)
Traction Control:
Rarely equipped, generally not available.
Airbags:
Driver and passenger front airbags standard on most models.
Seatbelts:
Three-point seatbelts with pretensioners for front occupants.
Child Seat Anchors:
ISOFIX/LATCH child seat anchorage points typically present.
Audio System:
Basic AM/FM radio with CD player, often with cassette tape functionality. Speaker configuration typically 4 speakers.
Navigation:
Rarely factory-equipped, typically aftermarket installations.
Cruise Control:
Optional on higher trim levels.
Parking Sensors:
Not typically factory-equipped.
Bluetooth:
Not factory-equipped, requires aftermarket installation.
Usb Port:
Not factory-equipped, requires aftermarket installation.
Oil Change:
Every 7,500 - 10,000 km or 6-12 months, whichever comes first (refer to manual for exact interval based on driving conditions).
Oil Filter Replacement:
At every oil change.
Air Filter Replacement:
Every 20,000 - 30,000 km or as needed based on inspection.
Spark Plug Replacement:
Every 40,000 - 60,000 km (depending on plug type).
Coolant Flush:
Every 40,000 - 50,000 km or 2-3 years.
Transmission Fluid Change:
Manual: Inspect every 30,000 km, change as recommended. Automatic: Every 60,000 km or 4 years.
Engine Oil Type:
API SG or higher, SAE 10W-30 or 10W-40 (check manual for specific climate recommendations and viscosity grades).
Engine Oil Capacity:
Approx. 3.7 Liters (with filter, for 4G13/4G15 variants)
Coolant Type:
Ethylene glycol-based coolant, Mitsubishi Genuine Long Life Coolant (LLC) or equivalent, mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4.
Power Steering Fluid Type:
Use Automatic Transmission Fluid (ATF) DEXRON-II or III, or a power steering fluid specified by Mitsubishi.
Common Complaints:
Interior trim rattles, wear on suspension bushings (especially in off-road use), occasional issues with the HVAC blower motor resistor, potential for rust in certain climates if not maintained, minor electrical gremlins in older vehicles.
Recommendations:
Regular inspection of drive belts, hoses, and exhaust system. Checking and topping up all fluid levels. Paying close attention to suspension and steering components due to the vehicle's off-road capability.
Heritage:
Mitsubishi Motors has a long history of producing durable and capable off-road vehicles, most notably the Pajero (Montero) line, known for its go-anywhere reputation.
Positioning:
The Pajero iO was conceived as a smaller, more accessible, and lighter-weight sibling to the larger, full-size Pajero, designed to appeal to a broader market seeking urban practicality with off-road potential.
Name Variants:
Marketed as Pajero iO in most global markets, but as Pajero Pinin in Italy and often referred to as Mitsubishi Pajero Junior in Japan (though the Junior was a different, earlier model).
Manufacturing Location:
Japan
Production Years:
1998-2007 (This manual covers the 2000-2002 facelift/update period)
Awards:
Specific awards for the Pajero iO are not widely publicized in major international automotive award circuits, but it was generally well-received in markets where it was sold for its compact size, maneuverability, and off-road credentials.
