🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero Pinin

Product Type:

Workshop Service Repair Manual

Platform Code:

H61, H76, H77

👋 Introduction

Segment:

Compact SUV / Crossover Utility Vehicle (CUV)

Target Audience:

Enthusiasts, DIY mechanics, professional repair shops

Key Competitors:

Honda CR-V, Toyota RAV4, Nissan X-Trail (early models), Suzuki Vitara, Land Rover Freelander

Vehicle Strengths:

Compact dimensions, capable 4WD system (Super Select II or Easy Select), reliable Mitsubishi engines, good value proposition

Manual Benefit:

Enables owners and technicians to perform all scheduled maintenance and repairs accurately, reducing reliance on expensive dealerships and improving vehicle longevity.

📋 Manual Details

Model Years:

1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006

Estimated Pages:

Comprehensive (exact number varies by engine/drivetrain configuration, but typically over 1000 pages for complete coverage)

Type:

Workshop Service Repair Manual

Language:

English

Format:

Downloadable Digital Format (likely PDF)

📖 Manual Coverage

Powertrain:

Engine mechanicals, fuel system, ignition system, exhaust system, cooling system, lubrication system

Transmission Drivetrain:

Manual transmission, Automatic transmission, Transfer case, Drive axles, CV joints, Driveshafts, Differentials

Chassis:

Suspension (front and rear), Steering system, Braking system (front and rear), Wheels and tires

Electrical:

Body electrical system, Lighting system, Instrument cluster, Audio system, Power accessories, Battery, Charging system, Starter system

Body Exterior:

Body panels, Doors, Hood, Tailgate, Bumpers, Glass, Seals, Exterior trim, Paint and corrosion protection

Body Interior:

Seating systems, Dashboard, Interior trim panels, Airbag system, Seat belts, HVAC system (heating, ventilation, and air conditioning)

General Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement

Engine Repair:

Engine overhaul, cylinder head removal and installation, piston and connecting rod service, crankshaft service, timing belt/chain replacement

Transmission Repair:

Transmission removal and installation, clutch replacement, internal transmission component repair, differential service

Suspension Steering Brakes:

Shock absorber/strut replacement, spring replacement, ball joint service, tie rod end replacement, brake pad/rotor replacement, brake caliper service, bleeding brake system

Electrical Diagnostics:

Wiring diagrams, troubleshooting procedures for common electrical faults, component testing, sensor diagnosis

Bodywork Repair:

Panel replacement, dent repair, rust repair, glass replacement, bumper repair/replacement

Troubleshooting:

Diagnostic charts, symptom-based troubleshooting guides for engine performance, electrical issues, and mechanical faults

Specifications Torques:

Detailed torque specifications for all fasteners, critical clearance measurements, engine and transmission specifications

Depth:

Comprehensive (from basic maintenance to complete engine and transmission overhauls, including advanced diagnostics and electrical system repairs)

📊 Manual Specifications

File Type:

PDF

Quality:

High-resolution, clear text and diagrams, optimized for printing and screen viewing

Binding:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

Text Search:

Searchable text content for quick information retrieval

⚙️ Engine Specifications

Engine Code 1:

4G93 (1.8L SOHC)

Engine Code 2:

4G93 DOHC (GDI - Gasoline Direct Injection, less common)

Engine Code 3:

4G94 (2.0L SOHC)

Engine Code 4:

4G94 DOHC (GDI)

Engine Code 5:

4G13 (1.3L SOHC - primarily for specific markets, less common)

Engine Code 6:

4G15 (1.5L SOHC - primarily for specific markets, less common)

Engine Code 7:

4D68 (2.0L SOHC Turbo Diesel - less common in this generation)

Displacement 1 8L:

1834 cc

Displacement 2 0L:

1997 cc

Power Output 4G93 1 8L:

Approx. 114-125 PS (84-92 kW) depending on specific tune and market

Power Output 4G94 2 0L:

Approx. 130-135 PS (96-99 kW) depending on specific tune and market

Torque 4G93 1 8L:

Approx. 16.0 - 17.3 kgf·m (157 - 169 Nm) depending on tune

Torque 4G94 2 0L:

Approx. 18.0 - 18.5 kgf·m (177 - 181 Nm) depending on tune

Injection Type:

Multi-point Fuel Injection (MPI) for most non-GDI engines. Gasoline Direct Injection (GDI) for specific variants.

Fuel Type:

Unleaded Gasoline (Octane rating varies by market, typically 91 RON recommended)

Configuration:

Inline 4-cylinder

Orientation:

Transverse

Valvetrain:

SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft) depending on engine

🔧 Transmission

Transmission Type Std:

5-speed Manual Transmission (5MT)

Transmission Type Opt:

4-speed Automatic Transmission (4AT)

Drivetrain:

Part-time 4WD (Easy Select) or Full-time 4WD with center differential lock (Super Select II) depending on trim and market.

Transfer Case:

2-speed transfer case with high and low range gearing for 4WD models.

Manual Transmission Fluid:

API GL-4, SAE 75W-85 or 75W-90 (refer to specific manual for exact viscosity)

Automatic Transmission Fluid:

DIA QUEEN ATF SP III or equivalent (refer to specific manual for exact type)

Manual Gear Ratios:

Varies by specific transmission model; detailed ratios provided in manual.

Automatic Gear Ratios:

Varies by specific transmission model; detailed ratios provided in manual.

📐 Dimensions

Length:

Approximately 3745 - 3765 mm (short wheelbase)

Width:

Approximately 1695 mm

Height:

Approximately 1620 - 1700 mm (depending on roof rails, etc.)

Wheelbase:

Approximately 2220 mm (short wheelbase)

Ground Clearance:

Typically around 195-205 mm

Curb Weight:

Approximately 1300 - 1450 kg, depending on engine, transmission, and drivetrain

Gross Vehicle Weight Rating:

Typically around 1800 - 1900 kg

Towing Capacity:

Typically rated up to 1500 kg (braked), consult specific market regulations and manual for exact figures.

Cargo Volume:

Sufficient for its class, expandable with folding rear seats. Specific volume figures depend on configuration and measurement method.

🛡️ Safety Features

Crash Test Ratings:

Varies by market and specific tests conducted. Euro NCAP ratings were generally average for its class at the time.

Braking System:

Front ventilated disc brakes, Rear drum or disc brakes depending on specification. ABS (Anti-lock Braking System) available on higher trims.

Traction Control:

Traction control systems (TCL) or Active Stability Control (ASC) available on some later models or higher trims.

Airbags:

Driver and front passenger airbags standard on most models. Side airbags optional or standard on higher trims.

Seatbelts:

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

Rollover Protection:

Reinforced body structure for enhanced rollover protection.

💡 Technology Features

Audio System:

Factory fitted radio/cassette player or CD player. Speaker configuration varies by trim level.

Navigation:

Optional GPS navigation systems were available on higher trims in some markets.

ABS:

Anti-lock Braking System (ABS) available on many models.

Cruise Control:

Optional cruise control system available on higher trim levels.

Auxiliary Input:

Limited connectivity features by modern standards. May have an auxiliary input for audio devices on later models.

Power Accessories:

Power windows, power door locks, and power mirrors available on mid to higher trim levels.

🔧 Maintenance

Oil Change Interval Petrol:

Every 7,500 - 10,000 miles (12,000 - 15,000 km) or 12 months, whichever comes first (refer to manual for specific recommendation based on driving conditions).

Air Filter Replacement:

Every 15,000 - 20,000 miles (24,000 - 32,000 km) or 24 months, or more frequently in dusty conditions.

Spark Plug Replacement Petrol:

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

Timing Belt Replacement:

Crucial item! Typically every 60,000 - 90,000 miles (96,000 - 144,000 km) or 4-5 years. Failure can cause catastrophic engine damage. This manual will detail the procedure and recommended intervals.

Engine Oil Type:

API SL/SM/SN, ACEA A3/B4 or similar, SAE 10W-30 or 10W-40 is common. Specific grade depends on climate and engine. Manual will provide exact specifications.

Engine Oil Capacity:

Approximately 4.0 - 4.5 liters for most 1.8L/2.0L engines (including filter). Check manual for exact capacity.

Coolant Type:

Ethylene glycol based, long-life coolant, typically Pink or Red (Mitsubishi Super Long Life Coolant or equivalent).

Coolant Capacity:

Approximately 6.0 - 7.0 liters. Check manual for exact capacity.

Brake Fluid Type:

DOT 3 or DOT 4.

Power Steering Fluid Type:

Dexron II or III automatic transmission fluid (ATF) or specific Mitsubishi power steering fluid. Check manual.

Engine Timing Belt:

Critical to replace per schedule. Overdue replacement is a major failure point.

Suspension Components:

Wear on ball joints, tie rod ends, and bushings can occur, especially with off-road use. Symptoms include clunking noises and imprecise steering.

Exhaust System:

Rusting of exhaust pipes and mufflers can occur in certain climates.

Electrical Connectors:

Corrosion in electrical connectors, particularly in areas with high humidity or road salt, can lead to intermittent issues.

Ignition Coils:

Failure of ignition coils can lead to misfires and rough running.

📚 Vehicle History

Mitsubishi Offroad Legacy:

Mitsubishi has a long and distinguished history in off-road vehicles, exemplified by the larger Pajero/Montero, which provided a foundation of engineering expertise for the Pinin.

Concept And Launch:

The Pajero Pinin (known as Mitsubishi Pajero iO or Pajero TR4 in other markets) was launched in 1998, designed as a more compact and city-friendly alternative to the larger Pajero, while retaining genuine off-road capability.

Development Partnership:

In some markets, the Pinin was developed in conjunction with Carrozzeria Pininfarina, hence the 'Pinin' designation in Europe, highlighting its stylish design.

Production Period:

1998 - 2007 (with significant sales in the 1999-2006 period covered by this manual)

Manufacturing Locations:

Primarily Japan, with some assembly potentially occurring in other Mitsubishi plants globally depending on the market.

🏆 Awards & Recognition

European Design Award:

The 'Pinin' designation in Europe hints at design recognition, potentially linked to the collaboration with Pininfarina, although specific major awards are not widely documented for this specific model.

Offroad Capability Reviews:

Generally praised for its compact size and capable 4WD system for light to moderate off-road use, outperforming many front-wheel-drive based crossovers.