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Mitsubishi Pajero Sport 2002 Repair Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero Sport Year: 2002 Codes Chassis Code: K90 Series (K94W, K96W, K97W, K99W) 👋 Introduction Market Position Segment: Mid-size SUV, Body-on-frame construction, known...
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Type: Car
Vendor:
Sku: 391065
Mitsubishi Pajero Sport 2002 Repair Service Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Pajero Sport
Year:
2002
Codes
Chassis Code:
K90 Series (K94W, K96W, K97W, K99W)
👋 Introduction
Market Position
Segment:
Mid-size SUV, Body-on-frame construction, known for off-road capability.
Competitive Analysis
Key Competitors 2002:
Toyota 4Runner, Nissan Pathfinder, Jeep Grand Cherokee, Ford Explorer.
Key Features
Off Road Emphasis:
Robust chassis, selectable 4WD system (Super Select II for some variants), good ground clearance.
Powertrain Options:
Proven Mitsubishi engines and transmissions, offering reliability and performance.
📋 Manual Details
Coverage Areas
Manual Type:
Repair Service Manual
Language:
English
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Comprehensive diagnosis, repair, and overhaul for 4D56, 6G72, and 6G74 engine variants.
Transmission:
Detailed repair and maintenance procedures for V5A5A (5-speed automatic) and W1A5A (4-speed automatic) transmissions, including troubleshooting and overhaul.
Drivetrain:
Front and rear differential diagnosis and repair, transfer case operation and maintenance, propeller shaft and driveshaft servicing.
Suspension Steering:
Front independent suspension (double wishbone) and rear multi-link suspension servicing, power steering system diagnosis and repair, steering gear and linkage.
Brakes:
Front and rear brake system servicing (disc/drum configurations), ABS system diagnosis, hydraulic system bleeding, parking brake.
Electrical Electronics:
Complete wiring diagrams for all vehicle systems, ECU diagnosis, sensor testing, lighting systems, power windows, central locking, audio systems.
Bodywork Interior:
Body panel repair, door mechanisms, glass replacement, interior trim removal and installation, HVAC system servicing.
Cooling Heating Ac:
Radiator, fan clutch, water pump, thermostat, heater core, A/C compressor, refrigerant system servicing.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, belt adjustments.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting guides for common and complex issues across all major systems.
Repair:
Step-by-step repair instructions for component removal, installation, and adjustment, including engine rebuilds, transmission overhauls, and suspension component replacement.
Diagnostics:
OBD-II diagnostic trouble code (DTC) interpretation and diagnosis, specific sensor testing procedures, ECM/PCM troubleshooting.
Technical Depth
Depth Level:
Comprehensive, from basic maintenance to in-depth mechanical and electrical system overhauls, suitable for professional technicians.
📊 Manual Specifications
File Format
File Type:
Searchable PDF
Print Quality
Resolution:
High resolution for clear text and diagrams.
Binding Type
Binding Style:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine 1
Engine Code:
4D56
Configuration:
2.5L (2477cc) Inline-4 Turbocharged Diesel
Bore X Stroke:
91.1 mm x 95.0 mm
Compression Ratio:
21.0:1
Fuel System:
Direct Injection, Turbocharged
Horsepower Ps:
114 PS @ 4000 rpm (approx.)
Torque Nm:
270 Nm @ 2000 rpm (approx.)
Primary Engine 2
Engine Code:
6G72
Configuration:
3.0L (2972cc) V6 SOHC 24-Valve
Bore X Stroke:
91.1 mm x 76.0 mm
Compression Ratio:
8.9:1
Fuel System:
Multi-point Fuel Injection (MPI)
Horsepower Ps:
177 PS @ 5500 rpm (approx.)
Torque Nm:
255 Nm @ 4500 rpm (approx.)
Primary Engine 3
Engine Code:
6G74
Configuration:
3.5L (3497cc) V6 SOHC 24-Valve
Bore X Stroke:
93.0 mm x 85.8 mm
Compression Ratio:
8.5:1
Fuel System:
Multi-point Fuel Injection (MPI)
Horsepower Ps:
181 PS @ 4500 rpm (approx.)
Torque Nm:
308 Nm @ 3000 rpm (approx.)
Performance
Engine Management:
ECU controlled fuel injection and ignition timing.
🔧 Transmission
Standard
Type:
4-speed Automatic (W1A5A) or 5-speed Automatic (V5A5A) depending on engine and trim.
Optional
Type:
5-speed Manual Transmission (R5M31 for some variants).
Features
Drivetrain Options:
Part-time 4WD or Full-time 4WD (Super Select II system).
Transfer Case:
Two-speed transfer case with center differential lock (on Super Select II systems).
📐 Dimensions
Exterior
Length:
Approx. 4695 mm (varies by model variant)
Width:
Approx. 1775 mm
Height:
Approx. 1800 mm (varies by model variant)
Wheelbase:
Approx. 2725 mm
Weights
Curb Weight:
Approx. 1850 kg - 2050 kg (depending on configuration)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Not consistently rated or publicly available for this specific model year in all markets.
Active Features
ABS:
Available on select models.
Traction Control:
Available on select models (Active Traction Control - ATC).
Passive Features
Airbags:
Driver and front passenger airbags standard on most models.
Seatbelts:
3-point seatbelts with pre-tensioners for front occupants.
💡 Technology Features
Infotainment
Audio System:
Factory fitted AM/FM radio with CD player, often with cassette tape integration. Speaker configurations vary by trim.
Navigation:
Optional navigation systems were available on higher trims but were typically basic by modern standards.
Driver Assistance
Cruise Control:
Available on most models.
Connectivity
Bluetooth:
Not factory equipped for this model year. Aftermarket integration is common.
🔧 Maintenance
Service Intervals
Engine Oil Filter:
Every 5,000 - 10,000 km or 6 months (depending on driving conditions and oil type, refer to manual for specifics).
Transmission Fluid Auto:
Every 40,000 - 80,000 km (depending on driving conditions, ATF fluid type is critical).
Transfer Case Fluid:
Every 40,000 - 80,000 km.
Differential Fluid Front Rear:
Every 40,000 - 80,000 km.
Timing Belt Gasoline Engines:
Approximately 100,000 km or 5 years (critical replacement interval, refer to manual).
Fluid Specifications
Engine Oil Viscosity:
API SG/SH/SJ classification, SAE 10W-30 or 10W-40 (check manual for ambient temperature suitability).
Automatic Transmission Fluid:
DIA QUEEN ATF-SP II M (or equivalent MERCON/Dexron III compatible fluid for older specs, but DIA QUEEN is preferred).
Power Steering Fluid:
DIA QUEEN PSF (or compatible ATF).
Known Issues
Diesel Engine Glow Plugs:
Can fail over time, leading to hard starting in cold weather.
Automatic Transmission Longevity:
Early models can experience wear in torque converter lock-up clutch or internal seals if not maintained regularly.
Suspension Bushings:
Wear on control arm bushings and ball joints due to off-road use or age.
Cooling System Leaks:
Radiator hoses and water pump seals can degrade over time.
📚 Vehicle History
Brand Heritage
Mitsubishi SUV Legacy:
Mitsubishi has a long history of producing capable off-road vehicles, beginning with the Pajero (Montero in some markets) in 1982.
Model Evolution
Pajero Sport Introduction:
The Pajero Sport (also known as Montero Sport) was introduced in 1996 as a more lifestyle-oriented SUV built on a ladder frame chassis, sharing components with the Pajero but with a distinct body style.
Production
Global Markets:
Produced for various global markets, including Asia, Australia, South America, and parts of Europe. The 2002 model represents the first generation (1996-2007).
🏆 Awards & Recognition
Recognitions
Off Road Awards:
While the Pajero Sport itself may not have specific widely publicized awards for this year, the Pajero lineage has consistently been recognized for its off-road prowess in various global competitions and consumer reviews.
Ratings
Consumer Reviews General:
Generally praised for its ruggedness, off-road capability, and durable powertrains, though less refined on-road manners compared to monocoque SUVs.
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