🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero Sport

Year:

2002

Chassis Code:

K90 Series (K94W, K96W, K97W, K99W)

Engine Codes General:

4D56 (2.5L Diesel), 6G72 (3.0L V6 Petrol), 6G74 (3.5L V6 Petrol)

👋 Introduction

Vehicle Segment:

Mid-size SUV (Sport Utility Vehicle), Body-on-frame construction.

Target Audience:

Families, off-road enthusiasts, those seeking robust and capable utility vehicles.

Key Competitors 2002:

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

Body Styles:

5-door SUV.

Drivetrain Options:

Rear-Wheel Drive (RWD) and Super Select II 4WD system (optional).

Off Road Capability:

Renowned for its robust chassis, capable 4WD system, and good ground clearance.

📋 Manual Details

Market Coverage:

Global (specific to 2002 model year variants)

Estimated Page Count:

1000+

Manual Type:

Full Service & Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Powertrain:

Engine mechanical (all variants), Fuel system, Ignition system, Exhaust system, Cooling system, Lubrication system, Turbocharger system (if applicable)

Drivetrain:

Manual Transmission, Automatic Transmission, Transfer Case (4WD Systems), Front Axle, Rear Axle, Driveshafts, CV Joints

Chassis & Suspension:

Front Suspension (Double Wishbone), Rear Suspension (Multi-link), Steering System (Hydraulic Power Steering), Brakes (ABS, ventilated discs front, solid discs rear), Wheels & Tires

Electrical:

Battery, Starting System, Charging System, Lighting System, Instrument Cluster, Gauges, Switches, Fuses & Relays, Engine Control Unit (ECU) Wiring Diagrams, Body Control Module (BCM) Systems

Body & Interior:

Body Panels, Doors, Hood, Tailgate, Glass, Interior Trim, Seats, HVAC (Heating, Ventilation, and Air Conditioning), Seats, Seatbelts, SRS Airbag System

Routine Maintenance:

Oil Changes, Filter Replacements (oil, air, fuel), Spark Plug Replacement, Coolant Flushes, Brake Fluid Replacement, Gearbox Oil Changes

Engine Repair:

Engine Rebuilds, Cylinder Head Overhaul, Piston & Ring Replacement, Valve Adjustment, Timing Belt/Chain Service, Fuel Injector Servicing, Turbocharger Rebuild

Transmission & Drivetrain Repair:

Clutch Replacement, Transmission Overhaul (Manual & Automatic), Transfer Case Repair, Differential Servicing, CV Joint Boot Replacement

Brake System Repair:

Brake Pad & Rotor Replacement, Brake Caliper Overhaul, ABS System Diagnostics & Repair, Brake Line Replacement

Suspension & Steering Repair:

Shock Absorber/Strut Replacement, Bushing Replacement, Ball Joint Replacement, Tie Rod End Replacement, Power Steering Pump & Rack Repair

Electrical System Troubleshooting:

Wiring Diagram Interpretation, Fault Code Diagnosis, Sensor Testing, Component Replacement (alternator, starter, sensors), ECU Diagnosis

HVAC System Service:

Refrigerant Charging, Component Replacement (compressor, condenser, evaporator), Blower Motor Replacement, Blend Door Actuator Repair

Diagnostic Procedures:

Step-by-step diagnostic routines for common and rare faults, including OBD-II diagnostics and component-specific testing.

Troubleshooting Guides:

Comprehensive fault finding charts based on symptoms, directing technicians to specific causes and repair procedures.

Rebuild Procedures:

Detailed instructions for complete engine, transmission, and differential rebuilds, including torque specifications and clearances.

Technical Data:

Includes precise specifications for clearances, torque values, fluid capacities, electrical resistance, pressures, and more.

📊 Manual Specifications

File Format:

PDF

Searchability:

Text-searchable PDF for quick information retrieval.

Image Quality:

High-resolution diagrams, illustrations, and photographs.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Completeness:

Full service, repair, and maintenance coverage.

⚙️ Engine Specifications

4D56 2.5L Turbo Diesel:

Displacement: 2.5 Liters (2477 cc), Configuration: Inline 4-cylinder, DOHC, Turbocharged, Power: Approx. 115-134 hp (depending on market/tune), Torque: Approx. 240-280 Nm, Fuel System: Direct Injection, Common Rail (later variants) or Indirect Injection.

6G72 3.0L V6 Petrol:

Displacement: 3.0 Liters (2972 cc), Configuration: V6, SOHC, Power: Approx. 175-181 hp, Torque: Approx. 250-260 Nm, Fuel System: Multi-Point Fuel Injection (MPI).

6G74 3.5L V6 Petrol:

Displacement: 3.5 Liters (3497 cc), Configuration: V6, SOHC/DOHC (depending on specific variant), Power: Approx. 197-220 hp, Torque: Approx. 300-330 Nm, Fuel System: Multi-Point Fuel Injection (MPI).

0-60 Mph Estimate:

Varies significantly by engine and drivetrain, typically 9-12 seconds for petrol V6 models.

Fuel Type:

Diesel (4D56), Unleaded Petrol (6G72, 6G74)

🔧 Transmission

Standard Transmission:

5-speed Manual Transmission

Optional Transmission:

4-speed Automatic Transmission (INVECS-II with Sports Mode)

4Wd System:

Mitsubishi Super Select II 4WD System (optional): Offers 2H, 4H, 4HLC (Locked Centre Diff), 4LLC (Locked Low Range Centre Diff) modes, allowing on-the-fly shifting between 2WD and 4WD High.

📐 Dimensions

Wheelbase Mm:

2725 mm

Length Mm:

4690 mm

Width Mm:

1775 mm

Height Mm:

1800 mm

Ground Clearance Mm:

Approx. 205-215 mm (depending on tire size/suspension)

Curb Weight Kg:

1800 - 2000 kg (Varies by engine and equipment)

Towing Capacity Kg:

Typically around 2000-2500 kg (braked, market dependent)

🛡️ Safety Features

NHTSA Front Impact Rating:

Information may vary by market; generally considered robust for its era.

ABS:

Anti-lock Braking System (standard or optional depending on trim/market).

Traction Control:

Traction Control System (TCS) may be available on higher trims or later models.

Airbags:

Driver and front passenger airbags standard. Side airbags may be optional.

Seatbelts:

Pre-tensioning front seatbelts.

💡 Technology Features

Audio System:

Factory fitted AM/FM/CD player with optional premium sound systems. Speaker configurations vary by trim level.

Navigation:

Touchscreen navigation systems were optional on higher trims, typically featuring early GPS technology.

Cruise Control:

Standard on most models.

Power Accessories:

Power windows, power door locks, power mirrors were common features, with some models offering power seats.

🔧 Maintenance

Engine Oil Change Interval:

Typically 5,000-7,500 miles or 6-12 months (refer to manual for specific engine and oil type).

Timing Belt Replacement:

For 6G72/6G74 V6 engines, typically every 60,000-100,000 miles (critical for preventing engine damage). The 4D56 diesel may have a timing chain.

Engine Oil Viscosity Petrol:

API SG or higher, SAE 10W-30 or 10W-40 recommended (check manual for exact specification).

Engine Oil Viscosity Diesel:

API CG-4 or higher, SAE 15W-40 recommended (check manual for exact specification).

Coolant:

Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol based coolant with corrosion inhibitors).

Transmission Fluid Manual:

API GL-4, SAE 75W-90 Gear Oil.

Transmission Fluid Automatic:

Diamond ATF SP-III (or equivalent DEXRON III/MERCON compatible fluid, check manual).

Brake Fluid:

DOT 3 or DOT 4.

Diesel Glow Plugs:

Glow plugs can fail over time, leading to hard starting in cold weather for the 4D56 diesel engine.

Timing Belt Wear:

Critical to replace on schedule for V6 petrol engines to prevent catastrophic failure.

Rear Suspension Bushings:

Bushings in the rear multi-link suspension can wear out, causing clunks or poor handling.

Automatic Transmission Reliability:

While generally robust, periodic fluid changes are crucial for longevity of the INVECS-II automatic.

Body Rust:

As with many SUVs of this era, rust can be an issue in areas with harsh winters or coastal environments, particularly on the chassis and around wheel arches.

📚 Vehicle History

Mitsubishi SUV Lineage:

Builds on Mitsubishi's long history of producing capable off-road vehicles, dating back to the original Pajero (Montero).

Generation:

Second Generation Pajero Sport (Launched 1996 as Mitsubishi Challenger in some markets, renamed Pajero Sport globally).

Manufacturing Locations:

Japan, Thailand, Brazil (depending on market distribution).

🏆 Awards & Recognition

Off Road Acclaim:

The Pajero platform is highly regarded in off-road circles, and the Pajero Sport inherits this reputation for durability and capability.

Consumer Reports Reliability Trend:

Reliability ratings varied by specific year and engine combination; the manual provides essential data for proactive maintenance.

Iso Certification Production:

Mitsubishi manufacturing facilities typically adhere to ISO quality standards.