🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero Sport

Production Years:

1999, 2000, 2001, 2002

Chassis Codes:

K70, K80, K90 Series

👋 Introduction

Segment:

Mid-size SUV / Sport Utility Truck

Key Selling Points:

Rugged off-road capability, body-on-frame construction, powerful engine options, available Super Select 4WD system.

Key Competitors Era:

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

Platform:

Based on the Pajero (Montero) platform, often sharing components with the Triton (L200) pickup truck.

Powertrain Flexibility:

Offered with various engine and transmission combinations catering to different needs.

📋 Manual Details

Covered Styles:

All body styles (e.g., 2-door, 4-door)

Estimated Page Count:

Detailed technical manuals for this era typically range from 1000-2500+ pages. Exact count not specified.

Manual Type:

Service and Repair Manual

Language:

English

Format:

Digital (likely PDF)

📖 Manual Coverage

Engine Mechanical:

Engine overhaul, component testing, timing procedures, lubrication system, cooling system, fuel injection system (MPI), emission control systems.

Engine Electrical:

Ignition system, starter motor, alternator, battery, ECU (Engine Control Unit) diagnostics and component identification, sensor troubleshooting.

Transmission Manual:

Manual transmission disassembly, assembly, inspection, shift linkage adjustment, clutch system service.

Transmission Automatic:

Automatic transmission overhaul, hydraulic control systems, torque converter service, valve body diagnostics, fluid and filter replacement.

Drivetrain:

Transfer case (Super Select II) operation and service, front and rear differential service, driveshafts, CV joints, propeller shafts.

Suspension:

Front independent suspension (Double Wishbone), rear multi-link suspension, shock absorbers, coil springs, anti-roll bars, bushings, alignment specifications.

Steering:

Power steering system, steering gearbox, steering column, tie rods, wheel alignment parameters.

Brakes:

Front ventilated disc brakes, rear drum or disc brakes (model dependent), ABS (Anti-lock Braking System) diagnostics, brake fluid specifications, bleeding procedures, parking brake service.

Body And Frame:

Body panel removal/installation, door mechanisms, glass replacement, interior trim, structural components, anti-corrosion treatment.

Electrical System:

Lighting systems (headlamps, taillamps, interior), power windows, power locks, mirrors, wiper system, horn, audio system wiring, fuse box diagrams, relay locations.

Climate Control:

Air conditioning system (R134a), heater core service, blower motor, HVAC controls, refrigerant charging procedures.

Routine Maintenance:

Oil and filter changes, air filter replacement, spark plug replacement, coolant checks and changes, brake fluid flush, differential fluid changes, transfer case fluid changes.

Diagnostic Procedures:

Troubleshooting charts for common symptoms, electrical circuit testing, engine performance diagnostics, ABS system fault finding.

Repair Procedures:

Step-by-step instructions for major component repairs, including engine rebuilds, transmission overhauls, brake caliper replacement, suspension component replacement.

Installation Procedures:

Guidance on installing new parts or components, torque specifications for critical fasteners.

Specification Tables:

Torque specifications for all major fasteners, engine tolerances, diagnostic trouble codes (DTCs).

Depth Of Coverage:

Comprehensive. Covers everything from basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures.

Schematics Included:

Full electrical schematics for all vehicle systems.

Troubleshooting Guides:

Detailed troubleshooting trees and diagnostic flowcharts.

📊 Manual Specifications

File Format Type:

PDF

Searchability:

Likely text-searchable PDF for easy navigation.

Image Resolution:

High-resolution images and diagrams suitable for printing.

Binding:

Not applicable for digital format. If a printed version were available, it would typically be comb-bound or perfect-bound.

Paper Quality:

Not applicable for digital format.

⚙️ Engine Specifications

Engine Family:

6G7 Series V6 and 4D5/4M4 Series Inline-4 Diesel

Gasoline Engine Options:

3.0L V6 (6G72), 3.5L V6 (6G74 - less common in this specific generation for some markets)

Diesel Engine Options:

2.5L Turbo Diesel (4D56), 2.8L Turbo Diesel (4M40), 3.2L Direct Injection Turbo Diesel (4M41 - later models/markets)

3.0L V6 (6G72) Power:

Approx. 175-181 hp (varies by market and tuning)

3.0L V6 (6G72) Torque:

Approx. 176-180 lb-ft (varies by market and tuning)

2.8L Turbo Diesel (4M40) Power:

Approx. 125-134 hp

2.8L Turbo Diesel (4M40) Torque:

Approx. 200-217 lb-ft

Gasoline Fuel Delivery:

Electronic Fuel Injection (EFI), Multi-Point Injection (MPI)

Diesel Fuel Delivery:

Direct Injection (DI) or Indirect Injection (IDI) with Turbocharging (depending on specific engine variant)

🔧 Transmission

Standard Transmission:

5-speed Manual Transmission

Optional Transmission:

4-speed Automatic Transmission

4Wd System:

Super Select II 4WD System (Part-time 4WD with 2H, 4H, 4HLC, 4LLC modes, often with locking rear differential option).

📐 Dimensions

Wheelbase:

Approx. 2,725 mm (107.3 inches) for 4-door models

Length:

Varies by body style, but around 4,600 mm (181.1 inches) for 4-door models

Width:

Approx. 1,775-1,800 mm (69.9-70.9 inches)

Height:

Approx. 1,750-1,800 mm (68.9-70.9 inches)

Curb Weight:

Approx. 1,800 - 2,100 kg (3,968 - 4,630 lbs) depending on configuration.

🛡️ Safety Features

Crash Test Ratings:

Data for specific model years and regions may vary. Typically tested by organizations like NHTSA or Euro NCAP. Manual will detail specific safety system performance.

Braking System:

Standard front disc, rear drum/disc. ABS optional or standard depending on trim and market.

Stability Control:

Traction Control (TCL) may be available on higher trims, but not standard across all models.

Airbags:

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

Seatbelts:

3-point seatbelts with pretensioners for front occupants, 3-point or 2-point for rear occupants.

💡 Technology Features

Audio System:

Basic AM/FM radio with CD player. Cassette players may be present on earlier models. Speaker configurations vary by trim.

Navigation:

Aftermarket or dealer-installed navigation systems may have been available; not typically integrated from factory for this model year.

Cruise Control:

Typically available as an option or on higher trim levels.

Power Accessories:

Power windows, power door locks, power mirrors standard or optional depending on trim.

🔧 Maintenance

Engine Oil Change:

Typically every 5,000-7,500 miles (8,000-12,000 km) or 6 months, depending on driving conditions and oil type. Consult manual for specifics.

Transmission Fluid Change Auto:

Every 30,000-50,000 miles (48,000-80,000 km), depending on driving conditions. Manual specifies specific fluid type and procedures.

Transmission Fluid Change Manual:

Every 50,000-70,000 miles (80,000-110,000 km).

Coolant Change:

Initial change at 50,000 miles, then every 30,000-50,000 miles or 2-4 years.

Engine Oil Viscosity:

Commonly 5W-30 or 10W-30 for gasoline, 15W-40 or 10W-40 for diesel. Manual will specify exact API/ACEA ratings and viscosity for each engine.

Transmission Fluid Type Auto:

Likely Mitsubishi DiaQueen Super ATF SP-II or equivalent Dexron/Mercon compatible fluids.

Transmission Fluid Type Manual:

GL-4 or GL-5 gear oil, viscosity typically 75W-90.

Brake Fluid Type:

DOT 3 or DOT 4

Common Wear Items:

Front suspension bushings, ball joints, tie rod ends, exhaust system components (due to environmental exposure), potentially diesel injection pump seals (on older diesels).

Diesel Specific Considerations:

Glow plug operation, potential for turbocharger wear on high-mileage units, specific fuel filter maintenance.

📚 Vehicle History

Mitsubishi Offroad Legacy:

Mitsubishi has a long and successful history in off-road motorsport, notably with the Dakar Rally-winning Pajero lineage, establishing a reputation for ruggedness and capability.

First Generation:

The Pajero Sport (also known as Montero Sport, Challenger) was introduced in 1996 as a more rugged, body-on-frame SUV derived from the Pajero, targeting a slightly different market segment focused on practicality and durability.

Global Markets:

Sold globally under various names, including Mitsubishi Pajero Sport (Australia, Europe), Mitsubishi Montero Sport (North America), Mitsubishi Challenger (Japan, certain SE Asian markets).

🏆 Awards & Recognition

Offroad Capability Awards:

While specific model year awards for the Pajero Sport might not be widely publicized, the Pajero lineage consistently received accolades for its off-road prowess and durability in various global markets and independent reviews.