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1999-2002 Mitsubishi Pajero Sport Service Repair Workshop Manual Download PDF

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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero Sport Model Alias: Montero Sport (North America), Challenger (Japan, Australia) Generation Generation: 1st Generation Codes Chassis Codes: K90 series 👋 Introduction Market...
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Type: Car
Vendor:
Sku: 52665
1999-2002 Mitsubishi Pajero Sport Service Repair Workshop Manual Download PDF
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Pajero Sport
Model Alias:
Montero Sport (North America), Challenger (Japan, Australia)
Generation
Generation:
1st Generation
Codes
Chassis Codes:
K90 series
👋 Introduction
Market Position
Positioning:
Mid-size, body-on-frame SUV positioned as a capable off-roader and family vehicle, often seen as a more affordable alternative to the Toyota Land Cruiser Prado or Nissan Pathfinder of the era.
Competitive Analysis
Key Competitors:
Toyota 4Runner/Land Cruiser Prado, Nissan Pathfinder, Jeep Cherokee (XJ/WJ), Ford Explorer, Chevrolet Blazer.
Key Features
Platform Sharing:
Based on the Mitsubishi Triton (L200) pickup truck platform, offering robust construction and off-road capability.
Drivetrain Options:
Available in 2WD and 4WD configurations, with the highly regarded Super Select 4WD system in many markets.
Body Styles:
Primarily offered as a 5-door SUV, with some markets receiving a 3-door variant.
📋 Manual Details
Coverage Areas
Applicable Years:
1999, 2000, 2001, 2002
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Factory Service Repair Workshop Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Yes
Engine Control System Efi:
Yes
Fuel System:
Yes
Exhaust System:
Yes
Cooling System:
Yes
Lubrication System:
Yes
Ignition System:
Yes
Manual Transmission Getrag:
Yes
Automatic Transmission Invvecs:
Yes
Transfer Case Super Select:
Yes
Front Axle And Suspension:
Yes
Rear Axle And Suspension:
Yes
Brake System:
Yes
Steering System:
Yes
Wheel And Tires:
Yes
Body And Frame:
Yes
Interior And Exterior Trim:
Yes
HVAC System:
Yes
Electrical System Lighting:
Yes
Electrical System Instruments Gauges:
Yes
Electrical System Audio Visual:
Yes
Electrical System Power Accessories:
Yes
Safety Systems Airbags:
Yes
Diagnostics Troubleshooting:
Yes
Procedures Included
Routine Maintenance:
Yes
Component Diagnosis:
Yes
Component Repair And Overhaul:
Yes
Wiring Diagrams:
Yes
Torque Specifications:
Yes
Special Tools:
Yes
Technical Depth
Depth:
Comprehensive (from basic maintenance to full engine/transmission rebuilds)
📊 Manual Specifications
File Format
File Type:
Searchable PDF
Print Quality
Image Resolution:
High-resolution, suitable for printing
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code Gas 1:
6G72
Engine Name Gas 1:
3.0L V6 SOHC (12-valve)
Displacement Gas 1:
2972 cc
Horsepower Gas 1:
Approx. 177 hp @ 5200 rpm (specific output varied by market and emissions regulations)
Torque Gas 1:
Approx. 245 Nm (181 lb-ft) @ 3500 rpm (specific output varied by market and emissions regulations)
Engine Code Diesel 1:
4D56
Engine Name Diesel 1:
2.5L 4-Cylinder SOHC Turbo Diesel
Displacement Diesel 1:
2477 cc
Horsepower Diesel 1:
Approx. 109 hp @ 4000 rpm (specific output varied by market)
Torque Diesel 1:
Approx. 240 Nm (177 lb-ft) @ 2000 rpm (specific output varied by market)
Fuel System
Fuel Delivery Gas:
Electronic Fuel Injection (EFI)
Fuel Type Gas:
Unleaded Gasoline
Fuel Type Diesel:
Diesel
🔧 Transmission
Standard
Transmission Type Common:
4-speed Automatic (INVECS-II)
Optional
Transmission Type Optional:
5-speed Manual (Getrag)
Features
4Wd System Name:
Super Select 4WD
4Wd Modes:
2H, 4H, 4HLC (with locked center differential), 4LLC (with locked center differential and low range gearing).
📐 Dimensions
Exterior
Length:
Approx. 4,520 mm (178.0 in)
Width:
Approx. 1,775 mm (69.9 in)
Height:
Approx. 1,770 mm (69.7 in) (varies slightly with roof rails)
Wheelbase:
Approx. 2,725 mm (107.3 in)
Ground Clearance:
Approx. 205 mm (8.1 in)
Weights
Curb Weight:
Approx. 1,700 - 1,900 kg (3,748 - 4,189 lbs) (varies by configuration)
🛡️ Safety Features
Ratings
Safety Rating Organizations:
NHTSA, Euro NCAP (ratings vary by market and testing year)
Active Features
ABS:
Available (typically standard on higher trims)
Passive Features
Airbags:
Driver and front passenger airbags standard on many models.
Seatbelts:
Three-point seatbelts with pretensioners for front occupants.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM cassette or CD players, often with 4-6 speakers. Aftermarket head units are common upgrades.
Driver Assistance
Cruise Control:
Available on most models.
Traction Control:
Less common on this generation, not a widespread feature.
Connectivity
Connectivity Options:
Primarily limited to audio connectivity. No factory Bluetooth or USB ports.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions and oil type.
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.
Spark Plug Replacement Gas:
Approx. 60,000 miles (96,000 km) for platinum or iridium plugs.
Fluid Specifications
Engine Oil Type Gas:
API SG or higher, SAE 10W-30 or 10W-40 (refer to manual for specific viscosity based on temperature).
Engine Oil Capacity Gas:
Approx. 4.5 - 5.0 liters (4.8 - 5.3 US quarts) with filter change (6G72 V6).
Transmission Fluid Type Auto:
Diamond ATF SP-II M or equivalent.
Transmission Fluid Capacity Auto:
Approx. 7.5 - 9.0 liters (7.9 - 9.5 US quarts) for full refill (INVECS-II).
Transfer Case Fluid Type:
API GL-3 or GL-4 SAE 75W-90 Hypoid Gear Oil.
Differential Fluid Type Front Rear:
API GL-5 SAE 80W-90 Hypoid Gear Oil.
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors (e.g., Mitsubishi Super Long Life Coolant).
Known Issues
Common Issue Power Steering Leaks:
Leaking power steering hoses or pumps can be a concern, particularly with age and mileage.
Common Issue Automatic Transmission Harshness:
Some models may experience rough shifting or delayed engagement in the automatic transmission, often related to fluid condition or valve body issues.
Common Issue Radiator Corrosion:
Radiator tank corrosion and leaks can occur, especially if the coolant is not maintained properly.
Common Issue Timing Belt Replacement:
The 6G72 V6 uses a timing belt that requires replacement at recommended intervals (typically 60,000-90,000 miles) to prevent catastrophic engine damage.
Common Issue Super Select 4Wd Actuator:
The vacuum actuator for the front hub lockout or the electronic components controlling the 4WD system can sometimes fail, preventing proper engagement.
📚 Vehicle History
Brand Heritage
Mitsubishi Offroad History:
Mitsubishi has a long and distinguished history in off-road motorsport, notably the Paris-Dakar Rally, which informed the design and engineering of vehicles like the Pajero lineage, including the Pajero Sport.
Model Evolution
Pajero Sport Origin:
Developed as a more affordable, sport-utility variant of the Pajero (Montero) platform, sharing its robust ladder frame and powertrain options but with distinct styling and often a shorter wheelbase.
Production
Manufacturing Locations:
Primarily produced in Japan, with assembly also occurring in various international plants for local markets.
Production Start Year:
1996
Production End Year For Gen1:
2008 (though sales continued in some markets)
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