🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero Sport

Model Code:

K90 Series (General)

Generation:

First Generation

Model Years Covered:

1999, 2000, 2001, 2002

👋 Introduction

Vehicle Segment:

Mid-size SUV / Sport Utility Truck (based on Pajero platform)

Target Audience:

Families, off-road enthusiasts, commercial users requiring robust utility.

Key Competitors:

Toyota 4Runner, Nissan Xterra, Ford Explorer, Jeep Cherokee (XJ/WJ era).

Body Styles:

Typically offered as a 5-door SUV, with potential for 2-door variants in some markets.

Chassis Construction:

Body-on-frame construction, providing robust off-road capability and towing strength.

📋 Manual Details

Manual Coverage Scope:

Comprehensive workshop service and repair

Page Count:

4000

Manual Type:

Workshop Service Manual / Repair Manual

Language:

English (Assumed, typical for such manuals)

Format:

PDF

📖 Manual Coverage

Engine:

Detailed diagnostics, repair, overhaul for all engine variants including timing belt/chain service, fuel injection, ignition systems, cooling system, lubrication system.

Transmission:

Coverage for both manual and automatic transmissions, including clutch service, gearbox overhaul, torque converter, transmission control unit (if applicable), fluid change procedures, and shift linkage adjustments.

Drivetrain:

Front and rear axle repairs, differential servicing, driveshaft and CV joint maintenance, 4WD system operation and repair (including transfer case).

Suspension:

Front independent suspension (likely double wishbone), rear solid axle with coil springs or leaf springs (depending on specific variant), shock absorber replacement, bushing inspection and replacement, wheel alignment specifications.

Steering:

Power steering system diagnostics and repair, steering rack or gearbox overhaul, steering column maintenance, wheel alignment.

Brakes:

Front disc brakes, rear drum or disc brakes (depending on trim), ABS system diagnostics and repair, brake fluid replacement, caliper and master cylinder overhaul, parking brake adjustment.

Electrical System:

Complete wiring diagrams for all circuits, starter motor, alternator, battery, lighting system (headlights, taillights, interior), horn, wipers, power windows, power locks, fuse and relay box location and identification, basic diagnostics.

Body And Chassis:

Body panel removal and installation, door and tailgate repair, interior trim removal, chassis lubrication points, frame straightening (if applicable).

HVAC:

Air conditioning system (refrigerant type, servicing), heating system, blower motor, climate control unit diagnostics and repair.

Routine Maintenance:

Oil and filter changes, air filter replacement, fuel filter replacement, spark plug replacement, coolant flush and replacement, brake fluid flush, lubrication.

Troubleshooting:

Diagnostic procedures for common drivability issues, electrical faults, cooling system problems, braking system malfunctions, with symptom-based troubleshooting charts.

Major Repairs:

Engine rebuilds, transmission overhauls, suspension component replacement, steering system repairs, brake system overhauls, bodywork repairs.

Diagnostics:

Detailed diagnostic procedures, including methods for checking sensor readings, actuator function, and component testing. May include OBD-II (On-Board Diagnostics) information if applicable to the model years.

Component Replacement:

Step-by-step instructions for replacing key components such as alternators, starter motors, water pumps, radiators, fuel pumps, brake pads, discs, and more.

Specifications:

Torque specifications for all fasteners, engine clearances, timing specifications, fluid capacities and types, tire pressures, wheel alignment settings.

Depth Of Information:

In-depth, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic adjustments to complete component overhauls and system diagnostics.

Diagnostic Tools:

Details on necessary specialized tools and diagnostic equipment for accurate repairs and troubleshooting.

Diagrams And Illustrations:

Includes exploded views, wiring diagrams, troubleshooting flowcharts, and step-by-step photographic or illustrative guides.

📊 Manual Specifications

File Format:

PDF

Print Quality Expectation:

High-resolution PDF suitable for printing, ensuring clarity of text and diagrams.

Binding Type Digital:

N/A (Digital Format)

Paper Type Digital:

N/A (Digital Format)

Text Searchability:

Searchable PDF text for quick information retrieval.

Device Compatibility:

Accessible on computers, tablets, and smartphones with PDF reader software.

⚙️ Engine Specifications

Engine Options:

Likely includes the 4G64 2.4L SOHC I4 and the 6G72 3.0L SOHC V6. Diesel variants (e.g., 4D56) may also be present in certain markets.

4G64 2.4L Specs:

Approx. 133-147 hp, 135-155 lb-ft torque (market dependent). Sequential multi-port fuel injection.

6G72 3.0L V6 Specs:

Approx. 175-195 hp, 180-200 lb-ft torque (market dependent). Sequential multi-port fuel injection.

Horsepower Range:

130 - 200 hp (approx.)

Torque Range:

130 - 200 lb-ft (approx.)

Fuel Delivery:

Electronic Fuel Injection (EFI) / Multi-Point Fuel Injection (MPFI)

Recommended Fuel:

Unleaded gasoline (Octane rating as per vehicle plate/manual)

🔧 Transmission

Standard Transmission:

5-speed manual transmission

Optional Transmission:

4-speed automatic transmission

Drivetrain Layout:

Part-time 4WD system with available Super Select 4WD (allows shifting between 2WD and 4WD on the fly, and locking the center differential).

Transfer Case:

Two-speed transfer case with high and low range gearing for enhanced off-road capability.

📐 Dimensions

Length:

Approx. 4,695 mm (5-door)

Width:

Approx. 1,775 mm

Height:

Approx. 1,745 mm

Wheelbase:

Approx. 2,725 mm

Curb Weight:

Approx. 1,700 - 1,900 kg (depending on engine and configuration)

Towing Capacity:

Typically rated around 2,500 - 3,000 kg (check specific market regulations and vehicle capacity)

🛡️ Safety Features

Crash Test Ratings:

No specific standardized ratings (like NHTSA/Euro NCAP) readily available for this specific generation and early model years. However, built with body-on-frame construction which typically offers good structural integrity.

ABS:

Anti-lock Braking System (ABS) available on higher trims.

Traction Control:

Traction control systems were less common on base models of this era, but might be available on certain trims/markets.

Airbags:

Driver and front passenger airbags standard on most models, side airbags less common.

Seatbelts:

Three-point seatbelts for all occupants, with pre-tensioners for front seats.

💡 Technology Features

Audio System:

Factory-installed AM/FM/Cassette or CD players, often with basic speaker systems. Aftermarket head unit upgrades are common.

Climate Control:

Manual climate control systems with rotary knobs for fan speed, temperature, and air direction. Some higher trims may have automatic climate control.

Cruise Control:

Available on most models, operated via steering wheel or dashboard stalk.

Power Features:

Power windows, power door locks, power mirrors standard on most trims.

Bluetooth:

Not a standard feature for this model year; aftermarket solutions required.

Usb Ports:

Not a standard feature for this model year.

🔧 Maintenance

Oil Change Interval:

Typically every 7,500 - 10,000 km or 6 months, whichever comes first (refer to manual for exact specification based on driving conditions).

Timing Belt Replacement:

For 4G64 engines, typically around 90,000 - 100,000 km or 5-7 years. For 6G72, consult manual as some versions may use timing chains. Crucial to follow this for engine longevity.

Coolant Replacement:

Every 40,000 - 50,000 km or 2-3 years.

Transmission Fluid Change:

Manual: every 60,000 km. Automatic: every 40,000 - 60,000 km (check condition).

Engine Oil Type:

API SG or higher. Viscosity: 10W-30 or 10W-40 (depending on ambient temperature). Consult manual for precise SAE grade.

Coolant Type:

Ethylene glycol-based antifreeze (Mitsubishi Dia Queen Super Long Life Coolant or equivalent).

Brake Fluid Type:

DOT 3 or DOT 4.

Transmission Fluid Manual:

API GL-4 or GL-5 SAE 75W-90 or 80W-90 gear oil.

Transmission Fluid Automatic:

Mitsubishi Dia Queen ATF-SP III or equivalent.

Transfer Case Fluid:

API GL-4 or GL-5 SAE 75W-90 or 80W-90 gear oil.

Differential Fluid:

API GL-5 SAE 80W-90 or 85W-140 gear oil.

Common Wear Items:

Ball joints, tie rod ends, bushings (especially rear trailing arm), exhaust system components, clutch wear (manual transmissions).

Engine Specific Concerns:

Timing belt tensioner/idler pulley failure (4G64) if not replaced at recommended intervals, potential for head gasket issues on higher mileage V6 engines, fuel injector clogging.

Electrical Gremlins:

Intermittent issues with power windows, door locks, or dashboard lights can sometimes occur due to aging wiring or switches.

Drivetrain Durability:

While generally robust, issues with transfer case actuator (if electronically controlled) or front CV boots can arise with off-road use or high mileage.

📚 Vehicle History

Mitsubishi Offroad Legacy:

Mitsubishi has a long and successful history in off-road vehicles, notably with the Pajero (Montero) lineage, known for its durability and capability.

Pajero Sport Origin:

The Pajero Sport (also known as Montero Sport in some markets, and Challenger in Australia) was introduced as a more affordable, utilitarian, and often more rugged derivative of the larger, more luxurious Pajero/Montero SUV.

Manufacturing Locations:

Primarily manufactured in Japan, with assembly plants in various other countries depending on the market (e.g., Thailand, Brazil).

🏆 Awards & Recognition

Offroad Capability Awards:

While not typically winning mainstream automotive awards, the Pajero Sport (and its Pajero brethren) are consistently recognized for their robust off-road performance and durability by off-road publications and enthusiasts.

Reliability Reputation:

Generally considered reliable vehicles, especially the mechanical components, when properly maintained. Strong reputation for longevity and ability to withstand tough conditions.

Manufacturing Standards:

Produced under Mitsubishi's quality control standards, adhering to Japanese automotive industry practices.