🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero Sport

Generation Name:

First Generation (K80/K90 Series)

Chassis Codes:

K80 Series (Short Wheelbase), K90 Series (Long Wheelbase)

👋 Introduction

Segment:

Mid-size SUV / Sport Utility Truck (often referred to as Montero Sport outside North America).

Competitors:

Competed against vehicles like Toyota 4Runner, Jeep Cherokee (XJ), Ford Explorer, Chevrolet Blazer, Nissan Pathfinder during its production run.

Features:

Rugged body-on-frame construction, available V6 engine, robust 4WD system (Super Select 4WD II), practical utility, and off-road capability.

Off Road Capability:

Renowned for its off-road prowess thanks to the robust chassis, advanced 4WD system, and good ground clearance. This manual provides the detailed information to maintain and repair these systems.

📋 Manual Details

Years Covered:

1999, 2000, 2001, 2002

Estimated Pages:

Over 1500 (typical for a complete factory service manual)

Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Powertrain:

Engine mechanical, fuel system, ignition system, cooling system, lubrication system, exhaust system, engine electrical, ECM/PCM diagnostics.

Transmission Drivetrain:

Automatic Transmission (AT), Manual Transmission (MT), Transfer Case (4WD systems), Drive Axles, Driveshafts, CV Joints.

Chassis:

Suspension (front and rear), steering system, braking system (ABS, EBD), wheels and tires.

Electrical Body:

Body electrical systems (lighting, wipers, horn), interior and exterior trim, doors, windows, seats, HVAC system, audio system, wiring diagrams.

Engine Performance Tuning:

Basic information on engine tuning adjustments, though extensive ECU remapping data is unlikely in a factory service manual for this era.

Maintenance:

Routine maintenance, scheduled service intervals, fluid changes, filter replacements, spark plug replacement, belt replacement.

Repair Rebuild:

Engine overhaul, transmission repair and overhaul, suspension component replacement, brake caliper/rotor replacement, steering component replacement, electrical component diagnostics and repair.

Diagnostics Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical system diagnosis, fuel system diagnosis, performance issues.

Special Tools Jigs:

Identification and usage of specialized tools required for specific repair procedures.

Engine Mechanical Procedures:

Engine assembly/disassembly, cylinder head removal/installation, piston and connecting rod service, crankshaft and bearing service, camshaft and valve train inspection/replacement.

Fuel System Procedures:

Fuel pump testing, fuel injector diagnosis and replacement, fuel filter replacement, fuel tank removal/installation, EVAP system diagnostics.

Brake System Procedures:

Brake pad and rotor replacement, brake caliper overhaul, brake line inspection and replacement, ABS modulator diagnostics, brake bleeding procedures.

Electrical System Procedures:

Alternator and starter motor testing/replacement, battery service, fuse and relay diagnosis, lighting system repair, wiper and washer system troubleshooting, horn circuit diagnosis.

HVAC Procedures:

A/C system refrigerant handling (with appropriate safety precautions), compressor replacement, evaporator and condenser service, blower motor replacement, cabin air filter replacement (if applicable).

Chassis Procedures:

Front and rear suspension component replacement (shocks, struts, springs, control arms, ball joints), steering gear box/rack and pinion service, power steering system diagnosis and repair.

Body And Interior Procedures:

Door panel removal, interior trim component replacement, seat adjustment mechanism repair, body panel alignment, weatherstrip inspection and replacement, exterior trim piece installation/removal.

Depth:

Comprehensive, covering all mechanical, electrical, and body systems from basic maintenance to complete rebuilds and advanced diagnostics.

Diagnostic Tools Required:

Standard automotive tools, multimeter, fuel pressure gauge, vacuum gauge, scan tool (OBD-II compliant for models equipped with it), specific Mitsubishi diagnostic tools (if any mentioned).

Torque Specifications:

Detailed torque specifications for all critical fasteners in engine, transmission, suspension, steering, and braking systems.

Wiring Diagrams:

Comprehensive, color-coded wiring diagrams for all electrical systems, including engine control, lighting, chassis electronics, and interior accessories.

Coverage Scope:

Covers all aspects of vehicle service and repair, intended for use by professional technicians and advanced DIY enthusiasts.

📊 Manual Specifications

Quality:

High-resolution, searchable PDF with clear diagrams and illustrations.

Printability:

Printable pages allowing users to print specific sections or the entire manual.

Binding:

N/A (Digital PDF)

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Code Displacement:

6G72 (3.0L SOHC V6) / 6G74 (3.5L SOHC V6) - Engine availability varies by market and trim.

Engine Type Construction:

V6, SOHC (Single Overhead Camshaft), 24 valves. Cast iron block, aluminum cylinder heads. Timing belt driven.

Horsepower Torque 3.0L:

Approx. 175-185 HP / 200-220 lb-ft torque (figures vary by market and tuning).

Horsepower Torque 3.5L:

Approx. 195-215 HP / 230-250 lb-ft torque (figures vary by market and tuning).

Injection Type:

Multi-point Fuel Injection (MPI)

🔧 Transmission

Transmission Type:

4-speed Automatic Transmission (V4A51) or 5-speed Manual Transmission (V5MT1) - Availability dependent on trim and market.

Transmission Options:

Varies by market; typically automatic was more common, manual available on sportier trims or specific regions.

Drivetrain System:

4WD (Four-Wheel Drive) with Super Select 4WD II system, offering 2H, 4H, 4HLC (Locked Center Differential), 4LLC (Locked Low Range).

Transfer Case Features:

Super Select 4WD II system offers driver-selectable modes for various terrain conditions, including true full-time 4WD operation with a locked center differential in 4HLC and 4LLC modes.

📐 Dimensions

Wheelbase Long Wheelbase:

Approx. 2755 mm (108.5 inches)

Wheelbase Short Wheelbase:

Approx. 2500 mm (98.4 inches)

Length Long Wheelbase:

Approx. 4660 mm (183.5 inches)

Width:

Approx. 1775 mm (69.9 inches)

Height:

Approx. 1715 mm (67.5 inches)

Curb Weight Range:

Approx. 1900 - 2100 kg (4189 - 4630 lbs), depending on configuration.

🛡️ Safety Features

Crash Test Notes:

Specific crash test ratings from agencies like NHTSA or IIHS for this model year range are often limited or vary by country. Generally, body-on-frame SUVs of this era offered robust but less advanced safety structures compared to modern unibody designs.

Braking System:

Anti-lock Braking System (ABS) and Electronic Brakeforce Distribution (EBD) were often available, particularly on higher trims.

Traction Control:

Traction control systems were less common or optional on early models, becoming more prevalent in later years of this generation. Typically not found on base models.

Restraints:

Driver and front passenger airbags, front seatbelt pretensioners. Side airbags were less common or optional.

💡 Technology Features

Audio System:

Factory AM/FM/CD player with optional cassette. Speaker configurations vary by trim level. Early models may have basic digital displays for climate control.

Cruise Control:

Cruise control was commonly available, particularly on higher trim levels.

Connectivity Options:

Limited by modern standards. No integrated Bluetooth or USB ports from the factory. Antenna for radio reception.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, using appropriate oil viscosity.

Timing Belt Interval:

For 6G7x engines, timing belt replacement is crucial, typically around 60,000 - 100,000 miles (100,000 - 160,000 km) or 5-7 years. Consult manual for exact interval and procedure due to interference engine design.

Engine Oil Viscosity:

API SG/SH/SJ rated oil, SAE 10W-30 or 10W-40 recommended for most climates. Consult manual for precise viscosity and capacity.

Transmission Fluid Automatic:

Mitsubishi DiaQueen ATF-SPII or equivalent Dexron III/Mercon compatible fluid. Capacity approx. 8-10 liters for full drain and fill.

Coolant:

Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Capacity approx. 9-11 liters.

Transfer Case Fluid:

API GL-4 or GL-5, SAE 75W-90 gear oil. Capacity approx. 2.1 liters.

Rear Differential Fluid:

API GL-5, SAE 80W-90 gear oil. Capacity approx. 1.6 liters.

Power Steering Fluid:

ATF Dexron II/III or equivalent power steering fluid.

Common Wear Items:

Suspension bushings and ball joints (due to SUV duty), front brake pads and rotors, exhaust system components, aging rubber hoses and seals.

Powertrain Notes:

Timing belt maintenance is critical for the 6G7x V6 engines to prevent catastrophic failure. Automatic transmission cooler lines can sometimes corrode and leak. Some models may experience fuel injector issues or idle control valve problems.

Electrical Notes:

Window regulators, power lock actuators, and body control module issues can arise with age. Wiring harness chafing, particularly in the engine bay or near suspension components, is also possible.

📚 Vehicle History

Brand Legacy:

Mitsubishi has a long history in the SUV market, with the Pajero lineage (Montero in North America) being a flagship, known for durability and off-road prowess.

Generation Overview:

The first generation Pajero Sport (based on the Pajero/Montero platform but with a distinct chassis and styling) was launched in 1996 and continued through various updates until the early 2000s. This manual covers a significant portion of its initial production run.

Model Variants:

Available in 2WD and 4WD configurations. Body styles included short-wheelbase (often more of a two-door utility) and long-wheelbase (four-door SUV). Trim levels varied by market (e.g., LS, XLS, Exceed).

Manufacturing Locations:

Primarily manufactured in Japan, with some assembly or production occurring in other global locations depending on market.

🏆 Awards & Recognition

Awards History:

While specific awards for the Pajero Sport (first generation) are less publicized than its larger Pajero sibling, the overall Pajero/Montero line has a strong reputation for off-road capability and durability, often cited in enthusiast reviews and adventure publications.