Market Segment:
Mid-size SUV, Body-on-frame construction, offering off-road capability and utility.
Key Competitors:
Toyota 4Runner, Nissan Pathfinder, Ford Explorer, Jeep Grand Cherokee, Chevrolet Trailblazer.
Vehicle Strengths:
Robust chassis, proven 4WD systems (Super Select 4WD-II), strong off-road performance, durable engines, spacious interior, good towing capacity.
Manual Value Proposition:
Empowers owners and technicians with the knowledge to maintain, diagnose, and repair their Pajero/Montero Sport effectively, reducing reliance on dealership services and extending vehicle life.
Engine:
Engine mechanical, engine control system (ECU), fuel system, ignition system, cooling system, lubrication system, emission control system, starting system, charging system.
Transmission:
Automatic transmission (INVECS-II Sport Mode), Manual transmission, Transfer case, Drivetrain, Driveshafts, Axles, Differential.
Chassis And Body:
Suspension (front and rear independent), Steering system, Braking system (ABS), Wheels and Tires, Chassis, Frame, Body construction, Doors, Hood, Tailgate, Glass, Mirrors, Interior trim, Exterior trim.
Electrical:
Electrical system overview, wiring diagrams, battery, alternator, starter motor, lighting system (headlights, taillights, interior lights), instrumentation, gauges, power windows, power locks, wipers, horn, audio system, climate control system, SRS (Airbag) system, immobilizer system, keyless entry system.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-ups, spark plug replacement, belt replacement, brake inspection and service, tire rotation and balancing.
Repair And Rebuild:
Engine overhaul, cylinder head service, piston and connecting rod replacement, crankshaft service, transmission overhaul, differential overhaul, brake caliper rebuild, suspension component replacement, steering rack repair.
Diagnostics And Troubleshooting:
Diagnostic trouble codes (DTCs), symptom-based troubleshooting, component testing, electrical system diagnostics, fuel system diagnostics, emissions system diagnostics.
Installation And Adjustment:
Component installation procedures, timing belt adjustment, brake bleeding, wheel alignment, headlight aiming, seat adjustment.
Depth Of Coverage:
Comprehensive. Covers everything from routine maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and wiring diagrams. Suitable for professional technicians and experienced DIYers.
File Format:
PDF (typically high resolution, searchable)
Print Quality Consideration:
Designed for clarity and readability when printed, with sharp text and diagrams. Users can print specific sections as needed.
Binding Type:
N/A (Downloadable format)
Paper Type Consideration:
N/A (Digital format). Recommend durable paper if printing.
Engine Code Petrol:
6G72 (3.0L V6 SOHC MPI)
Engine Code Diesel:
4M41 (3.2L DOHC DI-D Common Rail Turbo Diesel)
Horsepower 6G72:
Approximately 170-180 hp @ 5000-5500 rpm (depending on specific market tune)
Torque 6G72:
Approximately 245-255 Nm @ 4000 rpm (depending on specific market tune)
Horsepower 4M41:
Approximately 160-175 hp @ 3500-3800 rpm (depending on specific market tune)
Torque 4M41:
Approximately 370-400 Nm @ 2000-2500 rpm (depending on specific market tune)
Fuel Delivery 6G72:
Multi-Point Fuel Injection (MPI)
Fuel Delivery 4M41:
Direct Injection Diesel (DI-D) with Common Rail Turbocharging
Displacement 6G72:
2972 cc
Displacement 4M41:
3200 cc
Standard Transmission Type:
Likely 4-speed Automatic (INVECS-II Sport Mode) for many markets, but 5-speed Manual was also available.
Optional Transmission Type:
5-speed Manual Transmission (for certain engine/trim combinations)
Transfer Case:
Super Select 4WD-II (SS4-II) with electronic engagement, offering 2H, 4H, 4HLC (Locked Center Diff), 4LLC (Locked Low Range and Center Diff). Some base models might have a simpler Easy Select 4WD system.
Transmission Fluid Spec Auto:
Mitsubishi DiaQueen ATF-J2 or equivalent (Manual and exact specification will be detailed in the manual).
Transmission Fluid Spec Manual:
GL-4 or GL-5 gear oil, specific viscosity grade (e.g., 75W-90) detailed in the manual.
Length:
Approx. 4740 - 4810 mm (depending on market and bumper design)
Width:
Approx. 1800 - 1820 mm
Height:
Approx. 1800 - 1870 mm (including roof rails)
Wheelbase:
Approx. 2725 mm
Curb Weight:
Approx. 1900 - 2100 kg (depending on engine, drivetrain, and equipment)
Gross Vehicle Weight Rating Gvwr:
Approx. 2500 - 2650 kg
Cargo Volume:
Variable depending on seating configuration, typically over 800 liters behind the second row.
NHTSA Ratings:
Varies by market and specific model year. Generally received 3-4 star ratings in frontal and side impact tests where available.
ABS:
Standard on most models, often with EBD (Electronic Brakeforce Distribution).
Traction Control:
Optional or standard on higher trims, may be integrated with AWD system.
Electronic Stability Control Esc:
Optional or standard on higher trims in some markets.
Airbags:
Front airbags standard. Side airbags and curtain airbags available on higher trims.
Seatbelts:
3-point seatbelts with pre-tensioners for front occupants, 3-point or lap belts for rear occupants.
Rollover Protection:
Body-on-frame construction provides inherent structural integrity. Features like Electronic Stability Control (ESC) can mitigate rollover risk.
Infotainment System:
Basic factory fitted radio/CD players common. Higher trims may feature premium audio systems, and aftermarket head unit upgrades are popular for modern features like Apple CarPlay/Android Auto.
Cruise Control:
Available on most trims, controlled via steering wheel or dashboard buttons.
Parking Sensors:
Optional on higher trims or dealer-installed accessory.
Connectivity Features:
Limited native connectivity on models of this era. AUX input for audio, and external devices can be connected via aftermarket solutions.
Oil Change Interval:
Typically every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first. Specifics depend on engine type and driving conditions. Manual will provide precise schedule.
Air Filter Replacement Interval:
Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on dusty conditions. Manual will specify.
Spark Plug Replacement Interval Petrol:
For 6G72 (NGK Iridium/Platinum): Approx. 60,000-100,000 miles (96,000-160,000 km). Manual is crucial for exact type and interval.
Timing Belt Replacement Interval Petrol:
For 6G72: Recommended every 60,000-90,000 miles (96,000-144,000 km) due to interference engine design. Crucial maintenance item.
Timing Chain Consideration Diesel:
The 4M41 diesel engine uses a timing chain, which generally has a longer lifespan than a belt and is designed to last the life of the engine, but may require tensioner and guide checks.
Engine Oil Spec Petrol:
API SN or higher, ILSAC GF-5 or higher. Viscosity: 10W-30 or 5W-30 (check manual for climate-specific recommendations).
Engine Oil Spec Diesel:
API CJ-4 or CK-4, ACEA E9 or E7. Viscosity: 5W-30 or 10W-40 (check manual for climate-specific recommendations).
Coolant Spec:
Mitsubishi Super Long Life Coolant (SLLC) - Pink or Green, based on type. Manual will specify the correct type and mixture ratio for optimal corrosion protection.
Brake Fluid Spec:
DOT 3 or DOT 4 (check manual). Always use fresh, sealed fluid.
Common Wear Items:
Suspension bushings, ball joints, tie rod ends, exhaust system components, alternator, starter motor, fuel injectors (especially on older diesels), turbocharger seals (on diesel).
Diesel Specific Concerns:
Potential for injector issues, EGR valve clogging, glow plug failures, and turbocharger wear if not properly maintained. Diesel particulate filter (DPF) if equipped in certain markets can clog.
Petrol Specific Concerns:
Timing belt failure can cause catastrophic engine damage (6G72). Spark plug fouling and coil pack issues can occur. Can be prone to oil leaks from seals and gaskets.
Mitsubishi Offroad Legacy:
Mitsubishi has a long and successful history in off-road racing, most notably with multiple victories in the Dakar Rally with the Pajero (Montero) Evolution models, which has directly influenced the development and capability of their production SUVs.
Pajero Sport Lineage:
The Pajero Sport (Montero Sport) was introduced in 1996 as a more affordable, body-on-frame SUV based on the Pajero/Montero platform, but with a distinct chassis and styling. This second generation (2000-2008) received a significant facelift for the 2004 model year, updating styling and often powertrain options. The manual covers the post-facelift models.
Manufacturing Location:
Primarily produced in Japan by Mitsubishi Motors, with some regional assembly plants depending on the market.
Offroad Capability Awards:
While the Pajero Sport itself may not have specific standalone awards for this generation, the Pajero/Montero lineage has consistently been recognized for its off-road prowess and durability in various automotive publications and enthusiast reviews.
Consumer Satisfaction Surveys:
Generally ranks well for reliability and off-road capability among its peers, though specific model year ratings may vary. The manual helps maintain this reliability.
