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Mitsubishi Pajero Sport 2000 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero Sport Year: 2000 Codes Chassis Code Prefix: K90 Series 👋 Introduction Market Position Segment: Mid-size SUV / Off-road vehicle Competitive Analysis Competitors...
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Mitsubishi Pajero Sport 2000 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Pajero Sport
Year:
2000
Codes
Chassis Code Prefix:
K90 Series
👋 Introduction
Market Position
Segment:
Mid-size SUV / Off-road vehicle
Competitive Analysis
Competitors Circa 2000:
Toyota 4Runner, Nissan Pathfinder, Ford Explorer, Jeep Cherokee/Grand Cherokee, Isuzu Rodeo.
Key Features
Off Road Capability:
Body-on-frame construction, available Super Select 4WD-II system, robust suspension, good ground clearance.
Practicality:
Spacious interior, versatile cargo area, durable materials.
📋 Manual Details
Coverage Areas
Coverage Scope:
Full Service and Repair
Page Count
Estimated Page Count:
1000+
Manual Type
Type:
Workshop Manual / Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine electrical, manual transmission, automatic transmission, transfer case, differentials, driveshafts.
Chassis:
Suspension (front and rear), steering system, braking system (front and rear discs/drums), wheels and tires.
Body And Electrical:
Body panels, doors, windows, interior trim, HVAC (Heating, Ventilation, and Air Conditioning), electrical system (lighting, power accessories, wiring diagrams), instrumentation, safety systems (airbags, seatbelts).
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, lubrication.
Repair And Rebuild:
Engine disassembly and assembly, transmission overhaul, brake caliper rebuild, suspension component replacement, bodywork repairs, electrical component diagnosis and replacement.
Diagnostics And Troubleshooting:
Step-by-step diagnostic procedures for common and complex issues, fault code interpretation (if applicable), wiring diagrams for troubleshooting.
Technical Depth
Depth:
Comprehensive, covering routine maintenance to full engine and transmission rebuilds. Includes detailed torque specifications, clearances, and assembly procedures.
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, searchable text, printable pages.
Print Quality
Print Readability:
Optimized for digital viewing and printing, ensuring clarity of diagrams and text.
Binding Type
Binding For Download:
N/A (Digital PDF)
Paper Type
Paper Type For Download:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code Petrol:
6G72 (3.0L V6 SOHC)
Engine Code Diesel:
4D56 (2.5L Turbo-Diesel I4)
Performance V6 Petrol
Horsepower 6G72:
Approx. 170-177 hp (depending on market tune)
Torque 6G72:
Approx. 245-260 Nm (depending on market tune)
Performance Diesel
Horsepower 4D56:
Approx. 118 hp
Torque 4D56:
Approx. 240 Nm
Fuel System Petrol
Fuel Injection:
Multi-point Fuel Injection (MPI)
Fuel System Diesel
Fuel Injection:
Direct Injection, Turbocharged
Cooling System
Cooling Type:
Pressurized liquid cooling system
Lubrication System
Oil Type Petrol:
API SG/SH or higher, SAE 10W-30 or 10W-40 recommended (check manual for specific grade)
Oil Type Diesel:
API CF-4/CG-4 or higher, SAE 15W-40 recommended (check manual for specific grade)
🔧 Transmission
Standard
Transmission Type Petrol:
5-speed Manual Transmission (e.g., KM145)
Optional
Transmission Type Auto:
4-speed Automatic Transmission (e.g., V4A51)
Features
Drivetrain:
Part-time 4WD or available Super Select 4WD-II (with center differential lock and low-range gearing).
Fluid Specifications Auto
Atf Type:
DIA-QUEEN ATF-SPII or equivalent (check manual for exact specification)
Fluid Specifications Manual
Mtf Type:
GL-4 SAE 75W-90 or GL-5 SAE 75W-90 (check manual for exact specification)
📐 Dimensions
Exterior Length
Length:
Approx. 4,600-4,700 mm (varies slightly by body style/market)
Exterior Width
Width:
Approx. 1,775-1,815 mm
Exterior Height
Height:
Approx. 1,800-1,850 mm
Wheelbase
Wheelbase:
Approx. 2,725 mm
Ground Clearance
Ground Clearance:
Approx. 200-215 mm (unladen)
Weights
Curb Weight:
Approx. 1,800-2,000 kg (varies by engine, transmission, and trim)
Towing Capacity:
Typically rated around 2,500 kg (check local regulations and vehicle specifics)
Tire Size
Standard Tire Size:
265/70R15 or 265/70R16 (common fitments)
Wheel Bolt Pattern
Bolt Pattern:
6x139.7 mm (6 studs, 139.7mm PCD)
Wheel Size
Standard Wheel Size:
15x7JJ or 16x7JJ
🛡️ Safety Features
Ratings
Crash Test Results:
Information not readily available for this specific year/model in standardized global ratings like NHTSA/Euro NCAP. Refer to owner's manual or regional compliance.
Active Features
ABS:
Available Anti-lock Braking System (ABS) on some trims.
Traction Control:
Traction control systems were less common on base models of this era; available on higher trims or optional.
Passive Features
Airbags:
Driver and front passenger airbags standard on most models.
Seatbelts:
Three-point inertia-reel seatbelts for front and rear occupants.
Body Construction:
Reinforced impact-absorbing body structure.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette or CD player with basic speaker setup. Aftermarket head units are common upgrades.
Navigation:
Navigation systems were not standard or widely available on this generation; typically an aftermarket addition.
Driver Assistance
Cruise Control:
Available on higher trim levels or as an optional extra.
Connectivity
Bluetooth Usb:
Not equipped from factory. Bluetooth and USB integration would be aftermarket.
🔧 Maintenance
Service Intervals Oil
Engine Oil Change:
Every 5,000-7,500 km or 6 months, whichever comes first (for petrol). Diesel may have slightly different intervals.
Service Intervals Filters
Oil Filter Replacement:
Replace with every oil change.
Air Filter Replacement:
Inspect every 15,000 km, replace as needed (or every 30,000 km).
Service Intervals Fluids
Coolant Flush:
Every 40,000 km or 2 years (using Mitsubishi Super Long Life Coolant or equivalent).
Service Intervals Brakes
Brake Fluid Change:
Every 2 years or 40,000 km.
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4
Power Steering Fluid Type:
Dexron II or III ATF or specified Mitsubishi fluid
Known Issues
Diesel Engine 4D56:
Timing belt replacement is critical (typically every 100,000 km or 5 years). Potential for turbocharger wear over time. Glow plug issues in cold climates.
Petrol Engine 6G72:
Head gasket failures have been reported on some examples, especially if overheated. Spark plug and ignition coil issues can cause misfires. EGR system can sometimes get clogged.
Transmission Auto:
Valve body issues or torque converter problems can occur with high mileage or lack of regular ATF changes. Overheating can lead to transmission damage.
Suspension And Steering:
Ball joint wear, tie rod end wear, and bushings can degrade over time, leading to knocking noises and steering play, especially if used off-road frequently.
Electrical:
Alternator, starter motor, and power window regulators can be common failure points with age.
📚 Vehicle History
Brand Heritage
Mitsubishi SUV Legacy:
Mitsubishi has a long history in producing robust off-road vehicles, starting with the iconic Pajero (Montero in North America) in the early 1980s. The Pajero Sport is a derivative built on a ladder frame, sharing many components with the Triton/ استرادا pickup truck.
Model Evolution
Pajero Sport Generation:
This 2000 model falls into the first generation (K90 series, produced 1996-2006). It was designed as a more affordable, rugged, and practical alternative to the monocoque-bodied Pajero, often targeting utility and off-road enthusiasts.
Production
Production Locations:
Primarily manufactured in Japan and Thailand.
Market Availability:
Sold globally under various names, including Mitsubishi Challenger (Australia), Mitsubishi Montero Sport (North America and other markets), and Mitsubishi Pajero Sport.
🏆 Awards & Recognition
Recognitions
Off Road Awards:
While the Pajero Sport itself may not have specific widely publicized awards for this year, the Pajero lineage is highly regarded for its off-road prowess and reliability, often winning or placing well in international off-road challenges and rallies.
Ratings
Consumer Satisfaction General:
Generally perceived as a durable and capable SUV, especially for its price point, though specific consumer satisfaction ratings for the 2000 model are varied depending on the market and maintenance history.
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