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

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The Mitsubishi Pajero Sport, also known as the Montero Sport in North America and Challenger in Japan and Australia, is a rugged, body-on-frame SUV built on the robust Mitsubishi Triton...
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1999-2002 Mitsubishi Pajero Sport Service Repair Workshop Manual Download PDF1999-2002 Mitsubishi Pajero Sport Service Repair Workshop Manual Download PDF1999-2002 Mitsubishi Pajero Sport Service Repair Workshop Manual Download PDF1999-2002 Mitsubishi Pajero Sport Service Repair Workshop Manual Download PDF
The Mitsubishi Pajero Sport, also known as the Montero Sport in North America and Challenger in Japan and Australia, is a rugged, body-on-frame SUV built on the robust Mitsubishi Triton pickup truck platform. Produced from 1996 through 2008 for its first generation, this capable vehicle was engineered as a versatile off-roader and family transporter, often positioned as an economical alternative to competitors like the Toyota 4Runner. Available in 2WD and 4WD configurations, many models featured the advanced Super Select 4WD system, offering multiple modes for various terrains. The Pajero Sport was offered primarily as a 5-door SUV, though a 3-door variant was also available in select markets, showcasing Mitsubishi's strong heritage in off-road performance derived from its motorsport success. This comprehensive Factory Service Repair Workshop Manual covers the 1st Generation Pajero Sport models from 1999 to 2002. With over 1500 pages, it provides in-depth information on all major vehicle systems, including engine mechanicals, fuel, exhaust, cooling, lubrication, ignition, manual and automatic transmissions, transfer case, axles, suspension, brakes, steering, wheels, tires, body, interior, HVAC, and electrical systems. The manual details routine maintenance, component diagnosis and repair, wiring diagrams, torque specifications, and special tools, making it an essential resource for owners, mechanics, and technicians to ensure the proper upkeep and repair of their vehicle.
🏷️ 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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