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Mitsubishi Pajero Sport 1999-2002 Workshop Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero Sport Years Covered: 1999, 2000, 2001, 2002 Codes Chassis Codes: K90 Series (K94W, K96W, K97W, K99W) 👋 Introduction Market Position Segment: Mid-size...
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Mitsubishi Pajero Sport 1999-2002 Workshop Service Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Pajero Sport
Years Covered:
1999, 2000, 2001, 2002
Codes
Chassis Codes:
K90 Series (K94W, K96W, K97W, K99W)
👋 Introduction
Market Position
Segment:
Mid-size SUV / Sport Utility Truck
Purpose:
Family vehicle, light off-roading, towing, utility
Competitive Analysis
Key Competitors:
Toyota 4Runner, Nissan Pathfinder, Ford Explorer, Jeep Cherokee (XJ/WJ), Isuzu Rodeo, Chevrolet Blazer
Key Features
Body Styles:
2-door (short wheelbase), 4-door (long wheelbase)
Drivetrain:
Rear-Wheel Drive (RWD) and 4-Wheel Drive (4WD) with Super Select II transfer case
Chassis Construction:
Body-on-frame construction
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Service and Repair
Page Count
Estimated Pages:
Over 1000 pages (typical for comprehensive workshop manuals)
Manual Type
Type:
Comprehensive Workshop Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (mechanical, lubrication, cooling, fuel, ignition, exhaust), Transmission (manual & automatic), Transfer Case, Differentials (front & rear), Driveshafts, Axles
Chassis:
Suspension (front & rear), Steering, Brakes (hydraulic, ABS), Wheels & Tires
Electrical:
Battery, Charging System, Starting System, Ignition System, Lighting, Instrumentation, Wiper & Washer Systems, Power Windows, Power Locks, Audio System, Air Conditioning, ECU, SRS (Airbag) System, Fuses & Relays, Wiring Diagrams
Body:
Body Exterior Panels, Doors, Hood, Tailgate, Interior Trim, Seats, Bumpers, Glass
Procedures Included
Maintenance:
Scheduled Maintenance, Fluid Changes, Filter Replacements, Lubrication Points, Tune-Up Procedures
Diagnostics:
Troubleshooting Guides, Symptom-based Diagnostics, Diagnostic Trouble Codes (DTCs), Sensor Testing, Electrical System Diagnostics
Repair:
Component Removal & Installation, Overhaul Procedures, Adjustments, Calibration, Specific Component Repair (e.g., engine rebuild, transmission overhaul)
Specifications:
Torque Specifications, Clearances, Fluid Capacities, Electrical Specifications, Performance Data
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds)
📊 Manual Specifications
File Format
Format:
PDF
Searchable:
Likely searchable text (depending on PDF creation)
Print Quality
Quality:
High Resolution (suitable for printing)
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G64 (2.4L SOHC I4), 6G72 (3.0L SOHC V6), 6G74 (3.5L SOHC V6 - predominantly for export markets)
Displacement 2.4L:
2351 cc
Displacement 3.0L:
2972 cc
Displacement 3.5L:
3497 cc
Performance
Horsepower 2.4L:
~133-144 hp @ 5500 rpm (varies by market/tuning)
Torque 2.4L:
~175-185 lb-ft @ 2500-3000 rpm (varies)
Horsepower 3.0L:
~175-180 hp @ 5500 rpm (varies)
Torque 3.0L:
~230-240 lb-ft @ 4500 rpm (varies)
Horsepower 3.5L:
~190-200 hp @ 5000-5500 rpm (varies)
Torque 3.5L:
~270-280 lb-ft @ 3000-4000 rpm (varies)
Fuel System
Injection:
Electronic Fuel Injection (EFI) / Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Emissions:
Catalytic Converter, OBD-II Compliant (market dependent)
🔧 Transmission
Standard
Manual:
5-speed Manual Transmission (e.g., KM220, KM222)
Optional
Automatic:
4-speed Automatic Transmission (e.g., V4A51, W4A51)
Features
Transfer Case:
Super Select II 4WD system (with full-time 4WD, 2WD, 4WD High, 4WD Low, and center differential lock options on some models)
📐 Dimensions
Exterior
Wheelbase 2Dr:
Approx. 2500 mm (98.4 in)
Wheelbase 4Dr:
Approx. 2725 mm (107.3 in)
Length 4Dr:
Approx. 4670-4770 mm (183.9-187.8 in) (varies with bumper/spare tire carrier)
Width:
Approx. 1775-1830 mm (69.9-72.0 in)
Height:
Approx. 1710-1755 mm (67.3-69.1 in)
Weights
Curb Weight:
Approx. 1700-2000 kg (3748-4409 lbs) (varies greatly by engine, drivetrain, and trim)
Gross Vehicle Weight Rating:
Approx. 2300-2600 kg (5070-5732 lbs)
Cargo
Cargo Volume 4Dr:
Significant space behind rear seats, expandable with seats folded
🛡️ Safety Features
Ratings
NHTSA:
Information not readily available for this specific model year in all markets, generally rated as average for its class at the time.
Active Features
ABS:
Available (Anti-lock Braking System), standard on higher trims/later models
Traction Control:
Rarely standard, may be present on very high-end trims or specific market variants.
Passive Features
Airbags:
Driver and Passenger Airbags (standard on most, optional on base models)
Seatbelts:
3-point front and rear seatbelts (with pretensioners for front occupants)
Rollover Protection:
Reinforced chassis and roof structure
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/Cassette/CD player, often with 4-6 speakers. Aftermarket upgrades are common.
Climate Control:
Manual or automatic climate control on higher trims. HVAC system is robust but can develop leaks or fan issues.
Driver Assistance
Cruise Control:
Available on most models.
Rear View Camera:
Not available from the factory for this generation.
Connectivity
Bluetooth:
Not available from the factory.
🔧 Maintenance
Service Intervals
Oil Change:
Every 5,000 - 7,500 miles or 6-12 months, whichever comes first (check manual for specific engine)
Air Filter:
Every 15,000 - 30,000 miles or as needed based on driving conditions
Spark Plugs:
Every 30,000 - 60,000 miles (depending on plug type - standard, platinum, iridium)
Timing Belt:
Critical: Every 60,000 - 90,000 miles or 4-6 years for 4-cylinder (4G64). V6 models (6G7x) typically use timing chains, which are generally maintenance-free but may require inspection for wear or noise.
Fluid Specifications
Engine Oil 2.4L:
API SG or SH, SAE 10W-30 or 10W-40 (check manual for viscosity by temperature)
Engine Oil 3.0L/3.5L:
API SG or SH, SAE 10W-30 or 10W-40 (check manual for viscosity by temperature)
Coolant:
Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol based coolant with corrosion inhibitors) - typically a 50/50 mix with distilled water.
Transmission Fluid Auto:
DIAQueen ATF-SP-II M or equivalent Dexron III/Mercon compatible fluid.
Transmission Fluid Manual:
API GL-4, SAE 75W-90 or 75W-85 gear oil.
Transfer Case Fluid:
API GL-4, SAE 75W-90 or 75W-85 gear oil.
Differential Fluid:
API GL-5, SAE 80W-90 gear oil.
Brake Fluid:
DOT 3 or DOT 4.
Known Issues
Engine 2.4L:
Head gasket failures, oil leaks, ignition coil issues.
Engine V6:
Timing belt tensioner issues (on older models/engines if not maintained), oil leaks, intake manifold gaskets.
Transmission:
Automatic transmission solenoid issues, manual transmission clutch wear.
Suspension:
Worn ball joints, tie rod ends, and sway bar links due to off-road use and age.
Electrical:
Corroded ground points, faulty window regulators, HVAC blower motor issues, occasional ECU failures.
Frame Rust:
Common in areas with heavy road salt usage. Requires thorough inspection and rust prevention.
📚 Vehicle History
Brand Heritage
Mitsubishi SUVs:
Mitsubishi has a long history in off-road vehicles, starting with the original Pajero (Montero) in 1982.
Model Evolution
Pajero Sport Origins:
The Pajero Sport (or Montero Sport in North America) was introduced in 1996 as a more affordable, less rugged alternative to the full-size Pajero, built on a lighter-duty chassis derived from the Pajero Evolution rally car and sharing components with the L200/Triton pickup truck.
Generation One:
This period (1999-2002) represents the latter part of the first generation Pajero Sport (1996-2008).
Production
Manufacturing Location:
Primarily Japan, also assembled in other countries for specific markets (e.g., Thailand, Brazil).
🏆 Awards & Recognition
Recognitions
Off Road Capability:
While not winning specific awards for this model, the Pajero platform is renowned for its off-road prowess, especially the Pajero Evolution variants which competed successfully in rally raids.
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