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Mitsubishi Pajero Sport 1999-2002 Workshop Service Manual

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This manual covers the Pajero Sport, specifically the K90 Series (K94W, K96W, K97W, K99W) produced between 1999 and 2002. Designed as a mid-size SUV, the Pajero Sport is built on...
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Mitsubishi Pajero Sport 1999-2002 Workshop Service ManualMitsubishi Pajero Sport 1999-2002 Workshop Service ManualMitsubishi Pajero Sport 1999-2002 Workshop Service ManualMitsubishi Pajero Sport 1999-2002 Workshop Service Manual
This manual covers the Pajero Sport, specifically the K90 Series (K94W, K96W, K97W, K99W) produced between 1999 and 2002. Designed as a mid-size SUV, the Pajero Sport is built on a robust body-on-frame chassis, offering both rear-wheel drive and capable four-wheel drive systems, including the versatile Super Select II transfer case. Available in 2-door and 4-door body styles, this vehicle was engineered for family use, light off-roading, towing, and general utility, drawing on extensive heritage in off-road vehicle development. It was positioned to compete with other popular SUVs of its era, known for its blend of practicality and off-road capability. This comprehensive workshop service manual provides detailed guidance for the maintenance, repair, and troubleshooting of your Pajero Sport. Its scope encompasses all major systems, including the powertrain (engine, transmission, transfer case, differentials), chassis (suspension, steering, brakes), electrical systems, and body components. Within its extensive pages, you will find step-by-step procedures for scheduled maintenance, diagnostic strategies for identifying and resolving common issues, detailed technical specifications, and essential safety guidelines. This manual is an indispensable resource for owners and technicians seeking to ensure the optimal performance, reliability, and longevity of their vehicle.
🏷️ 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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