🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero Sport

Model Generation:

First Generation (K80/K90)

Model Years Covered:

1999-2002

Chassis Codes:

K85W, K94W, K96W, K97W, K99W

Engine Codes Covered:

4G64, 6G72, 4M40, 4M41

👋 Introduction

Market Position:

The Mitsubishi Pajero Sport (also known as Montero Sport in some markets) of this era was positioned as a capable, mid-size body-on-frame SUV, offering robust off-road prowess and rugged utility. It competed against vehicles like the Toyota 4Runner, Nissan Pathfinder, and Jeep Cherokee.

Competitive Analysis:

Differentiated itself with strong off-road capability, often featuring Super Select 4WD systems (depending on market/trim) and available diesel engines in many global markets. Its truck-like construction provided durability and towing capacity, appealing to a segment prioritizing utility and adventure.

Key Features:

Body-on-frame construction, available 4WD systems (including advanced transfer cases), robust naturally aspirated and turbocharged engines, spacious interior, good cargo capacity, capable off-road performance, and a generally reliable drivetrain.

📋 Manual Details

Coverage Areas:

North America, Europe, Asia, Australia (specific regional variations may exist)

Page Count:

Detailed and extensive, estimated 2000+ pages (typical for factory service manuals of this era and scope)

Manual Type:

Factory Service and Repair Manual

Language:

English

Format:

Digital (likely PDF, CD-ROM origin)

📖 Manual Coverage

Systems Covered:

Engine Mechanical, Engine Control Systems (ECI/MPI), Fuel System, Exhaust System, Cooling System, Lubrication System, Ignition System, Starting System, Charging System, Clutch, Manual Transmission, Automatic Transmission, Transfer Case, Drive Shafts, Differentials, Suspension (Front & Rear), Steering System, Brake System (Front & Rear), ABS, Power Steering, Wheels & Tires, Body & Frame, Doors, Hood, Tailgate, Interior Trim, Exterior Trim, Climate Control (HVAC), SRS Airbag System, Electrical Systems (Wiring Diagrams, Components), Body Control Modules, Lighting, Wipers & Washers, Audio System, Security System

Procedures Included:

Scheduled Maintenance, Routine Inspections, Troubleshooting Guides, Diagnostic Procedures, Component Removal & Installation, Repair Procedures, Overhaul/Rebuild Procedures, Electrical Troubleshooting, Wiring Harness Repair, Body Panel Alignment, Climate Control Servicing, Brake System Bleeding & Component Replacement, Suspension Geometry Adjustment, Drivetrain Component Servicing, Engine Tune-Up Specifications, Emission Control Systems Diagnosis, HVAC System Refrigerant Servicing

Technical Depth:

Comprehensive factory-level detail, suitable for professional technicians and advanced DIY enthusiasts. Covers everything from basic fluid changes and filter replacements to full engine and transmission rebuilds, complex electrical diagnostics, and bodywork repairs. Includes detailed torque specifications, tolerances, and diagnostic flowcharts.

📊 Manual Specifications

File Format:

PDF (searchable text, bookmark navigation, high-resolution images)

Print Quality:

High-resolution scans of original factory documentation, ensuring clarity of text and diagrams.

Binding Type:

Digital (N/A for digital format, but original would be bound)

Paper Type:

Digital (N/A for digital format, but original would be high-quality paper)

⚙️ Engine Specifications

Primary Engine Gas:

3.0L V6 SOHC MPI (6G72)

Primary Engine Gas Hp:

Approx. 175-190 hp (market dependent)

Primary Engine Gas Torque:

Approx. 230-250 lb-ft (market dependent)

Primary Engine Diesel:

2.8L 4-Cylinder SOHC Turbo Diesel (4M40)

Primary Engine Diesel Hp:

Approx. 125 hp (market dependent)

Primary Engine Diesel Torque:

Approx. 240 lb-ft (market dependent)

Secondary Engine Gas:

2.4L 4-Cylinder SOHC MPI (4G64)

Secondary Engine Gas Hp:

Approx. 130-145 hp (market dependent)

Engine Management:

Electronic Multi-Point Fuel Injection (MPI) or Direct Injection for diesel (DI-D common in later models, but MPI for this era's 4M40 is typical)

Fuel Type Gas:

Unleaded Gasoline (Octane rating specified in manual)

Fuel Type Diesel:

Diesel Fuel (specified grade)

🔧 Transmission

Standard Transmission:

5-Speed Manual Transmission

Optional Transmission:

4-Speed Automatic Transmission

4Wd System:

Available with Part-Time 4WD or Full-Time/Selectable 4WD (e.g., Super Select 4WD II, depending on market and trim)

Transfer Case:

Two-speed transfer case with various modes (e.g., 2H, 4H, 4HLc, 4LLc for Super Select systems)

Gear Ratios:

Specific gear ratios for manual and automatic transmissions detailed in the manual.

Transmission Fluid Spec Auto:

ATF SP-II M or equivalent (refer to manual for exact specification)

Transmission Fluid Spec Manual:

API GL-4 or GL-5 gear oil (refer to manual for specific viscosity and specification)

📐 Dimensions

Wheelbase:

Approx. 2725 mm (107.3 inches)

Overall Length:

Approx. 4705 mm (185.2 inches)

Overall Width:

Approx. 1775 mm (69.9 inches)

Overall Height:

Approx. 1720 mm (67.7 inches) (depending on roof rack/options)

Curb Weight:

Varies by configuration, typically 1900-2100 kg (4189-4630 lbs)

Gross Vehicle Weight Rating:

Detailed in manual, typically around 2500 kg (5511 lbs)

Towing Capacity:

Varies by market and configuration, consult manual and local regulations.

🛡️ Safety Features

NHTSA Rating:

NHTSA ratings for this era varied by model year and specific testing, generally moderate for the time. Detailed crash test data is in the manual or available from NHTSA archives.

Active Features:

ABS (Anti-lock Braking System) was available on higher trims, particularly with disc brakes. Limited-slip differential (LSD) often available on rear axle.

Passive Features:

Front airbags for driver and passenger. Seatbelt pre-tensioners. Reinforced cabin structure.

💡 Technology Features

Infotainment System:

Basic AM/FM/CD or Cassette players. Optional premium audio systems. Limited digital integration compared to modern vehicles.

Driver Assistance:

ABS was the primary driver assistance feature available. Traction control and stability control were not common on this generation.

Connectivity:

No factory Bluetooth or USB connectivity. Analog systems for entertainment and basic vehicle functions.

🔧 Maintenance

Oil Change Interval:

Typically 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions. Refer to manual for specific recommendation and oil type.

Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on environment. Manual provides specific intervals.

Spark Plug Replacement:

Varies by plug type (copper, platinum, iridium), typically 30,000-100,000 miles. Manual specifies exact type and interval.

Timing Belt Replacement:

Crucial for 6G72 V6. Typically 60,000-90,000 miles (96,000-144,000 km) or 5-7 years. Non-compliance leads to catastrophic engine failure. Manual details replacement procedure and intervals.

Engine Oil Spec:

API SN/SP, SAE 10W-30 or 5W-30 recommended. Consult manual for exact viscosity based on temperature and engine type.

Engine Coolant Spec:

Mitsubishi Diaqueen Super Long Life Coolant (SLLC) or equivalent (Ethylene Glycol based, typically orange or pink). Dilution 50/50 with distilled water.

Brake Fluid Spec:

DOT 3 or DOT 4. Refer to manual for specific recommendation and replacement interval.

Power Steering Fluid Spec:

Dexron III/Mercon equivalent or specified Mitsubishi fluid. Consult manual.

Known Issues:

Timing belt failure (if not replaced on schedule), potential for head gasket leaks (especially on higher mileage 6G72 V6 engines), suspension component wear (ball joints, bushings), radiator leaks, differential seal leaks, ABS sensor failures, and diesel engine glow plug issues. Manual provides diagnostic procedures for these and more.

📚 Vehicle History

Brand Heritage:

Mitsubishi has a long history in automotive manufacturing, with a strong legacy in rugged, go-anywhere vehicles like the Pajero (and its offshoots). The Pajero nameplate is renowned for its off-road capability and durability.

Model Evolution:

The Pajero Sport (first generation) was introduced in 1996 as a more affordable and slightly smaller alternative to the larger, more luxurious Pajero. It was based on the Pajero's chassis and drivetrain but featured a distinct body design, often with a more utilitarian appeal. It was essentially the second generation of the Pajero 'Junior' or 'Sport' variant.

Production Years:

1996-2008 (First Generation)

Manufacturing Locations:

Primarily Japan, with assembly also occurring in other countries for various markets (e.g., Thailand, Brazil).

🏆 Awards & Recognition

Recognitions:

While specific 'awards' might be scarce for this model, it was recognized for its off-road capability and utility, often receiving positive reviews in enthusiast publications for its value and robustness. It shared platform DNA with the highly acclaimed Pajero.