🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero Sport

Generation:

First Generation (K90 Series)

Chassis Code:

K90 Series

👋 Introduction

Segment:

Mid-size SUV / Sport Utility Vehicle

Niche:

Rugged, off-road capable, family-friendly SUV with a body-on-frame construction.

Competitors:

Toyota Land Cruiser Prado, Nissan Pathfinder, Ford Explorer, Jeep Grand Cherokee, Land Rover Discovery.

Off Road:

Renowned for its off-road prowess, particularly with Mitsubishi's Super Select 4WD system.

Durability:

Known for its robust construction and mechanical durability, often used in demanding conditions.

Versatility:

Offers a blend of passenger comfort, cargo space, and towing capability.

📋 Manual Details

Covered Years:

1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008

Estimated Pages:

1500+

Type:

Complete Workshop Service Repair Manual

Language:

English

Format:

Downloadable PDF

📖 Manual Coverage

Engine:

Detailed diagnostics, repair procedures, engine overhaul, cooling system, lubrication system, fuel system, emission control system, ignition system, engine mechanical, turbocharging (if applicable).

Transmission:

Manual and Automatic transmission repair, diagnostics, fluid specifications, torque converter, clutch, shift controls, removal and installation.

Drivetrain:

Front-wheel drive, Rear-wheel drive, Four-wheel drive (Super Select 4WD) system, differentials (front and rear), drive shafts, propeller shafts, hubs, CV joints.

Suspension:

Front independent suspension (torsion bar), Rear solid axle suspension (coil spring), shock absorbers, springs, control arms, bushings, alignment specifications.

Steering:

Power steering system diagnosis and repair, steering column, steering gear, tie rod ends, power steering pump and fluid.

Brakes:

Front disc brakes, Rear drum or disc brakes, ABS (Anti-lock Braking System) diagnostics and repair, brake booster, master cylinder, brake lines, parking brake.

Electrical:

Wiring diagrams for all circuits, charging system (alternator, battery), starting system (starter motor), lighting system, instrument cluster, power windows, power locks, mirrors, horn, wipers, fuses, relays.

Body And Chassis:

Body panel repair, rust prevention, door mechanisms, interior trim, seat adjustments, roof rack installation, frame repair, chassis lubrication points.

HVAC:

Air conditioning system diagnosis and repair, heating system, ventilation, cabin air filter replacement, refrigerant handling.

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flush, brake fluid flush, transmission fluid change, differential fluid change, tire rotation and balancing.

Troubleshooting:

Step-by-step diagnostic flowcharts for common problems, symptom-based troubleshooting, diagnostic trouble codes (DTCs) interpretation.

Repair:

Detailed disassembly and reassembly procedures for all major components, including engine, transmission, suspension, brakes, steering, and electrical systems.

Specifications:

Torque specifications for all fasteners, fluid capacities and types, diagnostic parameters, clearances, and tolerances.

Depth:

Comprehensive coverage suitable for professional technicians and advanced DIY enthusiasts. Includes detailed schematics, diagrams, and service bulletins.

📊 Manual Specifications

File Type:

PDF

Searchable:

Yes

Printable:

Yes

Resolution:

High-resolution, clear text and diagrams

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Code Gasoline 1:

4G63

Engine Type Gasoline 1:

2.4L Inline-4 SOHC MPI

Displacement Gasoline 1:

2351 cc

Horsepower Gasoline 1:

Approx. 133-145 hp @ 5500 rpm (varies by market and tune)

Torque Gasoline 1:

Approx. 190-210 Nm @ 4000 rpm (varies by market and tune)

Fuel System Gasoline 1:

Multi-point Fuel Injection (MPI)

Fuel Type Gasoline 1:

Unleaded Gasoline

Engine Code Diesel 1:

4D56

Engine Type Diesel 1:

2.5L Inline-4 SOHC Turbocharged Direct Injection (TD)

Displacement Diesel 1:

2477 cc

Horsepower Diesel 1:

Approx. 105-134 hp @ 4000 rpm (varies by market and tune)

Torque Diesel 1:

Approx. 240-290 Nm @ 2000 rpm (varies by market and tune)

Fuel System Diesel 1:

Direct Injection, Turbocharged

Fuel Type Diesel 1:

Diesel

Engine Code Gasoline 2:

6G72

Engine Type Gasoline 2:

3.0L V6 SOHC MPI

Displacement Gasoline 2:

2972 cc

Horsepower Gasoline 2:

Approx. 177-180 hp @ 5500 rpm (varies by market and tune)

Torque Gasoline 2:

Approx. 260-270 Nm @ 4000 rpm (varies by market and tune)

Fuel System Gasoline 2:

Multi-point Fuel Injection (MPI)

Fuel Type Gasoline 2:

Unleaded Gasoline

🔧 Transmission

Transmission Type Standard:

5-speed Manual

Transmission Type Optional:

4-speed Automatic (with lock-up torque converter)

4Wd System:

Super Select 4WD (selectable 2WD, 4WD High, 4WD Low with locking center differential, and often 4WD High Locked).

📐 Dimensions

Length:

Approx. 4710-4740 mm (varies by body style/region)

Width:

Approx. 1775-1830 mm (varies by body style/region)

Height:

Approx. 1750-1850 mm (varies by body style/region)

Wheelbase:

Approx. 2725 mm

Ground Clearance:

Approx. 200-220 mm

Curb Weight:

Approx. 1800-2100 kg (varies by engine, transmission, and trim)

🛡️ Safety Features

Crash Test Data:

Limited public data for this specific generation and model year range, but generally built to robust construction standards of the era.

ABS:

Available, particularly on higher trims and later models.

Airbags:

Driver airbag standard; passenger airbag available on some models.

Seatbelts:

3-point seatbelts with pretensioners (front), 2-point or 3-point (rear).

💡 Technology Features

Audio System:

Factory-installed AM/FM radio with CD player and/or cassette tape player, typically with 4-6 speakers. Upgradable.

Navigation:

Optional on higher trim levels, usually a dealer-installed or factory-integrated unit of its era.

Cruise Control:

Available on most models.

Parking Sensors:

Rare for this generation, typically aftermarket if fitted.

Usb Port:

Not factory standard; typically added via aftermarket head unit upgrades.

Bluetooth:

Not factory standard; typically added via aftermarket head unit upgrades.

🔧 Maintenance

Oil Change Gasoline:

Every 5,000-10,000 km or 6 months (refer to specific owner's manual for exact interval and oil type).

Oil Change Diesel:

Every 5,000-7,500 km or 6 months (refer to specific owner's manual for exact interval and oil type).

Air Filter Replacement:

Every 20,000-40,000 km or annually.

Spark Plug Replacement Gasoline:

Every 40,000-100,000 km depending on plug type (standard, platinum, iridium).

Timing Belt Replacement:

Crucial for 4G63 and 4D56 engines. Typically every 80,000-100,000 km or 5-7 years. Critical to follow manual recommendations.

Coolant Flush:

Every 40,000-80,000 km or 2-4 years.

Engine Oil Gasoline:

API SG/SH or higher, SAE 10W-30 or 10W-40 (check owner's manual for exact spec and viscosity for climate).

Engine Oil Diesel:

API CG-4/CH-4 or higher, SAE 15W-40 (check owner's manual for exact spec and viscosity for climate).

Transmission Fluid Automatic:

DIA QUEEN ATF-II or equivalent (check manual for exact type).

Transmission Fluid Manual:

API GL-4, SAE 75W-85 or 75W-90 (check manual for exact type).

Differential Fluid:

API GL-5, SAE 80W-90 or 85W-140 (check manual for front, rear, and transfer case).

Coolant:

Mitsubishi Super Long Life Coolant (or equivalent high-quality ethylene glycol coolant, typically a 50/50 mix with distilled water).

Timing Belt Failure:

Critical to replace at recommended intervals to prevent catastrophic engine damage. Some models have interference engines.

Rust And Corrosion:

Common in older vehicles, especially in areas with salt exposure. Inspect chassis, body panels, and frame.

Suspension Wear:

Bushings, ball joints, and tie rod ends can wear over time, leading to clunks and imprecise steering.

Oil Leaks:

Valve cover gaskets, oil pan gaskets, and crankshaft seals can develop leaks.

4Wd System Issues:

Actuator problems or sensor failures in the Super Select 4WD system can lead to engagement issues.

📚 Vehicle History

Off Road Legacy:

Mitsubishi has a long and storied history in off-road vehicles, dating back to the original Pajero (Montero in North America).

Positioning:

The Pajero Sport (or Montero Sport) was introduced as a more affordable, sport-oriented sibling to the larger, more luxurious Pajero/Montero, sharing its chassis with the Triton/L200 pickup truck.

Market Introduction:

Launched in 1996 as a 1997 model year vehicle in many markets.

Manufacturing Locations:

Primarily manufactured in Japan, but also produced in other facilities depending on the market (e.g., Thailand, Brazil).

Production Years:

First Generation: 1996-2008.

🏆 Awards & Recognition

Off Road Awards:

While specific awards for the Pajero Sport of this generation are less publicized than the full-size Pajero, its lineage and capabilities have consistently earned it praise in off-road capability reviews and enthusiast circles.

Consumer Satisfaction:

Generally considered a reliable and durable vehicle, particularly favored for its off-road performance and utility.