🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero Sport / Challenger

Alternative Model Names:

Mitsubishi Montero Sport, Mitsubishi Nativa, Mitsubishi Shogun Sport, Mitsubishi Pajero Dakar, Mitsubishi G-Wagon

Chassis Code:

K90 Series (Pajero Sport/Challenger)

Generation:

1st Generation (1996-2008)

Applicable Years:

1997-Present (Manual covers 1998 Model Year, and likely extends to other years of the 1st generation)

👋 Introduction

Segment:

Mid-size SUV / Off-road Vehicle

Competitors:

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

Off Road Capability:

Renowned for its robust chassis, Super Select 4WD system (on many variants), and capable suspension, making it a strong contender in the off-road segment.

Durability Reliability:

Generally perceived as a durable and reliable vehicle, especially its mechanical components, when properly maintained.

Powertrain Options:

Available with both capable gasoline and robust diesel engines, paired with manual or automatic transmissions.

📋 Manual Details

Markets Covered:

Global (indicated by multiple model names)

Vehicle Variants Covered:

All variants of Pajero Sport/Challenger within the specified model years and engine types.

Type:

Workshop Manual / Service Manual / Repair Manual

Language:

English

Format:

PDF (delivered as a RAR archive)

📖 Manual Coverage

Engine Mechanical:

Detailed procedures for engine disassembly, assembly, inspection, and repair.

Engine Lubrication Cooling:

Coverage of oil pump, oil filter, oil pan, radiator, water pump, thermostat, and cooling fan systems.

Engine Fuel Emission:

Fuel injection systems (MPI), fuel pump, fuel filter, fuel tank, and emissions control systems (catalytic converter, EGR).

Accelerator Control:

Throttle body, accelerator cable/linkage, cruise control system (if applicable).

Fuel Exhaust:

Fuel lines, exhaust manifold, catalytic converter, mufflers, and pipework.

Clutch:

Clutch disc, pressure plate, release bearing, clutch master cylinder, slave cylinder, and hydraulic lines (for manual transmission models).

Manual Transmission:

Gearbox disassembly, assembly, inspection, lubrication, and shift mechanism.

Automatic Transmission:

ATF system, torque converter, valve body, planetary gears, and electronic control systems.

Propeller Shaft Differential:

Universal joints, driveshafts, front and rear differential units, axle housing, and bearings.

Front Axle:

Front differential, CV joints, suspension mounting points, and wheel hubs.

Rear Axle:

Rear axle housing, drive axles, differential, and bearings (for RWD and 4WD configurations).

Front Suspension:

Independent suspension components (wishbones, springs, dampers, anti-roll bar), steering knuckles, and wheel bearings.

Rear Suspension:

Solid axle or independent suspension (depending on model variant), leaf springs, coil springs, dampers, and Panhard rod.

Brake System:

Brake fluid, master cylinder, brake lines, calipers, rotors, pads, rear drums/shoes, ABS system (if equipped), and parking brake.

Steering System:

Steering rack/box, power steering pump, fluid, hoses, tie rods, and steering column.

Restraint System:

Seat belts, airbags (SRS system), and related sensors and control modules.

Body And Trim:

Body panel removal/installation, interior trim components, doors, windows, bumpers, and seals.

Heater Air Conditioner:

HVAC system components, blower motor, evaporator, condenser, refrigerant, and controls.

Electrical System:

Battery, alternator, starter, ignition system, lighting, dashboard instruments, fuses, relays, and wiring diagrams.

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, lubrication, and inspection procedures.

Diagnostics Troubleshooting:

System fault finding, diagnostic trouble codes (DTCs), and common problem resolutions.

Repair Rebuild:

Step-by-step instructions for component removal, repair, and reassembly.

Installation Adjustment:

Procedures for installing new parts and adjusting critical systems.

Depth:

Comprehensive (covering everything from basic maintenance to complete engine and transmission rebuilds).

Diagrams Illustrations:

Includes detailed diagrams, exploded views, and illustrations for clarity.

Torque Specifications:

Provides precise torque values for all critical fasteners.

Wiring Diagrams:

Detailed electrical wiring schematics for all vehicle systems.

📊 Manual Specifications

Download Type:

RAR archive (requires WinRAR or compatible software for extraction)

Extracted Format:

PDF

Searchable Text:

Likely searchable if the PDF is OCR'd, typical for professional workshop manuals.

Quality:

Assumed high quality professional PDF, suitable for printing.

Binding:

N/A (Digital download)

Paper Type:

N/A (Digital download)

⚙️ Engine Specifications

Engine 1 Code:

6G72

Engine 1 Type:

V6 SOHC/DOHC Petrol

Engine 1 Displacement:

3.0 Liters (2972 cc)

Engine 1 Fuel System:

Multi-Point Fuel Injection (MPI)

Engine 2 Code:

4D56

Engine 2 Type:

Inline 4-cylinder SOHC/DOHC Turbo Diesel

Engine 2 Displacement:

2.5 Liters (2477 cc)

Engine 2 Fuel System:

Direct Injection (DI) with Turbocharging and Intercooler (common variants).

Engine 3 Code:

6A12

Engine 3 Type:

V6 SOHC/DOHC Petrol

Engine 3 Displacement:

2.0 Liters (1998 cc)

Engine 4 Code:

6A13

Engine 4 Type:

V6 SOHC/DOHC Petrol

Engine 4 Displacement:

2.5 Liters (2498 cc)

🔧 Transmission

Manual Transmission:

5-speed manual transmission (e.g., W5M51)

Automatic Transmission:

4-speed automatic transmission (e.g., V4A51)

4Wd System:

Super Select 4WD system with locking center differential and low-range gearing (common on higher trims).

Transfer Case:

Two-speed transfer case with modes for 2H, 4H, 4HLc, and 4LLc.

📐 Dimensions

Body Styles:

5-door SUV

Curb Weight:

Approx. 1850 - 2000 kg (Varies with engine and configuration)

Gross Vehicle Weight:

Approx. 2500 - 2650 kg

🛡️ Safety Features

Crash Test Ratings:

Varies by market and testing organization; often received moderate to good ratings for its era.

Airbags:

Driver and passenger airbags (standard on many later models and export markets).

Seat Belts:

3-point seat belts with pretensioners for front occupants.

ABS:

Anti-lock Braking System (ABS) - often standard or optional depending on trim and market.

💡 Technology Features

Audio System:

Factory fitted radio/cassette or CD players, often with basic speaker systems. Upgrade options common.

Cruise Control:

Available on higher trim levels, controlled via steering wheel or stalk. (Covered in manual).

🔧 Maintenance

Oil Change:

Typically every 5,000-10,000 km or 6-12 months, depending on oil type and driving conditions (refer to manual for specific recommendation).

Timing Belt Replacement:

For 6G72 and 6A1x engines, timing belt replacement is critical, usually around 100,000 km or 5-7 years. The 4D56 diesel typically uses a timing chain. (Crucial to verify with manual for specific engine).

Engine Oil:

API SG/SH/SJ or higher; viscosity grade typically 10W-30 or 5W-30 for petrol, 15W-40 or 10W-30 for diesel. (Manual confirmation essential).

Coolant:

Ethylene glycol-based antifreeze mixed with distilled water (50/50 ratio). (Manual confirmation essential).

Brake Fluid:

DOT 3 or DOT 4 brake fluid (Manual confirmation essential).

Transmission Fluid Manual:

API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil. (Manual confirmation essential).

Transmission Fluid Automatic:

Mitsubishi ATF SP-II M or SP-III (Manual confirmation essential).

Power Steering Fluid:

ATF Dexron II/III or specified power steering fluid. (Manual confirmation essential).

Suspension Wear:

Common wear items include ball joints, bushings, and tie rod ends due to off-road use and vehicle weight.

Diesel Engine Glow Plugs:

Glow plugs on the 4D56 diesel can degrade over time, affecting cold starting. (Covered in manual).

Automatic Transmission Harsh Shifts:

Can sometimes develop harsh shifting or slipping; often related to fluid condition or solenoid issues. (Covered in manual).

Exhaust Manifold Cracks:

On some petrol V6 engines, exhaust manifold cracks can occur due to thermal stress. (Covered in manual).

📚 Vehicle History

Mitsubishi Heritage:

Mitsubishi has a long-standing reputation for producing robust and capable off-road vehicles, tracing back to the iconic Pajero and Jeep models.

Pajero Sport Challenger Lineage:

The Pajero Sport (also known as Challenger in some markets) was developed as a more affordable and distinctively styled alternative to the flagship Pajero, often built on a ladder frame chassis derived from the Triton pickup truck.

Production Years:

1997 - Present (First generation ran until 2008, with subsequent generations following).

Manufacturing Locations:

Primarily Japan, with significant production also occurring in Thailand and other international plants.

🏆 Awards & Recognition

Off Road Awards:

While specific model awards might be rare, the Pajero/Montero platform is consistently recognized for its off-road prowess in various tests and by enthusiast publications.