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Mitsubishi

Mitsubushi PAJERO SPORT 1999 2000 2001 2002 Factory CHASSIS Service Repair Workshop Manual

Mitsubushi PAJERO SPORT 1999 2000 2001 2002 Factory CHASSIS Service Repair Workshop Manual

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Vehicle data plateRef 365422
Brand
Mitsubishi
Vehicle
Cars
Models covered
Express, Mitsubushi, Pajero Sport
Years
1999, 2000, 2001, 2002
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

What happens after you pay

  • Download link opens on the order page immediately
  • The same link is emailed to you — re-download any time
  • Open on phone, tablet or PC; print only the pages you need
  • Not sure it covers your model year? Ask us before you buy
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Pajero Sport
Model Generation:
First Generation (K90 Series)
Model Years Covered:
1999, 2000, 2001, 2002
Chassis Code:
K90 Series
👋 Introduction
Market Position
Vehicle Segment:
Mid-size SUV, often referred to as a Sport Utility Vehicle (SUV) or Pajero Sport.
Target Audience:
Individuals seeking off-road capability, utility, and a robust vehicle for diverse terrains.
Competitive Analysis
Key Competitors:
Toyota 4Runner, Nissan Pathfinder, Ford Explorer, Jeep Cherokee (XJ/WJ).
Key Features
Off Road Capability:
Body-on-frame construction, available 4WD system (Super Select 4WD-i is common in some markets for Pajero series, though specific to Sport needs verification), and robust suspension contribute to off-road prowess.
Durability:
Known for its rugged construction and reliability, making it suitable for demanding use.
Practicality:
Offers ample passenger and cargo space, suitable for families and recreational activities.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Workshop Manual
Language:
English
Format:
PDF (Adobe Acrobat)
Availability:
Digital Download
Platform Compatibility:
PC, Mac, iPad, Android Tablets, iPhone, Android Phones
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Full coverage including disassembly, inspection, assembly, and troubleshooting of engine components.
Engine Lubrication:
Detailed information on oil pump, oil passages, oil filter, and lubrication system operation.
Fuel System:
Coverage of fuel tank, fuel pump, fuel lines, fuel injectors, and fuel pressure regulation.
Engine Cooling:
In-depth information on radiator, coolant, thermostat, water pump, and cooling fan operation.
Intake And Exhaust:
Details on air intake system, throttle body, exhaust manifolds, catalytic converter, and muffler.
Engine Electrical:
Comprehensive coverage of ignition system, starter motor, alternator, battery, and wiring diagrams.
Engine And Emission Control:
Information on emission control devices, sensors (e.g., O2 sensor, MAF sensor), and engine management systems.
Clutch:
Detailed procedures for clutch inspection, adjustment, and replacement.
Manual Transmission:
Full coverage of manual gearbox components, operation, and repair procedures.
Propeller Shaft:
Information on driveshaft, universal joints, and maintenance.
Front Axle:
Coverage of front differential, CV joints, and steering knuckle components.
Rear Axle:
Details on rear differential, axle shafts, and housing.
Wheel And Tire:
Information on wheel bearings, tire pressure, rotation, and balancing.
Power Plant Mount:
Coverage of engine and transmission mounts for vibration isolation.
Front Suspension:
Detailed procedures for shock absorbers, springs, control arms, and alignment.
Rear Suspension:
Information on rear shock absorbers, springs, links, and alignment.
Service Brakes:
Comprehensive coverage of brake system, including hydraulic components, disc/drum brakes, and ABS.
Parking Brakes:
Details on parking brake mechanism and adjustment.
Steering:
Coverage of steering wheel, steering column, power steering system, and tie rods.
Body:
Information on body structure, panels, doors, windows, and exterior trim.
Exterior:
Details on bumpers, lighting, mirrors, and other external components.
Interior:
Coverage of seats, dashboard, door panels, and interior trim.
Supplemental Restraint System Srs:
Information on airbags, seatbelt pretensioners, and SRS system troubleshooting.
Chassis Electrical:
Coverage of lighting, wipers, horn, power windows, central locking, and instrument cluster.
Heater Air Conditioner And Ventilation:
Detailed information on HVAC system components, operation, and service.
Procedures Included
Maintenance:
Includes routine maintenance tasks like oil changes, filter replacements, fluid checks, and inspections.
Troubleshooting:
Provides diagnostic procedures and flowcharts for identifying and resolving common problems.
Repair:
Step-by-step instructions for disassembling, repairing, and reassembling various vehicle systems.
Diagnostics:
Guides for using diagnostic tools and interpreting fault codes.
Component Replacement:
Detailed instructions for replacing specific parts and components.
Adjustment:
Procedures for adjusting various systems, such as brakes, clutch, and parking brake.
Specifications And Tolerances:
Essential technical data, torque specifications, and service tolerances for accurate repairs.
Technical Depth
Depth Level:
Comprehensive factory-level detail, suitable for DIY enthusiasts and professional mechanics.
Diagnostic Tools:
Information may implicitly cover the use of common diagnostic tools and scan equipment.
Rebuild Procedures:
Likely includes full rebuild procedures for major components like the engine and transmission.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
PDF format typically allows for text searching of keywords.
Print Quality
Printability:
Fully printable, allowing for individual pages or the entire manual.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Naturally Aspirated Gasoline (Likely V6 MIVEC or Inline-4 Diesel depending on market, but V6 is common for this generation in many regions).
Engine Code Example:
Commonly 6G72 (3.0L V6 SOHC/DOHC MIVEC) or 4D56 (2.5L Inline-4 Turbo Diesel).
Performance
Displacement Example:
3.0 Liters (for V6 gasoline), 2.5 Liters (for diesel).
Horsepower Range Example:
Approximately 170-210 HP for V6 gasoline, 115-135 HP for diesel.
Torque Range Example:
Approximately 245-280 Nm for V6 gasoline, 250-300 Nm for diesel.
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI) for gasoline engines, direct injection for diesel.
Fuel Type:
Unleaded gasoline (for gasoline engines), Diesel fuel (for diesel engines).
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
4-speed Automatic Transmission
Features
Drive System:
Part-time 4WD or available Full-time 4WD system (depending on trim and market).
📐 Dimensions
Exterior
Length Example:
Approximately 4690 mm (184.6 inches)
Width Example:
Approximately 1775 mm (69.9 inches)
Height Example:
Approximately 1745 mm (68.7 inches)
Weights
Curb Weight Range Example:
Approximately 1800-2000 kg (3968-4409 lbs)
🛡️ Safety Features
Ratings
NHTSA Ratings:
N/A (Vehicle safety ratings vary by region and testing agency for this model year.)
Active Features
Antilock Braking System:
Available ABS on certain trim levels.
Four Wheel Drive:
Key active safety feature for improved traction in various conditions.
Passive Features
Airbags:
Driver and front passenger airbags are standard or optional depending on trim.
Seatbelts:
Three-point seatbelts with pretensioners for front occupants.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM stereo with CD player or cassette deck, often with 4-6 speakers.
Driver Assistance
Cruise Control:
Available on higher trim levels.
Connectivity
Power Accessories:
Power windows, power locks, and power mirrors are common options.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first, depending on driving conditions.
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km).
Spark Plug Replacement Gasoline:
Around 60,000-100,000 miles (96,000-160,000 km) depending on spark plug type (platinum/iridium).
Fluid Specifications
Engine Oil Type:
Refer to manual for specific viscosity (e.g., 10W-30, 10W-40) and API service classification (e.g., API SJ or higher).
Coolant Type:
Ethylene glycol-based coolant (e.g., Mitsubishi DiaQueen Super Long Life Coolant or equivalent).
Transmission Fluid Manual:
API GL-4 or GL-5, SAE 75W-90 gear oil.
Transmission Fluid Automatic:
Mitsubishi DiaQueen ATF SP-III or equivalent.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine Mounts:
Wear and tear on engine and transmission mounts can lead to increased vibration.
Suspected Catalytic Converter:
Can fail over time, leading to reduced engine performance and check engine lights.
Transfer Case Lever Actuator:
Some 4WD systems might experience issues with the actuator for the transfer case lever.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors:
Mitsubishi Motors has a long history of producing robust and capable off-road vehicles, stemming from its Pajero lineage, which is a highly respected name in the SUV segment globally.
Model Evolution
Pajero Sport Lineage:
The Pajero Sport (also known as Montero Sport in North America and other markets) is a derivative of the Pajero/Montero platform, offering a more road-biased and less extreme off-road focus than its sibling, while retaining significant capability.
Production
Manufacturing Plants:
Produced in various Mitsubishi plants globally, including Japan and Thailand.
🏆 Awards & Recognition
Recognitions
Off Road Awards:
While specific awards for the Pajero Sport of this exact vintage might be less documented, the Pajero lineage has received numerous accolades for off-road performance and durability over the years.

Delivery & file format

This is a digital PDF download, not a printed book. After payment the download link appears on your order confirmation page and is emailed to the address you entered. Files open in any PDF reader on phone, tablet or computer and can be printed.

Check the model year and engine before you buy

Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.

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