Mitsubishi Pajero Sport / Montero Sport 1998 thru 2004, repair e-manual

Content

General

• How to use this manual
• Troubleshooting / inspection service points
• Treatment before / after the fording of a stream
• Vehicle identification
• Major specifications
• Precaution before service

Engine lubrication

• General information
• Lubricants
• Special tools
• On-vehicle service
• Engine oil cooler

Fuel

• Multipoint fuel injection (MPI)
• Diesel fuel
• Fuel supply

Engine cooling

• General information
• Service specifications
• Lubricant
• Sealants
• Cooling fan
• Thermostat
• Water pump
• On-vehicle service
• Water hose and water pipe
• Radiator

Intake and exhaust

• Service specifications
• Special tool
• On-vehicle service
• Air cleaner
• Intercooler and intercooler fan-ECU
• Intake manifold
• Turbocharger and exhaust manifold
• Turbocharger
• Exhaust manifold
• Exhaust pipe and main muffler

Engine electrical

• Charging system
• Starting system
• Ignition system
• Glow system

Engine and emission control

• Engine control system
• Auto cruise control system

Clutch

• General information
• Service specifications
• Lubricant
• On-vehicle service
• Clutch pedal
• Clutch control

Manual transmission

• General information
• Lubricant
• Sealants
• On-vehicle service
• Transmission control
• Transmission assembly
• 4WD indicator ECU

Propeller shaft

• General information
• Service specifications
• Lubricant
• Special tools
• Propeller shaft

Front axle

• General information
• Service specifications
• Lubricant
• Special tools
• On-vehicle service
• Front hub
• Knuckle
• Driver shaft
• Inner shaft
• Differential carried
• Freewheel clutch

Rear axle

• General information
• Service specifications
• Lubricant
• Special tools
• On-vehicle service
• Axle assembly
• Axle shaft
• Differential carried

Wheel and tyre

• General information
• Service specifications
• Troubleshooting
• On-vehicle service
• Wheel and tyre
• Underfloor spare tyre carried

Power plant mount

• General information
• Special tool
• Rear engine mounting
• Front differential mounting
• Front engine mounting
• Front suspension crossmember

Front suspension

• General information
• Special tool
• Sealants
• On-vehicle service
• Shock absorber
• Lower arm and torsion bar
• Stabilizer bar

Rear suspension

• General information
• Special tool
• Sealants
• On-vehicle service
• Shock absorber
• Lower arm
• Stabilizer bar
• Coil spring and axle bumper

Service brakes

• Brake system
• Anti-skid system

Parking brakes

• General information
• On-vehicle service
• Service specifications
• Lubricants
• Sealant
• Parking brake lever
• Parking brake cable
• Parking brake drum

Steering

• On-vehicle service
• Service specifications
• Lubricants
• Sealant
• Steering wheel and shaft
• Power steering gear box
• Power steering oil pump
• Power steering hoses
• Steering linkage

Body

• Body mounting
• Hood
• Fender
• Glass
• Door
• Tailgate
• Sunroof

Exterior

• Bumper
• Wiper and washer
• Door mirror

Interior and supplemental restraint system (SRS)

• Service specifications
• Special tool
• Instrument panel
• Floor console
• Trims
• Mirror
• Seat
• Seat belt
• Air bag

Chassis electrical

• Battery
• Ignition switch and immobilizer system
• Combination meters
• Multi-meter
• Outside thermo sensor
• Headlamp and front combination lamp
• Fog lamp
• Speakers
• Antenna
• Heater
• Air conditioner

Heater, air conditioner and ventilation

• General information
• Service specifications
• Lubricants
• Sealant
• Special tool
• Troubleshooting
• On-vehicle service
• Condenser and condenser fan
• Motor
• Heater control assembly and A/C switch
• Refrigerant line
• Heater unit and heater core
• Engine coolant temperature switch
• Blower assembly and idle-up system
• Resistor
• Evaporator
• Ventilators
• Rear heater unit
• Compressor and tension pulley

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