Mitsubishi Pajero / Montero Sport 1999–2002 Repair Manual Set (P/N PWJE9812)

Use the model-year chassis sections with the matching engine-family manual for on-vehicle service and internal engine repair. Later chassis updates refer back to procedures in the base manual.

Coverage limits: The additional engine publications cover several Mitsubishi applications; select their procedures by engine and configuration. Detailed off-vehicle transmission overhaul is referred to separate transmission workshop manuals. The engine-chapter PDF in the additional 1998 chassis folder is damaged and cannot be opened.

PDF Search, Chapter Access and File Contents

Search and diagram detail: Text search works only in some files and sections; many engine pages cannot be searched. Chapter PDFs contain bookmarks, but numerous links in the central cover/index file point to unavailable paths. Small connector and terminal numbers require zooming.

The ZIP contains 122 readable, printable PDFs totaling 5,598 pages, plus one damaged PDF whose page count cannot be established. The total already includes the seven-page cover/index, 32 chassis selection pages, 89 engine front-matter pages, two earlier-chassis front-matter pages and six separate bulletin pages. Blank pages and embedded bulletins are also included; overlapping engine editions contain repeated material.

Engine Repair, Drivetrain Tests and Chassis Service

The following selected contents illustrate the repair coverage. Additional topics include service checks before and after stream crossings and cruise-control troubleshooting.

• Engine repair: Step-by-step timing-belt and cylinder-head work, plus piston, crankshaft, bearing and oil-pump inspection in the matching engine manuals.

• Fuel-system diagnosis: MPI fault-code charts, data lists, actuator tests and analyzer waveforms, with separate mechanical and Step III diesel-injection procedures.

• Transmission and 4WD: Clutch controls, transmission removal, V4A51 stall and hydraulic-pressure tests, line-pressure adjustment and freewheel-clutch checks.

• Axles and steering: Hub, drive-shaft and differential repair, with pinion adjustments, steering gear-box overhaul and power-steering pump testing.

• Brakes and suspension: Disc-brake service, ABS wheel-sensor diagnosis, hydraulic-unit actuator checks, torsion-bar work and wheel-alignment adjustments.

• Electrical systems: Alternator and starter testing, immobilizer diagnosis, ECU-terminal charts, connector views and electrical test circuits.

• Body and climate control: Door and window service, SRS diagnosis, refrigerant-system checks and later automatic air-conditioning troubleshooting.

Written for service mechanics, these procedures assume workshop measuring equipment, special tools and familiarity with vehicle diagnostic testing.

Engine Variants and Internal Repair

The 4D56 chapters distinguish mechanical injection from electronically controlled Step III pump operation. The later update changes idle-speed checks and cylinder-head gasket and bolt instructions.

The engine-family manuals extend the chassis procedures with internal disassembly, inspection and reassembly information. Standard values, wear limits and rework dimensions support decisions about component reuse and machining.

The 6G72 timing-belt instructions identify the risk of damaging the auto-tensioner push rod through rapid compression. Revised lash-adjuster cleaning instructions are also included.

Fault Isolation and Transmission Testing

Fault-code charts connect symptoms with MUT-II readings, actuator tests and ECU-terminal measurements. This lets mechanics match electrical checks to the affected circuit before replacing components.

Illustrations include the Regulated Voltage Test circuit, Engine-ECU Connector Terminal Arrangement, Air Flow Sensor analyzer waveforms, ABS Hydraulic Unit Check timing chart and V4A51 Parking and Neutral hydraulic circuit.

The automatic-transmission section explains stall-test results and provides hydraulic-pressure port locations and line-pressure adjustment information. Its diagnostic charts distinguish pressure, clutch and torque-converter faults.

Steering, Body and Air Conditioning

Steering coverage includes pump and gear-box disassembly, cross-shaft clearance and starting-torque adjustment. The steering-wheel chapter warns that hammering during removal can damage the collapsible mechanism.

Body procedures address door fit, window-glass adjustment and power-window safety checks. Air-conditioning chapters cover leak detection, charging, compressor-clutch testing and automatic-control sensor diagnosis.

The general chapters specify lifting support points and SRS precautions. The manufacturer reserves SRS service for authorized Mitsubishi dealers.

Examples of Axle Adjustment Data

The front-axle section specifies a final-drive gear backlash standard of 0.11–0.16 mm. The rear-axle section gives a drive-gear backlash standard of 0.13–0.18 mm, alongside separate pinion turning-torque and differential inspection data.