1999–2002 Mitsubishi Montero Sport Service Manual (P/N PNO C4077-90960)

• Model and configuration coverage: Covers 1999–2002 K9-series 4WD wagons sold as the Mitsubishi Montero Sport, Pajero Sport, and Challenger, including K94W/K94WG and K96W/K96WG families, left- and right-hand-drive layouts, standard- and wide-fender bodies, the 6G72 SOHC 3.0L MPI gasoline engine, and the 4D56 2.5L turbo-diesel—including the 2002 Step III version.
• Engine repair procedures: Documents timing-belt and timing-belt B service, camshaft and crankshaft oil-seal replacement, oil-pan and oil-screen work, cylinder-head-gasket service, valve-clearance and drive-belt adjustment, and engine-assembly removal and installation for the covered 6G72 and 4D56 variants.
• Fuel and engine-management diagnosis: Provides MUT-II workflows, diagnostic-code and symptom charts, service-data tables, ECU terminal checks, oscilloscope inspections, injector and throttle-body service, diesel injection-nozzle and pump checks, and 4D56 Step III sensor, actuator, boost-control, and EGR testing.
• Transmission and 4WD drivetrain work: Details the V5MT1 5-speed manual and V4A51 4-speed automatic, plus clutch controls, transmission removal and installation, hydraulic testing, shift/key interlocks, propeller shafts, front hubs and knuckles, drive shafts, differential carriers, axle shafts, and the freewheel clutch.
• Brake, steering, and suspension coverage: Addresses basic brake and ABS troubleshooting, the load-sensing proportioning valve, disc brakes, ABS hydraulic unit, wheel-speed and G-sensors, parking brakes, power-steering gear and pump service, steering linkage, torsion-bar front suspension, rear coil-spring suspension, and wheel/tire diagnosis.
• SRS, electrical, HVAC, and body systems: Maps SRS maintenance and post-collision diagnosis, front impact sensors, SRS-ECU, airbag modules and clock spring, immobilizer and instrument systems, lighting, keyless entry, manual and automatic air conditioning, doors, glass, sunroof, seats, and exterior hardware.
• Factory revisions and service bulletins: Incorporates MSB-00E11-001 for the 6G72 change from a separate to an integral aluminum oil pan at effective model LY6620 and later, along with factory corrections for the immobilizer, load-sensing proportioning valve, parking brake, wheel balancing, motor antenna, and fuel-system connector identification.
• Document identity and scope: 1,523 PDF pages across 32 factory section files plus a separate cover page. The set contains Mitsubishi Publication No. PWJE9812 and supplements PWJE9812-A and PWJE9812-B, together with 2002 model-year revision pages. Full internal engine and transmission rebuilding, complete vehicle wiring, and collision body-repair data belong to separate publications.

Configuration Breaks That Matter

The factory model tables separate the 6G72 MPI gasoline vehicles from the 4D56 diesel versions and identify GLX/GLS, wide-fender, and steering-position variations. V5MT1 manual-transmission coverage runs throughout the set. The V4A51 automatic appears on applicable 6G72 models beginning with the 2000 model year, while the listed 4D56 configurations retain the manual transmission.

The 2002 diesel material is a major technical break rather than a routine carryover. Dedicated Step III chapters cover the electronically controlled injection pump, engine-ECU diagnosis, injection-timing and idle checks, variable-geometry turbocharger controls, EGR cooler and catalyst changes, revised cylinder-head-gasket and timing-belt work, and the added oil-pan cover. These sections keep earlier mechanically controlled 4D56 procedures from being mixed with the later electronic system.

Repair and Diagnostic Depth

Engine chapters center on on-vehicle inspection, adjustment, and major-unit removal or installation. They cover compression and intake-manifold vacuum checks, ignition and injection timing, belt tension, lubrication and cooling-system tests, turbocharger checks, sealant locations, and component-specific torque, clearance, and inspection categories. Special-tool references remain tied to the procedures, including MUT-II sub-assembly MB991502, cylinder-head-bolt wrench MD998051, and angle gauge MB991614 where applicable.

The MPI, diesel fuel, automatic-transmission, ABS, SRS, immobilizer, and automatic-A/C sections follow Mitsubishi fault-isolation formats. Diagnosis-code tables, probable-cause charts, connector locations, harness checks, terminal identification, reference values, actuator tests, and final verification are laid out by system. Representative views include the Multipoint Fuel Injection System Diagram, the 4D56 Step III Control System Diagram, the V4A51 Hydraulic Circuit, A/T Control Component Location, the emission-control Vacuum Circuit Diagram, and SRS-ECU connector and front-impact-sensor views.

Drivetrain and chassis repair reaches into front-hub, knuckle, drive-shaft, inner-shaft, axle-shaft, differential-carrier, propeller-shaft, brake, steering, and suspension removal, inspection, adjustment, and installation. The automatic-transmission revision also covers the reshaped 2002 oil pan, its sealing method, and the related fluid-capacity change. The axle, brake, steering, and suspension groups provide the associated preload, backlash, runout, alignment, pressure-test, wear-limit, and torque-reference data.

Manual-Specific Repair Warnings

The integral-pan bulletin warns that oil-pan remover MD998727 can damage the aluminum 6G72 pan. The 2002 4D56 variable-geometry turbocharger is identified as non-disassemblable, so no internal turbo rebuild procedure is presented. For SRS-ECU connector testing, Mitsubishi specifies ultra-fine probe MB991222; ordinary probing can damage the harness and strip plating from the terminals.

Follow the manual’s SRS isolation requirements before handling airbag components, use proper support equipment during engine, transmission, axle, or crossmember removal, and use approved recovery equipment for refrigerant service.

Scope Before Purchase

This chassis workshop manual covers engine and transmission diagnosis, adjustment, and major-unit removal and installation, but not full off-vehicle engine or transmission overhaul. System-level circuit diagrams and ECU terminal charts are present; the separate PHJE9810 electrical wiring manual is not included. Collision repair dimensions and structural procedures belong to the separate PBJE9808 body repair manual.