1997–1999 Mitsubishi Pajero Sport A/C & SRS Service Manual (P/N 96J30097)

• 2,318-page PDF set combining a 1,335-page 1997-1999 Mitsubishi Montero Sport repair reference, a 934-page Mitsubishi Pajero Sport factory workshop manual dated September 1998, and a separate 49-page 1994 Mitsubishi Montero wiring-diagram file.
• Covers the Montero Sport 4G64 2.4L SOHC four-cylinder and 6G72 3.0L SOHC V6, with 2WD/4WD systems, manual-transmission service, and R4AW3/V4AW3 automatic-transmission diagnosis.
• Factory Pajero Sport coverage is configuration-specific: K94W, K94WG, and K96WG 4WD wagons with the V5MT1 5-speed manual transmission, using either the 4D56 2.5L diesel or 6G72 3.0L MPI gasoline engine.
• Covers 6G72 and 4D56 timing-belt, camshaft, cylinder-head-gasket, oil-seal, oil-pan, and engine-assembly work, plus clutch, transmission, propeller-shaft, axle, differential, freewheel-clutch, steering, suspension, brake, and ABS repair procedures.
• Provides model-specific HVAC and SRS diagnosis, 2.4L/3.0L OBD fault testing, no-code symptom charts, sensor-range and pin-voltage data, MUT-II procedures, and R4AW3/V4AW3 TCM input, output, solenoid, and shift-control checks.
• Diagram coverage includes system wiring, connector and component-location views, diagnostic flowcharts, exploded assemblies, differential contact-pattern references, and the related torque, pressure-test, capacity, clearance, adjustment, and electrical specifications.

Coverage and Configuration

This package contains two main service sources with different market and drivetrain coverage. The 1,335-page Montero Sport reference is organized around 1997-1999 U.S.-market 2.4L and 3.0L vehicles and extends well beyond HVAC and airbags. It includes engine performance, brakes and ABS, steering and suspension, front and rear axles, transfer case, automatic and manual transmission service, chassis electrical equipment, maintenance, component locations, vacuum diagrams, and system wiring.

The September 1998 Mitsubishi factory volume applies to Pajero Sport/Challenger 4WD models with a 5-speed manual transmission. Its model table separates K94W/K94WG 4D56 diesel vehicles from K96WG 6G72 gasoline vehicles, including GLX/GLS and wide-fender coding. It does not represent blanket 2.4L coverage and does not contain an automatic-transmission chapter. The factory foreword also identifies separate companion publications for the full engine group, dedicated electrical wiring, structural body repair, and parts information. Those companion titles should not be confused with the workshop chapters supplied here.

A 49-page wiring PDF in the package is titled for the 1994 Mitsubishi Montero, not the 1997-1999 Sport. Treat it as supplemental older-model material; the relevant Montero Sport wiring appears in the 1,335-page reference through dedicated 2.4L, 3.0L, and system-specific diagram sections.

System Diagnostics and Shop Utility

The Montero Sport material provides the strongest internal engine repair depth for the 6G72 3.0L SOHC V6. It covers engine removal, intake and exhaust service, cylinder-head work, timing-belt installation, camshaft and rocker-arm service, crankshaft oil seals, water pump, oil pan, lubrication system, cylinder-head overhaul, cylinder-block inspection, and engine specifications. The 2.4L coverage is concentrated on adjustments, engine-control diagnosis, fuel and ignition components, wiring, pin-voltage charts, sensor-range charts, coded tests, and no-code symptom testing rather than a dedicated model-specific internal overhaul chapter.

Drivetrain coverage includes R4AW3/V4AW3 self-diagnosis, TCM terminal data, speed and temperature sensors, shift and lock-up solenoids, shift-lock adjustment, clutch hydraulics, manual-transmission service, transfer-case work, propeller shafts, front and rear axle removal, differential overhaul, limited-slip setup, rear differential-lock testing, and freewheel-clutch service. Brake sections cover hydraulic bleeding, load-sensing proportioning-valve checks, disc and drum service, booster and master-cylinder work, plus separate 2WD and 4WD ABS DTC routines for wheel-speed sensors, hydraulic units, solenoid circuits, G-sensor inputs, and 4WD detection circuits.

HVAC content includes A/C performance testing, control-unit and switch diagnosis, thermosensor and inlet-sensor checks, blower motor/resistor testing, dual-pressure-switch and compressor-clutch checks, evaporator and heater-core service, compressor and condenser removal, refrigerant-line repair, rear-heater coverage, and diesel idle-up or gasoline-engine outside-temperature-sensor sections. R-12/R-134a identification, oil compatibility, service valves, recovery/recycling, evacuation, charging, and leak-testing guidance are included. The SRS chapters cover MUT-II diagnosis, DTC fault isolation, impact sensors, SRS-ECU, driver and passenger modules, clockspring service, post-collision checks, deployment, cleanup, and module disposal.

The included MAP inspection articles add condition-based shop inspection criteria for HVAC, brake, steering, drivetrain, electrical, engine, exhaust, suspension, and restraint components. These are useful for inspection reporting and repair recommendations, while the model-specific chapters provide the removal, installation, testing, adjustment, and overhaul references.

Technical References and Safety

Representative technical drawings include the A/C control and condenser-fan circuit, SRS component-location and air-bag wiring, 2WD/4WD ABS schematics, R4AW3/V4AW3 TCM and solenoid circuits, 2.4L/3.0L engine-management diagrams, and front/rear differential exploded views with gear-tooth contact patterns. Special-tool references include MUT-II MB991502, SRS Check Harness MB991613, steering-wheel puller MB990803, and Mitsubishi pullers, installers, holders, and gauges used throughout engine, axle, steering, and brake repair.

The SRS procedures warn against measuring air-bag squib resistance because test current can deploy a module; incorrect clockspring centering can sever the internal flat cable. ABS sensor rings must be pressed into the hubs rather than hammered, since impact can demagnetize them and corrupt the wheel-speed signal. The refrigerant sections keep R-12 and R-134a oils and service equipment separate because cross-contamination can cause A/C component or compressor failure. Refrigerant recovery and SRS work require the specified equipment, electrical isolation, and the handling procedures contained in the manuals.