Mitsubishi Pajero iO QA / Pajero Pinin 1999–2002 Workshop Manual Set (P/N CKRE00E1)

Use the chassis groups for on-vehicle diagnosis and assembly removal, then match the engine or transmission code to the application notes in the overhaul manuals before selecting parts or bench procedures. The 4G1 book provides component-level engine coverage, including the 4G18 listed for certain Pajero iO and Montero iO applications. The four Pinin chassis families in the table use 4G9 engines.

The V4AW4 automatic transmission group covers diagnosis, testing, adjustment, and assembly removal and installation. Internal overhaul coverage is for the manual gearbox. Mitsubishi references separate Electrical Wiring (EKRE00E1), Body Repair (BKRE00E1), and Technical Information (IKRE00E1) manuals outside this ZIP.

PDF Search, Bookmarks, and Diagram Detail

Search and navigation: Text search works in all files. Chapter bookmarks work within the individual PDFs, while the cover's cross-file bookmarks point to folders absent from the archive. Small connector and terminal labels in dense diagrams are clearest when zoomed in.

The ZIP contains 1,910 pages across 36 printable PDFs. That total includes the eight-page cover and front matter file, chapter dividers, note pages, and appended service bulletins.

Engine, 4WD, and Chassis Service

This selection of workshop procedures focuses on the major repair and diagnostic groups. The chassis sections also cover radiator fan troubleshooting and alternator output testing.

• Engine mechanical repair: Covers on-vehicle inspection, timing belt and camshaft service, cylinder head gasket replacement, oil pan and crankshaft and camshaft seal work, and engine removal and installation.

• GDI and MPI diagnosis: Use MUT-II trouble codes, data lists, actuator tests, and ECU terminal checks to trace fuel pressure, injector, throttle control, sensor, and emissions faults.

• Transmission and transfer case: Covers V5M21 disassembly, inspection, selective fitting, and reassembly, plus V4AW4 road tests, shift-pattern checks, converter stall tests, and hydraulic and line-pressure tests.

• Axles and suspension: Covers propeller shaft, hub and knuckle service, free-wheel clutch diagnosis, front and rear differential repair, and front and rear suspension work.

• Brakes and steering: Includes service and parking brake procedures, ABS and electronic brake-force distribution troubleshooting, and power steering pressure testing and bleeding.

• Body and cabin systems: Covers doors, glass, sunroof, trim, seats, lighting, instruments, immobilizer, SWS multiplex functions, airbag and pretensioner diagnosis, and A/C performance and refrigerant leak checks.

Mitsubishi wrote the chassis procedures for service mechanics working with workshop test equipment and special tools.

Model-Year and Drivetrain Differences

The 2000 model tables pair H66W with the 4G93 GDI engine. The 2001 tables add the 4G94 GDI in the H67W three-door and H77W five-door. The 2002 material retains those GDI configurations and adds 4G93 SOHC MPI variants in H66W and H76W.

The later full-time 4WD setup uses a planetary center differential with a viscous coupling in place of the earlier driver-selectable arrangement. The full-time setup drops the transfer control lever and 4WD indicator control unit. The Group 22 sectional view shows the hardware difference before teardown, and Group 23 provides the V4AW4 hydraulic circuit and shift-pattern charts for interpreting test results.

Engine Overhaul and Electrical References

The 4G9 book covers cylinder head and valve train work, piston and connecting rod inspection, crankshaft and cylinder block checks, and oil pump overhaul. Tool references include the MB991653 cylinder head bolt wrench, MB991668 belt tension meter set, and MB990925 bearing and oil seal installer set. The assembly views and tool lists identify the pullers, holders, gauges, and installers used alongside torque tables, clearances, wear limits, and approved fluid specifications.

The 4G94 GDI and MPI control diagrams, connector views, and ECU terminal charts help trace a failed circuit to the right test point. The SWS communication diagram shows how the ETACS-ECU, front ECU, and window controls share data lines. The A/C group also covers refrigerant recovery, compressor service, and control-system diagnosis.

Camshaft and SRS Service Cautions

Incorrect crankshaft positioning during camshaft sprocket work can bring the valves into contact with the pistons. Group 52B warns that probing an airbag squib can trigger deployment and shows the clock spring alignment needed to avoid cable damage.

Use suitable lifting equipment for heavy assemblies. Mitsubishi directs SRS service to authorized Mitsubishi dealers.

Front Differential and ABS Test Values

For the 2000-model front axle, the standard final-drive gear backlash is 0.11–0.16 mm with the drive pinion held stationary. The differential gears have a separate standard backlash of 0–0.076 mm and a service limit of 0.2 mm.

For 4WD ABS diagnosis, the standard internal resistance measured across the wheel speed sensor terminals is 1.30–1.58 kΩ. The ABS group also gives the ECU terminal pairs for checking the sensor circuits at the harness.