Description
Factory Mitsubishi Pajero Sport Workshop Manual (1997–2008)
This is the official factory-level service manual for the first-generation Mitsubishi Pajero Sport — sold across the United States and Canada as the Montero Sport — covering every model year from 1997 through 2008. Wiring diagrams, torque specs, and step-by-step overhaul procedures are all included.
Powertrain & Drive Coverage
| Component | Variants Covered |
|---|---|
| Petrol | 3.0L 6G72 V6, 3.5L 6G74 V6 |
| Diesel | 2.5L 4D56 Turbo |
| Transmissions | 5-speed manual, 4-speed automatic |
| Drive | 4×2 and 4×4 with Super Select transfer case |
| Model Years | 1997–2008 |
| Badge Twins | Mitsubishi Montero Sport (North America), Mitsubishi Challenger (select markets) |
Common Pajero Sport Repairs Covered
| System | Procedures |
|---|---|
| 4D56 Turbo Diesel | Timing belt replacement, injector removal, turbocharger inspection and rebuild |
| Transfer Case / 4WD System | Super Select 4WD actuator diagnosis, transfer case fluid service, front differential overhaul |
| Suspension | Front torsion bar adjustment, shock absorber replacement, ball joint and wheel bearing service |
| Electrical / Charging | Alternator replacement, wiring harness diagnosis, instrument cluster circuit testing |
Format & Delivery
PDF. Instant download; lifetime re-downloads.
Frequently Asked Questions
Is the 4D56 turbo diesel timing belt replacement procedure included?
Yes. The manual contains the full timing belt replacement procedure for the 2.5L 4D56 turbodiesel, including belt tension specifications, camshaft and crankshaft alignment marks, and recommended replacement intervals. This is one of the most critical maintenance items on the 4D56 engine, and the manual walks through each step with detailed illustrations.
Does this manual cover the Montero Sport sold in the United States?
Yes. The Mitsubishi Montero Sport is the North American market name for the Pajero Sport K80/K90 platform. This manual covers all K80 and K90 chassis variants regardless of market name, so US owners of the Montero Sport will find the procedures, specifications, and wiring diagrams fully applicable to their vehicle.
Are Super Select 4WD transfer case procedures included?
Yes. The drivetrain section covers the Super Select four-wheel-drive system in full, including actuator diagnostics, transfer case disassembly and reassembly, fluid specifications, and front and rear differential overhaul procedures for both 4×2 and 4×4 configurations.
What format is the manual?
The manual is delivered as a PDF file. After purchase you receive an instant download link and can re-download at any time. The file is fully searchable and can be viewed on Windows, Mac, tablets, or smartphones, and individual pages can be printed for bench use.
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