Mitsubishi Pajero Sport K90 - Service Manual - Repair Manual

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MITSUBISHI PAJERO SPORT K90 - SERVICE  MANUAL

- English Service Manual to Mitsubishi Pajero Sport K90.

- G-TITLE
-- FOREWORD
-- WARNING!
- 00
-- GENERAL [00]
-    HOW TO USE THIS MANUAL
-    HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
-    TREATMENT BEFORE/AFTER FORDING A STREAM
-    VEHICLE IDENTIFICATION
-    MAJOR SPECIFICATIONS
-    PRECAUTIONS BEFORE SERVICE
-    SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
-    SUPPORT LOCATIONS FOR LIFTING AND JACKING
-    STANDARD PARTS-TIGHTENING-TORQUE TABLE
- 11
-- ENGINE [11]
-    ENGINE [11A]
-    GENERAL INFORMATION
-    SERVICE SPECIFICATIONS
-    SEALANT
-    SPECIAL TOOLS
-    ON-VEHICLE SERVICE
-    CRANKSHAFT PULLEY
-    CAMSHAFT
-    CAMSHAFT OIL SEAL
-    OIL PAN AND OIL SCREEN
-    CYLINDER HEAD GASKET
-    TIMING BELT
-    CRANKSHAFT FRONT OIL SEAL
-    CRANKSHAFT REAR OIL SEAL
-    ENGINE ASSEMBLY
-    ENGINE [11B]
-    GENERAL INFORMATION
-    SERVICE SPECIFICATIONS
-    SEALANTS
-    SPECIAL TOOLS
-    ON-VEHICLE SERVICE
-    CRANKSHAFT PULLEY
-    CAMSHAFT AND CAMSHAFT OIL SEAL
-    OIL PAN AND OIL SCREEN
-    CYLINDER HEAD GASKET
-    TIMING BELT AND TIMING BELT B
-    CRANKSHAFT FRONT OIL SEAL
-    CRANKSHAFT REAR OIL SEAL
-    ENGINE ASSEMBLY
- 12
-- ENGINE LUBRICATION [12]
-    GENERAL INFORMATION
-    LUBRICANTS
-    SPECIAL TOOLS
-    ON-VEHICLE SERVICE
-    ENGINE OIL COOLER
- 13
-- FUEL [13]
-    MULTIPOINT FUEL INJECTION (MPI) [13A]
-    GENERAL INFORMATION
-    SERVICE SPECIFICATIONS
-    SEALANT
-    SPECIAL TOOLS
-    TROUBLESHOOTING
-    ON-VEHICLE SERVICE
-    INJECTOR
-    THROTTLE BODY
-    DIESEL FUEL [13B]
-    GENERAL INFORMATION
-    SERVICE SPECIFICATIONS
-    SPECIAL TOOL
-    ON-VEHICLE SERVICE
-    INJECTION NOZZLE
-    INJECTION PUMP
-    FUEL SUPPLY [13C]
-    GENERAL INFORMATION
-    FUEL TANK
-    FUEL FILTER

- 14
-- ENGINE COOLING [14]
-    GENERAL INFORMATION
-    SERVICE SPECIFICATIONS
-    LUBRICANT
-    SEALANTS
-    ON-VEHICLE SERVICE
-    COOLING FAN
-    THERMOSTAT
-    WATER PUMP
-    WATER HOSE AND WATER PIPE
-    RADIATOR
- 15
-- INTAKE AND EXHAUST [15]
-    SERVICE SPECIFICATIONS
-    SPECIAL TOOL
-    ON-VEHICLE SERVICE
-    AIR CLEANER
-    INTERCOOLER AND INTERCOOLER FAN-ECU
-    INTAKE MANIFOLD
-    TURBOCHARGER AND EXHAUST MANIFOLD
-    TURBOCHARGER
-    EXHAUST MANIFOLD
-    EXHAUST PIPE AND MAIN MUFFLER
- 16
-- ENGINE ELECTRICAL [16]
-    CHARGING SYSTEM
-    GENERAL INFORMATION
-    SERVICE SPECIFICATIONS
-    SPECIAL TOOL
-    ON-VEHICLE SERVICE
-    ALTERNATOR
-    STARTING SYSTEM
-    GENERAL INFORMATION
-    SERVICE SPECIFICATIONS
-    STARTER MOTOR
-    IGNITION SYSTEM
-    GENERAL INFORMATION
-    SERVICE SPECIFICATIONS
-    SPECIAL TOOL
-    ON-VEHICLE SERVICE
-    CAMSHAFT POSITION SENSOR AND CRANKSHAFT ANGLE SENSOR
-    GLOW SYSTEM
-    GENERAL INFORMATION
-    SERVICE SPECIFICATIONS
-    SEALANT
-    ON-VEHICLE SERVICE
-    GLOW PLUG
- 17
-- ENGINE AND EMISSION CONTROL [17]
-    ENGINE CONTROL SYSTEM
-    GENERAL INFORMATION
-    SERVICE SPECIFICATIONS
-    SEALANT
-    ON-VEHICLE SERVICE
-    ACCELERATOR CABLE AND PEDAL
-    AUTO-CRUISE CONTROL SYSTEM

-    GENERAL INFORMATION
-    SPECIAL TOOL
-    TROUBLESHOOTING
-    ON-VEHICLE SERVICE
-    AUTO-CRUISE CONTROL
-    EMISSION CONTROL SYSTEM
-    GENERAL INFORMATION
-    SERVICE SPECIFICATIONS
-    VACUUM HOSE
-    CRANKCASE EMISSION CONTROL SYSTEM
-    EVAPORATIVE EMISSION CONTROL SYSTEM
-    EXHAUST GAS RECIRCULATION (EGR) SYSTEM
-    CATALYTIC CONVERTER
-    CANISTER AND TWO-WAY VALVE
-    EMISSION CONTROL SYSTEM
-    GENERAL INFORMATION
-    SERVICE SPECIFICATIONS
-    SEALANT
-    SPECIAL TOOL
-    EXHAUST GAS RECIRCULATION (EGR) SYSTEM
- 21
-- CLUTCH [21]
-    GENERAL INFORMATION
-    SERVICE SPECIFICATIONS
-    LUBRICANTS
-    ON-VEHICLE SERVICE
-    CLUTCH PEDAL
-    CLUTCH CONTROL
- 22
-- MANUAL TRANSMISSION [22]
-    GENERAL INFORMATION
-    LUBRICANTS
-    SEALANTS

-    ON-VEHICLE SERVICE
-    TRANSMISSION CONTROL
-    TRANSMISSION ASSEMBLY
-    4WD INDICATOR-ECU
- 25
-- PROPELLER SHAFT [25]
-    GENERAL INFORMATION
-    SERVICE SPECIFICATIONS
-    LUBRICANT
-    SPECIAL TOOLS
-    PROPELLER SHAFT
- 26
-- PROPELLER SHAFT [25]
-    GENERAL INFORMATION
-    SERVICE SPECIFICATIONS
-    LUBRICANT
-    SPECIAL TOOLS
-    PROPELLER SHAFT
- 27
-- REAR AXLE [27]
-    GENERAL INFORMATION
-    SERVICE SPECIFICATIONS
-    LUBRICANTS
-    SEALANTS
-    SPECIAL TOOLS
-    ON-VEHICLE SERVICE

-    AXLE ASSEMBLY
-    AXLE SHAFT
-    DIFFERENTIAL CARRIER
- 31
-- WHEEL AND TYRE [31]
-    GENERAL INFORMATION
-    SERVICE SPECIFICATIONS
-    TROUBLESHOOTING
-    ON-VEHICLE SERVICE
-    WHEEL AND TYRE
-    UNDERFLOOR SPARE TYRE CARRIER
- 32
-- POWER PLANT MOUNT [32]
-    GENERAL INFORMATION
-    SPECIAL TOOL
-    FRONT ENGINE MOUNTING
-    REAR ENGINE MOUNTING
-    FRONT DIFFERENTIAL MOUNTING
-    FRONT SUSPENSION CROSSMEMBER
- 33a
-- FRONT SUSPENSION [33A]
-    GENERAL INFORMATION
-    SERVICE SPECIFICATIONS
-    SEALANTS
-    SPECIAL TOOLS
-    ON-VEHICLE SERVICE
-    SHOCK ABSORBER AND UPPER ARM
-    LOWER ARM AND TORSION BAR
-    STABILIZER BAR
- 34
-- REAR SUSPENSION [34]
-    GENERAL INFORMATION
-    SERVICE SPECIFICATIONS
-    SPECIAL TOOLS
-    ON-VEHICLE SERVICE
-    LOWER ARM
-    SHOCK ABSORBER AND LATERAL ROD
-    COIL SPRING AND AXLE BUMPER
-    STABILIZER BAR
- 35
-- SERVICE BRAKES [35]
-    BASIC BRAKE SYSTEM [35A]
-    GENERAL INFORMATION
-    SERVICE SPECIFICATIONS
-    LUBRICANTS

-    SEALANT
-    SPECIAL TOOL
-    TROUBLESHOOTING
-    ON-VEHICLE SERVICE
-    BRAKE PEDAL
-    MASTER CYLINDER AND BRAKE BOOSTER
-    LOAD SENSING PROPORTIONING VALVE
-    FRONT DISC BRAKE
-    REAR DISC BRAKE
-    ANTI-SKID BRAKING SYSTEM (ABS) [35B]
-    GENERAL INFORMATION
-    SERVICE SPECIFICATIONS
-    LUBRICANT
-    SPECIAL TOOLS
-    TROUBLESHOOTING
-    ON-VEHICLE SERVICE
-    MASTER CYLINDER AND BRAKE BOOSTER
-    HYDRAULIC UNIT
-    WHEEL SPEED SENSOR
-    G-SENSOR
- 36
-- PARKING BRAKES [36]
-    GENERAL INFORMATION
-    SERVICE SPECIFICATIONS
-    LUBRICANTS
-    SEALANT
-    ON-VEHICLE SERVICE
-    PARKING BRAKE LEVER
-    PARKING BRAKE CABLE
-    PARKING BRAKE DRUM
- 37a
-- STEERING [37A]
-    GENERAL INFORMATION
-    SERVICE SPECIFICATIONS
-    LUBRICANTS
-    SEALANTS
-    SPECIAL TOOLS
-    ON-VEHICLE SERVICE
-    STEERING WHEEL AND SHAFT
-    POWER STEERING GEAR BOX
-    POWER STEERING OIL PUMP
-    POWER STEERING HOSES
-    STEERING LINKAGE
- 42
-- BODY [42]
-    BODY MOUNTING
-    HOOD
-    FENDER
-    SEALANT
-    FENDER
-    FUEL FILLER DOOR
-    WINDOW GLASS
-    ADHESIVES
-    SPECIAL TOOL
-    WINDOW REPAIR
-    WINDSHIELD
-    QUARTER WINDOW GLASS
-    TAILGATE WINDOW GLASS
-    DOOR
-    SERVICE SPECIFICATIONS
-    SEALANT
-    SPECIAL TOOLS
-    TROUBLESHOOTING
-    ON-VEHICLE SERVICE
-    DOOR ASSEMBLY
-    DOOR TRIM AND WATERPROOF FILM
-    DOOR GLASS AND REGULATOR
-    DOOR HANDLE AND LATCH
-    WINDOW GLASS RUNCHANNEL AND DOOR OPENING WEATHERSTRIP
-    TAILGATE
-    SEALANT
-    SPECIAL TOOL
-    TROUBLESHOOTING
-    ON-VEHICLE SERVICE
-    TAILGATE ASSEMBLY
-    TAILGATE TRIM AND WATERPROOF FILM
-    TAILGATE HANDLE AND LATCH
-    SUNROOF
-    SEALANT AND ADHESIVE
-    ON-VEHICLE SERVICE
-    SUNROOF
- 51
-- EXTERIOR [51]
-    FRONT BUMPER
-    REAR BUMPER
-    BUMPER GUARD
-    GRILLE, MOULDING AND GARNISH
-    SPECIAL TOOL
-    GRILLE, MOULDING AND GARNISH
-    EXTERIOR PARTS
-    WIDE FENDER
-    SIDE STEP
-    SIDE STEP
-    WINDSHIELD WIPER AND WASHER
-    SERVICE SPECIFICATION
-    WINDSHIELD WIPER AND WASHER
-    REAR WIPER AND WASHER
-    SERVICE SPECIFICATION
-    REAR WIPER AND WASHER
-    HEADLAMP WASHER
-    MARKS
-    DOOR MIRROR
-    SPECIAL TOOL
-    DOOR MIRROR
- 52
-- INTERIOR AND SUPPLEMENTAL RESTRAINT SYSTEM (SRS) [52]
-    INTERIOR [52A]
-    SERVICE SPECIFICATIONS
-    SPECIAL TOOL
-    INSTRUMENT PANEL
-    INSTRUMENT PANEL
-    FLOOR CONSOLE
-    TRIMS
-    INSIDE REAR VIEW MIRROR
-    FRONT SEAT
-    REAR SEAT
-    FRONT SEAT BELT
-    REAR SEAT BELT
-    SUPPLEMENTAL RESTRAINT SYSTEM (SRS) [52B]
-    GENERAL INFORMATION
-    SRS SERVICE PRECAUTIONS
-    SERVICE SPECIFICATION
-    SEALANT
-    SPECIAL TOOLS
-    TEST EQUIPMENT
-    TROUBLESHOOTING
-    SRS MAINTENANCE
-    POST-COLLISION DIAGNOSIS
-    INDIVIDUAL COMPONENT SERVICE
-    WARNING/CAUTION LABELS
-    FRONT IMPACT SENSORS
-    SRS AIR BAG CONTROL UNIT (SRS-ECU)
-    AIR BAG MODULES AND CLOCK SPRING
-    AIR BAG MODULE DISPOSAL PROCEDURES
-    SENSOR CABLE INSTALLATION PROCEDURES
- 54
-- CHASSIS ELECTRICAL [54]
-    BATTERY
-    SERVICE SPECIFICATION
-    ON-VEHICLE SERVICE
-    IGNITION SWITCH AND IMMOBILIZER SYSTEM
-    SPECIAL TOOL
-    TROUBLESHOOTING
-    IGNITION SWITCH AND IMMOBILIZER SYSTEM
-    COMBINATION METERS
-    SERVICE SPECIFICATIONS
-    SEALANT
-    SPECIAL TOOLS
-    TROUBLESHOOTING
-    ON-VEHICLE SERVICE
-    COMBINATION METERS
-    MULTI-METER
-    TROUBLESHOOTING
-    ON-VEHICLE SERVICE
-    MULTI-METER
-    OUTSIDE THERMO SENSOR
-    SERVICE SPECIFICATIONS
-    OUTSIDE THERMO SENSOR
-    HEADLAMP AND FRONT COMBINATION LAMP
-    SERVICE SPECIFICATIONS
-    SPECIAL TOOLS
-    TROUBLESHOOTING
-    ON-VEHICLE SERVICE
-    HEADLAMP AND FRONT COMBINATION LAMP
-    FRONT FOG LAMP
-    SERVICE SPECIFICATIONS
-    SPECIAL TOOL
-    ON-VEHICLE SERVICE
-    FRONT FOG LAMP
-    TURN-SIGNAL LAMP
-    REAR COMBINATION LAMP
-    REAR FOG LAMP
-    SPECIAL TOOL

-    REAR FOG LAMP
-    HIGH-MOUNTED STOP LAMP
-    RHEOSTAT
-    SPECIAL TOOL
-    RHEOSTAT
-    HAZARD WARNING LAMP SWITCH
-    SPECIAL TOOL
-    HAZARD WARNING LAMP SWITCH
-    HORN
-    CIGARETTE LIGHTER
-    ACCESSORY SOCKET
-    RADIO AND TAPE PLAYER
-    SPECIAL TOOL
-    TROUBLESHOOTING
-    RADIO AND TAPE PLAYER
-    SPEAKER
-    ANTENNA
-    SPECIAL TOOL
-    ANTENNA
-    REAR WINDOW DEFOGGER
-    SPECIAL TOOL
-    ON-VEHICLE SERVICE
-    REAR WINDOW DEFOGGER SWITCH
- 55
-- HEATER, AIR CONDITIONER AND VENTILATION [55]

-    GENERAL INFORMATION
-    SERVICE SPECIFICATIONS
-    LUBRICANTS
-    SEALANT
-    SPECIAL TOOL
-    TROUBLESHOOTING
-    ON-VEHICLE SERVICE
-    HEATER CONTROL ASSEMBLY AND A/C SWITCH
-    HEATER UNIT AND HEATER CORE
-    BLOWER ASSEMBLY AND RESISTOR
-    EVAPORATOR
-    REAR HEATHER UNIT
-    COMPRESSOR AND TENSION PULLEY
-    CONDENSER AND CONDENSER FAN MOTOR
-    REFRIGERANT LINE
-    ENGINE COOLANT TEMPERATURE SWITCH
-    IDLE-UP SYSTEM
-    OUTSIDE AIR TEMPERATURE SENSOR
-    VENTILATORS