Mitsubishi Pajero Sport Montero Workshop Repair Manual 1982-2006 PDF - MMTBSPJR8206OPES.zip
Full service and repair documentation, complete with Electrical Wiring Diagrams, covering the 1982-2006 Mitsubishi Pajero and Pajero Sport — everything you need to service, troubleshoot, fix, and rebuild these vehicles to the same standard as a professional technician.
This 1982-2006 workshop service repair manual for the Mitsubishi Pajero and Pajero Sport contains:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
'00-'03 Pajero Pinin
'01-'02 Pajero
'01-'03 Pajero
'01-'03 Pajero_Montero
'01-'03 Pajero_Montero (EN-DE-ES-FR)
'01 Pajero (EN-DE-ES-FR)
'03 Montero
'03 NP Pajero
'04 Montero, Montero Sport
'06 Montero
'87 Montero
'89 Montero
'91-'02 Pajero_Montero (EN-DE-ES-FR)
'91-'03 Pajero
'91-'99 Pajero
'93 Montero
'98 Montero
'98 Pajero Sport
'99-'01 Pajero Sport
'99-'02 Pajero Sport
'99 Pajero Sport
'83-'96 Pick-ups, Montero.pdf
'83 Montero.pdf
'84 Montero.pdf
'92-'95 Montero.pdf
'92 Montero.pdf
'97-'99 Montero Sport.pdf
PRODUCT DETAILS:
Total Pages: 3.1 GB
File Format: PDF
Language: English
TABLE OF CONTENTS
GR00000100-11A...1
ENGINE MECHANICAL...1
GENERAL DESCRIPTION...2
ENGINE DIAGNOSIS...3
SPECIAL TOOLS...4
ON-VEHICLE SERVICE...7
DRIVE BELT TENSION CHECK...7
AUTO-TENSIONER CHECK...7
IGNITION TIMING CHECK...7
CURB IDLE SPEED CHECK...8
IDLE MIXTURE CHECK...9
COMPRESSION PRESSURE CHECK...10
MANIFOLD VACUUM CHECK...12
LASH ADJUSTER CHECK...12
ENGINE ASSEMBLY...14
REMOVAL SERVICE POINTS...17
INSTALLATION SERVICE POINT...17
CAMSHAFT AND VALVE STEM SEAL...18
REMOVAL SERVICE POINTS...19
INSTALLATION SERVICE POINTS...20
CAMSHAFT OIL SEAL...23
REMOVAL SERVICE POINTS...23
INSTALLATION SERVICE POINTS...24
OIL PAN AND OIL SCREEN...25
REMOVAL SERVICE POINT...26
INSTALLATION SERVICE POINT...26
INSPECTION...27
CRANKSHAFT OIL SEAL...27
INSTALLATION SERVICE POINTS...28
REMOVAL SERVICE POINT...29
INSTALLATION SERVICE POINTS...30
CYLINDER HEAD GASKET...31
REMOVAL SERVICE POINT...32
INSTALLATION SERVICE POINTS...32
TIMING BELT...35
REMOVAL SERVICE POINTS...37
INSTALLATION SERVICE POINTS...38
INSPECTION...42
AUTO-TENSIONER...42
SPECIFICATIONS...42
GR00000100-80...45
CONFIGURATION DIAGRAMS...45
GR00000200-12...47
ENGINE LUBRICATION...47
GENERAL DESCRIPTION...48
SPECIAL TOOL...48
ON-VEHICLE SERVICE...49
ENGINE OIL CHECK...49
ENGINE OIL REPLACEMENT...49
ENGINE OIL FILTER REPLACEMENT...50
ENGINE OIL PRESSURE CHECK...51
ENGINE OIL COOLER...52
SPECIFICATIONS...53
GR00000200-80A...55
CONFIGURATION DIAGRAMS...55
OVERALL CONFIGURATION DIAGRAM...56
HOW TO READ CONFIGURATION DIAGRAMS...57
ENGINE COMPARTMENT...58
ENGINE...60
TRANSMISSION...62
DASH PANEL...64
FLOOR CONSOLE...70
FRONT FLOOR AND ROOF...74
REAR FLOOR AND UNDER FLOOR...76
DOOR...77
BACK DOOR...78
GR00000300-11...79
ENGINE...79
GR00000300-80B...81
SPLICE LOCATIONS...81
HOW TO READ SPLICE LOCATIONS...82
INDEX...83
ENGINE COMPARTMENT...85
ENGINE...85
DASH PANEL...86
FLOOR CONSOLE...90
FRONT FLOOR AND ROOF...91
REAR FLOOR AND UNDER FLOOR...92
DOOR...93
BACK DOOR...93
GR00000400-13B...95
FUEL SUPPLY...95
GENERAL DESCRIPTION...96
FUEL SUPPLY DIAGNOSIS...96
SYMPTOM PROCEDURES...97
INSPECTION PROCEDURE 1: Engine Malfunctions Due to Insufficient Fuel Supply...97
DIAGNOSIS...97
STEP 1. Using scan tool MB991958, read the diagnostic trouble code (DTC)...97
STEP 2. Check the fuel pressure...98
STEP 3. Check for bending, twisting or clogging of the fuel pipe or hose...98
STEP 4. Check the fuel pump module operation...98
STEP 5. Check the inside of the fuel tank for contamination and rust...98
STEP 6. Retest the system...98
SPECIAL TOOLS...99
ON-VEHICLE SERVICE...100
FUEL LEVEL SENSOR CHECK...100
FUEL LEVEL SENSOR REPLACEMENT...100
FUEL PUMP OPERATION CHECK...100
FUEL PUMP MODULE REPLACEMENT...100
FUEL TANK DIFFERENTIAL PRESSURE SENSOR CHECK...101
LEVELING VALVE CHECK...101
FUEL TANK...102
REMOVAL SERVICE POINTS...105
INSTALLATION SERVICE POINT...105
INSPECTION...105
FUEL SHUT-OFF VALVE CHECK...105
FUEL TANK ROLLOVER VALVE ASSEMBLY CHECK...106
ASSEMBLY SERVICE POINT...108
SPECIFICATIONS...108
GR00000400-90...109
CIRCUIT DIAGRAMS...109
HOW TO READ CIRCUIT DIAGRAMS...112
WIRE COLOR CODES...117
JUNCTION BLOCK...118
JOINT CONNECTOR...120
CENTRALIZED JUNCTION...124
POWER DISTRIBUTION SYSTEM...132
STARTING SYSTEM...141
IGNITION SYSTEM...142
CHARGING SYSTEM...144
MFI SYSTEM...146
INVECS-II 5A/T...160
HEADLIGHT...170
TAILLIGHT, POSITION LIGHT, SIDE MARKER LIGHT, LICENSE PLATE LIGHT AND LIGHTING MONITOR TONE ALARM...174
FOG LIGHT...178
DOME LIGHT, REAR PERSONAL LIGHT AND CARGO SPACE LIGHT...182
DOOR LIGHT...186
GLOVE BOX LIGHT...188
VANITY MIRROR LIGHT...189
IGNITION KEY HOLE ILLUMINATION LIGHT AND KEY REMINDER TONE ALARM...190
SIDE STEP LIGHT...192
TURN-SIGNAL LIGHT AND HAZARD WARNING LIGHT...196
STOPLIGHT...200
BACKUP LIGHT...202
HORN...203
METER AND GAUGE...204
FUEL WARNING LIGHT, OIL PRESSURE WARNING LIGHT, BRAKE WARNING LIGHT...208
POWER WINDOWS...210
CENTRAL DOOR LOCKING SYSTEM AND FORGOTTEN KEY PREVENTION FUNCTION...214
SINGLE MANUAL AIR CONDITIONING SYSTEM...224
DUAL MANUAL AIR CONDITIONING SYSTEM ...230
DUAL MANUAL AIR CONDITIONING SYSTEM ...240
DUAL MANUAL AIR CONDITIONING SYSTEM ...248
AUTOMATIC AIR CONDITIONING SYSTEM ...258
AUTOMATIC AIR CONDITIONING SYSTEM ...268
REMOTE CONTROLLED MIRROR...279
WINDSHIELD WIPER AND WASHER...280
REAR WIPER AND WASHER...284
DEFOGGER AND DOOR MIRROR HEATER ...288
DEFOGGER AND DOOR MIRROR HEATER ...290
CLOCK...293
RADIO AND CD PLAYER ...294
RADIO AND CD PLAYER ...298
VIDEO ENTERTAINMENT SYSTEM (VES)...302
CIGARETTE LIGHTER AND ASHTRAY ILLUMINATION LIGHT...308
ACCESSORY SOCKET...309
RV METER...310
SUNROOF...314
SEAT BELT TONE ALARM...318
AUTO-CRUISE CONTROL SYSTEM...320
ACTIVE TRAC 4WD II SYSTEM...326
HYDRAURIC BRAKE BOOSTER (HBB), ELECTRONIC BRAKE-FORCE DISTRIBUTION (EBD), ANTI-LOCK BRAKING SYSTEM (ABS), MITSUBISHI ACTIVE SKID AND TRACTION CONTROL SYSTEM (M-ASTC)...334
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)...344
POWER SEAT...348
HEATED SEAT...352
HEATED SEAT (CONTINUED)...354
THEFT-ALARM SYSTEM...356
IMMOBILIZER SYSTEM...364
TIRE PRESSURE MONITORING SYSTEM (TPMS)...368
RHEOSTAT...372
GR00000500-13...375
FUEL...375
GR00000600A-13A...377
MULTIPORT FUEL INJECTION (MFI)...377
GENERAL DESCRIPTION...378
MULTIPORT FUEL INJECTION (MFI) DIAGNOSIS...380
DIAGNOSTIC FUNCTION...380
HOW TO CONNECT THE SCAN TOOL (MUT-III)...385
HOW TO READ AND ERASE DIAGNOSTIC TROUBLE CODES...385
HOW TO READ DATA LIST...386
HOW TO PERFORM ACTUATOR TEST...387
PROVISIONAL DTCs [MUT-III OBD-II Test Mode - Results (Mode 7)]...387
DIAGNOSTIC BY DIAGNOSTIC TEST MODE II (INCREASED SENSITIVITY)...390
SYSTEM READINESS TEST STATUS...406
DIAGNOSTIC TROUBLE CODE PROCEDURES...417
DTC P0031: Heated Oxygen Sensor Heater Control Circuit Low (bank 1, sensor 1)...417
Logic Flow Chart...419
DIAGNOSIS...420
STEP 1. Check harness connector B-07 at the right bank heated oxygen sensor (front) for damage...420
STEP 2. Check the right bank heated oxygen sensor (front)...421
STEP 3. Measure the power supply voltage at right bank heated oxygen sensor (front) harness side connector B-07...422
STEP 4. Check harness connector B-22X at the MFI relay for damage...422
STEP 5. Measure the power supply voltage at PCM connector D-132 by backprobing...423
STEP 6. Check harness connector D-132 at PCM for damage...423
STEP 7. Check for open circuit or short circuit to ground between right bank heated oxygen sensor (front) connector B-07 (terminal No. 3) and PCM connector D-132 (terminal No. 25)...424
STEP 8. Check harness connector D-132 at PCM for damage...425
STEP 9. Check for harness damage between MFI relay connector B-22X (terminal No. 1) and right bank heated oxygen sensor (front) connector B-07 (terminal No. 1)...426
STEP 10. Check for harness damage between right bank heated oxygen sensor (front) connector B-07 (terminal No. 3) and PCM connector D-132 (terminal No. 25)...427
STEP 11. Check the trouble symptoms...427
STEP 12. Test the OBD-II drive cycle...428
DTC P0032: Heated Oxygen Sensor Heater Control Circuit High (bank 1, sensor 1)...428
Logic Flow Chart...430
DIAGNOSIS...431
STEP 1. Check the right bank heated oxygen sensor (front)...431
STEP 2. Check the trouble symptoms...432
STEP 3. Test the OBD-II drive cycle...432
DTC P0037: Heated Oxygen Sensor Heater Control Circuit Low (bank 1, sensor 2)...433
Logic Flow Chart...435
DIAGNOSIS...436
STEP 1. Check harness connector C-14 at the right bank heated oxygen sensor (rear) for damage...436
STEP 2. Check the right bank heated oxygen sensor (rear)...437
STEP 3. Measure the power supply voltage at right bank heated oxygen sensor (rear) harness side connector C-14...438
STEP 4. Check harness connector B-22X at the MFI relay for damage...438
STEP 5. Measure the power supply voltage at PCM connector D-132 by backprobing...439
STEP 6. Check harness connector D-132 at PCM for damage...439
STEP 7. Check for open circuit or short circuit to ground between right bank heated oxygen sensor (rear) connector C-14 (terminal No. 3) and PCM connector D-132 (terminal No. 24)...440
STEP 8. Check harness connector D-132 at PCM for damage...441
STEP 9. Check for harness damage between MFI relay connector B-22X (terminal No. 1) and right bank heated oxygen sensor (rear) connector C-14 (terminal No. 1)...442
STEP 10. Check for harness damage between right bank heated oxygen sensor (rear) connector C-14 (terminal No. 3) and PCM connector D-132 (terminal No. 24)...443
STEP 11. Check the trouble symptoms...444
STEP 12. Test the OBD-II drive cycle...444
DTC P0038: Heated Oxygen Sensor Heater Control Circuit High (bank 1, sensor 2)...445
Logic Flow Chart...447
DIAGNOSIS...448
STEP 1. Check the right bank heated oxygen sensor (rear)...448
STEP 2. Check the trouble symptoms...448
STEP 3. Test the OBD-II drive cycle...449
DTC P0051: Heated Oxygen Sensor Heater Control Circuit Low (bank 2, sensor 1)...449
Logic Flow Chart...451
DIAGNOSIS...452
STEP 1. Check harness connector B-26 at the left bank heated oxygen sensor (front) for damage...452
STEP 2. Check the left bank heated oxygen sensor (front)...453
STEP 3. Measure the power supply voltage at left bank heated oxygen sensor (front) harness side connector B-26...454
STEP 4. Check harness connector B-22X at the MFI relay for damage...454
STEP 5. Measure the power supply voltage at PCM connector D-132 by backprobing...455
STEP 6. Check harness connector D-132 at PCM for damage...455
STEP 7. Check for open circuit or short circuit to ground between left bank heated oxygen sensor (front) connector B-26 (terminal No. 3) and PCM connector D-132 (terminal No. 10)...456
STEP 8. Check harness connector D-132 at PCM for damage...457
STEP 9. Check for harness damage between MFI relay connector B-22X (terminal No. 1) and left bank heated oxygen sensor (front) connector B-26 (terminal No. 1)...457
STEP 10. Check for harness damage between left bank heated oxygen sensor (front) connector B-26 (terminal No. 3) and PCM connector D-132 (terminal No. 10)...458
STEP 11. Check the trouble symptoms...458
STEP 12. Test the OBD-II drive cycle...459
DTC P0052: Heated Oxygen Sensor Heater Control Circuit High (bank 2, sensor 1)...459
Logic Flow Chart...461
DIAGNOSIS...462
STEP 1. Check the left bank heated oxygen sensor (front)...462
STEP 2. Check the trouble symptoms...463
STEP 3. Test the OBD-II drive cycle...463
DTC P0057: Heated Oxygen Sensor Heater Control Circuit Low (bank 2, sensor 2)...464
Logic Flow Chart...466
DIAGNOSIS...467
STEP 1. Check harness connector C-15 at the left bank heated oxygen sensor (rear) for damage...467
STEP 2. Check the left bank heated oxygen sensor (rear)...468
STEP 3. Measure the power supply voltage at left bank heated oxygen sensor (rear) harness side connector C-15...469
STEP 4. Check harness connector B-22X at the MFI relay for damage...469
STEP 5. Measure the power supply voltage at PCM connector D-132 by backprobing...470
STEP 6. Check harness connector D-132 at PCM for damage...470
STEP 7. Check for open circuit or short circuit to ground between left bank heated oxygen sensor (rear) connector C-15 (terminal No. 3) and PCM connector D-132 (terminal No. 18)...471