Mitsubishi Pajero Sport Common Problems

The Pajero Sport is Mitsubishi's seven-seat 4WD wagon built on the Triton ute's ladder chassis. Every used one here is the QE generation, launched in late 2015. All run the 2.4 litre 4N15 MIVEC turbo-diesel (133 kW and 430 Nm) with an 8-speed automatic. Seven seats became standard on GLS and Exceed in 2016, extra active safety arrived in 2018, and later updates freshened the styling and equipment. The engine uses a timing chain, a diesel particulate filter and EGR, so most of its known faults sit in the emissions hardware and the induction plumbing. It is generally regarded as a reliable, well-priced wagon that rewards careful maintenance.

Diesel particulate filter blockage (2.4L 4N15, 2015 to 2025)

The DPF needs sustained heat to burn off soot. A Pajero Sport used mostly for short, slow trips may not complete its regenerations, so the filter loads up, a warning light comes on and the engine can lose power. A highway run of about 20 minutes at least once a month helps. A dealer forced regeneration is usually a modest bill, but a filter that needs off-car cleaning or replacement is expensive, roughly $1,000 to $4,000 or more. Faulty DPF temperature sensors and split intercooler pipes can also trigger DPF faults.

EGR and inlet carbon build-up (2.4L 4N15, 2015 to 2025)

Like most modern diesels, the 4N15 recirculates exhaust gas into the intake. Mixed with oil vapour from the crankcase breather, the soot builds up in the inlet and EGR valve over time, causing rough running, smoke and warning lights. Industry commentary describes DPF and EGR complaints on this engine as about as common as on its rivals and largely sorted on later cars. Some owners fit a catch can, but check the warranty position first. An EGR valve and intake clean costs roughly $600 to $1,500.

Intercooler hose rubbing and splitting (2.4L 4N15, reported mainly 2016 to 2018)

Split or chafed intercooler hoses are among the most commonly reported Pajero Sport faults. On some cars the fan pulley rubs through the hose under boost, and in one case a motoring expert put this down to a supplier change and incorrect alignment marks. A failed hose causes a sudden loss of power, a whistle or a warning light. Some owners fit stronger aftermarket silicone hoses. A replacement hose is roughly a few hundred dollars fitted.

Valve clearances tightening (2.4L 4N15, 2015 to 2025)

The 4N15 needs its valve clearances checked and adjusted about every 60,000 km. The clearances tend to tighten rather than loosen, so the valves stop seating properly, and unlike a loose clearance there is no tapping noise to warn you. Skipping the adjustment can lead to poor running, hard starting and eventually burnt valves. The job takes several hours of labour, so the bill at the interval could run from several hundred dollars to over $1,000, and check that previous owners paid it.

Cracked cylinder head or head gasket (2.4L 4N15, 2015 to 2025)

A motoring expert has said cracked cylinder heads and failed head gaskets do occur on this engine, though how often is not known. One theory links some cracks to injectors that were over-tightened or forced out during earlier work. Warning signs are coolant loss with no visible leak, overheating, white smoke and a pressurised cooling system. Replacement heads are available, but it is a major job that usually runs to several thousand dollars.

Recalls and safety

Recall themes include cars fitted with a genuine Mitsubishi towbar, whose flange bolts could loosen so the towbar could detach (2015 to 2016 cars), a poorly coated tailgate spring end cap on 2016 models that could corrode and let the tailgate drop, and missing button battery warnings on some 2020 to 2022 remote keys. Ask a Mitsubishi dealer to check the VIN for open recalls, and see our recalls page.

Buying a used Mitsubishi Pajero Sport? What to check

• Driving pattern: Ask how the car was used, since a mostly short-trip city car is more likely to have DPF trouble, and look for any DPF warning on the dash.
• Intercooler hoses: Look at the intercooler hoses near the fan pulley for rub marks, oil and splits, and note whether silicone hoses have been fitted.
• Valve clearances: Check the service book shows a valve clearance adjustment about every 60,000 km.
• Coolant: Check the coolant is full and clean, watch the temperature gauge on the test drive and look for white smoke.
• Power and smoke: Accelerate hard from low revs and feel for flat spots, surging or limp mode, and watch for black smoke.
• Gearbox: The 8-speed auto should shift smoothly; if the car has towed, ask whether an extra transmission cooler was fitted.
• Park brake: Make sure the park brake releases fully and the car does not drag, since mud can make it stick and trigger a warning.
• Steering and underbody: Listen for creaks or knocks from the steering column, and check the bash plate mounts and underbody for off-road damage.
• Towbar: If a genuine towbar is fitted, confirm the bolt recall work has been done.

Run a PPSR check before you pay, and work through our Mitsubishi Pajero Sport buying checklist.

The verdict

A Pajero Sport from 2018 onwards gets the extra safety equipment, and any year is a good buy with a full logbook showing valve clearance adjustments and regular oil changes. Favour cars that have done plenty of highway driving, and check the intercooler hoses on 2016 to 2018 cars. Avoid cars with DPF warnings, coolant loss or patchy service history. For towing, budget for an extra transmission cooler if one is not already fitted.