🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero Sport

Year:

2004

Chassis Code:

K90 Series (for specific regional variations, e.g., K96W, K97W, K99W)

Engine Code Primary:

4G64 (2.4L SOHC MPI)

Engine Code Optional Diesel:

4D56 (2.5L SOHC Turbocharged Diesel Intercooled - Common in some markets)

Transmission Code Automatic:

V5A51 (5-speed Automatic)

Transmission Code Manual:

R5M21 or W5M33 (5-speed Manual - depending on engine/drivetrain)

👋 Introduction

Segment:

Compact to mid-size SUV, body-on-frame construction, known for ruggedness and off-road capability. Positioned as a more utilitarian and affordable alternative to larger SUVs and more refined unibody crossovers.

Key Competitors 2004:

Toyota 4Runner, Nissan Pathfinder, Ford Explorer, Jeep Cherokee/Grand Cherokee, Isuzu Rodeo/Axiom, Chevrolet TrailBlazer.

Off Road Capability:

Body-on-frame chassis, robust 4WD system (often with selectable modes or full-time 4WD options), good ground clearance, capable of tackling challenging terrain.

Durability:

Known for its robust construction and reliable mechanicals, making it a popular choice for families and off-road enthusiasts who value longevity.

Value Proposition:

Offered a strong combination of SUV utility, off-road prowess, and affordability compared to some key competitors at the time.

📋 Manual Details

Primary Regions Covered:

Global markets, with emphasis on regions where the Pajero Sport (often badged as Montero Sport outside Japan) was sold, including North America, Europe, Asia, Australia, and South America. Specific regional variations in specifications and equipment may be detailed.

Estimated Page Count:

Over 1000 pages (typical for a complete factory workshop manual)

Type:

Workshop Service and Repair Manual

Language:

English (primary), with potential for translated sections or regional variants in other languages.

Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Engine assembly, disassembly, cylinder head, block, crankshaft, pistons, connecting rods, lubrication system, cooling system, intake and exhaust systems, timing belt/chain, fuel injection system.

Engine Electrical:

Ignition system, starting system, charging system, engine control module (ECM) diagnostics, sensors, actuators, wiring diagrams.

Transmission:

Manual and automatic transmission operation, overhaul, removal/installation, clutch system, torque converter, transmission control module (TCM) diagnostics, shift linkage.

Drivetrain:

Four-wheel drive (4WD) system, transfer case, front and rear differentials, driveshafts, CV joints, propeller shafts, hub locking mechanisms (manual/automatic).

Suspension:

Front and rear suspension components (independent front, multi-link rear), shock absorbers, springs, control arms, bushings, sway bars, wheel alignment specifications.

Steering:

Power steering system, steering gear, steering column, tie rods, steering linkage, steering wheel removal/installation.

Brakes:

Front and rear brake systems (disc/drum configurations), hydraulic system, brake lines, master cylinder, brake calipers, wheel cylinders, parking brake, ABS system (if equipped), brake fluid specifications.

Body And Chassis:

Body construction, panel removal/installation, door mechanisms, glass, seals, interior trim, exterior trim, frame diagnostics, rust prevention.

Electrical System:

Battery, charging system, starting system, lighting (headlights, taillights, interior), horn, wipers, washers, power windows, power locks, mirrors, fuses, relays, body control module (BCM).

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant charging, component testing, blower motor, heater core, A/C compressor, condenser.

Safety Systems:

Airbag system (SRS) component location, diagnosis, and replacement procedures, seat belt mechanisms.

Maintenance:

Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt tensioning, tire rotation, brake inspection.

Diagnostics:

Troubleshooting charts, symptom-based diagnostics, diagnostic trouble codes (DTCs), circuit testing, component testing, engine performance analysis.

Repair:

Step-by-step repair procedures for all major mechanical and electrical components, including engine overhaul, transmission rebuilds, brake caliper replacement, suspension component repair, body panel replacement.

Installation:

Procedures for installing replacement parts and components, ensuring correct fitment and function.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all vehicle systems, aiding in troubleshooting and repair of electrical faults.

Specifications:

Detailed technical specifications, torque values, clearances, fluid types and capacities, diagnostic parameters.

Depth:

Comprehensive: Covers everything from routine maintenance and basic adjustments to complete engine and transmission overhauls, complex electrical diagnostics, and bodywork.

📊 Manual Specifications

Format:

PDF

Searchability:

Likely text-searchable PDF for efficient information retrieval.

Quality:

High-resolution scans of original factory documentation, ensuring clarity of text and diagrams.

Binding:

N/A (Digital PDF format)

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Displacement:

2.4 Liters (2351 cc)

Engine Configuration:

Inline-4 (Inline-Four Cylinder)

Engine Valvetrain:

SOHC (Single Overhead Camshaft), 16 Valves

Engine Aspiration:

Naturally Aspirated

Horsepower Approximate:

133-143 hp @ 5000-5500 rpm (varies by market and specific calibration)

Torque Approximate:

165-177 lb-ft @ 3500-4000 rpm (varies by market and specific calibration)

Engine Displacement Diesel:

2.5 Liters (2477 cc)

Engine Configuration Diesel:

Inline-4 (Inline-Four Cylinder)

Engine Valvetrain Diesel:

SOHC (Single Overhead Camshaft), 8 Valves

Engine Aspiration Diesel:

Turbocharged, Intercooled

Horsepower Approximate Diesel:

105-115 hp @ 4000-4200 rpm (varies by market)

Torque Approximate Diesel:

170-190 lb-ft @ 2000-2500 rpm (varies by market)

Fuel Type:

Unleaded Gasoline (for 4G64), Diesel Fuel (for 4D56)

Fuel Delivery Gasoline:

Multi-Point Fuel Injection (MPI)

Fuel Delivery Diesel:

Indirect Injection (IDI) with Turbocharger (typical for this era 4D56)

Cooling Type:

Liquid-Cooled

Oil Capacity Gasoline:

Approx. 4.5 - 5.0 Liters (4.7 - 5.3 US Quarts) with filter (verify specific engine variant)

Oil Specification Gasoline:

API SG/SH/SJ or higher, SAE 10W-30 or 10W-40 recommended (refer to manual for exact specification based on climate)

🔧 Transmission

Type:

5-Speed Manual Transmission (e.g., W5M33 or similar)

Type:

5-Speed Automatic Transmission (e.g., V5A51)

Drivetrain Options:

Rear-Wheel Drive (RWD), Part-time Four-Wheel Drive (4WD), available Full-time Four-Wheel Drive (4WD) with center differential (market dependent).

Transfer Case Type:

Two-speed transfer case with high and low range gearing for enhanced off-road capability.

Automatic Transmission Fluid Capacity:

Approx. 8.0 - 9.0 Liters (8.5 - 9.5 US Quarts) for refill after overhaul (refer to manual for drain/fill capacity)

Automatic Transmission Fluid Type:

Mitsubishi Diamond ATF SP-II M, SP-III, or equivalent DEXRON III/MERCON compatible fluid (verify with manual)

Manual Transmission Fluid Capacity:

Approx. 2.5 - 3.0 Liters (2.6 - 3.2 US Quarts) (verify specific transmission model)

Manual Transmission Fluid Type:

GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90 (verify specific transmission model and ambient temperature)

📐 Dimensions

Length Approximate:

4620 mm (181.9 inches)

Width Approximate:

1775 mm (69.9 inches)

Height Approximate:

1800 mm (70.9 inches)

Wheelbase Approximate:

2725 mm (107.3 inches)

Ground Clearance Approximate:

200-215 mm (7.9-8.5 inches) (varies with tire size and suspension)

Curb Weight Approximate Gasoline:

1800 - 1950 kg (3968 - 4300 lbs) (varies by trim, drivetrain, and equipment)

Gross Vehicle Weight Rating Gvwr Approximate:

2400 - 2500 kg (5291 - 5511 lbs) (verify specific model)

Cargo Volume Approximate Behind Rear Seat:

Varies significantly by configuration (often 2-row or 3-row seating), but generally generous for its class. Specific figures require manual consultation.

Towing Capacity Approximate:

Up to 2500 kg (5511 lbs) for braked trailers (verify local regulations and specific vehicle configuration)

🛡️ Safety Features

Crash Test Ratings General:

Vehicle safety ratings from this era vary by testing organization and region. Referencing specific Euro NCAP or NHTSA results for the 2004 model year is recommended. Generally considered a robust vehicle due to its chassis construction.

ABS:

Anti-lock Braking System (ABS) available on certain trims and markets.

Traction Control:

Traction Control System (TCS) may be available on higher trims.

Airbags:

Driver and front passenger airbags standard. Side airbags available on some models/trims.

Seat Belts:

Three-point seat belts with pretensioners for front occupants. Three-point or lap belts for rear occupants.

💡 Technology Features

Audio System:

Typically features an AM/FM radio with CD player. Higher trims might offer an upgraded sound system with more speakers.

Navigation:

Aftermarket navigation systems were common. Factory navigation was rare or not widely available for this model year.

Cruise Control:

Available on most trims, typically electronically controlled.

Auxiliary Inputs:

Standard for the era would not typically include USB or Bluetooth. Aftermarket head unit upgrades are common for this.

🔧 Maintenance

Oil And Filter Change:

Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first. (Refer to manual for exact mileage/time based on driving conditions).

Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or annually.

Spark Plug Replacement Gasoline:

Every 30,000-60,000 miles (48,000-96,000 km) depending on spark plug type (copper vs. platinum/iridium).

Timing Belt Replacement Gasoline 4G64:

Crucial! Typically every 60,000-90,000 miles (96,000-144,000 km) or 4-5 years. Failure can cause catastrophic engine damage.

Transmission Fluid Change Automatic:

Every 30,000-60,000 miles (48,000-96,000 km), especially under severe use.

Transmission Fluid Change Manual:

Every 40,000-80,000 miles (64,000-128,000 km).

Coolant Type:

Ethylene Glycol based coolant, typically a green or pink type. Mitsubishi Genuine Long Life Coolant or equivalent. Capacity around 8-9 Liters.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid (verify with manual). Check and top off as needed, flush every 2-3 years.

Power Steering Fluid Type:

ATF Dexron II/III or specific power steering fluid. Refer to manual for correct type.

Engine 4G64:

Occasional head gasket issues at higher mileage, potential for oil leaks from valve cover or oil pan gaskets, intake manifold gasket leaks can cause vacuum/idle issues.

Diesel 4D56:

Can be prone to injector issues, turbocharger wear, and glow plug failures. Requires diligent maintenance of fuel system and filters.

Drivetrain 4Wd:

Wear in transfer case bushings or chain, front differential seals, and CV joint boots can be issues, especially with off-road use. Manual hub lock mechanisms can seize if not exercised.

Suspension:

Front ball joints and tie rod ends can wear, leading to steering looseness and tire wear. Rear trailing arm bushings can degrade.

Transmission Automatic:

Valve body issues or solenoid failures can cause shifting problems. Torque converter issues at higher mileage.

📚 Vehicle History

Mitsubishi SUV Legacy:

Mitsubishi has a long and distinguished history in SUVs, notably with the Pajero (Montero) line, known for its off-road prowess and durability since the 1980s. The Pajero Sport (Montero Sport) is an extension of this lineage, often built on a similar chassis but with a more compact and sport-oriented focus.

Generation:

This 2004 model falls within the first generation of the Pajero Sport (MS) that began production in 1996. It received styling updates and mechanical refinements over its lifespan.

Manufacturing Locations:

Primarily manufactured in Japan (at the Nagoya Plant) and also produced in other facilities globally for various markets (e.g., Brazil, Thailand).

🏆 Awards & Recognition

Off Road Awards:

While not typically winning 'Car of the Year' awards in the traditional sense, the Pajero Sport and its Pajero lineage have consistently received praise and accolades from off-road publications and enthusiasts for their capability and durability.