🏷️ Basic Information

Make:

Mitsubishi

Model:

Shogun Sport

Year:

2004

Common Name:

Montero Sport (North America), Pajero Sport (other markets)

Vehicle Type:

Body-on-frame SUV

Generation Name:

Second Generation (K90 Series)

Chassis Code:

K90 series

👋 Introduction

Positioning:

A capable and rugged SUV, positioned as a durable and off-road oriented vehicle.

Competitors:

Toyota 4Runner, Nissan Pathfinder, Ford Explorer, Jeep Grand Cherokee (in relevant markets)

Features:

Body-on-frame construction, capable 4WD system (Super Select 4WD likely), robust engine options, spacious interior.

Value:

Provides owners and independent mechanics with factory-level diagnostic and repair information, enabling significant cost savings on labor.

📋 Manual Details

Markets Covered:

Global (with specific regional variations likely)

Estimated Pages:

Hundreds (Specific count not provided, but implied to be extensive)

Type:

Factory Service Repair Manual

Manual Origin:

Official Factory Manual (OEM)

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Service, Repair, Troubleshooting, Engine Control System, Fuel Injection/Fuel System, Cooling System, Emission System, Periodic Lubrication

Drivetrain:

Transmission Service/Repair, Differential/Drive, Axle

Chassis:

Brake System, Suspension, Steering, Chassis/Body

Electrical:

Wiring Diagram, Electrical System

Comfort And Convenience:

Heater/Air Conditioner, Interior

Safety Systems:

Restraint System

Interior Systems:

Interior trim removal and installation, seating systems, dashboard components, climate control systems (heater core, A/C compressor, blower motor), door mechanisms, and upholstery.

Body And Chassis:

Body panel removal and installation, chassis frame inspection and repair, suspension mounting points, exhaust system, fuel tank, bumpers, doors, hood, tailgate, and glass.

Fuel System:

Fuel pump operation, fuel injectors, fuel filter replacement, fuel tank removal, fuel pressure testing, and emission control systems (e.g., EVAP).

Exhaust System:

Catalytic converter inspection and replacement, muffler and pipe maintenance, exhaust manifold service, and O2 sensor replacement.

Maintenance:

General Maintenance, Periodic Lubrication

Troubleshooting:

Advanced Troubleshooting Guide

Repair:

Step-by-step repair procedures for all covered systems, Rebuild, Refurbish, Restore

Diagnostic Procedures:

Systematic diagnostic routines for engine, transmission, braking, electrical, and HVAC systems. Troubleshooting charts and flow diagrams are included.

Technical Specifications Inclusion:

Torque specifications for all critical fasteners, engine timing data, valve clearances, fluid capacities, tire pressures, and electrical component resistance values.

Wheel Alignment:

Specifications for camber, caster, and toe angles; procedures for adjustment and inspection.

Wheel Bearing Service:

Procedures for front and rear wheel bearing inspection, repacking, and replacement.

Brake Pad Replacement:

Step-by-step instructions for replacing front and rear brake pads and rotors, caliper service, and brake fluid bleeding.

Depth:

Comprehensive, factory-level detail, suitable for professional technicians and owners

Diagrams And Illustrations:

Extensive use of detailed diagrams, exploded views, and photographs to visually guide users through complex procedures.

📊 Manual Specifications

Format:

PDF

Compatibility:

Windows and Mac OS

Reader Requirement:

Adobe PDF Reader

Printability:

Fully printable, no restrictions

Resolution:

High Resolution

Binding:

Digital Download (Printable at user's discretion)

Paper Type:

N/A (Digital)

Delivery Method:

Instant Download Link Post-Payment

⚙️ Engine Specifications

Engine Options:

Likely candidates include the 3.0L 4D56 DOHC I4 Diesel, 3.5L 6G74 SOHC V6 Petrol, and potentially the 3.2L 4M41 DOHC DI I4 Diesel. (Specific engine details depend on market and trim.)

Power Output Range:

Varies by engine: Diesel engines typically 118-165 HP; Petrol V6 engines typically 170-200 HP.

Torque Output Range:

Varies by engine: Diesel engines typically 220-295 lb-ft; Petrol V6 engines typically 225-270 lb-ft.

Fuel Delivery:

MPI (Multi-Point Injection) for petrol engines, Common Rail Direct Injection (CRDI) for later diesel variants, or mechanically controlled injection for earlier diesel models.

Coolant Type:

Likely requires an ethylene glycol-based coolant (e.g., Long Life Coolant - LLC) with a 50/50 mix with distilled water. Specific Mitsubishi specification (e.g., MZ313952 or equivalent) should be confirmed in manual.

Displacement Options:

Common displacements include 2.5L (4D56 Diesel), 3.0L (6G72 V6 Petrol), 3.2L (4M41 Diesel), and 3.5L (6G74 V6 Petrol).

🔧 Transmission

Transmission Type:

Likely a 5-speed manual or 4-speed automatic transmission.

Transmission Options:

Higher trims or specific markets may have offered a 5-speed automatic transmission.

Drivetrain System:

Likely equipped with Mitsubishi's 'Super Select 4WD' system offering various modes including 2H, 4H, 4HLC (with locked center diff), and 4LLC (with locked center diff and low range gearing).

Automatic Transmission Fluid:

Likely requires Dexron III or a compatible synthetic fluid. Specific Mitsubishi part number or equivalent should be verified.

Manual Transmission Fluid:

Likely requires a GL-4 or GL-5 hypoid gear oil. Viscosity grade (e.g., 75W-90) will be specified. Specific Mitsubishi specification should be confirmed.

📐 Dimensions

Overall Length:

Approximately 4,655 mm (183.3 in) for long-wheelbase models.

Overall Width:

Approximately 1,775 mm (69.9 in).

Overall Height:

Approximately 1,705 mm (67.1 in) without roof rails.

Curb Weight:

Varies significantly by engine and configuration, typically ranging from 1,850 kg to 2,100 kg (4,079 lbs to 4,630 lbs).

Towing Capacity:

Typically rated around 2,500 kg (5,500 lbs) braked towing capacity, but always verify with local regulations and specific vehicle documentation.

🛡️ Safety Features

Crash Test Ratings:

Varies by market and testing agency. Early models might have lower ratings compared to modern vehicles. Specific NHTSA or Euro NCAP results for the 2004 model year should be researched.

Active Safety:

Anti-lock Braking System (ABS), Electronic Brakeforce Distribution (EBD), potentially Brake Assist (BA).

Passive Safety:

Front airbags, potentially side airbags (market dependent), seatbelt pre-tensioners, reinforced body structure.

💡 Technology Features

Infotainment Features:

Basic infotainment systems for this era typically include an AM/FM radio, CD player, and possibly cassette player. Speaker configuration would be standard (e.g., 4-6 speakers).

Driver Assistance Features:

Limited driver assistance features for this model year. Primarily focused on core mechanical and safety systems.

Connectivity Options:

No advanced connectivity features like Bluetooth or USB ports would be standard. Auxiliary inputs for audio might be present on higher trims.

🔧 Maintenance

Oil Change Interval:

Typically 5,000-7,500 miles (8,000-12,000 km) or 6-12 months for conventional oil, potentially longer for synthetic oil. Refer to manual for specific recommendations based on driving conditions.

Timing Belt Replacement:

For petrol engines, timing belt replacement is critical. Interval typically around 60,000-90,000 miles (96,000-144,000 km). Diesel engines may use a timing chain or belt; check manual.

Transmission Fluid Change:

Automatic transmission fluid typically every 30,000-60,000 miles (48,000-96,000 km) or as specified by severe service conditions. Manual transmission fluid check and potential change at similar intervals.

Engine Oil Type:

Varies by engine. Petrol engines likely require API SN/SP, ILSAC GF-5/GF-6 certified oil, typically 5W-30 or 10W-30. Diesel engines may require API CJ-4 or CK-4 rated oil. Specific viscosity grade and API service category are crucial.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid. Use of the correct specification is essential for brake system performance and longevity.

Power Steering Fluid:

Likely requires ATF Dexron III or a specific Mitsubishi power steering fluid. Refer to manual for correct type.

Coolant Capacity:

Capacity varies by engine, typically around 8-10 liters (approx. 8.5-10.5 quarts) when using a 50/50 mix. Specific quantity in manual.

Common Problems:

Potential for rust on body and frame (especially in areas with salt exposure), issues with the Super Select 4WD system engagement, occasional transmission solenoid problems, and diesel engine glow plug or injection system issues.

Oil Filter:

Part numbers vary by engine and manufacturer. Common aftermarket equivalents include Fram PH16, Bosch 3422, or K&N HP-3001. Consult manual for OEM part number (e.g., MD344818 for some models).

📚 Vehicle History

Heritage:

Mitsubishi has a long history of producing robust 4x4 vehicles, with iconic models like the Pajero (Montero/Shogun) and the L200 (Triton) pickup truck, which the Shogun Sport is closely related to.

Evolution Overview:

The Shogun Sport (Montero Sport/Pajero Sport) is a mid-size SUV based on the chassis of Mitsubishi's pickup truck line. The second generation (K90) was produced from 2000 to 2008, featuring updated styling, more powerful engines, and improved safety features over the first generation.

Production Plants:

Primarily manufactured in Japan, with potential assembly in other global locations depending on the market.

🏆 Awards & Recognition

Awards Received:

Specific awards for the 2004 Shogun Sport are not widely publicized. The model's strength lay in its utility and off-road capability rather than luxury or performance accolades.