🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero (Montero) & Pajero Sport

Model Year:

2004

Chassis Codes:

V63, V65, V68, V73, V75, V77, V78 (Pajero/Montero); K86, K96, K89, K99 (Pajero Sport)

Engine Codes:

6G72 (3.0L V6 SOHC/DOHC), 6G74 (3.5L V6 SOHC/DOHC), 6G75 (3.8L V6 SOHC MIVEC), 4M40 (2.8L L4 Turbo-Diesel), 4M41 (3.2L L4 Di-D Turbo-Diesel)

👋 Introduction

Segment:

Body-on-frame SUV (Pajero/Montero) and rugged, capable SUV (Pajero Sport), known for off-road prowess and durability

Competitors:

Toyota Land Cruiser Prado, Nissan Patrol, Ford Explorer, Jeep Grand Cherokee, Land Rover Discovery

Powertrain Options:

Wide range of capable V6 gasoline engines and robust diesel options, paired with advanced 4WD systems

Off Road Capability:

Renowned for its off-road performance, often featuring sophisticated 4WD systems like Mitsubishi's Super Select

Durability:

Built with robust construction, making them reliable workhorses and capable adventure vehicles

📋 Manual Details

Covered Models:

All Pajero (Montero) and Pajero Sport variants for the 2004 model year

Global Regions:

Includes specifications and procedures relevant to North American (Montero), European, Australian, and Asian market configurations

Estimated Page Count:

Estimated 3000+ pages (based on typical comprehensive workshop manuals of this era and size specification)

Type:

Workshop Repair Service Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Powertrain:

Engine mechanical, fuel injection, ignition, cooling, lubrication, exhaust, emissions control, turbocharger systems (if applicable)

Drivetrain:

Manual and Automatic Transmissions (including Super Select 4WD II system), Transfer Case, Drive Axles, CV Joints, Differentials (front, rear, center, locking differentials if equipped)

Chassis:

Suspension (front independent, rear independent/solid axle depending on variant), Steering system, Brake system (ABS, EBD, Brake booster, calipers, rotors, lines)

Electrical:

12V Battery system, Charging system (alternator), Starting system, Lighting (headlights, taillights, interior), Fuses and Relays, Instrument Panel, Powertrain Control Module (PCM), Body Control Module (BCM), SRS Airbag system, Power windows, locks, mirrors, seats, audio systems, HVAC controls

Body And Frame:

Body panel removal/installation, Doors, Hood, Tailgate, Bumpers, Glass, Interior trim, Underbody coatings, Chassis frame repair (if applicable for body-on-frame variants)

Maintenance:

Oil changes, filter replacements, coolant flushes, spark plug replacement, air filter replacement, belt inspection and replacement, brake fluid flush, differential fluid changes

Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, electrical circuit testing, component diagnosis

Repair:

Engine overhaul, transmission overhaul, differential rebuild, suspension component replacement, brake caliper/master cylinder replacement, steering rack replacement, electrical component repair/replacement

Installation:

Component installation and adjustment, torque specifications for all fasteners, alignment procedures

Depth:

Comprehensive rebuild procedures, detailed diagnostic flowcharts, wiring diagrams, exploded views of components, torque specifications, special tool requirements, clear step-by-step instructions

📊 Manual Specifications

Format:

PDF

Searchability:

Optimized for searchable text content, allowing quick navigation to specific topics

Resolution:

High-resolution scans ensuring clear readability of text and diagrams

Printability:

Printable pages for hard copy reference in a workshop environment

Binding:

N/A (Digital PDF format)

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Options 2004:

3.0L V6 (6G72), 3.5L V6 (6G74), 3.8L V6 (6G75 MIVEC), 2.8L Turbo-Diesel (4M40), 3.2L Di-D Turbo-Diesel (4M41)

3.0L V6 (6G72) Output:

Approx. 175-190 hp, 180-200 lb-ft torque (varies by market and spec)

3.5L V6 (6G74) Output:

Approx. 200-215 hp, 220-230 lb-ft torque (varies by market and spec)

3.8L V6 (6G75 Mivec) Output:

Approx. 215-235 hp, 250-260 lb-ft torque (varies by market and spec)

3.2L Di-D Turbo-Diesel (4M41) Output:

Approx. 160-175 hp, 280-300 lb-ft torque (varies by market and spec)

Injection Type:

Electronic Fuel Injection (MPI or GDI for later models, but likely MPI for 2004)

Fuel Type:

Unleaded Gasoline (Octane 87-91), Diesel

🔧 Transmission

Transmission Options:

4-speed Automatic, 5-speed Manual

Transmission Options:

Some high-end models or specific markets may have had 5-speed automatic transmissions available.

4Wd System:

Super Select 4WD II (allows on-the-fly shifting between 2WD, 4WD High, 4WD High with locked center differential, and 4WD Low, and often includes a locking rear differential as an option).

Transfer Case:

Integrated with 4WD system, providing different modes and gear reduction (low range)

📐 Dimensions

Wheelbase:

Approx. 2780mm (Pajero/Montero Long Wheelbase), 2500mm (Pajero/Montero Short Wheelbase - less common globally for 2004), 2725mm (Pajero Sport)

Length:

Approx. 4600-4800mm (LWB Pajero/Montero), 4060mm (SWB Pajero/Montero), 4610mm (Pajero Sport)

Width:

Approx. 1845-1875mm

Height:

Approx. 1865-1925mm

Curb Weight:

Approx. 1800-2200 kg (varies significantly by engine and trim)

Gross Vehicle Weight Rating:

Typically around 2500-2800 kg

Cargo Volume:

Highly variable depending on 5-door vs. 3-door configuration and seating arrangement. Typically substantial, exceeding 1000 liters with rear seats folded.

🛡️ Safety Features

NHTSA Ratings:

Varies by market and specific test year. Often good frontal and side impact ratings for its class and era, though rollover resistance was a common concern for SUVs of this type.

Active Safety:

Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), Traction Control System (TCS - sometimes optional/standard on higher trims), Active Stability Control (ASC - often optional/standard on higher trims)

Passive Safety:

Front airbags (driver and passenger), Side airbags (optional on some trims), Seatbelt pretensioners, Reinforced body structure

💡 Technology Features

Audio System:

Factory AM/FM/CD player, optional premium audio systems with more speakers and amplifiers. Some higher trims might have early navigation systems (less common).

Assistance Features:

Cruise control, parking sensors (less common on base models), ABS, EBD, optional TCS/ASC.

Connectivity Options:

Limited connectivity for the era. Primarily basic audio inputs. No Bluetooth or USB natively.

🔧 Maintenance

Oil Change Interval:

Typically 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions (severe vs. normal).

Transmission Fluid Change Interval:

Automatic: 30,000-60,000 miles (48,000-96,000 km) or every 2-3 years. Manual: 30,000-50,000 miles (48,000-80,000 km).

Coolant Replacement Interval:

Initial flush at 60,000 miles (96,000 km), then every 30,000 miles (48,000 km) or 2 years thereafter.

Engine Oil:

API Service SG, SH, or SJ classification; Viscosity SAE 5W-30, 10W-30, or 10W-40 depending on climate. Check manual for specific recommendations.

Automatic Transmission Fluid:

Dexron III or equivalent (e.g., ATF SP-II M or equivalent)

Manual Transmission Fluid:

API GL-4 or GL-5, SAE 75W-90 gear oil

Transfer Case Fluid:

API GL-4 or GL-5, SAE 75W-90 gear oil

Differential Fluid:

API GL-5, SAE 80W-90 gear oil (consider synthetic for heavy use or limited-slip differentials)

Coolant:

Ethylene glycol based coolant, 50/50 mix with distilled water (typically green or long-life pink/red coolant compatible with Japanese vehicles)

Common Problems:

Radiator leaks (especially with older plastic tanks), transmission solenoid failures (automatic), front differential bearing noise, transfer case actuator issues (Super Select system), potential for exhaust manifold cracks on V6 engines, rear main crankshaft seal leaks, interior trim rattles, power window regulator failures.

Maintenance Tips:

Regularly inspect coolant hoses and radiator, service the automatic transmission at recommended intervals, check and lubricate transfer case and differential breathers, ensure proper functioning of 4WD system components.

📚 Vehicle History

Mitsubishi SUV Legacy:

Mitsubishi has a long and storied history with off-road vehicles, dating back to the original Pajero (launched in 1982) which established its reputation for ruggedness and capability.

Pajero Generation 2004:

This 2004 model represents the third generation (1999-2006) of the Pajero/Montero, which transitioned to a unibody construction (monocoque) for improved on-road handling and refinement compared to its predecessors, while retaining excellent off-road capability.

Pajero Sport Evolution:

The Pajero Sport (also known as Montero Sport in North America for earlier generations, and Mitsubishi Challenger in Australia) is a more utilitarian, body-on-frame SUV based on the Pajero's chassis, offering robust construction and strong off-road credentials.

Manufacturing Locations:

Primarily Japan, with significant assembly operations in other countries like Brazil, Thailand, and Egypt.

🏆 Awards & Recognition

Off Road Awards:

The Pajero/Montero platform has a strong track record in off-road racing, including multiple wins in the Dakar Rally, contributing to its image as a highly capable and durable vehicle.

Consumer Ratings:

Generally well-regarded for reliability and off-road capability by consumer organizations and owners. Maintenance can be more involved for some systems.