🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero Sport

Year:

2004

Chassis Code:

K90 Series (specific variants may vary)

Engine Code Example:

4G64 (for gasoline variants), 4D56 (for diesel variants) - specific engine may depend on market and trim

👋 Introduction

Segment:

Mid-size SUV, body-on-frame construction, known for off-road capability and durability.

Competitors:

Jeep Cherokee (XJ/Liberty), Toyota 4Runner, Nissan Pathfinder, Ford Explorer, Chevrolet TrailBlazer.

Strengths:

Robust chassis, strong off-road credentials (Super Select II 4WD system on many models), reliable engine options, practical interior.

Target Audience:

Enthusiasts seeking an off-road capable vehicle, families needing a versatile SUV, those prioritizing durability and utility over luxury.

📋 Manual Details

Systems Covered:

Engine mechanical, fuel system, ignition system, cooling system, exhaust system, clutch, manual transmission, automatic transmission, transfer case, drive shafts, differentials, brakes, steering, suspension (front and rear), body electrical, HVAC, body panels, interior trim, diagnostic trouble codes (DTCs), troubleshooting, specifications.

Estimated Pages:

1500+

Type:

Factory Service Manual / Workshop Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Powertrain:

Comprehensive coverage of engine disassembly, assembly, diagnostics, and repair; transmission overhaul (manual and automatic); transfer case operation and servicing; drivetrain component maintenance.

Chassis And Body:

Detailed procedures for suspension repair, steering system maintenance, brake system servicing, and body panel repair/replacement.

Electrical And Diagnostics:

Extensive information on the vehicle's electrical system, including wiring diagrams, component testing, ECU diagnosis, and troubleshooting common electrical faults.

Routine Maintenance:

Oil changes, filter replacements, spark plug service, fluid checks and top-offs, belt inspection and replacement.

Major Repairs:

Engine rebuild, transmission overhaul, brake caliper replacement, suspension component renewal, radiator replacement.

Troubleshooting:

Systematic diagnostic procedures for identifying and resolving common and complex issues, including no-start conditions, performance problems, and electrical malfunctions.

Depth:

In-depth, covering everything from basic adjustments to complete component overhauls, suitable for professional mechanics and advanced DIY enthusiasts.

📊 Manual Specifications

File Type:

PDF

Searchable Text:

Likely, depending on the source scan quality. Crucial for efficient navigation.

Resolution:

High-resolution scans for clear diagrams and text.

Binding:

Not applicable (Digital PDF)

Paper:

Not applicable (Digital PDF)

⚙️ Engine Specifications

Gasoline Engine Option 1:

2.4L 4G64 SOHC I4 (16-valve)

Gasoline Engine Option 1 Power:

Approx. 133-145 hp @ 5500-5700 rpm (market dependent)

Gasoline Engine Option 1 Torque:

Approx. 190-210 Nm @ 2500-3000 rpm (market dependent)

Diesel Engine Option 1:

2.8L 4D56 DI-D DOHC I4 (16-valve) Turbocharged Common Rail Diesel

Diesel Engine Option 1 Power:

Approx. 128-160 hp @ 3500-4000 rpm (market dependent)

Diesel Engine Option 1 Torque:

Approx. 295-350 Nm @ 1800-2500 rpm (market dependent)

Fuel Type:

Unleaded gasoline (for 4G64), Diesel fuel (for 4D56)

Gasoline Injection:

Multi-point Fuel Injection (MPI)

Diesel Injection:

Common Rail Direct Injection (DI-D) with Turbocharger and Intercooler

Covered Engine Codes:

Manual includes detailed information for 4G64 and 4D56 engine variants specific to the 2004 Pajero Sport.

🔧 Transmission

Transmission Type Standard:

5-speed Manual Transmission (for most models/markets)

Transmission Type Optional:

4-speed Automatic Transmission (with Overdrive)

Transfer Case:

Super Select II 4WD system (on many models) offering 2H, 4H, 4HLC (4WD High Lock), and 4LLC (4WD Low Lock) modes.

Manual Transmission Fluid:

API GL-3 or GL-4, SAE 75W-90 or 80W-90 (check manual for specific viscosity recommendation)

Automatic Transmission Fluid:

DIA QUEEN ATF-SPII (or equivalent Dexron III/Mercon compatible fluid)

Manual Transmission Capacity:

Approx. 2.1-2.3 liters

Automatic Transmission Capacity:

Approx. 7.0-7.5 liters (dry fill)

📐 Dimensions

Overall Length:

Approx. 4,600 - 4,760 mm (varies by body style and bumper options)

Overall Width:

Approx. 1,775 - 1,815 mm

Overall Height:

Approx. 1,750 - 1,800 mm

Wheelbase:

Approx. 2,725 mm

Ground Clearance:

Approx. 200-215 mm

Curb Weight:

Approx. 1,800 - 2,000 kg (varies by engine, transmission, and trim)

Gross Vehicle Weight Rating:

Approx. 2,500 - 2,700 kg

Towing Capacity:

Typically around 1,500 - 2,500 kg (check local regulations and vehicle specific rating)

Bolt Pattern:

6 x 139.7 mm (6x5.5 inches)

Center Bore:

Approx. 93 mm

Wheel Size Standard:

16-inch alloy or steel wheels

Tire Size Standard:

265/70R16 or similar all-terrain tires

🛡️ Safety Features

NHTSA Crash Test Results:

Varies by market and specific testing year. Generally, body-on-frame SUVs of this era had moderate safety ratings.

ABS:

Standard on most variants.

Ebd:

Electronic Brakeforce Distribution (often integrated with ABS)

Traction Control:

Available on higher trims or specific markets.

Airbags:

Front airbags for driver and passenger standard. Side airbags available on some trims.

Seatbelts:

3-point ELR seatbelts with pretensioners and force limiters for front seats.

Child Seat Anchors:

ISOFIX or LATCH system provisions (market dependent).

💡 Technology Features

Audio System:

Factory-fitted AM/FM radio with CD player. Higher trims may include a cassette player or a multi-disc changer. Speaker configuration varies by trim.

Climate Control:

Manual air conditioning and heating system. Automatic climate control was less common in this generation.

Cruise Control:

Available on higher trim levels.

Auxiliary Input:

Not typically standard; aftermarket solutions may be required for modern device connectivity.

🔧 Maintenance

Engine Oil Change Interval:

Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first (depending on driving conditions).

Engine Oil Filter Replacement:

Replace with every oil change.

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 plug type (standard vs. iridium).

Fuel Filter Replacement Diesel:

Every 20,000-40,000 miles (32,000-64,000 km).

Timing Belt Replacement Gasoline 4G64:

Every 60,000 miles (96,000 km) or 4 years. This is a critical maintenance item.

Timing Chain Diesel 4D56:

Diesel 4D56 uses a timing chain, which typically requires less frequent maintenance or replacement compared to a belt.

Engine Oil Specification:

API SG/SH/SJ/SL, SAE 10W-30 or 10W-40 (check manual for specific viscosity and API rating for engine variant).

Coolant:

Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Mitsubishi Dia Queen Super Long Life Coolant is recommended.

Engine Oil Capacity 4G64:

Approx. 4.3-4.5 liters (with filter)

Engine Oil Capacity 4D56:

Approx. 7.0-7.5 liters (with filter)

Coolant Capacity:

Approx. 7.0-8.0 liters

Common Wear Items:

Ball joints, tie rod ends, sway bar links (due to off-road use and vehicle weight), exhaust system components, and clutch wear (on manual transmissions).

Diesel Specific Issues:

Potential for injector issues or turbocharger problems on higher mileage 4D56 engines if not properly maintained.

Electrical Gremlins:

While generally robust, some older vehicles may experience minor electrical issues, particularly with window regulators or central locking systems.

Torque Converter Lockup Strategy:

The manual details the operation and diagnostics of the automatic transmission's torque converter lockup clutch.

📚 Vehicle History

Mitsubishi 4X4 Legacy:

Mitsubishi has a long and storied history in off-road vehicles, dating back to the original Pajero (Montero/Shogun) launched in 1982. The Pajero Sport (also known as Montero Sport or Pajero Dakar in some markets) is a derivative based on the Pajero's robust chassis.

First Generation:

The Pajero Sport (first generation, KH) was introduced in 1996. The 2004 model represents a mid-cycle refresh or the later part of the first generation, depending on market introduction timelines.

Second Generation Introduction:

The second generation Pajero Sport (KG) was launched in 2008, significantly redesigning the exterior and introducing new technologies.

Manufacturing Locations:

Primarily manufactured in Japan (Okazaki Plant) and through CKD (Completely Knocked Down) kits in various other countries, including Thailand, Brazil, and the Philippines.

🏆 Awards & Recognition

Off Road Capability Recognition:

The Pajero Sport nameplate, derived from the highly regarded Pajero, is consistently recognized for its strong off-road performance and durability in reviews and owner feedback.

Consumer Satisfaction:

Generally receives positive ratings for reliability and value, particularly for its off-road prowess, though can be average in some on-road comfort metrics compared to unibody SUVs.