🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero Sport

Year:

2004

Chassis Code:

K90 Series (primarily K94W, K96W)

Engine Codes Commonly Covered:

4D56 (2.5L Diesel), 6G72 (3.0L V6 Petrol), 6G74 (3.5L V6 Petrol)

👋 Introduction

Segment:

Mid-size SUV / Sport Utility Truck (often based on the Triton/L200 platform)

Target Audience:

Buyers seeking a rugged, capable, and versatile vehicle for off-road adventures, towing, and general utility.

Key Competitors 2004:

Toyota 4Runner, Nissan Pathfinder, Ford Explorer, Jeep Grand Cherokee, Isuzu Trooper.

Off Road Capability:

Robust body-on-frame construction, available Super Select 4WD II system, good ground clearance, robust suspension.

Powertrain Options:

Choice of efficient diesel and powerful V6 gasoline engines.

Versatility:

Practical for family use, cargo hauling, and towing.

📋 Manual Details

Geographic Coverage:

Global (specifics may vary by region, but manual aims for comprehensive coverage)

Model Variants Covered:

All engine variants, trim levels, and configurations for the 2004 model year

Estimated Page Count:

1500+

Type:

Workshop Repair Service Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Powertrain:

Engine mechanical (including disassembly, assembly, inspection, repair for 4D56, 6G72, 6G74), Engine lubrication, Cooling system, Fuel system (injection, ignition, emissions), Exhaust system, Turbocharger system (if applicable)

Drivetrain:

Transmission (manual and automatic), Transfer case, Driveshafts, Differentials (front and rear), Axles, Wheel bearings

Chassis:

Suspension (front and rear), Steering system, Brakes (hydraulic, ABS, parking brake), Wheels and tires

Electrical:

Battery, Charging system, Starting system, Ignition system, Lighting system, Instrumentation, Audio system, Power accessories (windows, locks, mirrors), Air conditioning system, Body control modules, ECU/ECM diagnostic procedures

Body:

Body structure, Exterior panels, Doors, Hood, Tailgate, Glass, Interior trim, Seats, Bumpers, Body sealing

Maintenance:

Scheduled maintenance, Oil changes, Filter replacements, Fluid checks and top-ups, Spark plug replacement, Belt inspection and replacement, Brake pad/shoe replacement, Tire rotation

Diagnostics:

Troubleshooting guides, Symptom-based diagnostics, DTC (Diagnostic Trouble Code) interpretation, On-board diagnostics (OBD-II) procedures, Component testing

Repair:

Component removal and installation, Major component overhaul (engine, transmission), Suspension component replacement, Brake system repair, Electrical component repair, Body panel repair and alignment, HVAC system service

Specifications:

Torque specifications for all fasteners, Tightening sequences, Clearances and tolerances, Fluid capacities and types, Electrical system schematics, Diagnostic data

Depth:

Comprehensive, covering from basic maintenance tasks to in-depth mechanical repairs and advanced electrical diagnostics. Suitable for professional mechanics and advanced DIY enthusiasts.

📊 Manual Specifications

Format:

PDF

Searchability:

Text-searchable, allowing for quick location of specific information

Quality:

High-resolution scans, ensuring clarity of diagrams, schematics, and text

Type:

N/A (Digital PDF download)

Type:

N/A (Digital PDF download)

⚙️ Engine Specifications

Engine Code:

4D56

Type:

2.5L Inline-4 Turbocharged Diesel

Displacement:

2477 cc

Horsepower Approx:

114 - 135 hp (depending on market/tuning)

Torque Approx:

240 - 280 Nm (depending on market/tuning)

Engine Code:

6G72

Type:

3.0L V6 SOHC Petrol

Displacement:

2972 cc

Horsepower Approx:

175 - 185 hp

Torque Approx:

250 - 265 Nm

Engine Code:

6G74

Type:

3.5L V6 SOHC/DOHC Petrol

Displacement:

3497 cc

Horsepower Approx:

190 - 230 hp (depending on DOHC vs SOHC and market)

Torque Approx:

300 - 340 Nm (depending on DOHC vs SOHC and market)

Diesel:

Direct Injection, Turbocharged (Common Rail on later variants/markets, but likely mechanical injection for 2004)

Petrol:

Electronic Fuel Injection (EFI)

🔧 Transmission

Type:

5-speed Manual Transmission (common with diesel, optional with petrol)

Type:

4-speed Automatic Transmission (common with petrol V6 engines)

4Wd System:

Super Select 4WD II (selectable 2H, 4H, 4HLC, 4LLC) with locking center differential on some models.

📐 Dimensions

Length Approx:

4695 mm

Width Approx:

1775 mm

Height Approx:

1750 mm

Wheelbase Approx:

2725 mm

Cargo Volume Approx:

Highly variable, but substantial for its class with rear seats folded.

Curb Weight Approx:

1800 - 2000 kg (depending on engine and drivetrain)

Towing Capacity Approx:

Up to 2500 kg (braked trailer, market dependent)

🛡️ Safety Features

Crash Test Ratings:

Varies by region and testing authority. Generally considered robust for its era.

ABS:

Available/Standard depending on trim level.

E Bd:

Electronic Brake-force Distribution (often paired with ABS).

Airbags:

Driver and front passenger airbags standard on most models.

Seatbelts:

Three-point seatbelts with pre-tensioners and load limiters for front occupants.

Body Structure:

Reinforced safety cell, crumple zones.

💡 Technology Features

Audio System:

Typically a single-DIN or double-DIN radio with CD player. Speaker configuration varies by trim.

Navigation:

Rarely factory-fitted on this generation, aftermarket options were common.

Traction Control:

Optional on some higher trims.

Cruise Control:

Available on most petrol and higher-spec diesel models.

Auxiliary Input:

Not standard. Aftermarket solutions required for connecting modern audio devices.

🔧 Maintenance

Engine Oil Change:

Typically every 5,000-10,000 km or 6-12 months (refer to manual for specific engine/oil type).

Air Filter Replacement:

Every 20,000-40,000 km or as needed based on operating conditions.

Fuel Filter Replacement Diesel:

Every 40,000-60,000 km (crucial for diesel longevity).

Timing Belt Replacement Petrol V6:

Critical. Typically every 90,000-105,000 km or 5-7 years for 6G72/6G74 engines. Failure leads to catastrophic engine damage.

Engine Oil Petrol:

API SG/SH/SJ or ILSAC GF-2/GF-3, viscosity SAE 10W-30 or 10W-40 recommended (check manual for exact specification and capacity).

Engine Oil Diesel:

API CF/CG-4 or ACEA E2/E3, viscosity SAE 10W-30 or 15W-40 recommended (check manual for exact specification and capacity).

Transmission Fluid Auto:

Mitsubishi Diaqueen SPIII or equivalent ATF (check manual for exact specification and capacity).

Transmission Fluid Manual:

API GL-4, viscosity SAE 75W-90 or 80W-90 (check manual for exact specification and capacity).

Coolant:

Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Mitsubishi Super Long Life Coolant (or equivalent) is often specified.

Diesel Engine 4D56 Potential:

Head gasket failures under extreme heat or prolonged heavy load, injector issues, turbocharger wear.

Petrol Engine 6G7X Potential:

Timing belt failure (critical maintenance item), intake manifold gasket leaks, spark plug fouling on older models.

Drivetrain:

Rear differential pinion seal leaks, transfer case seal leaks, CV joint wear on off-road use.

Suspension:

Worn ball joints and control arm bushings due to off-road use or age, front shock absorber leaks.

Electrical:

Alternator failure, starter motor issues, minor electrical gremlins in body modules or window regulators.

📚 Vehicle History

Mitsubishi SUV Legacy:

Mitsubishi has a long history in producing capable off-road vehicles, dating back to the original Pajero/Montero.

Pajero Sport Lineage:

The Pajero Sport (also known as Montero Sport in some markets and Challenger in others) is a derivative of the Pajero platform, offering a more affordable and often more utilitarian option. This generation (K90) followed the first generation Pajero Sport (K80/K90) launched in 1996.

Production Years For K90 Generation:

1999 - 2008 (with facelifts occurring within this period).

Manufacturing Locations:

Primarily Japan, but also produced in other Mitsubishi global manufacturing facilities.

🏆 Awards & Recognition

Off Road Awards:

While not typically winning major 'Car of the Year' awards, the Pajero Sport platform has consistently been recognized for its robust off-road capability and value in its segment.

Customer Satisfaction:

Generally positive for reliability and capability, though comfort and refinement might lag behind some unibody SUVs.

Emissions Compliance:

Meets relevant emissions standards for the respective markets in 2004.