🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero

Year:

2004

Chassis Code:

V60/V70 Series (exact internal designation may vary by market, but generally refers to the third generation Pajero)

Generation:

Third Generation (1999-2006)

👋 Introduction

Market Position:

The Mitsubishi Pajero (also known as Montero in some markets) is a highly capable and popular full-size SUV known for its off-road prowess, robust construction, and comfortable ride. The 2004 model year represents a mature iteration of the third generation, offering a blend of luxury, utility, and performance, making it a competitor against vehicles like the Toyota Land Cruiser Prado, Nissan Patrol, and Land Rover Discovery.

Target Audience:

This manual is explicitly stated to be for 'do-it-yourselfers' as well as experienced mechanics, indicating it bridges the gap between basic maintenance guides and professional workshop manuals.

Competitive Analysis:

The 2004 Pajero distinguished itself with its monocoque body-on-ladder chassis construction, providing a better on-road handling experience compared to traditional body-on-frame SUVs. Its Super Select II 4WD system was a key selling point, offering excellent off-road capability and on-road versatility.

Key Features:

The manual is designed for ease of use by both novice and experienced technicians. It provides detailed substeps, notes, cautions, and warnings to ensure accuracy and safety during repairs. The inclusion of hundreds of photos and illustrations, along with enlarged insets, significantly aids in understanding complex procedures.

📋 Manual Details

Coverage Areas:

General Maintenance, Troubleshooting, Engine Service/Repair, Transmission Service/Repair, Brake System, Wiring Diagram, Electrical System, Suspension, Periodic Lubrication, Steering, Cooling System, Fuel Injection, Fuel System, Emission System, Heater/Air Conditioning, Engine Control System, Chassis/Body, Restraint System, Interior, Differential/Drive, Axle, and much more.

Specific Engine Coverage:

The manual covers the service and repair for the primary gasoline and diesel engines offered in the 2004 Mitsubishi Pajero, which would include the 3.8L V6 (6G75), 3.5L V6 (6G74), and 3.2L DI-D (4M41) diesel, among others depending on market availability.

Page Count:

Hundreds of pages (specific count not provided, but implied to be comprehensive)

Manual Type:

Factory Service Repair Manual (Workshop Manual)

Language:

English

Format:

PDF Download

📖 Manual Coverage

Systems Covered:

Engine mechanical, engine control, fuel system (injection, fuel pump, tank), exhaust and emission control, cooling system, lubrication system, ignition system, starting system, charging system, transmission (automatic and manual), driveline and axles, suspension (front and rear), steering system, brake system (hydraulic, ABS), body electrical, HVAC, interior systems, safety restraint systems, chassis and body components.

Engine Control System Coverage:

Detailed coverage of the Engine Control Module (ECM) or Powertrain Control Module (PCM), including sensor inputs (crankshaft position, camshaft position, MAF, MAP, O2, throttle position), actuator outputs (injectors, ignition coils), diagnostic trouble codes (DTCs), and emission control systems (EGR, EVAP).

Cooling System Coverage:

Covers radiator, water pump, thermostat, cooling fans, coolant hoses, heater core, and HVAC integration. Includes coolant specifications and flush procedures.

Fuel Injection Coverage:

Detailed procedures for fuel injectors, fuel pump, fuel pressure regulator, fuel filter replacement, and fuel system diagnostics. Includes specifications for fuel pressure and injector flow rates.

Chassis Body Coverage:

Covers frame inspection, body panel removal and installation, door mechanisms, hood and tailgate operation, bumper systems, and potential structural repairs.

Restraint System Coverage:

Focuses on the Supplemental Restraint System (SRS), including airbag module replacement, seatbelt pre-tensioner service, and SRS system wiring diagnostics and safety precautions during handling.

Differential Drive Axle Coverage:

Detailed procedures for front and rear differentials, transfer case operation and maintenance, driveshaft U-joints, CV joints, and axle seals. Includes fluid type and capacity for these components.

Heater Air Conditioner Coverage:

Detailed diagnosis and repair of the HVAC system, including refrigerant handling (R134a), compressor service, condenser, evaporator, blower motor, blend door actuators, and control panel operation.

Procedures Included:

Routine maintenance (oil changes, filter replacements, fluid checks), component removal and installation, engine overhaul, transmission rebuilds, brake system servicing (pads, rotors, calipers), suspension component replacement, steering system repair, electrical system diagnostics and repair, HVAC system servicing, troubleshooting common issues, torque specifications, diagnostic trouble codes (DTCs) and their resolutions, wiring diagrams interpretation.

Brake System Procedures:

Front and rear brake pad replacement, rotor resurfacing or replacement, caliper overhaul, brake fluid flush and bleeding, ABS system diagnostics and component testing (wheel speed sensors, ABS control module).

Suspension Procedures:

Front and rear shock absorber/strut replacement, coil spring replacement, control arm bushings, ball joint inspection and replacement, wheel bearing replacement, and alignment specifications.

Steering System Procedures:

Power steering pump, steering rack or gearbox diagnosis and repair, power steering fluid replacement, tie rod end replacement, and steering wheel alignment.

Electrical System Procedures:

Detailed troubleshooting for common electrical faults, lighting system repair, power window and lock diagnostics, starter and alternator testing, fuse and relay identification, and body control module (BCM) related issues.

Troubleshooting Procedures:

A dedicated section for troubleshooting, guiding users through identifying and resolving common vehicle problems, from minor drivability issues to major component failures, often cross-referenced with specific system chapters.

Technical Depth:

Comprehensive, from basic maintenance to complete overhaul and diagnostics. Suitable for both DIY enthusiasts and professional mechanics. Includes step-by-step instructions, detailed illustrations, photos, and wiring diagrams.

Diagnostic Capabilities:

The manual provides comprehensive diagnostic information, including symptom-to-cause charts, diagnostic flowcharts, and specific procedures for using scan tools to retrieve and interpret diagnostic trouble codes (DTCs) and live data.

Wiring Diagrams Detail:

The manual includes comprehensive wiring diagrams that clearly illustrate the electrical circuits for various systems, including component identification, wire colors, and connector pinouts, essential for electrical diagnostics.

Component Torque Specifications:

Crucial torque specifications for engine components, suspension parts, wheel lug nuts, and drivetrain fasteners will be provided to ensure correct assembly and prevent damage.

📊 Manual Specifications

File Format:

PDF

PDF Reader Requirement:

Adobe PDF Reader is required for viewing and printing.

Print Quality:

Printable without restriction, allowing users to print entire manual or specific pages.

Printability Feature:

All pages are printable, allowing users to create a physical copy or print only the sections relevant to their immediate task.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine Offered In 2004 Pajero:

3.8L V6 SOHC MIVEC (6G75) - This engine was a significant upgrade for the third generation, offering improved power and efficiency. Other engine options, such as the 3.5L V6 (6G74) and various diesel engines (e.g., 3.2L DI-D 4M41), were also available depending on the market. This manual likely covers the major variants.

Engine Code Identification:

The manual will likely reference specific engine codes (e.g., 6G75 for the 3.8L V6, 6G74 for the 3.5L V6, 4M41 for the 3.2L Di-D diesel) to ensure users are working on the correct engine variant.

3.8L V6 Mivec Performance Estimates:

Horsepower: Approximately 230-250 hp @ 5500-6000 rpm. Torque: Approximately 260-280 lb-ft @ 3750-4000 rpm. (Specific figures vary by market and tuning.)

Diesel Engine Variants Performance:

For diesel variants like the 3.2L DI-D (4M41), performance would typically be in the range of 160-170 hp and 300-315 lb-ft of torque, emphasizing torque for off-road and towing.

Fuel System Type:

Multi-point Fuel Injection (MPI) for gasoline engines. Common Rail Direct Injection (CRDI) for diesel engines.

🔧 Transmission

Standard Transmission:

Typically a 5-speed manual transmission for some engine variants, though automatic transmissions were far more common on higher trims and larger engines.

Optional Transmission:

4-speed Automatic Transmission (with electronically controlled shifts) or a 5-speed Automatic Transmission ( INVECS-II or INVECS-II Sport Mode) depending on engine and market.

Transmission Features:

The manual will cover the operation, maintenance, and repair of both manual and automatic transmissions, including fluid type, capacity, and service procedures. Emphasis on the Super Select II 4WD system is expected.

📐 Dimensions

Exterior Dimensions Typical Short Wheelbase:

Length: ~4600-4700 mm, Width: ~1850-1870 mm, Height: ~1800-1900 mm. (Long wheelbase variants and specific body styles will differ. The manual likely covers all variations.)

Wheelbase Options:

The Pajero was offered in both short-wheelbase (SWB) and long-wheelbase (LWB) configurations, affecting overall length and interior space. The manual will cover both.

Interior Features:

The manual will detail interior trim removal, component servicing (seats, dashboard, door panels), HVAC system components, and electrical connectors within the cabin.

Gross Vehicle Weight Rating:

Typically in the range of 2500-3000 kg (GVWR), depending on configuration. Curb weight would be less.

🛡️ Safety Features

Safety Ratings General:

While specific 2004 crash test ratings from NHTSA or IIHS may vary by market and year of testing, the Pajero generally offered good occupant protection for its class and era, featuring a strong chassis and safety equipment. The manual will cover the SRS (Supplemental Restraint System).

Active Safety Features:

Anti-lock Braking System (ABS), Electronic Brakeforce Distribution (EBD), Traction Control System (TCS), Active Stability Control (ASC) often available on higher trims.

Passive Safety Features:

Front airbags, side airbags (depending on trim level), seatbelt pretensioners, reinforced body structure.

💡 Technology Features

Infotainment Systems Available:

For 2004, infotainment was typically basic, often featuring a factory-installed AM/FM/CD player with auxiliary input (less common), and potentially a premium Rockford Fosgate audio system on higher trims. Navigation systems were optional and not widely integrated.

Driver Assistance Features:

ABS, Traction Control, and Stability Control were available features. Advanced driver-assistance systems (ADAS) like adaptive cruise control or lane-keeping assist were not typically offered in 2004.

Connectivity Options:

Limited by modern standards. Primarily focused on audio system connectivity, with some higher trims potentially offering basic hands-free phone integration (Bluetooth was nascent).

🔧 Maintenance

Typical Oil Change Interval:

Generally every 7,500 to 15,000 km (4,500 to 9,000 miles) or 6 to 12 months, whichever comes first, depending on driving conditions and engine oil type. The manual will provide specific intervals for all maintenance items.

Periodic Lubrication Coverage:

Includes detailed schedules and specifications for lubricating chassis components, suspension joints, and driveline points, essential for the longevity of a 4WD vehicle.

Engine Oil Specification Typical:

API Service SN/SM/SL or ILSAC GF-5/GF-4, SAE 5W-30 or 5W-40 viscosity grade for gasoline engines (e.g., 6G75 V6). Diesel engines will have specific oil requirements. The manual will list precise specifications, including Dexron for automatic transmissions and specific gear oil weights for differentials and transfer cases.

Coolant Type:

Typically a high-quality ethylene glycol-based antifreeze with appropriate corrosion inhibitors. Manual will specify exact type and mixture ratio.

Common Issues For 2004 Pajero:

Potential issues can include automatic transmission shifting problems, ABS sensor failures, exhaust manifold cracks (on some V6 engines), minor electrical gremlins, and wear on suspension components due to off-road use. The manual will offer diagnostic procedures for these and more.

📚 Vehicle History

Mitsubishi Brand Heritage:

Mitsubishi Motors has a long history in automotive manufacturing, with a significant focus on durable and capable vehicles, including iconic off-roaders like the Pajero, which has a strong legacy in rallies like the Dakar Rally.

Pajero Third Generation Evolution:

The third generation Pajero (launched in 1999) marked a significant departure with its move to a monocoque chassis with an integrated ladder frame. This improved on-road dynamics and safety. The 2004 model year represents a mid-cycle refinement or a standard year within this generation, with potential minor updates in features or powertrain.

Pajero Third Generation Key Innovations:

Introduction of the monocoque body-on-ladder chassis, independent front suspension for improved on-road comfort, and advanced 4WD systems like Super Select II and Active Traction Control (ATC).

Production Locations:

Primarily produced in Japan (Mizushima Plant), but also assembled in various CKD (Completely Knocked Down) or SKD (Semi Knocked Down) plants globally, depending on the market.

🏆 Awards & Recognition

Historical Recognitions For Pajero:

While specific awards for the 2004 model year are not widely publicized, the Pajero lineage is renowned for its success in extreme off-road endurance events like the Dakar Rally, which has contributed to its reputation for durability and capability.