Mitsubishi Pajero 2004 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero Year: 2004 Region Availability: Global (varies by specific market trim) Codes Chassis Code: V73W, V75W, V78W (varies by engine/drivetrain) 👋 Introduction Market...

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标签: 2004 Car Cars Misc Mitsubishi Pajero

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Pajero

Year:

Region Availability:

Global (varies by specific market trim)

Codes

Chassis Code:

V73W, V75W, V78W (varies by engine/drivetrain)

👋 Introduction

Market Position

Segment:

Full-size SUV, known for off-road capability and durability

Robust construction, capable four-wheel-drive systems (Super Select 4WD-II), comfortable interior for its class

Competitive Analysis

Competitors:

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

Key Features

Body Styles:

3-door (Short Wheelbase - SWB) and 5-door (Long Wheelbase - LWB)

Drivetrain:

Part-time 4WD and Full-time 4WD (Super Select 4WD-II)

Off Road Capability:

Body-on-frame construction, high ground clearance, locking center differential (on some models)

📋 Manual Details

Coverage Areas

Coverage Scope:

Complete factory service and repair information

Trim Levels Covered:

All available trim levels for the 2004 model year

Market Variants:

All major market variants (e.g., North America, Europe, Asia-Pacific)

Page Count

Estimated Page Count:

Hundreds (specific count not provided, but implies comprehensive coverage)

Manual Type

Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnostics, repair, and overhaul for all gasoline and diesel variants

Transmission:

Automatic and Manual transmission repair, clutch, driveline, and transfer case

Brakes:

Hydraulic system, ABS, EBD, brake pad/rotor replacement, caliper repair

Suspension:

Front and rear suspension, shock absorbers, springs, bushings, alignment specifications

Steering:

Power steering system, steering rack/box, tie rods, wheel alignment

Electrical:

Wiring diagrams, fuse box layouts, charging system, starting system, lighting, accessories

HVAC:

Air conditioning, heating, ventilation system repair and diagnostics

Bodywork:

Exterior and interior trim removal/installation, door mechanisms, glass, body panel repair

Chassis:

Frame and chassis component inspection and repair

Safety Systems:

Airbag system diagnostics and repair, seatbelt mechanisms

Procedures Included

Maintenance:

Routine service, oil changes, filter replacements, fluid checks

Diagnostics:

Troubleshooting guides, symptom-based fault finding, diagnostic trouble codes (DTCs)

Repair:

Component removal and installation, sub-assembly repair, engine rebuilds, transmission overhauls

Adjustment:

Brake adjustments, clutch adjustments, parking brake adjustments

Calibration:

Sensor calibration, electronic module calibration

Installation:

Accessory installation, component upgrades, timing belt/chain replacement procedures

Technical Depth

Depth:

Comprehensive (from basic maintenance to full engine/transmission rebuilds)

Diagnostic Capability:

Advanced, including detailed wiring diagrams and component testing procedures

Engine Rebuild:

Complete engine overhaul procedures, including torque specifications, clearances, and assembly order

Transmission Repair:

Detailed diagrams and procedures for automatic and manual transmission disassembly, inspection, and reassembly

📊 Manual Specifications

File Format

File Type:

Searchable:

Likely searchable text, allowing for quick information retrieval

Print Quality

Quality:

High-resolution for clear printing of diagrams and text

Binding Type

Binding:

N/A (Digital PDF Download)

Paper Type

Paper Type:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Primary Engine

Engine Code Example:

6G72 (3.0L V6 Gasoline), 6G74 (3.5L V6 Gasoline), 4M41 (3.2L Diesel)

Engine Type Example:

SOHC or DOHC V6 gasoline, Turbocharged Direct Injection Diesel (TDI)

Performance

Horsepower Range:

Approx. 170 HP (3.0L) to 235 HP (3.5L Gasoline), 165 HP (3.2L Diesel)

Torque Range:

Approx. 255 Nm (3.0L) to 345 Nm (3.5L Gasoline), 373 Nm (3.2L Diesel)

Fuel System

Fuel Delivery:

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

Recommended Fuel Gasoline:

Unleaded Gasoline, 91 Octane (RON/MON)

Recommended Fuel Diesel:

ULSD (Ultra-Low Sulfur Diesel)

🔧 Transmission

Standard

Transmission Type Standard:

5-speed Manual (less common), 4-speed Automatic (common)

Optional

Transmission Type Optional:

5-speed Automatic (on some higher trims/engines)

Features

Drivetrain Integration:

Seamless integration with Super Select 4WD-II system

Fluid Specifications

Automatic Transmission Fluid:

Diamond ATF SP-II M or SP-III (Consult specific engine/transmission for exact spec)

Manual Transmission Fluid:

GL-4 or GL-5 Gear Oil (Consult specific transmission for exact spec)

📐 Dimensions

Exterior

Length Lwb:

Approx. 4,890 mm (192.5 in)

Width:

Approx. 1,875 mm (73.8 in)

Height:

Approx. 1,865 mm (73.4 in)

Wheelbase Lwb:

Approx. 2,780 mm (109.4 in)

Cargo

Cargo Volume Seats Up:

Significant, variable depending on configuration (e.g., 3rd-row folded)

Weights

Curb Weight Range:

Approx. 1,900 kg to 2,200 kg (4,189 lbs to 4,850 lbs)

Towing Capacity:

Varies by market and configuration, typically up to 2500-3500 kg (5500-7700 lbs)

🛡️ Safety Features

Ratings

NHTSA Ratings:

Varies by market and specific tests conducted for the model year

Active Features

Standard Anti-lock Braking System

Standard Electronic Brakeforce Distribution

Passive Features

Airbags:

Driver and front passenger airbags standard, side airbags optional on some trims

Rollover Protection:

Reinforced chassis and body structure, higher center of gravity inherent to SUVs

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player with optional premium sound system, speaker configurations vary by trim

Navigation:

Optional factory GPS navigation system available on higher trims

Driver Assistance

Cruise Control:

Standard cruise control

Connectivity

Power Accessories:

Power windows, power locks, power mirrors (standard on most trims)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 7,500 - 15,000 km (4,500 - 9,000 miles) or 6-12 months, depending on driving conditions

Timing Belt Replacement:

For gasoline engines with timing belts (e.g., 6G72, 6G74), typically 90,000 - 100,000 km (56,000 - 62,000 miles)

Transmission Fluid Change:

Every 40,000 - 80,000 km (25,000 - 50,000 miles) for automatic transmissions

Fluid Specifications

Engine Oil Spec:

API SN/SP or ACEA A3/B4, viscosity typically 5W-30, 10W-30, or 10W-40 (Consult owner's manual/manual for exact spec based on engine and climate)

Coolant Type:

Mitsubishi Super Long Life Coolant (SLLC) or equivalent Ethylene Glycol based coolant with Organic Acid Technology (OAT)

Brake Fluid Type:

DOT 3 or DOT 4

Known Issues

Engine Timing Belt:

Risk of belt failure if not replaced at recommended intervals, causing catastrophic engine damage (for belt-driven engines)

Diesel Glow Plugs:

Potential for failure of glow plugs leading to hard starting in cold weather (4M41 diesel)

Suspension Bushings:

Wear and tear on suspension bushings over time, leading to clunks or imprecise handling

Automatic Transmission:

Some reports of rough shifting or overheating with heavy use or neglected maintenance

📚 Vehicle History

Brand Heritage

Mitsubishi SUV History:

Long lineage of rugged, off-road capable vehicles dating back to the original Pajero (1982)

Model Evolution

Generation Covered:

Third Generation Pajero (1999-2006)

Platform Changes:

Transition to monocoque chassis with integrated frame for improved on-road handling and safety

Production

Production Plant:

Multiple plants globally, primarily Japan

Popularity:

Hugely popular globally, particularly in markets valuing off-road prowess and utility

🏆 Awards & Recognition

Recognitions

Off Road Awards:

Multiple wins and high placings in challenging off-road rallies such as the Dakar Rally (historical context for the Pajero nameplate)

Ratings

Reliability Perception:

Generally considered reliable and durable, especially the powertrain and chassis components, when properly maintained.