🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero

Year:

2004

Chassis Code:

V60, V70 Series (based on region and specific model variant)

Engine Codes Common:

6G72 (3.0L V6), 6G74 (3.5L V6), 4M41 (3.2L DI-D Turbo Diesel)

👋 Introduction

Segment:

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

Competitors 2004:

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

Off Road Capability:

Renowned for its advanced Super Select 4WD-i system, robust chassis, and good ground clearance.

Versatility:

Suitable for both family transport and serious off-road excursions, with comfortable seating and cargo space.

Powertrain Options:

Offered with reliable V6 gasoline engines and a torquey turbo-diesel option, catering to different user preferences.

📋 Manual Details

Primary Regions Covered:

Global markets, reflecting international configurations

Estimated Page Count:

Detailed page count not specified, but typically over 1000 pages for comprehensive service manuals

Type:

Service and Repair Workshop Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Powertrain:

Engine mechanical, fuel system, ignition system, lubrication, cooling, exhaust, engine management (ECU), turbocharging (if applicable)

Drivetrain:

Manual transmission, automatic transmission, transfer case (including Super Select 4WD-i), front differential, rear differential, driveshafts, CV joints, hubs

Chassis:

Suspension (independent front, multi-link rear), steering system (power steering), brakes (ABS, EBD, disc/drum configurations), wheels and tires

Electrical:

Battery, charging system, starting system, lighting (headlights, taillights, interior), instrumentation, power windows, power locks, mirrors, wipers, horn, climate control electricals, audio system wiring

Body And Interior:

Body panels, doors, hood, tailgate, glass, interior trim, seats, HVAC ducting, safety restraints (airbags, seatbelts)

Diagnostics:

On-board diagnostics (OBD-II), fault code interpretation, diagnostic procedures, troubleshooting flowcharts

Scheduled Maintenance:

Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection/replacement, brake checks

Repair And Overhaul:

Engine disassembly and reassembly, transmission overhaul, brake caliper and master cylinder replacement, suspension component replacement, steering rack repair

Troubleshooting:

Step-by-step diagnostic guides for various common and uncommon issues across all systems

Component Replacement:

Detailed instructions for replacing individual components like alternators, starters, radiators, fuel pumps, sensors, etc.

Depth:

Comprehensive, covering basic maintenance to full engine and transmission rebuilds. Includes diagnostic procedures, specifications, and torque values.

📊 Manual Specifications

Quality:

High-resolution PDF, ensuring clarity of diagrams and text

Searchability:

Likely searchable text embedded in the PDF for easy information retrieval

Printability:

Designed to be printable, allowing for physical copies for workshop use

Binding Type:

N/A (Digital PDF download)

Paper Type:

N/A (Digital PDF download)

⚙️ Engine Specifications

3.0L V6 Petrol (6G72):

Displacement: 2,972 cc; Bore x Stroke: 82.4 x 93.0 mm; Compression Ratio: Typically 9.0:1; Horsepower: Approx. 177-189 PS (130-139 kW); Torque: Approx. 255-260 Nm (188-192 lb-ft)

3.5L V6 Petrol (6G74):

Displacement: 3,497 cc; Bore x Stroke: 93.0 x 85.8 mm; Compression Ratio: Typically 9.0:1 or 10.0:1 (MIVEC variants); Horsepower: Approx. 190-203 PS (140-149 kW); Torque: Approx. 300-314 Nm (221-231 lb-ft)

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

Displacement: 3,200 cc; Bore x Stroke: 98.5 x 105.0 mm; Compression Ratio: 15.0:1; Horsepower: Approx. 160-165 PS (118-121 kW); Torque: Approx. 373-379 Nm (275-280 lb-ft)

Acceleration 0 60Mph:

Varies significantly by engine and transmission, typically 9-12 seconds for gasoline variants.

Type:

Multi-point Fuel Injection (MPI) for gasoline engines, Direct Injection (DI) for diesel engines.

Fuel Type:

Unleaded Gasoline (RON 91 or higher), Diesel Fuel (CDP or ULSD)

Coolant Type:

Mitsubishi Diaqueen Super Long Life Coolant (SLLC) or equivalent (e.g., silicate-free ethylene glycol based)

Engine Oil Type Gasoline:

API SM/SN or ILSAC GF-4/GF-5, SAE 5W-30 or 10W-30 (check owner's manual for specific recommendation based on climate)

Engine Oil Type Diesel:

API CI-4/CJ-4 or ACEA E7/E9, SAE 5W-30 or 10W-30 (check owner's manual for specific recommendation)

🔧 Transmission

Type Gasoline V6:

4-speed Automatic (INVECS-II)

Type Diesel:

5-speed Manual Transmission (MT)

Type Gasoline V6:

5-speed Manual Transmission (MT)

Type Diesel:

4-speed Automatic (INVECS-II)

Transfer Case:

Super Select 4WD-i system (provides 2H, 4H, 4HLC, 4LLC modes)

Fluid Type:

Mitsubishi Diaqueen SPII-MV or equivalent ATF SP-II M, SP-III

Fluid Type:

API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil

📐 Dimensions

Wheelbase:

Approx. 2780 mm (109.4 inches)

Length:

Approx. 4700-4825 mm (185.0-190.0 inches) depending on body style

Width:

Approx. 1870-1890 mm (73.6-74.4 inches)

Height:

Approx. 1855-1880 mm (73.0-74.0 inches)

Curb Weight:

Approx. 1900-2150 kg (4189-4740 lbs) depending on configuration

Gross Vehicle Weight Rating:

Typically around 2700-2900 kg

Towing Capacity:

Varies by region, often rated up to 2500 kg (5500 lbs) braked trailer

Cargo Volume:

Substantial, with folding rear seats; specific figures vary but offer excellent utility.

Wheel Bolt Pattern:

6 x 139.7 mm (6 x 5.5 inches)

Common Tire Sizes:

265/70R16, 265/65R17, 265/60R18 (depending on trim and wheel size)

🛡️ Safety Features

Crash Test Ratings General:

Generally performed well for its era, though specific ratings vary by testing authority (e.g., Euro NCAP, NHTSA) and model configuration. Look for specific test results for the region of sale.

ABS:

Standard Anti-lock Braking System

Ebd:

Electronic Brakeforce Distribution

Traction Control:

Available Traction Control System (TCL) on some models

Stability Control:

Electronic Stability Control (ESC) may be available on higher trims or specific markets

Airbags:

Front driver and passenger airbags standard. Side airbags and curtain airbags may be optional or standard on higher trims.

Seatbelts:

Three-point seatbelts with pre-tensioners for front occupants, lap/shoulder belts for rear occupants.

Body Structure:

Reinforced impact-absorbing body structure

💡 Technology Features

Audio System:

Standard AM/FM stereo with CD player. Higher trims may feature premium sound systems (e.g., Rockford Fosgate) and multi-disc CD changers.

Navigation:

Optional GPS navigation system available on select higher-trim models.

Cruise Control:

Standard cruise control for highway driving comfort.

Rear View Camera:

Optional rear-view camera system available on some higher-end trims.

Power Accessories:

Power windows, power door locks, power mirrors are standard or available depending on trim level.

HVAC:

Manual or automatic climate control systems available, often with rear seat climate vents.

🔧 Maintenance

Oil And Filter Change:

Typically every 7,500 to 10,000 miles (12,000 to 15,000 km) or 6-12 months, whichever comes first. Check manual for exact recommendation.

Air Filter Replacement:

Every 15,000 to 30,000 miles (24,000 to 48,000 km) or as needed based on driving conditions.

Spark Plug Replacement Gasoline:

Platinum or Iridium plugs typically last 60,000 to 100,000 miles (96,000 to 160,000 km). Standard plugs would be much sooner.

Timing Belt Replacement Gasoline:

The 6G72 and 6G74 engines use a timing belt. Recommended replacement interval is typically 60,000 to 90,000 miles (96,000 to 144,000 km) or 5-7 years. **Crucial for preventing catastrophic engine damage.**

Timing Chain Diesel:

The 4M41 engine uses a timing chain, which generally requires less frequent maintenance but should be inspected for wear.

Coolant Flush:

First flush typically at 30,000 miles (48,000 km), then every 30,000 miles (48,000 km) thereafter, or every 2-3 years.

Transmission Fluid Change Automatic:

Every 30,000 to 60,000 miles (48,000 to 96,000 km), or more frequently with heavy towing or off-road use.

Brake Fluid Change:

Every 2-3 years or 30,000 miles (48,000 km) to maintain braking performance and prevent corrosion.

Transfer Case Fluid:

API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil (check manual for specific type, especially for LSD if equipped)

Differential Fluid Front Rear:

API GL-5, SAE 80W-90 or 85W-140 gear oil. Limited Slip Differential (LSD) equipped differentials may require specific LSD additive or fluid.

Power Steering Fluid:

Type A or Dexron II/III compatible ATF, or specific Mitsubishi power steering fluid.

Timing Belt Failure Gasoline:

Critical to replace on schedule. A failed timing belt on the 6G7 series engines will cause piston-to-valve contact, leading to severe engine damage.

Diesel Glow Plugs:

The 4M41 DI-D engine's glow plugs can degrade over time, leading to hard starting in cold weather. Proper testing and replacement are key.

Rear Differential Noise:

Some owners report rear differential noise, often related to worn bearings or improper fluid levels/type. Proper maintenance is crucial.

Suspension Wear:

As with any SUV, particularly one used off-road, suspension components like ball joints, bushings, and control arms can wear over time and require replacement.

Radiator Leaks:

Older radiators, especially if coolant is not maintained, can develop leaks.

📚 Vehicle History

Mitsubishi 4X4 Legacy:

Mitsubishi has a long and storied history in off-road vehicles, dating back to the 1930s with vehicles like the PX33 prototype and continuing through models like the Jeep (licence built) and Pajero/Montero/Shogun.

Pajero Generations:

The 2004 model belongs to the third generation (1999-2006), which introduced a monocoque (unibody) construction for improved on-road manners and ride comfort compared to previous body-on-frame designs, while retaining significant off-road prowess. It also featured independent front suspension.

Manufacturing Locations:

Primarily manufactured in Japan (Okazaki Plant), with production also occurring in other global facilities for specific markets.

Sales Performance:

The Pajero has been a consistent global seller, particularly popular in Australia, the Middle East, and parts of Europe and Africa. Its durability and off-road capability have built a strong reputation.

🏆 Awards & Recognition

Off Road Awards:

The Mitsubishi Pajero has a significant history of success in off-road endurance events, most notably the Dakar Rally, winning multiple times and cementing its reputation as a highly capable off-road vehicle.

Consumer Ratings General:

Generally well-regarded for its ruggedness, reliability, and off-road performance, though fuel economy and on-road ride can be points of criticism compared to less-capable SUVs.