🏷️ Basic Information

Make:

Mitsubishi

Model:

Pajero

Year:

2004

Model Code:

V70 Series (e.g., V73W, V75W, V78W, V77W)

👋 Introduction

Segment:

Full-size body-on-frame SUV, known for its off-road capability and durability.

Competitors:

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

Off Road Capability:

Renowned Super Select II 4WD system, locking differentials, robust suspension, and high ground clearance.

Durability:

Proven chassis and powertrain designed for demanding conditions and long service life.

Versatility:

Suitable for daily commuting, family transport, and serious off-road exploration.

📋 Manual Details

Global Coverage:

All Models/Engines/Trim/Transmissions

Estimated Pages:

Over 2000 pages (typical for comprehensive workshop manuals of this era)

Type:

Workshop Repair Service Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Powertrain:

Engine mechanical (assembly, disassembly, inspection), cooling system, fuel system, lubrication system, exhaust system, engine control systems (ECU, sensors, actuators).

Transmission:

Manual and Automatic transmission overhaul, clutch system, driveline (propeller shafts, drive shafts, differentials, axles).

Chassis:

Suspension systems (front and rear, independent and solid axle depending on variant), steering system, brake system (hydraulic, ABS, EBD), wheel alignment.

Electrical:

Wiring diagrams, starting and charging systems, lighting systems, instrument cluster, body electrical (power windows, mirrors, locks), audio systems, climate control electrical components.

Body:

Body construction, exterior panels, interior trim, doors, hoods, tailgates, glass, seating systems, HVAC system components.

Maintenance:

Scheduled maintenance tasks, oil change procedures, filter replacements, fluid checks and top-offs, lubrication points.

Troubleshooting:

Diagnostic flowcharts, common fault identification, symptom-based troubleshooting guides for engine, transmission, electrical, and chassis issues.

Repair:

Detailed step-by-step repair procedures for all major components, including engine rebuilds, transmission overhauls, suspension and brake repairs, electrical component replacement.

Diagnostics:

On-Board Diagnostics (OBD-II) system information, diagnostic trouble codes (DTCs), sensor data interpretation, use of diagnostic scan tools.

Depth:

Comprehensive from basic user maintenance to complete component overhaul and diagnostics, suitable for professional technicians and advanced DIY enthusiasts.

📊 Manual Specifications

File Quality:

High-resolution scans of original factory documentation, ensuring clarity of text and diagrams.

Searchability:

Likely text-searchable PDF if digitally created or expertly OCR'd, allowing quick access to specific information.

Printability:

Designed for easy printing of specific sections or the entire manual.

Binding:

N/A (Digital PDF format)

Paper Quality:

N/A (Digital PDF format)

⚙️ Engine Specifications

Engine Options:

3.0L 4-cylinder Turbo Diesel (4M41), 3.5L V6 SOHC (6G74), 3.8L V6 SOHC (6G75 - later models, possible inclusion).

Horsepower Range:

Approx. 145-200 hp (depending on engine variant and market).

Torque Range:

Approx. 290-440 Nm (depending on engine variant and market).

Diesel Injection:

Common Rail Direct Injection (CRDI) for 4M41 engine.

Gasoline Injection:

Multi-point Fuel Injection (MPI) for V6 engines.

4M41 Code:

3.2L Direct Injection Diesel Engine

6G74 Code:

3.5L V6 SOHC Engine

🔧 Transmission

Standard Transmission:

5-speed Manual Transmission (for some diesel variants)

Optional Transmission:

4-speed Automatic Transmission (with Sport Mode), 5-speed Automatic Transmission (for later V6 models).

4Wd System:

Super Select II 4WD system with electronic center differential lock, selectable 2WD/4WD modes, and low-range gearing.

Automatic Transmission Fluid:

DIA QUEEN ATF SP-III (or equivalent)

Manual Transmission Fluid:

GL-4 or GL-5 gear oil (specific viscosity to be confirmed in manual).

📐 Dimensions

Length:

Approx. 4700-4800 mm (depending on wheelbase and body style - short/long wheelbase variants)

Width:

Approx. 1800-1870 mm

Height:

Approx. 1840-1890 mm

Wheelbase:

Short wheelbase: ~2550 mm, Long wheelbase: ~2780 mm

Curb Weight:

Approx. 1900-2200 kg (depending on configuration)

Gross Vehicle Weight:

Approx. 2700-2900 kg

Cargo Volume:

Varies significantly with seating configuration (5-seater vs. 7-seater) and seat positions. Manual will detail specific capacities.

🛡️ Safety Features

NHTSA Rating 2004:

Specific ratings for 2004 model year vary by market and crash test configuration. Likely 4-star for frontal impact in US NCAP if tested.

ABS:

Anti-lock Braking System (ABS) standard on most models.

Ebd:

Electronic Brakeforce Distribution (EBD) often integrated with ABS.

Traction Control:

Traction Control System (TCL) available on higher trims or specific markets.

Airbags:

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

Seatbelts:

3-point seatbelts with pre-tensioners for front occupants, 3-point or lap belts for rear passengers.

💡 Technology Features

Audio System:

Factory-installed AM/FM radio with CD player. Premium audio systems with more speakers may be available on higher trims. Aux input or Bluetooth likely not standard.

Navigation:

Optional factory or dealer-installed GPS navigation system available on some higher-end trims.

Cruise Control:

Electronic cruise control system.

Parking Sensors:

Rear parking sensors may have been an option on some models.

Bluetooth:

Bluetooth hands-free calling functionality was not typically factory-standard on this model year. Aftermarket integration is common.

🔧 Maintenance

Oil Change Interval:

Typically 5,000-10,000 km (3,000-6,000 miles) or 6-12 months, depending on driving conditions and engine type. Manual will specify.

Timing Belt Interval:

For V6 gasoline engines, typically around 100,000 km (60,000 miles). Diesel engines may use a timing chain or belt with longer intervals. Manual is crucial.

Engine Oil Type:

API SG/SH/SJ or higher; SAE 10W-30 or 10W-40 for gasoline engines, 5W-40 or 10W-40 synthetic diesel oil for 4M41. Specific grades in manual.

Coolant:

Mitsubishi Super Long Life Coolant (MS-97641) or equivalent ethylene glycol-based coolant with appropriate inhibitors. Manual will specify type and mix ratio.

Brake Fluid:

DOT 3 or DOT 4 brake fluid. Manual will specify the exact requirement.

4M41 Diesel Particulates:

Potential for exhaust gas recirculation (EGR) valve clogging and turbocharger issues due to carbon buildup, especially with short trips. Regular cleaning and quality fuel are important.

V6 Engine Timing Belt:

Risk of catastrophic engine damage if timing belt is not replaced at recommended intervals. Cracked cylinder heads have been reported in some cases on older models, though less common on 2004.

Suspension Components:

Wear in bushings, ball joints, and tie rod ends can occur with high mileage or aggressive off-road use, affecting steering and ride quality.

Power Steering Pump:

Occasional reports of power steering pump leaks or noise.

Major Service Items:

Engine oil/filter, air filter, fuel filter (diesel), cabin filter, transmission fluid, differential fluid, transfer case fluid, coolant, spark plugs (petrol), timing belt/chain (diesel).

📚 Vehicle History

Mitsubishi Off Road:

Mitsubishi has a long and successful history in off-road racing, most notably winning the Dakar Rally multiple times with Pajero/Montero models, influencing their production vehicles.

Third Generation Pajero:

The 2004 model falls within the third generation (1999-2006), which introduced a significant shift with its monocoque chassis with integrated ladder frame, independent front suspension, and more refined interior.

Manufacturing Location:

Primarily manufactured in Japan (Okazaki Plant) and also assembled in various international locations depending on market.

🏆 Awards & Recognition

Dakar Rally Wins:

The Pajero nameplate (often in Montero guise) has achieved multiple outright wins in the prestigious Dakar Rally, validating its off-road prowess and durability.

4X4 Magazine Awards:

Consistently recognized in various 4x4 and off-road publications for its capability and value.