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.
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.
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)
Type:
2.5L Inline-4 Turbocharged Diesel
Horsepower Approx:
114 - 135 hp (depending on market/tuning)
Torque Approx:
240 - 280 Nm (depending on market/tuning)
Type:
3.0L V6 SOHC Petrol
Horsepower Approx:
175 - 185 hp
Torque Approx:
250 - 265 Nm
Primary Engine Petrol V6 Larger
Type:
3.5L V6 SOHC/DOHC Petrol
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)
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.
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.
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.
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.
