Mitsubishi Montero 2004 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Year: 2004 Codes Chassis Code: V73W, V75W, V77W, V78W Engine Codes General: 6G72, 6G74, 6G75 Generation Generation Designation: Third Generation (Pajero/Montero 1999-2006) 👋 Introduction Market Position Segment: Mid-size body-on-frame SUV, known for off-road capability and ruggedness Competitive Analysis Key Competitors 2004: Toyota 4Runner, Nissan Pathfinder, Jeep Grand Cherokee, Ford Explorer Key Features Vehicle Platform: Ladder frame construction providing robust durability Drivetrain: Available with rear-wheel drive (RWD) or Mitsubishi's advanced Super Select 4WD II system Key Features Manual Utility: Enables owners and technicians to perform all maintenance and repair tasks 📋 Manual Details Coverage Areas Global Regions: North America, Europe, Asia, Australia (specific to Montero naming convention) Page Count Estimated Page Count: 1500+ Manual Type Manual Type: Workshop Service Repair Manual (WSRM) Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, cooling system, exhaust system, transmission (manual and automatic), transfer case, drivetrain components (driveshafts, axles, differentials) Chassis: Suspension (front and rear independent, Super Select 4WD II), steering system, brake system (ABS, EBD), wheel and tire specifications Electrical: Engine control module (ECM), body control module (BCM), lighting system, instrument cluster, power accessories (windows, locks, mirrors), audio system, climate control system, wiring diagrams, diagnostic trouble codes (DTCs) Body And Frame: Exterior body panels, interior trim, doors, glass, seats, structural components Procedures Included Maintenance: Scheduled maintenance intervals, fluid changes (oil, coolant, transmission fluid, brake fluid, power steering fluid), filter replacements, lubrication, inspections Repair: Engine overhauls, transmission rebuilds, brake component replacement, suspension component repair, electrical system diagnostics and repair, body panel replacement, exhaust system repair Troubleshooting: Diagnostic procedures for common and uncommon issues, symptom-based troubleshooting charts, fault code interpretation Diagnostics: OBD-II diagnostics, specific sensor testing, actuator testing, wiring harness continuity checks Technical Depth Depth: Comprehensive factory-level detail, suitable for professional technicians and experienced DIY enthusiasts Accuracy: Factory-specifications, torque values, clearances, and procedures 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution scans, suitable for printing individual pages or the entire manual Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Option 1 Code: 6G72 Engine Option 1 Type: 3.0L SOHC V6 MIVEC Engine Option 1 Displacement: 2972 cc (181.4 ci) Engine Option 2 Code: 6G74 Engine Option 2 Type: 3.5L SOHC V6 MIVEC Engine Option 2 Displacement: 3497 cc (213.4 ci) Engine Option 3 Code: 6G75 Engine Option 3 Type: 3.8L SOHC V6 MIVEC Engine Option 3 Displacement: 3828 cc (233.6 ci) Performance 3.5L V6 (6G74) Horsepower: 200 hp @ 5000 rpm 3.5L V6 (6G74) Torque: 235 lb-ft @ 3750 rpm 3.8L V6 (6G75) Horsepower: 230 hp @ 5250 rpm 3.8L V6 (6G75) Torque: 260 lb-ft @ 3750 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Multi-point injection Fuel Type: Unleaded gasoline Emission Controls: Catalytic converters, oxygen sensors, EGR (where applicable) 🔧 Transmission Standard Transmission Option 1: 5-speed manual transmission (often paired with the 3.5L V6) Optional Transmission Option 2: 4-speed automatic transmission (INVECS-II with AI-Sport Mode, often paired with 3.0L and 3.5L V6) Transmission Option 3: 5-speed automatic transmission (INVECS-II with AI-Sport Mode, often paired with 3.8L V6) Features Transfer Case: Super Select 4WD II system (available on higher trims), offering 2H, 4H, 4HLC (Locking Center Differential), 4LLC (Low Range with Locking Center Differential) 📐 Dimensions Exterior Wheelbase: Approximately 2780 mm (109.4 inches) Length: Approximately 4730-4800 mm (186.2-189.0 inches) depending on trim/body style Width: Approximately 1870-1880 mm (73.6-74.0 inches) Height: Approximately 1860-1890 mm (73.2-74.4 inches) depending on roof rack/suspension Weights Curb Weight: Approximately 1900-2100 kg (4189-4630 lbs) 🛡️ Safety Features Ratings NHTSA Frontal Crash Test: 5-star rating (driver and passenger) in frontal crash tests for models equipped with side airbags. Active Features ABS: Standard Anti-lock Braking System (ABS) Ebd: Standard Electronic Brakeforce Distribution (EBD) Traction Control: Available Traction Control System (TCS) Passive Features Airbags: Driver and front passenger airbags; available side-impact airbags (curtain and/or torso) Seatbelts: Three-point seatbelts with pretensioners for all seating positions 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player, with optional premium audio systems (e.g., Rockford Fosgate on some trims) Navigation: Optional factory navigation system available on higher trim levels Driver Assistance Cruise Control: Standard cruise control Climate Control: Manual climate control and optional automatic climate control Connectivity Auxiliary Inputs: Typically no standard auxiliary audio input on factory systems of this era; aftermarket solutions may exist. 🔧 Maintenance Service Intervals Engine Oil Change Interval: Every 3,750 miles (6,000 km) or 3 months, whichever comes first (severe service); 7,500 miles (12,000 km) or 6 months (normal service) - consult manual for specific oil type recommendations. Transmission Fluid Change Interval: Every 30,000 miles (48,000 km) or 24 months, whichever comes first (automatic and manual transmissions) - always use specified fluid. Coolant Change Interval: Initial change at 5 years...
5-speed manual transmission (often paired with the 3.5L V6)
Optional
Transmission Option 2:
4-speed automatic transmission (INVECS-II with AI-Sport Mode, often paired with 3.0L and 3.5L V6)
Transmission Option 3:
5-speed automatic transmission (INVECS-II with AI-Sport Mode, often paired with 3.8L V6)
Features
Transfer Case:
Super Select 4WD II system (available on higher trims), offering 2H, 4H, 4HLC (Locking Center Differential), 4LLC (Low Range with Locking Center Differential)
📐 Dimensions
Exterior
Wheelbase:
Approximately 2780 mm (109.4 inches)
Length:
Approximately 4730-4800 mm (186.2-189.0 inches) depending on trim/body style
Width:
Approximately 1870-1880 mm (73.6-74.0 inches)
Height:
Approximately 1860-1890 mm (73.2-74.4 inches) depending on roof rack/suspension
Weights
Curb Weight:
Approximately 1900-2100 kg (4189-4630 lbs)
🛡️ Safety Features
Ratings
NHTSA Frontal Crash Test:
5-star rating (driver and passenger) in frontal crash tests for models equipped with side airbags.
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Ebd:
Standard Electronic Brakeforce Distribution (EBD)
Traction Control:
Available Traction Control System (TCS)
Passive Features
Airbags:
Driver and front passenger airbags; available side-impact airbags (curtain and/or torso)
Seatbelts:
Three-point seatbelts with pretensioners for all seating positions
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, with optional premium audio systems (e.g., Rockford Fosgate on some trims)
Navigation:
Optional factory navigation system available on higher trim levels
Driver Assistance
Cruise Control:
Standard cruise control
Climate Control:
Manual climate control and optional automatic climate control
Connectivity
Auxiliary Inputs:
Typically no standard auxiliary audio input on factory systems of this era; aftermarket solutions may exist.
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Every 3,750 miles (6,000 km) or 3 months, whichever comes first (severe service); 7,500 miles (12,000 km) or 6 months (normal service) - consult manual for specific oil type recommendations.
Transmission Fluid Change Interval:
Every 30,000 miles (48,000 km) or 24 months, whichever comes first (automatic and manual transmissions) - always use specified fluid.
Coolant Change Interval:
Initial change at 5 years or 100,000 miles, then every 2 years or 30,000 miles thereafter.
Fluid Specifications
Engine Oil Specification:
API SG, SH, SJ, SL or ACEA A2/A3; viscosity typically 5W-30 or 10W-30 depending on climate. Refer to manual for exact specification based on engine code.
Automatic Transmission Fluid:
DiaQueen ATF-SP III (or equivalent)
Manual Transmission Fluid:
API GL-3 or GL-4 SAE 75W-85 or 75W-90 gear oil. Consult manual for specific viscosity.
Brake Fluid:
DOT 3 or DOT 4 brake fluid
Known Issues
Common Issues List:
Sunroof drain tube blockages leading to interior water leaks, power steering pump leaks, potential ABS sensor issues, catalytic converter failure (depending on maintenance and emissions regulations).
Maintenance Impact:
Adherence to the manual's maintenance schedule significantly mitigates common issues and prolongs vehicle life.
📚 Vehicle History
Brand Heritage
Mitsubishi Offroad Legacy:
Mitsubishi has a long and successful history in off-road racing, notably the Dakar Rally with the Pajero, influencing the Montero's design and capability.
Model Evolution
Third Generation Focus:
The 2004 model is part of the third generation (1999-2006), which introduced a monocoque-inspired body-on-frame construction for improved on-road handling and a more integrated chassis.
Production
Manufacturing Locations:
Primarily manufactured in Japan (Pajero) and some models assembled in other locations for specific markets.
🏆 Awards & Recognition
Recognitions
Offroad Capability Recognition:
Consistently recognized by automotive publications and enthusiasts for its robust off-road capabilities and durable platform.
Ratings
Consumer Satisfaction Notes:
While specific awards for 2004 are scarce, the Montero line generally received favorable reviews for its utility and off-road prowess, though interior refinement and fuel economy were often cited as areas for improvement compared to unibody SUVs.
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