Mitsubishi Montero Sport 2004 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Sport Year: 2004 Codes Chassis Code: K80/K90 Series 👋 Introduction Market Position Segment: Mid-size Sport Utility Vehicle (SUV) / Body-on-frame SUV Target Audience: Individuals and families seeking rugged, off-road capable vehicles with ample passenger and cargo space, often used for towing or adventurous driving. Competitive Analysis Key Competitors 2004: Toyota 4Runner, Nissan Pathfinder, Ford Explorer, Jeep Grand Cherokee, Chevrolet TrailBlazer, Isuzu Rodeo Key Features Body Style: SUV (Sport Utility Vehicle) Chassis Construction: Body-on-frame construction, providing robust durability and off-road capability. Drivetrain: Available in 2WD (RWD) and 4WD configurations, featuring Mitsubishi's advanced Super Select 4WD system on higher trims. 📋 Manual Details Coverage Areas Covered Regions: Global (North America, Europe, Asia, Australia primarily based on typical Mitsubishi service documentation) Page Count Estimated Pages: Approximately 2000+ pages (typical for a comprehensive factory service manual) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, overhaul procedures for all engine variants, including component testing, timing, emissions, cooling, lubrication. Transmission Manual: Service, repair, and overhaul for manual transmissions (e.g., KM200, KM201), including clutch system, shift linkage, and internal components. Transmission Automatic: Service, repair, and overhaul for automatic transmissions (e.g., V4A51), including torque converter, valve body, electronic controls, fluid types, and capacities. Drivetrain 4Wd: Comprehensive coverage of the Super Select 4WD system, transfer case, front and rear differentials, drive shafts, CV joints, and hubs. Suspension Steering: Front independent suspension (double wishbone) and rear multi-link suspension, shock absorbers, springs, bushings, power steering system, and steering gear. Brakes: Front and rear brake systems (disc/drum or disc/disc), ABS, brake fluid specifications, bleeding procedures, component replacement (pads, rotors, calipers, lines). Electrical Lighting: Wiring diagrams, lighting system (headlights, taillights, interior), exterior lighting, bulb types and specifications. Electrical Accessories: Power windows, power locks, mirrors, wipers, horn, interior convenience features, fuse and relay identification. Body Exterior: Body panel removal and installation, doors, hood, tailgate, bumpers, glass replacement, trim components. Body Interior: Dashboard removal, seat removal and installation, interior trim panels, carpeting, headliner. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system diagnostics, refrigerant handling, component replacement (compressor, evaporator, heater core). Fuel System: Fuel pump, fuel injectors, fuel filter, fuel lines, fuel tank, emissions control system (EVAP). Exhaust System: Exhaust manifolds, catalytic converter, mufflers, pipes, hangers, oxygen sensors. Cooling System: Radiator, coolant hoses, water pump, thermostat, fan system (mechanical/electric), coolant types and capacities. Lubrication System: Oil pump, oil filter, oil pan, oil galleries, oil specifications. Engine Control System: ECU (Engine Control Unit), sensors (crankshaft, camshaft, O2, MAP, MAF, TPS), actuators, diagnostic trouble codes (DTCs) and troubleshooting. Air Conditioning System: Refrigerant circuits, compressor operation, condenser, receiver drier, expansion valve, climate control panel diagnostics. Procedures Included Basic Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement, air filter replacement. Engine Repair: Head gasket replacement, piston ring replacement, bearing replacement, timing belt/chain service, valve adjustment. Transmission Repair: Clutch replacement, transmission fluid and filter change, seal replacement, valve body service, complete transmission overhaul. Brake System Repair: Brake pad and rotor replacement, brake caliper service, brake line replacement, brake bleeding, ABS sensor replacement. Suspension Component Replacement: Shock absorber and strut replacement, ball joint replacement, tie rod end replacement, control arm bushing replacement. Electrical Diagnostics: Troubleshooting electrical faults, diagnosing sensor issues, circuit testing, using multimeters and oscilloscopes. Body Panel Repair Replacement: Panel alignment, dent repair, door hinge adjustment, tailgate and door glass replacement. Diagnostic Trouble Codes: Listing of DTCs, diagnostic procedures for each code, and recommended repair steps. Wheel Alignment: Specifications for camber, caster, and toe angles, adjustment procedures. Climate Control Service: HVAC system recharging, leak testing, component replacement (compressor, condenser, blower motor). Technical Depth Depth: Comprehensive: Covers everything from basic maintenance and fluid checks to complete engine and transmission overhauls, advanced electrical diagnostics, and bodywork. Diagnostic Capability: Advanced diagnostic procedures, including use of scan tools, identifying electrical issues, and interpreting sensor data. Torque Specifications: Detailed torque specifications for all critical fasteners across all major components. Wiring Diagrams: Full vehicle electrical wiring diagrams with component locations and harness routing. Troubleshooting Charts: Symptom-based troubleshooting flowcharts for common problems. Component Removal Installation: Step-by-step instructions with illustrations for removing and installing virtually every component on the vehicle. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF, allowing for quick location of specific information. Print Quality Quality: High-resolution, suitable for printing workshop-quality diagrams and text. Binding Type Binding: N/A (Digital PDF download) Paper Type Paper: N/A (Digital PDF download) ⚙️ Engine Specifications Primary Engine Engine Code Gasoline: 6G72 (3.0L SOHC V6) Engine Displacement 3.0L: 2972 cc Engine Configuration 3.0L: V6, SOHC (Single Overhead Camshaft) Horsepower 3.0L V6: Approx. 177-185 hp (depending on market and specific tune) Torque 3.0L V6: Approx. 245-255 Nm (181-188 lb-ft) Alternative Engine Engine Code Gasoline V6: 6G75 (3.5L SOHC...

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Labels: 2004 Car Cars Misc Mitsubishi Montero Sport

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Montero Sport

Year:

Codes

Chassis Code:

K80/K90 Series

👋 Introduction

Market Position

Segment:

Mid-size Sport Utility Vehicle (SUV) / Body-on-frame SUV

Target Audience:

Individuals and families seeking rugged, off-road capable vehicles with ample passenger and cargo space, often used for towing or adventurous driving.

Competitive Analysis

Key Competitors 2004:

Toyota 4Runner, Nissan Pathfinder, Ford Explorer, Jeep Grand Cherokee, Chevrolet TrailBlazer, Isuzu Rodeo

Key Features

Body Style:

SUV (Sport Utility Vehicle)

Chassis Construction:

Body-on-frame construction, providing robust durability and off-road capability.

Drivetrain:

Available in 2WD (RWD) and 4WD configurations, featuring Mitsubishi's advanced Super Select 4WD system on higher trims.

📋 Manual Details

Coverage Areas

Covered Regions:

Global (North America, Europe, Asia, Australia primarily based on typical Mitsubishi service documentation)

Page Count

Estimated Pages:

Approximately 2000+ pages (typical for a comprehensive factory service manual)

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnostics, repair, overhaul procedures for all engine variants, including component testing, timing, emissions, cooling, lubrication.

Transmission Manual:

Service, repair, and overhaul for manual transmissions (e.g., KM200, KM201), including clutch system, shift linkage, and internal components.

Transmission Automatic:

Service, repair, and overhaul for automatic transmissions (e.g., V4A51), including torque converter, valve body, electronic controls, fluid types, and capacities.

Drivetrain 4Wd:

Comprehensive coverage of the Super Select 4WD system, transfer case, front and rear differentials, drive shafts, CV joints, and hubs.

Suspension Steering:

Front independent suspension (double wishbone) and rear multi-link suspension, shock absorbers, springs, bushings, power steering system, and steering gear.

Brakes:

Front and rear brake systems (disc/drum or disc/disc), ABS, brake fluid specifications, bleeding procedures, component replacement (pads, rotors, calipers, lines).

Electrical Lighting:

Wiring diagrams, lighting system (headlights, taillights, interior), exterior lighting, bulb types and specifications.

Electrical Accessories:

Power windows, power locks, mirrors, wipers, horn, interior convenience features, fuse and relay identification.

Body Exterior:

Body panel removal and installation, doors, hood, tailgate, bumpers, glass replacement, trim components.

Body Interior:

Dashboard removal, seat removal and installation, interior trim panels, carpeting, headliner.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system diagnostics, refrigerant handling, component replacement (compressor, evaporator, heater core).

Fuel System:

Fuel pump, fuel injectors, fuel filter, fuel lines, fuel tank, emissions control system (EVAP).

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, pipes, hangers, oxygen sensors.

Cooling System:

Radiator, coolant hoses, water pump, thermostat, fan system (mechanical/electric), coolant types and capacities.

Lubrication System:

Oil pump, oil filter, oil pan, oil galleries, oil specifications.

Engine Control System:

ECU (Engine Control Unit), sensors (crankshaft, camshaft, O2, MAP, MAF, TPS), actuators, diagnostic trouble codes (DTCs) and troubleshooting.

Air Conditioning System:

Refrigerant circuits, compressor operation, condenser, receiver drier, expansion valve, climate control panel diagnostics.

Procedures Included

Basic Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, spark plug replacement, air filter replacement.

Engine Repair:

Head gasket replacement, piston ring replacement, bearing replacement, timing belt/chain service, valve adjustment.

Transmission Repair:

Clutch replacement, transmission fluid and filter change, seal replacement, valve body service, complete transmission overhaul.

Brake System Repair:

Brake pad and rotor replacement, brake caliper service, brake line replacement, brake bleeding, ABS sensor replacement.

Suspension Component Replacement:

Shock absorber and strut replacement, ball joint replacement, tie rod end replacement, control arm bushing replacement.

Electrical Diagnostics:

Troubleshooting electrical faults, diagnosing sensor issues, circuit testing, using multimeters and oscilloscopes.

Body Panel Repair Replacement:

Panel alignment, dent repair, door hinge adjustment, tailgate and door glass replacement.

Diagnostic Trouble Codes:

Listing of DTCs, diagnostic procedures for each code, and recommended repair steps.

Wheel Alignment:

Specifications for camber, caster, and toe angles, adjustment procedures.

Climate Control Service:

HVAC system recharging, leak testing, component replacement (compressor, condenser, blower motor).

Technical Depth

Depth:

Comprehensive: Covers everything from basic maintenance and fluid checks to complete engine and transmission overhauls, advanced electrical diagnostics, and bodywork.

Diagnostic Capability:

Advanced diagnostic procedures, including use of scan tools, identifying electrical issues, and interpreting sensor data.

Torque Specifications:

Detailed torque specifications for all critical fasteners across all major components.

Wiring Diagrams:

Full vehicle electrical wiring diagrams with component locations and harness routing.

Troubleshooting Charts:

Symptom-based troubleshooting flowcharts for common problems.

Component Removal Installation:

Step-by-step instructions with illustrations for removing and installing virtually every component on the vehicle.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable PDF, allowing for quick location of specific information.

Print Quality

Quality:

High-resolution, suitable for printing workshop-quality diagrams and text.

Binding Type

Binding:

N/A (Digital PDF download)

Paper Type

Paper:

N/A (Digital PDF download)

⚙️ Engine Specifications

Primary Engine

Engine Code Gasoline:

6G72 (3.0L SOHC V6)

Engine Displacement 3.0L:

2972 cc

Engine Configuration 3.0L:

V6, SOHC (Single Overhead Camshaft)

Horsepower 3.0L V6:

Approx. 177-185 hp (depending on market and specific tune)

Torque 3.0L V6:

Approx. 245-255 Nm (181-188 lb-ft)

Alternative Engine

Engine Code Gasoline V6:

6G75 (3.5L SOHC V6) - Likely for higher trim levels or specific markets.

Engine Displacement 3.5L:

3497 cc

Engine Configuration 3.5L:

V6, SOHC (Single Overhead Camshaft)

Horsepower 3.5L V6:

Approx. 200-220 hp

Torque 3.5L V6:

Approx. 280-310 Nm (207-229 lb-ft)

Fuel System

Fuel Injection:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (Octane rating may vary by market, typically 87 or 91 RON/AKI)

🔧 Transmission

Standard Transmission

Transmission Type Manual:

5-Speed Manual Transmission (e.g., KM200 Series)

Optional Transmission

Transmission Type Automatic:

4-Speed Automatic Transmission (e.g., V4A51 Series)

Features

Transfer Case 4Wd:

Super Select 4WD II (Electronic Control) - offering 2H, 4H, 4HLC (Locked Center Diff), 4LLC (Locked Center and Low Range Gears).

📐 Dimensions

Exterior

Length:

Approx. 4655 mm (183.3 in)

Width:

Approx. 1775-1815 mm (69.9-71.5 in)

Height:

Approx. 1750-1830 mm (68.9-72.0 in) (depending on roof rails)

Wheelbase:

Approx. 2725 mm (107.3 in)

Ground Clearance:

Approx. 200-215 mm (7.9-8.5 in)

Weights

Curb Weight:

Approx. 1850-2000 kg (4079-4409 lbs) (depending on engine and drivetrain)

Gross Vehicle Weight Rating Gvwr:

Approx. 2500-2600 kg (5511-5732 lbs)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

Likely 4-star for driver and passenger (based on similar vehicles of the era, specific rating may vary by country)

IIHS Side Impact:

Varies by year and specific testing; manual should confirm specific ratings if available.

Active Features

Standard on most models, Anti-lock Braking System

Traction Control:

Available on some higher trims or specific markets (TCL)

Passive Features

Airbags Front:

Dual front airbags (driver and passenger)

Airbags Side:

Optional side curtain airbags or side airbags may be available on higher trims or specific markets.

Seatbelts:

Three-point seatbelts with pretensioners for front occupants, three-point seatbelts for rear outboard occupants.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for CHildren) system or ISOFIX equivalent.

💡 Technology Features

Infotainment

Audio System:

Typically a factory-installed AM/FM/CD player, with options for premium sound systems on higher trims.

Display:

Basic digital or analog displays for climate control and audio; no integrated navigation or advanced infotainment screens common in later models.

Driver Assistance

Cruise Control:

Standard on most trims.

Parking Assist:

Rear parking sensors were an optional feature on some models.

Connectivity

Bluetooth:

Not typically available from the factory for this model year; aftermarket solutions would be required.

Usb Ports:

Not typically available from the factory for this model year.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first (refer to manual for specific interval and oil type).

Engine Air Filter Replacement:

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

Spark Plug Replacement:

Every 30,000-60,000 miles (48,000-96,000 km) depending on spark plug type (e.g., platinum or iridium).

Timing Belt Replacement:

Critical for 6G72 V6 engine. Typically every 60,000-105,000 miles (96,000-168,000 km) or 5-7 years. Manual will specify exact interval and should include water pump replacement.

Fluid Specifications

Engine Oil:

API SN/SP, ILSAC GF-5 or higher. Viscosity: SAE 5W-30 or 10W-30 recommended (check manual for precise spec).

Transmission Fluid Manual:

GL-4 or GL-5 gear oil, SAE 75W-90 recommended. Capacity approx. 2.5 liters.

Transmission Fluid Automatic:

Genuine Mitsubishi DIA QUEEN ATF SP-III or equivalent. Capacity approx. 7.5-8.5 liters (for total fill).

Coolant:

Mitsubishi Super Long Life Coolant (SLLC) or equivalent (Ethylene Glycol based, OAT type). Capacity approx. 8.5-9.5 liters.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid:

Genuine Mitsubishi Power Steering Fluid or ATF Dexron-III compatible. Capacity approx. 1.0-1.2 liters.

Known Issues

Timing Belt:

Failure to replace the timing belt at recommended intervals can lead to catastrophic engine damage (interference engine).

Exhaust Manifold Cracks:

Some V6 engines can develop cracks in the exhaust manifolds, leading to exhaust leaks and ticking noises.

Transfer Case Actuator Issues:

Early models of the Super Select 4WD system can experience issues with the electronic actuator, especially with infrequent use.

Heater Core Leaks:

Heater cores can sometimes develop leaks over time, leading to coolant loss and fogging of the windshield.

Suspension Bushings:

Wear and tear on suspension bushings (control arms, sway bars) can lead to clunking noises and reduced handling precision.

📚 Vehicle History

Brand Heritage

Mitsubishi Motors Heritage:

Mitsubishi Motors, a Japanese automaker with a long history in automotive and industrial manufacturing, known for rugged vehicles and innovative technology (e.g., Pajero/Montero lineage).

Model Evolution

Montero Sport Generation:

This 2004 model represents the second generation of the Montero Sport (also known as Pajero Sport in many markets), built on a platform shared with the Mitsubishi Triton/L200 pickup truck.

Design Philosophy:

Designed as a more affordable, yet capable, alternative to the larger full-size Montero (Pajero), emphasizing off-road prowess and utility.

Production

Production Years Second Gen:

1996-2008 (with a facelift in 2000 and 2004 for some markets).

Manufacturing Locations:

Primarily manufactured in Japan, with production also occurring in other countries depending on market distribution.

🏆 Awards & Recognition

Recognitions

Off Road Capability Awards:

While specific awards for the 2004 Montero Sport may be scarce, the model inherited the Montero lineage's reputation for robust off-road performance, often praised in enthusiast circles and comparative tests for its capability, especially with the Super Select 4WD system.

Ratings

Value For Money:

Often recognized in used car market analyses for its durability and affordability relative to its capabilities.

Certifications

Emissions Standards:

Compliant with relevant emissions standards for the model year in its primary markets (e.g., EPA in the US, Euro standards in Europe).