Mitsubishi Montero 2004 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Year: 2004 Codes Chassis Code: V70 Series (V73W, V75W, V78W) Engine Codes: 6G72 (3.0L V6), 6G74 (3.5L V6), 4M41 (3.2L Diesel Turbo) 👋 Introduction Market Position Segment: Full-size SUV, body-on-frame construction, known for off-road capability and durability. Competitive Analysis Competitors 2004: Toyota 4Runner, Nissan Pathfinder, Ford Explorer, Jeep Grand Cherokee, Chevrolet TrailBlazer. Key Features Off Road Capability: Available Super Select II 4WD system with lockable center and rear differentials, robust chassis. Engine Options: Powerful V6 gasoline engines and a capable turbodiesel option (market dependent). Interior Space: Spacious cabin, often with optional third-row seating, offering versatility for passengers and cargo. Durability: Renowned for its robust construction and long-term reliability, particularly in demanding conditions. 📋 Manual Details Coverage Areas Engine Mechanical: Complete engine overhaul, internal components, cylinder head, block, crankshaft, pistons, connecting rods, camshafts, timing system. Engine Electrical: Ignition system, fuel injection system (MPI/GDI), starting system, charging system, engine control module (ECM) diagnosis and wiring diagrams. Transmission Manual: Clutch, gearbox repair, gear selection mechanisms, overhaul procedures. Transmission Automatic: ATF change, torque converter, valve body, planetary gear sets, electronic control, diagnosis, overhaul. Drivetrain: Front/rear differentials, driveshafts, CV joints, transfer case (4WD systems including Super Select/Active Traction Control), hubs. Suspension: Front independent suspension (double wishbone), rear multi-link, springs, shock absorbers, bushings, alignment specifications. Steering: Power steering system, steering rack, column, linkages, hydraulic pump, fluid specifications. Brakes: Front disc brakes, rear disc brakes, ABS, EBD, brake fluid type, bleeding procedures, caliper and rotor specifications. Electrical System: Battery, alternator, starter, lighting systems (headlights, taillights, interior), fuses, relays, body control module (BCM) functions. Body And Chassis: Body panel removal/installation, doors, hood, tailgate, interior trim, structural components, rust repair, chassis alignment. HVAC: Air conditioning system (refrigerant type, charging), heating system, blower motor, climate control module, cabin filter replacement. Body Electrical: Power windows, power locks, mirrors, sunroof, wipers, horn, security system, audio system wiring. Diagnostic Troubleshooting: Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, wiring diagrams for electrical faults. Wiring Diagrams: Comprehensive electrical schematics for all major systems, including power distribution, grounds, and component connections. Page Count Estimated Page Count: 1500-2000+ (typical for full factory service manuals) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered All Major Systems: Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical, HVAC, Body, Chassis, Safety Systems. Procedures Included Maintenance Procedures: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt tensioning, lubrication. Repair Procedures: Component removal, installation, overhaul, and adjustment for all covered systems. Troubleshooting Procedures: Systematic diagnostic steps for common and complex issues, fault code interpretation. Technical Depth Depth: Comprehensive; from basic scheduled maintenance to complete engine and transmission rebuilds, including torque specifications, clearances, and diagnostic procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Typically text-searchable for quick information retrieval. Print Quality Quality: High-resolution, suitable for printing individual pages or the entire manual. Binding Type Format Description: Digital download (PDF), no physical binding. Paper Type Format Description: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine 1: 3.0L V6 SOHC (6G72) Engine 1 Power: Approx. 177 hp @ 5000 rpm Engine 1 Torque: Approx. 245 Nm (181 lb-ft) @ 3500 rpm Engine 2 Engine 2: 3.5L V6 SOHC MPI (6G74) Engine 2 Power: Approx. 197 hp @ 5000 rpm Engine 2 Torque: Approx. 314 Nm (231 lb-ft) @ 3500 rpm Engine 3 Engine 3: 3.2L 4-Cylinder Intercooled Turbo Diesel (4M41) - Market Specific Engine 3 Power: Approx. 175 hp @ 4000 rpm Engine 3 Torque: Approx. 373 Nm (275 lb-ft) @ 2000 rpm Performance Fuel Type: Unleaded gasoline (for 6G72/6G74), Diesel (for 4M41) Fuel System Injection Type: Multi-Point Fuel Injection (MPI) for 6G72/6G74, Common Rail Direct Injection (CRDI) for 4M41. Emission Control: Catalytic converter, O2 sensors, EGR (on diesel). 🔧 Transmission Standard Transmission Option 1: 5-speed Manual Transmission (for select engine/trim combinations) Optional Transmission Option 2: 4-speed Automatic Transmission (with Electronic Control and Sport Mode) Features Transfer Case: Available Super Select II 4WD system: 2H, 4H, 4HLC (with locked center differential), 4LLC (with locked center and rear differentials). Transmission Fluid Auto: DIAQueen ATF-SP II M or equivalent (Consult manual for specific variant) Transmission Fluid Manual: API GL-3/GL-4 SAE 75W-90 Gear Oil (Consult manual for specific variant) 📐 Dimensions Exterior Wheelbase: Approx. 2780 mm (109.4 inches) Length: Approx. 4720-4800 mm (185.8-189.0 inches) depending on model variant Width: Approx. 1800-1815 mm (70.9-71.5 inches) Height: Approx. 1850-1875 mm (72.8-73.8 inches) depending on roof rack configuration Interior Seating Capacity: 5 or 7 passengers (optional third row) Cargo Cargo Volume: Variable, typically offering significant cargo space with rear seats folded. Weights Curb Weight: Approx. 1900-2100 kg (4189-4630 lbs) depending on configuration. Towing Capacity: Up to 3000 kg (6614 lbs) depending on market and configuration (check local regulations and manual). 🛡️ Safety Features Ratings NHTSA Front...

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Sku: 70644

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Tags: 2004 Car Cars Misc Mitsubishi Montero

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Montero

Year:

Codes

Chassis Code:

V70 Series (V73W, V75W, V78W)

Engine Codes:

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

👋 Introduction

Market Position

Segment:

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

Competitive Analysis

Competitors 2004:

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

Key Features

Off Road Capability:

Available Super Select II 4WD system with lockable center and rear differentials, robust chassis.

Engine Options:

Powerful V6 gasoline engines and a capable turbodiesel option (market dependent).

Interior Space:

Spacious cabin, often with optional third-row seating, offering versatility for passengers and cargo.

Durability:

Renowned for its robust construction and long-term reliability, particularly in demanding conditions.

📋 Manual Details

Coverage Areas

Engine Mechanical:

Complete engine overhaul, internal components, cylinder head, block, crankshaft, pistons, connecting rods, camshafts, timing system.

Engine Electrical:

Ignition system, fuel injection system (MPI/GDI), starting system, charging system, engine control module (ECM) diagnosis and wiring diagrams.

Transmission Manual:

Clutch, gearbox repair, gear selection mechanisms, overhaul procedures.

Transmission Automatic:

ATF change, torque converter, valve body, planetary gear sets, electronic control, diagnosis, overhaul.

Drivetrain:

Front/rear differentials, driveshafts, CV joints, transfer case (4WD systems including Super Select/Active Traction Control), hubs.

Suspension:

Front independent suspension (double wishbone), rear multi-link, springs, shock absorbers, bushings, alignment specifications.

Steering:

Power steering system, steering rack, column, linkages, hydraulic pump, fluid specifications.

Brakes:

Front disc brakes, rear disc brakes, ABS, EBD, brake fluid type, bleeding procedures, caliper and rotor specifications.

Electrical System:

Battery, alternator, starter, lighting systems (headlights, taillights, interior), fuses, relays, body control module (BCM) functions.

Body And Chassis:

Body panel removal/installation, doors, hood, tailgate, interior trim, structural components, rust repair, chassis alignment.

HVAC:

Air conditioning system (refrigerant type, charging), heating system, blower motor, climate control module, cabin filter replacement.

Body Electrical:

Power windows, power locks, mirrors, sunroof, wipers, horn, security system, audio system wiring.

Diagnostic Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, wiring diagrams for electrical faults.

Wiring Diagrams:

Comprehensive electrical schematics for all major systems, including power distribution, grounds, and component connections.

Page Count

Estimated Page Count:

1500-2000+ (typical for full factory service manuals)

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

All Major Systems:

Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical, HVAC, Body, Chassis, Safety Systems.

Procedures Included

Maintenance Procedures:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt tensioning, lubrication.

Repair Procedures:

Component removal, installation, overhaul, and adjustment for all covered systems.

Troubleshooting Procedures:

Systematic diagnostic steps for common and complex issues, fault code interpretation.

Technical Depth

Depth:

Comprehensive; from basic scheduled maintenance to complete engine and transmission rebuilds, including torque specifications, clearances, and diagnostic procedures.

📊 Manual Specifications

File Format

File Type:

Searchability:

Typically text-searchable for quick information retrieval.

Print Quality

Quality:

High-resolution, suitable for printing individual pages or the entire manual.

Binding Type

Format Description:

Digital download (PDF), no physical binding.

Paper Type

Format Description:

N/A (Digital format)

⚙️ Engine Specifications

Primary Engine

Engine 1:

3.0L V6 SOHC (6G72)

Engine 1 Power:

Approx. 177 hp @ 5000 rpm

Engine 1 Torque:

Approx. 245 Nm (181 lb-ft) @ 3500 rpm

Engine 2

Engine 2:

3.5L V6 SOHC MPI (6G74)

Engine 2 Power:

Approx. 197 hp @ 5000 rpm

Engine 2 Torque:

Approx. 314 Nm (231 lb-ft) @ 3500 rpm

Engine 3

Engine 3:

3.2L 4-Cylinder Intercooled Turbo Diesel (4M41) - Market Specific

Engine 3 Power:

Approx. 175 hp @ 4000 rpm

Engine 3 Torque:

Approx. 373 Nm (275 lb-ft) @ 2000 rpm

Performance

Fuel Type:

Unleaded gasoline (for 6G72/6G74), Diesel (for 4M41)

Fuel System

Injection Type:

Multi-Point Fuel Injection (MPI) for 6G72/6G74, Common Rail Direct Injection (CRDI) for 4M41.

Emission Control:

Catalytic converter, O2 sensors, EGR (on diesel).

🔧 Transmission

Standard

Transmission Option 1:

5-speed Manual Transmission (for select engine/trim combinations)

Optional

Transmission Option 2:

4-speed Automatic Transmission (with Electronic Control and Sport Mode)

Features

Transfer Case:

Available Super Select II 4WD system: 2H, 4H, 4HLC (with locked center differential), 4LLC (with locked center and rear differentials).

Transmission Fluid Auto:

DIAQueen ATF-SP II M or equivalent (Consult manual for specific variant)

Transmission Fluid Manual:

API GL-3/GL-4 SAE 75W-90 Gear Oil (Consult manual for specific variant)

📐 Dimensions

Exterior

Wheelbase:

Approx. 2780 mm (109.4 inches)

Length:

Approx. 4720-4800 mm (185.8-189.0 inches) depending on model variant

Width:

Approx. 1800-1815 mm (70.9-71.5 inches)

Height:

Approx. 1850-1875 mm (72.8-73.8 inches) depending on roof rack configuration

Interior

Seating Capacity:

5 or 7 passengers (optional third row)

Cargo

Cargo Volume:

Variable, typically offering significant cargo space with rear seats folded.

Weights

Curb Weight:

Approx. 1900-2100 kg (4189-4630 lbs) depending on configuration.

Towing Capacity:

Up to 3000 kg (6614 lbs) depending on market and configuration (check local regulations and manual).

🛡️ Safety Features

Ratings

NHTSA Front Driver:

Likely rated 4 stars (based on similar vehicles of the era, consult specific NHTSA data if available)

NHTSA Front Passenger:

Likely rated 4 stars (based on similar vehicles of the era, consult specific NHTSA data if available)

Active Features

Standard Anti-lock Braking System (ABS).

Standard Electronic Brakeforce Distribution (EBD).

Traction Control:

Available Active Traction Control (ATC) or Active Stability Control (ASC) depending on trim.

Passive Features

Airbags:

Driver and front passenger airbags. Side airbags and curtain airbags may be optional or standard on higher trims.

Seatbelts:

3-point seatbelts with pretensioners for front occupants, 3-point seatbelts for all rear occupants.

Body Structure:

Reinforced impact zones, side-impact door beams.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, often with premium Rockford Fosgate audio system on higher trims.

Navigation:

Optional factory GPS navigation system available on some models.

Driver Assistance

Cruise Control:

Standard cruise control.

Parking Sensors:

Optional rear parking assist sensors available on some trims.

Connectivity

Auxiliary Input:

May feature an auxiliary input jack for external audio devices on some later production models or via aftermarket modifications.

🔧 Maintenance

Service Intervals

Oil Change Gasoline:

Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first (consult owner's manual for exact spec).

Oil Change Diesel:

Every 3,000-5,000 miles (5,000-8,000 km) or 6 months, whichever comes first (consult owner's manual for exact spec).

Engine Air Filter:

Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).

Spark Plugs Gasoline:

Approx. 60,000-100,000 miles (96,000-160,000 km) depending on plug type (e.g., iridium).

Timing Belt Gasoline:

Replace at 60,000-105,000 miles (96,000-168,000 km) or every 5-7 years. Crucial for 6G72/6G74 engines to prevent catastrophic failure. (Consult manual for specific interval).

Fluid Specifications

Engine Oil Gasoline:

API SG/SH/SJ/SL, SAE 5W-30 or 10W-30 (check manual for ambient temp recommendations).

Engine Oil Diesel:

API CF/CF-4/CG-4, SAE 15W-40 or 10W-40 (check manual for ambient temp recommendations).

Coolant:

Mitsubishi Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based coolant with deionized water. Typically a 50/50 mix.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Known Issues

Suspension Bushings:

Wear on suspension bushings (control arm, sway bar) can lead to clunking noises and poor handling.

Ignition Coils:

Coil-on-plug systems can be prone to failure, leading to misfires.

Transfer Case Actuator:

In rare cases, the electronic actuator for the 4WD system can fail, preventing engagement. The manual will cover diagnostics for this.

Exhaust Manifold:

Cracks in exhaust manifolds can occur, leading to exhaust leaks and ticking noises.

📚 Vehicle History

Brand Heritage

Mitsubishi Motors:

Mitsubishi Motors Corporation, a Japanese multinational automotive manufacturer with a long history dating back to 1917.

Model Evolution

Montero Generation 3:

The 2004 Montero belongs to the third generation (1999-2006), which introduced a significant redesign with a unibody chassis (monocoque) combined with a ladder frame for enhanced ride comfort and handling while retaining off-road capability.

Previous Generations:

First generation (1982-1991), Second generation (1991-1999) known for its body-on-frame construction and legendary off-road prowess.

Production

Manufacturing Locations:

Primarily manufactured in Japan, with some assembly potentially occurring in other global locations.

🏆 Awards & Recognition

Recognitions

Off Road Awards:

Montero lineage historically recognized for off-road prowess, often cited in 'best off-road SUV' comparisons of its era.

Ratings

Consumer Reports:

Ratings varied, with strengths in capability and weaknesses sometimes noted in reliability compared to some competitors (consult historical CR data).

Certifications

Emissions Standards:

Meets EPA emissions standards for the respective model year.