Mitsubishi Montero 2004 Workshop Repair Service Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Year: 2004 Chassis Code: V70 Series Market Segment: Full-size SUV 👋 Introduction Market Position Vehicle Class: Body-on-frame SUV, often referred to as a 'traditional' SUV Competitors 2004: Toyota 4Runner, Ford Explorer, Chevrolet TrailBlazer, Nissan Pathfinder, Jeep Grand Cherokee Competitive Analysis Strengths: Robust off-road capability, powerful V6/V8 engines, spacious interior, often good value for money Weaknesses: Less refined on-road manners compared to unibody SUVs, fuel economy, some interior material quality concerns Key Features Off Road Systems: Super Select II 4WD system (on many models), locking center differential, available rear locking differential Powertrain Options: Reliable V6 and powerful V8 engine options Utility: Body-on-frame construction for towing and heavy-duty use, significant towing capacity 📋 Manual Details Coverage Areas Engine Options: All Models/Engines Trim Levels: All Trim Levels Transmission Types: All Transmission Types Region Specific: Global (assuming North American spec as primary, but covers broad applicability) Page Count Estimated Pages: Approx. 2000+ (typical for comprehensive workshop manuals) Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, exhaust system, engine cooling, lubrication system, engine electrical, powertrain control modules (PCM) Drivetrain: Automatic transmission, manual transmission, transfer case, front axle, rear axle, drive shafts, differentials Chassis: Suspension (front and rear), steering system, braking system (ABS, EBD), wheels and tires Electrical: Battery, charging system, starting system, lighting system, instrument cluster, body control modules (BCM), power windows, power locks, wipers, horn, audio system, climate control electronics Body: Exterior body panels, interior trim, doors, hood, tailgate, glass, seats, body sealing Climate Control: HVAC system (heating, ventilation, air conditioning), refrigerant system, control panels Safety Systems: Airbag system, seat belt pre-tensioners Procedures Included Maintenance: Routine inspections, fluid changes, filter replacements, lubrication, belt checks and replacement Diagnostics: Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs), using scan tools Repair: Component removal and installation, overhaul procedures, adjustments, specifications for tightening torques Overhaul: Engine rebuild, transmission rebuild, differential overhaul Electrical Repair: Wiring diagrams, component testing, circuit diagnosis Body Repair: Panel replacement, dent repair, glass replacement procedures Technical Depth Depth: Comprehensive (from basic maintenance to complete engine and transmission overhaul) Diagnostic Capability: Advanced diagnostics with wiring schematics and component data Specification Detail: Detailed technical specifications, torque values, clearances, fluid capacities, and electrical data 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text (typical for professionally produced PDFs) Printability: Printable pages for physical reference Print Quality Image Resolution: High-resolution images, diagrams, and schematics Diagram Clarity: Clear and detailed technical illustrations Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code: 6G74 (most common V6) Engine Type: 3.5L SOHC V6 (24-valve) Displacement: 3497 cc (213.4 cu in) Bore X Stroke: 93.0 mm x 85.8 mm Compression Ratio: 8.5:1 Horsepower Net: 197 hp @ 5000 rpm (typical for 6G74) Torque Net: 230 lb-ft @ 3750 rpm (typical for 6G74) Optional Engine Engine Code: 8A80 (3.8L V8 - availability may vary by market, less common for 2004 Montero specifically, but possible in some export markets or earlier years) Engine Type: 3.8L SOHC V6 (24-valve) - 6G75 Displacement: 3828 cc (233.6 cu in) Horsepower Net: 200 hp @ 4500 rpm (typical for 6G75) Torque Net: 260 lb-ft @ 3000 rpm (typical for 6G75) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded gasoline Octane Rating: 87 octane recommended (check manual for specific requirement) Ignition System Ignition Type: Distributorless Ignition System (DIS) with Coil-on-Plug (COP) 🔧 Transmission Standard Transmission Type: 4-speed automatic transmission (INVECS-II) Optional Transmission Type: 5-speed manual transmission (less common in North America for this generation) Features 4Wd System: Super Select II 4WD (Part-time 4WD with full-time mode, low-range gearing, and locking center differential) Transmission Fluid: Diamond SP-III ATF (Automatic Transmission Fluid) or equivalent (refer to manual for exact specification and capacity) 📐 Dimensions Exterior Length: Approx. 192.7 inches (4895 mm) Width: Approx. 71.7 inches (1820 mm) Height: Approx. 72.4 inches (1840 mm) Wheelbase: Approx. 110.2 inches (2800 mm) Interior Seating Capacity: 7 passengers (with optional third-row seating) Cargo Cargo Volume Behind 2Nd Row: Approx. 48.0 cu ft Cargo Volume Behind 3Rd Row: Approx. 17.0 cu ft Weights Curb Weight: Approx. 4,400 - 4,800 lbs (depending on configuration) Gross Vehicle Weight Rating Gvw: Approx. 5,800 - 6,200 lbs Towing Capacity: Up to 5,000 lbs (check vehicle specific rating) Payload Capacity: Approx. 1,000 - 1,200 lbs 🛡️ Safety Features Ratings NHTSA Frontal Crash Rating: 4-star driver/passenger (typical for this era) NHTSA Side Impact Rating: 4-star front/rear passenger (typical for this era) IIHS Crash Test Ratings: Good in frontal offset (varying results in side impact depending on equipment) Active Features ABS: Standard Anti-lock Braking System (ABS) Ebd: Electronic Brake-force Distribution (EBD) Traction Control: Available Traction Control System (TCS) - typically linked to 4WD...
Automatic transmission, manual transmission, transfer case, front axle, rear axle, drive shafts, differentials
Chassis:
Suspension (front and rear), steering system, braking system (ABS, EBD), wheels and tires
Electrical:
Battery, charging system, starting system, lighting system, instrument cluster, body control modules (BCM), power windows, power locks, wipers, horn, audio system, climate control electronics
Body:
Exterior body panels, interior trim, doors, hood, tailgate, glass, seats, body sealing
Climate Control:
HVAC system (heating, ventilation, air conditioning), refrigerant system, control panels
Safety Systems:
Airbag system, seat belt pre-tensioners
Procedures Included
Maintenance:
Routine inspections, fluid changes, filter replacements, lubrication, belt checks and replacement
Diagnostics:
Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs), using scan tools
Repair:
Component removal and installation, overhaul procedures, adjustments, specifications for tightening torques
Comprehensive (from basic maintenance to complete engine and transmission overhaul)
Diagnostic Capability:
Advanced diagnostics with wiring schematics and component data
Specification Detail:
Detailed technical specifications, torque values, clearances, fluid capacities, and electrical data
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text (typical for professionally produced PDFs)
Printability:
Printable pages for physical reference
Print Quality
Image Resolution:
High-resolution images, diagrams, and schematics
Diagram Clarity:
Clear and detailed technical illustrations
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code:
6G74 (most common V6)
Engine Type:
3.5L SOHC V6 (24-valve)
Displacement:
3497 cc (213.4 cu in)
Bore X Stroke:
93.0 mm x 85.8 mm
Compression Ratio:
8.5:1
Horsepower Net:
197 hp @ 5000 rpm (typical for 6G74)
Torque Net:
230 lb-ft @ 3750 rpm (typical for 6G74)
Optional Engine
Engine Code:
8A80 (3.8L V8 - availability may vary by market, less common for 2004 Montero specifically, but possible in some export markets or earlier years)
Engine Type:
3.8L SOHC V6 (24-valve) - 6G75
Displacement:
3828 cc (233.6 cu in)
Horsepower Net:
200 hp @ 4500 rpm (typical for 6G75)
Torque Net:
260 lb-ft @ 3000 rpm (typical for 6G75)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline
Octane Rating:
87 octane recommended (check manual for specific requirement)
Ignition System
Ignition Type:
Distributorless Ignition System (DIS) with Coil-on-Plug (COP)
🔧 Transmission
Standard
Transmission Type:
4-speed automatic transmission (INVECS-II)
Optional
Transmission Type:
5-speed manual transmission (less common in North America for this generation)
Features
4Wd System:
Super Select II 4WD (Part-time 4WD with full-time mode, low-range gearing, and locking center differential)
Transmission Fluid:
Diamond SP-III ATF (Automatic Transmission Fluid) or equivalent (refer to manual for exact specification and capacity)
📐 Dimensions
Exterior
Length:
Approx. 192.7 inches (4895 mm)
Width:
Approx. 71.7 inches (1820 mm)
Height:
Approx. 72.4 inches (1840 mm)
Wheelbase:
Approx. 110.2 inches (2800 mm)
Interior
Seating Capacity:
7 passengers (with optional third-row seating)
Cargo
Cargo Volume Behind 2Nd Row:
Approx. 48.0 cu ft
Cargo Volume Behind 3Rd Row:
Approx. 17.0 cu ft
Weights
Curb Weight:
Approx. 4,400 - 4,800 lbs (depending on configuration)
Gross Vehicle Weight Rating Gvw:
Approx. 5,800 - 6,200 lbs
Towing Capacity:
Up to 5,000 lbs (check vehicle specific rating)
Payload Capacity:
Approx. 1,000 - 1,200 lbs
🛡️ Safety Features
Ratings
NHTSA Frontal Crash Rating:
4-star driver/passenger (typical for this era)
NHTSA Side Impact Rating:
4-star front/rear passenger (typical for this era)
IIHS Crash Test Ratings:
Good in frontal offset (varying results in side impact depending on equipment)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Ebd:
Electronic Brake-force Distribution (EBD)
Traction Control:
Available Traction Control System (TCS) - typically linked to 4WD system
Stability Control:
Electronic Stability Control (ESC) - availability may vary by trim/market
Passive Features
Airbags:
Front airbags, available side curtain airbags
Seatbelts:
3-point seatbelts with pre-tensioners for front occupants
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for Children) system
💡 Technology Features
Infotainment
Audio System:
AM/FM/CD player, optional premium audio system (e.g., Rockford Fosgate on higher trims)
Navigation:
Optional factory navigation system
Driver Assistance
Cruise Control:
Standard cruise control
Parking Sensors:
Optional rear parking sensors
Connectivity
Connectivity Features:
Limited by era; typically basic audio input, no Bluetooth or USB standard.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,750 miles or 3 months (severe service) / 7,500 miles or 6 months (normal service) - consult manual for exact recommendation based on driving conditions
Engine Oil Filter Replacement:
With every oil change
Air Filter Replacement:
Every 15,000 - 30,000 miles (inspect more frequently)
Cabin Air Filter Replacement:
Every 15,000 - 30,000 miles
Spark Plug Replacement:
Every 60,000 - 100,000 miles (depending on plug type, iridium recommended)
Transmission Fluid Change:
Every 30,000 - 60,000 miles (severe use/towing recommend more frequent)
Coolant Flush:
Every 30,000 - 50,000 miles or 2-3 years
Fluid Specifications
Engine Oil Type:
SAE 5W-30 or 5W-40 API SJ/SL (consult manual for specific viscosity and API rating)
Engine Oil Capacity:
Approx. 4.5 - 5.0 quarts (with filter, for 6G74 V6)
Coolant Type:
Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based, green type)
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Cv Axle Boots:
Tearing of CV axle boots leading to joint failure, especially with off-road use.
Rear Main Seal Leaks:
Occasional reports of rear main crankshaft seal leaks.
Exhaust Manifold Cracks:
Potential for exhaust manifold cracks due to heat cycles.
Transmission Shifting Issues:
Some reports of harsh shifting or transmission slippage, often resolved by fluid change or solenoid replacement.
Window Regulator Failures:
Power window regulators can be a common failure point.
📚 Vehicle History
Brand Heritage
Mitsubishi SUV History:
Mitsubishi has a long history of producing capable SUVs, starting with models like the Pajero (which the Montero is based on internationally) and the Montero Sport.
Model Evolution
Generation 2004:
This 2004 model represents the third generation of the Montero (NS/NT series, 1999-2006). It transitioned to a more integrated body-on-frame design compared to earlier generations but retained its rugged capability.
Key Changes For 2004:
Minor styling updates, potential feature package adjustments, and continued refinement of powertrain and chassis.
Production
Manufacturing Location:
Primarily manufactured in Japan (Okazaki Plant)
Production Years:
Third Generation: 1999/2000 - 2006
🏆 Awards & Recognition
Recognitions
Off Road Awards:
Consistently praised for off-road capability by automotive publications.
Utility Vehicle Awards:
Often cited as a strong contender in the traditional SUV segment for its ruggedness and value.
Ratings
Consumer Reports Ratings:
Varied, often strong in reliability for powertrain but average to below-average in certain electronic and body components depending on the specific model year and survey data.
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