🏷️ Basic Information

Make:

Mitsubishi

Model:

Montero Sport

Year:

2004

Platform:

Second Generation (K80/K90)

Chassis Code:

K84W, K94W

👋 Introduction

Vehicle Segment:

Mid-size SUV (Sport Utility Vehicle)

Target Demographic:

Families and individuals seeking rugged utility, off-road capability, and practicality

Key Competitors 2004:

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

Powertrain Options:

Proven V6 engines, available 4WD (Super Select 4WD-i or Easy Select 4WD)

Construction:

Body-on-frame construction for durability and off-road resilience

Interior Versatility:

Spacious cabin with foldable rear seats for cargo carrying

Off Road Prowess:

High ground clearance, robust suspension, and capable 4WD systems

📋 Manual Details

Primary Coverage:

North America (and other global markets where applicable)

Engine Variants Covered:

3.0L V6 (6G72), 3.5L V6 (6G74)

Transmission Variants Covered:

4-speed Automatic, 5-speed Manual

Estimated Page Count:

1500+

Manual Type:

Factory Service Manual (FSM)

Scope:

Comprehensive Workshop and Repair Guide

Language:

English

Format:

PDF (Downloadable)

📖 Manual Coverage

Powertrain:

Engine mechanicals, fuel system, ignition system, exhaust system, engine control systems (ECU), cooling system, lubrication system

Drivetrain:

Manual and automatic transmission, transfer case, front and rear differentials, drive shafts, CV joints, hub assemblies

Chassis:

Suspension (front and rear), steering system, braking system (front discs, rear drums/discs), wheels and tires

Electrical:

Complete wiring diagrams, lighting, instrumentation, power windows, door locks, mirrors, audio system, charging system, starting system, HVAC controls, safety systems (airbags, ABS)

Body:

Body panels, doors, interior trim, seats, glass, bumpers, exterior trim, chassis and frame repair

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and changes, lubrication, tune-ups

Diagnostics:

Troubleshooting guides, symptom-based diagnosis, DTC code interpretation, electrical system testing

Repair:

Component removal and installation, engine overhaul, transmission overhaul, brake caliper rebuilding, suspension component replacement, electrical component repair

Specifications:

Torque specifications, clearances, fluid capacities, electrical resistance values, diagnostic test parameters

Special Tools:

Identification and usage of specialized tools required for specific repairs

Depth Level:

Comprehensive, covering basic to advanced repair and diagnostic procedures

Detail Level:

Step-by-step instructions with detailed diagrams, illustrations, and exploded views

Diagnostic Capability:

Detailed fault finding charts and diagnostic flowcharts for all major systems

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text for quick information retrieval

Print Readability:

High-resolution scans suitable for printing clear, legible pages

Binding Type For Print:

Not applicable for download, but designed for easy binding (e.g., spiral or three-ring)

Paper Type For Print:

Standard printer paper recommended

⚙️ Engine Specifications

Engine Code 1:

6G72

Engine Displacement 1:

3.0 Liters (2972 cc)

Engine Configuration 1:

SOHC V6

Horsepower 1:

Approx. 177 hp @ 5000 rpm

Torque 1:

Approx. 215 lb-ft @ 3500 rpm

Bore X Stroke 1:

91.1 mm x 76.0 mm

Compression Ratio 1:

8.9:1

Fuel Type 1:

Unleaded Gasoline

Engine Code 2:

6G74

Engine Displacement 2:

3.5 Liters (3497 cc)

Engine Configuration 2:

SOHC V6

Horsepower 2:

Approx. 197 hp @ 4800 rpm

Torque 2:

Approx. 233 lb-ft @ 3500 rpm

Bore X Stroke 2:

93.0 mm x 85.8 mm

Compression Ratio 2:

8.5:1

Fuel Type 2:

Unleaded Gasoline

Fuel Delivery:

Multi-point Fuel Injection (MPI)

🔧 Transmission

Transmission Type Standard:

4-speed Automatic (4G64/4G65 for some markets/engines, F4A51/V4A51 for V6)

Transmission Type Optional:

5-speed Manual (W5MG1)

4Wd System:

Available: Super Select 4WD-i (with center differential lock, 2WD/4H/4HLc/4LLc modes) or Easy Select 4WD

Automatic Transmission Features:

Electronically controlled, lock-up torque converter

Manual Transmission Features:

Robust design for off-road durability

📐 Dimensions

Length:

Approx. 179.9 inches (4570 mm)

Width:

Approx. 71.5 inches (1815 mm)

Height:

Approx. 67.1 inches (1705 mm)

Wheelbase:

Approx. 103.3 inches (2625 mm)

Ground Clearance:

Approx. 8.3 inches (211 mm)

Curb Weight:

Approx. 3800-4200 lbs (1724-1905 kg), depending on configuration

Gross Vehicle Weight Rating Gvw:

Approx. 5500 lbs (2500 kg)

Cargo Volume Behind Second Row:

Approx. 47.2 cubic feet

Cargo Volume With Second Row Folded:

Approx. 83.8 cubic feet

🛡️ Safety Features

NHTSA Front Impact Driver:

Likely 4-star (based on similar year models and IIHS ratings, specific 2004 Montero Sport data can be sparse)

NHTSA Front Impact Passenger:

Likely 4-star

IIHS Front Offset Crash Rating:

Good (for comparable models evaluated)

ABS:

Standard Anti-lock Braking System (ABS)

Traction Control:

Optional Traction Control System (TCS) on some models

Airbags:

Front driver and passenger airbags

Seat Belts:

Three-point seat belts with pretensioners for front occupants

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for CHildren) system

💡 Technology Features

Audio System:

Factory AM/FM/CD player with 4 or 6 speaker configurations. Optional premium audio systems may exist.

Navigation:

Rarely equipped with factory navigation in this model year; aftermarket solutions more common.

Cruise Control:

Standard or optional depending on trim level.

Auxiliary Input:

Unlikely to have factory AUX input; aftermarket adapters or Bluetooth kits are common upgrades.

🔧 Maintenance

Oil Change Interval:

Every 3,750 miles or 6 months (severe service) / 7,500 miles or 12 months (normal service) - Refer to manual for precise details based on oil type

Air Filter Replacement:

Every 15,000 miles or 12 months

Spark Plug Replacement:

Approx. 60,000-100,000 miles for iridium/platinum plugs (check specific plug type in manual)

Timing Belt Replacement:

Refer to manual, typically around 90,000-100,000 miles for V6 engines (critical maintenance item)

Engine Oil Type:

API SG, SH, SJ or ILSAC GF-2, GF-3 (Viscosity: SAE 5W-30 or 10W-30 recommended; check manual for specific ambient temperature recommendations)

Engine Oil Capacity 3.0L:

Approx. 4.8 US quarts (4.5 liters) with filter change

Engine Oil Capacity 3.5L:

Approx. 5.2 US quarts (4.9 liters) with filter change

Transmission Fluid Type Automatic:

DIA QUEEN ATF-SPII (or equivalent Dexron III/Mercon)

Transmission Fluid Capacity Automatic:

Approx. 3.5-4.0 US quarts (3.3-3.8 liters) for drain and fill

Transmission Fluid Type Manual:

API GL-4 or GL-5 Gear Oil (SAE 75W-90 recommended)

Transfer Case Fluid Type:

API GL-4 or GL-5 Gear Oil (SAE 75W-90 recommended)

Differential Fluid Type Front Rear:

API GL-5 Gear Oil (SAE 80W-90 recommended)

Coolant Type:

Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol based, green color) - 50/50 mix with distilled water

Brake Fluid Type:

DOT 3 or DOT 4

Common Wear Items:

CV axles, ball joints, tie rod ends, wheel bearings, brake pads/rotors due to typical SUV usage

Engine Considerations:

Timing belt integrity is crucial; neglect can lead to catastrophic engine damage. Monitor for potential oil leaks from valve covers or oil pan.

Transmission Considerations:

Regular fluid changes are vital for automatic transmission longevity. Manual transmissions are generally robust.

4Wd System Maintenance:

Ensure proper lubrication of transfer case and differential fluids. Check drive shaft U-joints for wear.

Electrical Quirks:

While generally reliable, older vehicles may develop issues with window regulators, door lock actuators, or sensor failures. Comprehensive wiring diagrams in the manual are essential for troubleshooting.

📚 Vehicle History

Mitsubishi Motors SUV Legacy:

Mitsubishi has a long history of producing capable SUVs, starting with models like the Pajero (Montero in North America). The Montero Sport builds on this off-road pedigree.

Montero Sport Generation 2 Dates:

1996-2008 (worldwide, with facelifts)

2004 Model Year Updates:

The 2004 model year falls within the second generation, which received updates throughout its run. Specific cosmetic or feature changes for 2004 may be minor compared to earlier or later second-gen models.

Manufacturing Locations:

Primarily Japan (Pajero Sport)

Market Presence:

Sold globally under various names including Pajero Sport, Challenger, and Montero Sport.

🏆 Awards & Recognition

Model Specific Awards 2004:

Specific awards for the 2004 Montero Sport are not widely documented as major accolades, but it was recognized for its value and off-road capability in various consumer surveys and reviews within its segment.

Consumer Reports Ratings:

Varies by year and specific attributes. Generally, older Mitsubishis of this era offered good value and mechanical robustness, though some minor electrical issues or interior material wear were occasionally noted.

Emissions Certification:

Compliant with EPA emissions standards for the 2004 model year.