Segment:
Full-size SUV, body-on-frame construction, known for off-road capability and durability.
Competitors 2004:
Toyota 4Runner, Nissan Pathfinder, Ford Explorer, Jeep Grand Cherokee, Chevrolet TrailBlazer.
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.
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.
Estimated Page Count:
1500-2000+ (typical for full factory service manuals)
Type:
Factory Service Manual / Workshop Manual
All Major Systems:
Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Electrical, HVAC, Body, Chassis, Safety Systems.
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.
Depth:
Comprehensive; from basic scheduled maintenance to complete engine and transmission rebuilds, including torque specifications, clearances, and diagnostic procedures.
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:
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:
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
Fuel Type:
Unleaded gasoline (for 6G72/6G74), Diesel (for 4M41)
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 Option 1:
5-speed Manual Transmission (for select engine/trim combinations)
Transmission Option 2:
4-speed Automatic Transmission (with Electronic Control and Sport Mode)
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)
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
Seating Capacity:
5 or 7 passengers (optional third row)
Cargo Volume:
Variable, typically offering significant cargo space with rear seats folded.
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).
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)
ABS:
Standard Anti-lock Braking System (ABS).
Ebd:
Standard Electronic Brakeforce Distribution (EBD).
Traction Control:
Available Active Traction Control (ATC) or Active Stability Control (ASC) depending on trim.
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.
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).
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.
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.
Mitsubishi Motors:
Mitsubishi Motors Corporation, a Japanese multinational automotive manufacturer with a long history dating back to 1917.
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.
Manufacturing Locations:
Primarily manufactured in Japan, with some assembly potentially occurring in other global locations.
