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2004 Mitsubishi Montero Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Year: 2004 Codes Chassis Code: V73W, V75W, V77W, V78W Engine Codes: 6G72 (3.0L V6), 6G75 (3.8L V6) 👋 Introduction Market Position Segment:...
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Type: Car
Vendor:
Sku: 396254
2004 Mitsubishi Montero Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Montero
Year:
2004
Codes
Chassis Code:
V73W, V75W, V77W, V78W
Engine Codes:
6G72 (3.0L V6), 6G75 (3.8L V6)
👋 Introduction
Market Position
Segment:
Full-size SUV, Body-on-frame SUV
Target Audience:
Families, off-road enthusiasts, towing needs.
Competitive Analysis
Competitors:
Toyota 4Runner, Nissan Pathfinder, Ford Explorer, Chevrolet TrailBlazer.
Key Features
Capability:
Renowned for off-road capability, robust construction, available four-wheel drive systems (Super Select 4WD-II).
Versatility:
Spacious interior, good for towing and hauling, family-friendly.
📋 Manual Details
Coverage Areas
Coverage:
Complete Service and Repair Procedures for all major vehicle systems.
Page Count
Page Count:
Extensive (typical for full dealership service manuals)
Manual Type
Manual Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine management (ECU).
Drivetrain:
Transmission (manual and automatic), transfer case, differentials, driveshafts, CV joints, axles.
Chassis:
Suspension (front and rear), steering system, braking system (including ABS), wheels and tires.
Electrical:
Battery, charging system, starting system, lighting system, wipers and washers, power windows, power locks, mirrors, horn, instrument cluster, audio system, climate control.
Body:
Body panels, doors, hood, tailgate, bumpers, interior trim, seats, glass.
HVAC:
Air conditioning, heating, ventilation, climate control systems.
Safety:
Airbag system, seatbelt systems.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, fluid checks and replacements, filter replacements, tune-ups.
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs) interpretation and clearing.
Repair:
Component removal, disassembly, inspection, repair, reassembly, and installation for all major systems.
Adjustment:
Brake adjustments, clutch adjustments, alignment procedures, door and panel adjustments.
Specifications:
Torque specifications, clearances, fluid capacities, wiring diagrams, diagnostic data.
Technical Depth
Depth:
Comprehensive, suitable for dealership technicians and advanced DIY enthusiasts.
📊 Manual Specifications
File Format
File Type:
PDF (Portable Document Format)
Searchability:
Likely text-searchable for efficient information retrieval.
Print Quality
Resolution:
High-resolution, suitable for printing individual pages or sections.
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Displacement 3.0L:
3.0 Liters (2972 cc)
Engine Type 3.0L:
6G72 SOHC V6
Horsepower 3.0L:
Approx. 177-190 hp (depending on market and specific tune)
Torque 3.0L:
Approx. 245-260 lb-ft (depending on market and specific tune)
Optional Engine
Engine Displacement 3.8L:
3.8 Liters (3828 cc)
Engine Type 3.8L:
6G75 SOHC V6
Horsepower 3.8L:
Approx. 215-230 hp
Torque 3.8L:
Approx. 255-275 lb-ft
Performance
Fuel Type:
Unleaded Gasoline
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Ignition System:
Electronic Ignition (Distributorless Ignition System - DIS on some models)
🔧 Transmission
Standard
Transmission Type:
4-Speed Automatic (Invvecs-II Sportronic)
Optional
Transmission Type Manual:
5-Speed Manual Transmission (less common on US models)
Features
Drive System:
Part-time 4WD or Full-time 4WD (Super Select 4WD-II with locking center differential and low range).
📐 Dimensions
Exterior
Length:
Approx. 187.4 - 191.7 inches (4760 - 4870 mm)
Width:
Approx. 71.7 - 72.4 inches (1820 - 1840 mm)
Height:
Approx. 70.1 - 70.7 inches (1780 - 1795 mm)
Wheelbase:
Approx. 109.4 inches (2780 mm)
Weights
Curb Weight:
Approx. 4,387 - 4,784 lbs (1990 - 2170 kg)
Cargo
Cargo Volume:
Varies significantly with seat configuration; typically around 70-80 cu ft behind front seats.
🛡️ Safety Features
Ratings
NHTSA Front Impact:
5-star driver and passenger (for models tested).
NHTSA Side Impact:
4-star front and rear passengers (for models tested).
Active Features
ABS:
Standard Anti-lock Braking System (ABS).
Traction Control:
Available Traction Control System (TCS).
Passive Features
Airbags:
Driver and front passenger airbags, available side-impact airbags.
Seatbelts:
3-point seatbelts with pretensioners.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player, optional premium sound systems available.
Navigation:
Optional factory navigation system available on higher trim levels.
Driver Assistance
Cruise Control:
Standard cruise control.
Connectivity
Power Accessories:
Power windows, power locks, power mirrors standard on most trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 3,750 miles (6,000 km) or 6 months, whichever comes first, using conventional oil. 7,500 miles (12,000 km) or 12 months with synthetic oil.
Air Filter Replacement:
Every 30,000 miles (48,000 km) or as needed based on driving conditions.
Spark Plug Replacement:
Platinum: 60,000 miles (96,000 km). Iridium: 100,000 miles (160,000 km).
Fluid Specifications
Engine Oil Viscosity:
SAE 5W-30 (recommended for most climates). Check owner's manual for specific viscosity based on temperature.
Engine Oil Capacity:
Approx. 4.5 - 5.5 quarts (4.3 - 5.2 liters) with filter, depending on engine.
Transmission Fluid Type Automatic:
Diamond SP-III ATF (or equivalent). Check manual for exact specification.
Coolant Type:
Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors).
Known Issues
Common Concern 1:
Cracked exhaust manifolds (particularly on V6 engines due to heat cycles).
Common Concern 2:
Transmission issues (e.g., shifting problems, solenoid failures) can occur with high mileage.
Common Concern 3:
Sway bar links and bushings can wear, leading to clunking noises over bumps.
Common Concern 4:
Oxygen sensor failures, leading to check engine lights and poor fuel economy.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors:
Japanese automaker with a long history of producing robust and capable vehicles.
Model Evolution
Montero Generations:
The 2004 model is part of the third generation (1999-2006), which featured a significant redesign with a unibody construction (Pajero 'i.o' platform for the US market, unlike previous generations' body-on-frame) and independent front suspension for improved on-road manners while retaining off-road prowess.
Production
Manufacturing Location:
Japan (for export markets).
🏆 Awards & Recognition
Recognitions
Off Road Capability:
Consistently praised for its off-road prowess and durable chassis by automotive publications and enthusiasts.
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