Segment:
Mid-size SUV, body-on-frame construction, known for off-road capability and ruggedness.
Competitors:
Jeep Cherokee (XJ), Toyota 4Runner, Ford Explorer, Chevrolet Blazer, Nissan Pathfinder.
Vehicle Strengths:
Robust chassis, capable 4WD systems (Super Select 4WD-II on some models), durable engines, comfortable ride for an SUV of its era.
Value:
Provides essential factory-level repair and maintenance information, enabling owners to perform a wide range of services, saving on dealership costs and extending vehicle life.
Model Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004
Estimated Page Count:
Hundreds (exact number not specified but implied to be extensive)
Type:
Factory Service Manual / Workshop Manual / Repair Manual
Format:
Digital (Downloadable PDF)
Engine:
Detailed repair and overhaul procedures for all gasoline and diesel engines offered in the 1996-2004 Montero Sport Challenger, including timing belt/chain, cooling system, lubrication, fuel injection, ignition, and emissions.
Transmission:
Comprehensive coverage of automatic and manual transmissions, including removal, installation, disassembly, assembly, clutch service, torque converter, and troubleshooting.
Drivetrain:
Includes front and rear differentials, drive shafts, CV joints, transfer case operation and repair, and 4WD system diagnostics.
Brakes:
Detailed procedures for hydraulic systems, ABS, brake fluid, rotor and pad replacement, caliper service, parking brake adjustments, and bleeding.
Suspension:
Front and rear suspension components, shock absorber/strut replacement, coil springs, bushings, ball joints, tie rod ends, and wheel alignment specifications.
Steering:
Power steering system service, steering gearbox/rack and pinion repair, steering column, and linkage adjustments.
Electrical:
Extensive coverage of the vehicle's electrical system, including wiring diagrams, lighting, starting and charging systems, fuses, relays, instrument panel, power accessories, and starter/alternator testing.
HVAC:
Air conditioning system diagnosis and repair, refrigerant handling, blower motor, heater core, and climate control unit service.
Bodywork:
Body panel removal and installation, door mechanisms, interior trim, glass replacement, and corrosion prevention.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, and lubrication points.
Troubleshooting:
Diagnostic flowcharts and step-by-step troubleshooting guides for common drivability, electrical, and mechanical issues.
Repair:
Detailed, step-by-step repair instructions for virtually all vehicle components, from minor adjustments to major overhauls.
Installation:
Instructions for installing new or replacement parts, including proper torque specifications and alignment procedures.
Depth:
Comprehensive, covering all aspects from basic maintenance to complete engine and transmission rebuilds, including detailed diagnostic procedures and specifications.
Engine Options Common:
3.0L V6 (6G72), 3.5L V6 (6G74), 2.5L Turbo Diesel (4D56T - less common in some markets but covered)
Horsepower Torque 3.0L V6:
Approx. 175-195 hp, 180-195 lb-ft torque (varies by year and tune)
Horsepower Torque 3.5L V6:
Approx. 195-215 hp, 210-230 lb-ft torque (varies by year and tune)
Fuel Delivery:
Electronic Multi-Point Fuel Injection (MPI) for gasoline engines.
Coolant Type:
Long-life, ethylene glycol-based coolant (e.g., Mitsubishi DiaQueen Super Long Life Coolant, or equivalent).
Oil Viscosity Recommendation:
Typically 5W-30 or 10W-30, depending on climate and specific engine (refer to manual for exact specification).
Timing Belt Replacement Interval:
Approximately 60,000-90,000 miles or 5-7 years for 6G7 series V6 engines (critical maintenance item).
Standard Transmission:
Manual transmission (e.g., 5-speed) availability depended on market and trim.
Optional Transmission:
Automatic transmission (e.g., 4-speed automatic) was widely available.
4Wd System:
Super Select 4WD-II (SS4-II) or Easy Select 4WD systems were common, offering various modes including 2WD, 4WD High, 4WD High Locked, and 4WD Low Locked.
Automatic Transmission Fluid:
Typically ATF SP-II or SP-III (Mitsubishi DiaQueen ATF) or equivalent DEXRON III/MERCON compatible fluid (verify specific model).
Manual Transmission Fluid:
GL-4 or GL-5 gear oil, typically 75W-90 viscosity (verify specific model).
Wheelbase:
Approximately 109.7 inches (2785 mm)
Length:
Approximately 183.1 inches (4650 mm)
Width:
Approximately 70.1 inches (1780 mm)
Height:
Approximately 66.7 inches (1695 mm)
Curb Weight:
Varies by configuration, but typically in the range of 3,900 - 4,300 lbs (1770 - 1950 kg).
Towing Capacity:
Varies by engine and configuration, typically around 2,000 - 5,000 lbs (900 - 2270 kg).
Engine Oil Change:
Every 3,750 to 7,500 miles (6,000 to 12,000 km) or 6 to 12 months, depending on driving conditions and oil type used. Consult manual for precise interval.
Transmission Fluid Change:
Automatic transmission fluid: 30,000-60,000 miles (48,000-96,000 km). Manual transmission fluid: 60,000-90,000 miles (96,000-145,000 km).
Transfer Case Differential Oil Change:
Every 30,000-60,000 miles (48,000-96,000 km).
Brake Fluid Type:
DOT 3 or DOT 4, depending on original equipment specification (verify in manual).
Power Steering Fluid:
Power steering fluid, or ATF Dexron II/III compatible fluid (verify in manual).
Common Problems:
Timing belt tensioner failure on V6 engines (critical to replace belt and tensioner/idlers), potential for differential seals and axle seal leaks, transfer case actuator issues on some 4WD systems, occasional electrical gremlins in older vehicles.
Filter Part Numbers Example:
Oil filter: MD340800 (example), Air filter: MR212447 (example). Exact part numbers vary by engine and specific application. Manual will list correct numbers.
