🏷️ Basic Information

Make:

Mitsubishi

Model:

Montero & Montero Sport

Model Variant:

Montero (3rd Generation - NM/NP Pajero/Shogun), Montero Sport (1st Generation - K90 Series)

Applicable Years:

2004, 2005, 2006, 2007, 2008

Chassis Codes Montero:

NM (2000-2002), NP (2003-2006)

Chassis Codes Montero Sport:

K90 Series (PA/PB/PC)

👋 Introduction

Segment:

Mid-size SUV (Montero), Mid-size SUV/Pickup-based SUV (Montero Sport)

Key Attributes:

Ruggedness, off-road capability, V6 engine power, body-on-frame construction (Montero), utility, value proposition (Montero Sport)

Competitors Montero:

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

Competitors Montero Sport:

Toyota 4Runner (entry trims), Nissan Xterra, Ford Explorer Sport Trac, Chevrolet Trailblazer

Montero Platform:

Based on the third-generation Pajero (NM/NP), featuring independent front suspension and a robust chassis

Montero Sport Platform:

Based on the Pajero Sport (K90), utilizing a ladder frame chassis and often sharing components with Mitsubishi pickup trucks

Manual Value Proposition:

Empowers owners and independent repair shops with the detailed information necessary for accurate diagnosis and repair, significantly reducing reliance on dealerships and expensive labor.

📋 Manual Details

Geographical Coverage:

North America (Montero), Global (Pajero/Montero Sport)

Trim Level Coverage:

All trim levels including XLS, Limited (Montero), ES, LS, XLS, SE (Montero Sport)

Estimated Page Count:

1500-2500 (Highly comprehensive, often bundled across multiple volumes or a single large PDF)

Manual Type:

Complete Workshop Service and Repair Manual

Language:

English

Format:

Downloadable PDF

📖 Manual Coverage

Powertrain:

Engine mechanical, fuel system, ignition system, lubrication, cooling, exhaust, engine control systems (ECU), transmission (automatic & manual), transfer case, driveline (front & rear axles, CV joints)

Chassis:

Suspension (front & rear, independent & solid axle depending on model), steering system, brake system (hydraulic, ABS, parking brake), wheels and tires

Electrical:

Battery, charging system, starting system, lighting, instruments and gauges, HVAC controls, body electrical (windows, locks, mirrors), audio system, power distribution, wiring diagrams

Body:

Body structure, exterior panels, doors, glass, interior trim, seats, bumpers, body hardware, diagnosis and repair of body damage

Maintenance Procedures:

Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement, brake pad/rotor replacement, air filter replacement

Repair Procedures:

Engine overhaul, transmission overhaul, suspension component replacement, brake caliper/master cylinder repair, steering rack replacement, electrical component diagnosis and replacement, body panel repair and replacement

Diagnostic Procedures:

Troubleshooting charts, fault code diagnosis (OBD-II), component testing, wiring diagram interpretation, systematic diagnostic approaches

Special Procedures:

Wheel alignment specifications, torque specifications for all fasteners, diagnostic connector locations, reset procedures, airbag system safety precautions

Diagnostic Depth:

Advanced diagnostics including sensor data interpretation, actuator testing, and circuit analysis

Rebuild Depth:

Complete engine and transmission rebuild procedures with detailed component specifications and tolerances

Electrical Diagrams:

Comprehensive, high-resolution wiring diagrams for all major systems, including power distribution, grounds, and signal paths

📊 Manual Specifications

File Format:

PDF

Searchability:

Fully searchable text for quick information retrieval

Printability:

Printable pages for easy workshop use

Image Resolution:

High-resolution images and diagrams

Binding Type:

N/A (Downloadable)

Paper Type:

N/A (Downloadable)

⚙️ Engine Specifications

Engine Code Montero V6:

6G75 (3.8L V6 SOHC/MIVEC)

Displacement Montero V6:

3.8 Liters (3828 cc)

Bore X Stroke Montero V6:

95.0 mm x 88.0 mm

Compression Ratio Montero V6:

9.5:1

Horsepower Montero V6:

230-240 hp @ 5500-6000 rpm (varies by year and MIVEC implementation)

Torque Montero V6:

255-265 lb-ft @ 3750-4000 rpm (varies by year and MIVEC implementation)

Fuel System Montero:

Multi-point Fuel Injection (MPI)

Engine Code Montero Sport V6:

6G72 (3.0L V6 SOHC) / 6G74 (3.5L V6 SOHC)

Displacement Montero Sport V6:

3.0 Liters (2972 cc) or 3.5 Liters (3497 cc)

Horsepower Montero Sport V6:

177-200 hp @ 5000-5500 rpm

Torque Montero Sport V6:

180-220 lb-ft @ 3500-4000 rpm

Fuel System Montero Sport:

Multi-point Fuel Injection (MPI)

Engine Code Montero Sport I4:

4G64 (2.4L I4 SOHC)

Displacement Montero Sport I4:

2.4 Liters (2351 cc)

Horsepower Montero Sport I4:

130-143 hp @ 5000-5500 rpm

Torque Montero Sport I4:

145-154 lb-ft @ 3500-4000 rpm

Fuel System Montero Sport I4:

Multi-point Fuel Injection (MPI)

Engine Breathing:

Naturally Aspirated

Fuel Type:

Unleaded Gasoline

Fuel Octane Recommendation:

87 AKI (Octane rating may vary based on specific market and engine tune)

🔧 Transmission

Standard Transmission Montero:

5-Speed Manual (less common in later NP models), 4-Speed Automatic (INVECS-II)

Optional Transmission Montero:

5-Speed Automatic (INVECS-II/III with Sport Mode) for 3.8L models

Drivetrain Montero:

Full-time 4WD with Active Traction Control (ATC) and Sportronic shifter, or part-time 4WD with electronic locking rear differential (optional on higher trims)

Standard Transmission Montero Sport:

5-Speed Manual, 4-Speed Automatic (INVECS-II)

Optional Transmission Montero Sport:

4-Speed Automatic (INVECS-II) was common, especially with V6 engines

Drivetrain Montero Sport:

Part-time 4WD (Super Select II) or Full-time 4WD depending on trim and market. Includes low-range gearing.

Automatic Transmission Fluid Spec:

Diamond ATF SP-II M or equivalent (check manual for exact spec, typically Dexron III/Mercon compatible if SP-II M is unavailable)

Manual Transmission Fluid Spec:

API GL-4 or GL-5, SAE 75W-90 (check manual)

Transfer Case Fluid Spec:

API GL-4 or GL-5, SAE 75W-90 (check manual)

📐 Dimensions

Length Montero:

Approx. 188.4 - 192.1 inches (4785 - 4880 mm)

Width Montero:

Approx. 77.0 inches (1956 mm)

Height Montero:

Approx. 72.2 - 73.0 inches (1835 - 1855 mm)

Wheelbase Montero:

Approx. 109.4 inches (2780 mm)

Length Montero Sport:

Approx. 177.2 - 183.7 inches (4500 - 4665 mm)

Width Montero Sport:

Approx. 70.1 - 70.3 inches (1780 - 1785 mm)

Height Montero Sport:

Approx. 66.5 - 67.1 inches (1690 - 1705 mm)

Wheelbase Montero Sport:

Approx. 106.3 inches (2700 mm)

Curb Weight Montero:

Approx. 4,500 - 4,900 lbs (2041 - 2223 kg)

Curb Weight Montero Sport:

Approx. 3,900 - 4,500 lbs (1769 - 2041 kg)

Cargo Volume Behind 3Rd Row Montero:

Approx. 15.0 - 18.0 cu ft

Cargo Volume Behind 2Nd Row Montero:

Approx. 45.0 - 50.0 cu ft

Cargo Volume Max Montero:

Approx. 75.0 - 80.0 cu ft

🛡️ Safety Features

NHTSA Rollover Resistance Montero:

4/5 stars (depending on year and configuration)

IIHS Front Crash Rating Montero:

Good (for vehicles tested)

ABS:

Standard (4-wheel disc brakes with ABS)

Traction Control:

Standard (Active Traction Control - ATC on Montero)

Electronic Stability Control:

Available on some later models (check specific trim)

Airbags Front:

Driver and front passenger airbags (standard)

Airbags Side:

Available side curtain airbags for front and second-row passengers on some trims/years

Seatbelts:

3-point height-adjustable front seat belts with pretensioners, 3-point rear seat belts

💡 Technology Features

Audio System:

Premium Rockford Fosgate audio system available on Limited trims (often with subwoofer), AM/FM/CD player, optional satellite radio

Navigation:

Factory-integrated DVD-based navigation system available on higher trims

Audio System:

AM/FM/CD player, often with 6-speaker setup. Premium audio not as common as in Montero.

Cruise Control:

Standard on most models

Parking Assist:

Rear parking sensors available on select trims

Auxiliary Input:

3.5mm auxiliary audio input jack available on some models/trims

Power Outlets:

12V accessory power outlets (front console, cargo area)

🔧 Maintenance

Oil Change Interval:

Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, whichever comes first (refer to specific manual for exact recommendation based on driving conditions)

Air Filter Replacement Interval:

Every 30,000 - 45,000 miles (48,000 - 72,000 km)

Spark Plug Replacement Interval:

Platinum/Iridium plugs: 60,000 - 100,000 miles (96,000 - 160,000 km) (refer to specific plug type and manual)

Coolant Replacement Interval:

Every 30,000 - 60,000 miles (48,000 - 96,000 km) or 2-4 years (depends on coolant type)

Engine Oil Spec:

SAE 5W-30 or 5W-40 API SN/SM/SL (check manual for exact viscosity and API rating, often synthetic recommended)

Engine Oil Capacity 3.8L:

Approx. 5.3 quarts (5.0 liters) with filter

Engine Oil Capacity 3.5L:

Approx. 5.1 quarts (4.8 liters) with filter

Coolant Type:

Mitsubishi Diaqueen Super Long Life Coolant (SLLC) or equivalent (blue type, typically ethylene glycol based)

Brake Fluid Spec:

DOT 3 or DOT 4 (check manual)

Power Steering Fluid Spec:

Mitsubishi Diaqueen PSF or equivalent (Dexron III ATF sometimes used, verify with manual)

Montero Common Issues:

Rear differential actuator failure (4WD system), transmission solenoid issues, catalytic converter failure (especially on early 3.8L), water pump leaks, occasional ABS sensor failures

Montero Sport Common Issues:

Transfer case actuator issues, front suspension bushings wear, minor oil leaks from valve covers or oil pan, catalytic converter issues (less common than Montero), ABS sensor failures

📚 Vehicle History

Mitsubishi Motors History:

Founded in 1870 as a shipping company, Mitsubishi Group diversified into automobiles in the early 20th century. Known for robust, capable vehicles, particularly in the SUV and truck segments.

Montero Generations:

The 2004-2008 models represent the latter part of the 3rd generation (NM/NP), introduced in 2000. Known for significant upgrades in refinement, safety, and technology over previous generations.

Montero Sport Generations:

The 2004-2008 models correspond to the first generation (K90 series) Montero Sport, which was produced from 1996 to 2007 (globally). It was later replaced by the Endeavor in North America.

Montero Production Location:

Japan (primarily Mizushima Plant)

Montero Sport Production Location:

Japan (Pajeros) and Thailand (Montero Sport)

🏆 Awards & Recognition

Montero Off Road Reputation:

Consistently recognized for its strong off-road capabilities and ruggedness, often lauded by off-road enthusiasts and publications.

Montero Value Retention:

Historically offered good value retention due to its durability and capability, especially in well-maintained examples.