🏷️ Basic Information

Make:

Mitsubishi

Model:

Montero Sport

Year:

2004

Chassis Code:

K90 Series (Montero Sport)

👋 Introduction

Segment:

Compact/Mid-size SUV (Body-on-frame chassis), often categorized as a Sport Utility Truck due to its truck-like construction.

Competitors 2004:

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

Platform Shared With:

Shared platform and many mechanical components with the Mitsubishi Pajero/Montero (full-size SUV) and Mitsubishi L200/Triton pickup truck.

Body On Frame Construction:

Robust body-on-frame construction provides durability and off-road capability, distinguishing it from unibody SUVs.

Engine Options:

Offered with potent V6 engines, providing ample power for towing and off-road use.

4Wd System:

Available with a capable part-time 4WD system, often featuring a transfer case with high and low range gearing, and in some configurations, locking differentials for enhanced off-road traction.

📋 Manual Details

Engine Coverage:

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

Transmission Coverage:

4-Speed Automatic (V4A51), 5-Speed Manual (V5M31)

Drivetrain Coverage:

2WD (RWD), 4WD (Part-time 4-wheel drive with transfer case and differential locks)

Estimated Pages:

Approximately 1500+ pages (Software compilation)

Type:

Official Factory Service Manual / Repair Manual Software

Language:

English

Format:

Digital Software (CD-ROM/Downloadable)

📖 Manual Coverage

Engine Mechanical:

Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication system, cooling system, fuel injection system, emission control systems.

Engine Electrical:

Ignition system, starter system, charging system, engine control module (ECM), sensors, actuators, wiring diagrams.

Transmission Manual:

Clutch, gearbox components, shift mechanisms, synchronizers, bearings, seals, internal and external linkages.

Transmission Automatic:

Torque converter, planetary gear sets, hydraulic control system, valve body, transmission control module (TCM), shift solenoids, cooler system.

Drivetrain Transfer Case:

Transfer case operation, gear sets, shift actuators, lubrication, maintenance, repair procedures.

Suspension Steering:

Front and rear suspension components (struts, shocks, control arms, ball joints, bushings), power steering system (pump, rack and pinion, hoses), wheel alignment specifications.

Brakes:

Front and rear brake systems (discs, calipers, pads, rotors, wheel cylinders), anti-lock braking system (ABS) components and diagnostics, parking brake system, brake fluid specifications and bleeding procedures.

Electrical Chassis:

Lighting system (headlights, taillights, interior lights), horn, wipers, washers, power windows, power locks, mirrors, seats, instrument cluster, dashboard controls.

Body Exterior:

Body panels, doors, hood, tailgate, bumpers, glass, seals, trim, exterior lighting, mirrors, body repair techniques.

Body Interior:

Seats, upholstery, dashboard, console, door panels, headliner, carpeting, interior trim, airbags, seatbelts, climate control system components.

Climate Control:

Air conditioning system (compressor, condenser, evaporator, refrigerant), heating system, blower motor, HVAC controls, cabin air filter.

Safety Systems:

Airbag system (SRS module, sensors, modules, wiring), seatbelt pre-tensioners, component diagnostics.

Maintenance Procedures:

Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, tire rotations, brake inspections, battery maintenance.

Diagnostic Procedures:

Troubleshooting guides, symptom-based diagnostics, DTC (Diagnostic Trouble Code) interpretation and resolution, wiring diagram interpretation for electrical issues.

Repair Procedures:

Step-by-step repair instructions for all major vehicle systems, including component removal, disassembly, cleaning, inspection, repair, reassembly, and installation.

Component Replacement:

Detailed instructions for replacing components such as engine parts, transmission units, suspension parts, brake components, electrical modules, and body panels.

Specifications Data:

Torque specifications for fasteners, engine clearances, fluid capacities, electrical resistance values, pressure specifications, alignment angles, and other critical technical data.

Depth:

Comprehensive: Covers everything from basic maintenance and inspections to advanced engine and transmission overhauls, complex electrical diagnostics, and body repair.

Diagnostic Tools:

Information on using diagnostic scan tools and interpreting their data.

Wiring Diagrams:

Detailed electrical wiring diagrams for all circuits, including power distribution, grounds, and component connections, essential for electrical troubleshooting.

📊 Manual Specifications

File Type:

Proprietary Software Application (typically requiring installation on a Windows PC)

Print Ability:

Printable pages from the software interface.

Binding:

N/A (Software, not a physical book)

Paper Quality:

N/A (Software, not a physical book)

⚙️ Engine Specifications

Engine 1 Displacement:

3.0 Liters (2972 cc)

Engine 1 Configuration:

SOHC V6 (6G72)

Engine 1 Horsepower:

Approximately 175-185 hp @ 5500-5750 rpm (varies slightly by trim/market)

Engine 1 Torque:

Approximately 200-215 lb-ft @ 3500-4000 rpm (varies slightly by trim/market)

Engine 2 Displacement:

3.5 Liters (3497 cc)

Engine 2 Configuration:

SOHC V6 (6G74)

Engine 2 Horsepower:

Approximately 200-215 hp @ 5000-5500 rpm (varies slightly by trim/market)

Engine 2 Torque:

Approximately 220-235 lb-ft @ 3500-4000 rpm (varies slightly by trim/market)

Fuel Delivery:

Electronic Fuel Injection (EFI), Multi-port Fuel Injection (MPFI).

Fuel Type:

Unleaded Gasoline (87 octane recommended, higher octane may be preferred for optimal performance).

Ignition Type:

Distributorless Ignition System (DIS) with coil-on-plug (COP) or coil pack ignition.

Cooling Type:

Pressurized liquid cooling system.

Oil Type Recommendation:

SAE 5W-30 or 10W-30 (API Service SG, SH, SJ, or SL), refer to manual for exact specification.

Emission Systems:

Catalytic converter, Oxygen (O2) sensors, Exhaust Gas Recirculation (EGR) system (on some models).

🔧 Transmission

Standard Type:

4-Speed Automatic Transmission (V4A51)

Optional Type:

5-Speed Manual Transmission (V5M31)

Automatic Control:

Electronically controlled with lock-up torque converter.

Manual Clutch:

Hydraulic clutch actuation.

Drivetrain:

2WD (Rear-Wheel Drive) and 4WD (Part-time, electronically controlled transfer case with high/low range).

Automatic Fluid Type:

Mitsubishi Diamond ATF SP-II or SP-III (or equivalent Dexron III/Mercon compatible fluid, consult manual for precise specification).

Manual Fluid Type:

API GL-3 or GL-4 Gear Oil (e.g., 75W-90), consult manual for precise specification.

📐 Dimensions

Wheelbase:

Approximately 106.7 inches (2710 mm)

Length:

Approximately 179.9 inches (4570 mm)

Width:

Approximately 69.1 inches (1755 mm)

Height:

Approximately 67.5 inches (1715 mm) (varies by trim/suspension)

Curb Weight:

Approximately 3900 - 4400 lbs (1770 - 2000 kg) depending on configuration.

Towing Capacity:

Up to 5,000 lbs (2268 kg) (properly equipped, consult manual and local regulations).

Payload Capacity:

Approximately 1000 - 1400 lbs (454 - 635 kg) (varies by configuration).

Wheel Bolt Pattern:

5 x 114.3 mm (5 x 4.5 inches)

Standard Tire Size:

235/75R15 or 265/70R16 (varies by trim).

🛡️ Safety Features

NHTSA Rollover Rating:

Four-Star (for 2WD models) and Five-Star (for 4WD models) in the NHTSA rollover resistance test for 2004 models.

Traction Control:

Available Traction Control System (TCS) on some models.

ABS:

Standard Anti-lock Braking System (ABS) on front and rear wheels.

Airbags:

Driver and front passenger airbags, available side-impact airbags.

Seatbelts:

Three-point seatbelts with pretensioners for front seats, rear three-point seatbelts.

💡 Technology Features

Audio System:

Factory AM/FM stereo with CD player, cassette player (on some models), and optional premium sound system with amplifier and subwoofer.

Climate Control Interface:

Manual or automatic climate control with rotary knobs and buttons.

Cruise Control:

Standard or optional cruise control.

Auxiliary Inputs:

Limited connectivity features for the era; may have 12V power outlets. Bluetooth or USB connectivity not typically factory-equipped.

Instrument Cluster:

Analog gauges for speedometer, tachometer, fuel level, and engine temperature. Warning lights for various systems.

🔧 Maintenance

Oil Change Interval:

Typically every 3,750 - 7,500 miles (6,000 - 12,000 km) or 6-12 months, depending on driving conditions and oil type used. Consult manual for specific recommendations.

Air Filter Replacement:

Every 30,000 miles (48,000 km) or as needed based on inspection.

Cabin Air Filter Replacement:

Every 15,000 - 30,000 miles (24,000 - 48,000 km) or annually.

Fuel Filter Replacement:

Typically every 60,000 miles (96,000 km) for in-tank filters, consult manual for location and type.

Transmission Fluid Change Automatic:

Every 30,000 - 60,000 miles (48,000 - 96,000 km) or as per severe duty schedule. Consult manual for specific interval and procedure.

Coolant Flush:

Every 30,000 - 60,000 miles (48,000 - 96,000 km) or 2-4 years. Use Mitsubishi Super Long Life Coolant (SLLC) or equivalent.

Brake Fluid Replacement:

Every 2 years or 30,000 miles (48,000 km) to maintain performance and prevent corrosion. Use DOT 3 or DOT 4 fluid.

Engine Oil Capacity:

Approximately 4.5 - 5.0 quarts (4.3 - 4.7 liters) for 3.0L, 5.0 - 5.5 quarts (4.7 - 5.2 liters) for 3.5L, with filter change. Consult manual.

Transmission Fluid Capacity Automatic:

Approximately 7.0 - 8.0 quarts (6.6 - 7.6 liters) for a fluid change and filter replacement. Consult manual.

Common Issues:

Rear main seal leaks, occasional transmission solenoid issues, exhaust manifold cracks, power steering leaks, and some electrical gremlins (e.g., window regulators).

Maintenance Tips:

Regularly inspect and replace PCV valve, keep engine clean to prevent heat buildup, and ensure proper cooling system maintenance to avoid overheating.

📚 Vehicle History

Mitsubishi History:

Mitsubishi Motors, a Japanese automaker, has a long history of producing durable and capable vehicles, including off-road vehicles like the Pajero/Montero.

Montero Sport Generation:

The 2004 model represents the second generation of the Montero Sport, introduced in 1996 (as the Montero Sport in North America) and received a significant facelift for the 2001 model year, which carried through to 2004.

Production Location:

Primarily manufactured in Japan and also in other international assembly plants.

🏆 Awards & Recognition

Awards Or Ratings:

While not typically a recipient of major individual awards, the Montero Sport was recognized for its off-road capability and value in its segment during its production run. Its strong family resemblance and mechanical commonality with the highly regarded Montero (Pajero) added to its appeal.