2003 Mitsubishi Montero Service and Repair Manual

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Factory-Grade Data

2003 Mitsubishi Montero service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you diagnose issues correctly, follow proven repair steps, and use wiring diagrams and system sections to track faults faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical diagnostics with wiring diagrams
  • Coverage across major systems: engine, transmission/driveline, brakes, steering, suspension, HVAC, and more

Trims covered

  • Limited Sport Utility 4-Door
  • XLS Sport Utility 4-Door

Engines covered

  • 3.8L 3797CC 230Cu. In. V6 GAS SOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2003 Mitsubishi Montero Recalls & Complaints

NHTSA #04V31900006/07/2004Component: FUEL SYSTEM, GASOLINE:STORAGE

ON CERTAIN SPORT UTILITY VEHICLES, WHEN THE FUEL TANK IS FULL AND THE VEHICLE IS PARKED FACING FORWARD ON AN UPWARD SLOPE, THE FUEL TANK LEVELING VALVE MAY NOT MAINTAIN PROPER SEALING IN THE EVENT THE

Consequence

IF THE FUEL LEVELING VALVE DOES NOT SEAL PROPERLY, FUEL MAY LEAK ONTO THE GROUND. FUEL LEAKAGE IN T

Remedy

DEALERS WILL REPLACE THE LEVELING VALVE. THE RECALL BEGAN ON AUGUST 30, 2004. OWNERS SHOULD CONTAC

NHTSA #04V42800001/09/2004Component: EQUIPMENT:OTHER:LABELS

CERTAIN PASSENGER VEHICLES FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 208, 'OCCUPANT CRASH PROTECTION.' THE BILINGUAL ENGLISH/SPANISH REMOVABLE AIR BAG WARNING L

Consequence

THIS DOES NOT MEET THE REQUIREMENTS OF THE STANDARD.

Remedy

MITSUBISHI CARIBBEAN WILL MAIL A CUSTOMER NOTIFICATION LETTER CONTAINING A WRITTEN DESCRIPTION AND A

TSB #10240443

This is a Dealer Letter sent to dealers informing that Mitsubishi Technical Training has launched the 3rd quarterly technician quiz for 2023.

TSB #10235609

This Technical Service Bulletin provides instructions and material safety data sheets for removal of rap-film adhesive residue.

TSB #10235606

This is a Dealer Letter sent to dealers informing that Mitsubishi Technical Training has launched the 2nd quarterly technician quiz for 2023.

TSB #10235608

This Technical Service Bulletin reviews the regulations that require a label showing the reduction in load carrying capacity be affixed to vehicles when the total net weight of accessories is more than 1.5 percent of the vehicle's gross veh

TSB #10211530

This Technical Service Bulletin was sent to dealers to explain the difference between normal dew condensation, which is a natural phenomenon, and water penetration caused by improper sealing or a defective/broken part.

TSB #10170852

This Technical Service Bulletin updates the door adjustment procedure in the Body Section of the applicable service manuals.

TSB #10170070

This TSB contains troubleshooting steps for diagnosis of various customer complaints relating to the audio system speakers in Mitsubishi vehicles equipped with original equipment audio components.

TSB #10170099

This is an index of Tech Talk newsletter articles released in 2012.

Showing the 8 most recent of 49 technical service bulletins on file with NHTSA.

20060406Component: AIR BAGSCrash reported3 injured

DT*: THE CONTACT STATED WHILE DRIVING 55MPH A DEER WAS STRUCK WITH THE FRONT END OF THE VEHICLE. WHILE APPLYING BRAKE PRESSURE THE VEHICLE BEGAN TO GAIN SPEED, SPUN AROUND, VEERED OFF THE ROAD AND RO

20061130Component: AIR BAGSCrash reported1 injured

I WAS OPERATING A 2003 MITSUBISHI MONTERO WHEN I REAR ENDED A MERCURY MOUNTAINEER AND PROJECTED IT INTO 2 OTHER VEHICLES...... HEAVY DAMAGE TO THE FRONT END OF MY MONTERO, HOWEVER, MY DRIVER SIDE AIR

20090129Component: SERVICE BRAKES, HYDRAULICCrash reported

IN 2007 I HAD THE BRAKES TO MY 2003 MITSUBUSHI MONTERO LIMITED REPLACED BECAUSE I FELT THEY MY TRUCK WOULD NOT STOP AS DESIRED. AFTER HAVING THE BRAKES REPLACED IT APPEARS THAT THE PROBLEM BECAME WORS

20050509Component: SEAT BELTS:FRONT:RETRACTORCrash reported

DT: HUSBAND HAD A VEHICLE WRECK, THE CAR WOULD NOT STOP ON SNOW. CONTACT FELT TIRES WERE NOT RIGHT FOR CLIMATE. HAD TIRES ROTATED AND PRESSURE CHECKED REGULARLY. WAS TOLD BY MANUFACTURER THAT THE PS

20050509Component: SEATS:FRONT ASSEMBLY:RECLINERCrash reported

DT: HUSBAND HAD A VEHICLE WRECK, THE CAR WOULD NOT STOP ON SNOW. CONTACT FELT TIRES WERE NOT RIGHT FOR CLIMATE. HAD TIRES ROTATED AND PRESSURE CHECKED REGULARLY. WAS TOLD BY MANUFACTURER THAT THE PS

Showing the 5 most serious of 53 complaints filed with NHTSA.

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