2004 Mitsubishi Montero Service and Repair Manual

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Factory-Grade Data

2004 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 3828CC 230Cu. In. V6 GAS SOHC Naturally Aspirated
  • 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

2004 Mitsubishi Montero Recalls & Complaints

NHTSA #04V09500020/02/2004Component: EQUIPMENT:OTHER:LABELS

ON CERTAIN SPORT UTILITY VEHICLES, THE VEHICLE CAPACITY WEIGHTS AS STATED ON THE TIRE AND LOADING INFORMATION LABEL ARE IN ERROR.

Consequence

THIS INFORMATION COULD POTENTIALLY RESULT IN CONSUMERS LOADING THEIR VEHICLES BEYOND THE GROSS VEHIC

Remedy

OWNERS WILL BE SENT REPLACEMENT LABELS WITH INSTRUCTIONS ON HOW TO INSTALL THEM. THE RECALL BEGAN O

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 43 technical service bulletins on file with NHTSA.

20220623Component: SERVICE BRAKES

2004 Mitsubishi Montero Limited: Hydraulic Brake Booster is malfunctioning, making a ("gobble-gobble", squirrel-like chirping sound) almost every time the brake pedal is pressed. Hwy driving, without

20220623Component: STEERING

2004 Mitsubishi Montero Limited: Hydraulic Brake Booster is malfunctioning, making a ("gobble-gobble", squirrel-like chirping sound) almost every time the brake pedal is pressed. Hwy driving, without

20170929Component: UNKNOWN OR OTHER

THERE ARE HOLES IN FRAME IN FRONT AREA THE REST OF FRAME FROM CONVER IS OK WANTED TO KNOW WHAT OR HOW GET FIXED THIS WAS LIKE THIS WHEN I PURCHASED IT IF I NEED TO SEND PHOTOS LET ME KNOW SOME HOW IT

20140909Component: SERVICE BRAKES

TL* THE CONTACT OWNS A 2004 MITSUBISHI MONTERO. WHILE DRIVING APPROXIMATELY 60 MPH AND ATTEMPTING TO ENGAGE THE BRAKES, THE BRAKE PEDAL WAS HARD TO DEPRESS. THE EMERGENCY BRAKE HAD TO BE ACTIVATED I

20071009Component: SERVICE BRAKES, HYDRAULIC:POWER ASSIST:HYDRAULIC:HOSES, LINES/PIPING,

TL*THE CONTACT OWNS A 2004 MITSUBISHI MONTERO. THE CONTACT STATED THAT THE INSTRUMENT PANEL BRAKE LIGHTS ILLUMINATED. IN ADDITION, THERE WAS A COMPLETE LOSS OF BRAKE POWER. THE CONTACT STATED THAT

Showing the 5 most serious of 7 complaints filed with NHTSA.

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