2004 Mitsubishi Montero Sport Service and Repair Manual

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Covers all 2004 Montero Sport trims — XLS Premium Sport Utility 4-Door, LS Sport Utility 4-Door, XLS Sport Utility 4-Door +1 more ·
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2004 Mitsubishi Montero Sport 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

  • XLS Premium Sport Utility 4-Door
  • LS Sport Utility 4-Door
  • XLS Sport Utility 4-Door
  • XLS Touring Sport Utility 4-Door

Engines covered

  • 3.5L 3497CC 215Cu. 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
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

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 20 technical service bulletins on file with NHTSA.

20060105Component: AIR BAGS:FRONTALCrash reported1 injured

DT*: THE CONTACT STATED WHILE DRIVING ON SLIPPERY ROADS THE CONSUMER HIT A PUDDLE AND ROLLED OVER A FENCE INTO A WATER RESERVE. UPON IMPACT, BOTH FRONTAL AIRBAGS FAILED TO DEPLOY AND THE DRIVER'S SE

20060105Component: SEAT BELTS:FRONT:BUCKLE ASSEMBLYCrash reported1 injured

DT*: THE CONTACT STATED WHILE DRIVING ON SLIPPERY ROADS THE CONSUMER HIT A PUDDLE AND ROLLED OVER A FENCE INTO A WATER RESERVE. UPON IMPACT, BOTH FRONTAL AIRBAGS FAILED TO DEPLOY AND THE DRIVER'S SE

20151119Component: FUEL/PROPULSION SYSTEM

FILL SUV WITH GAS AND IT ALL LEAKED OUT UNDER THE SUV.

20151021Component: FUEL/PROPULSION SYSTEM

TL* THE CONTACT OWNS A 2004 MITSUBISHI MONTERO SPORT. THE CONTACT DETECTED THE ODOR OF FUEL IN THE VEHICLE. THE CONTACT STATED THAT THE FAILURE BECAME PROGRESSIVELY WORSE OVER TIME. AFTER FULLY REFUEL

20141001Component: ENGINE AND ENGINE COOLING

HEAT GAUGE IS FAULTY AND IT WILL BLOW HOT HEAT ONLY OUT OF DRIVER SIDE VENTS AND BLOWS COLD OUT OF THE REST OF THE VENTS. HEAT GAUGE SAYS ITS RUNNING FINE BUT IT IS REALLY OVERHEATING TO THE BOILING P

Showing the 5 most serious of 6 complaints filed with NHTSA.

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