MitsubishiMontero Sport20043.5L/mitsubishi/montero-sport/2004/3-5l/

2004 Mitsubishi Montero Sport — 3.5L

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2004 Montero Sport 3.5L.

Body SUVEngine 3.5LTransmission Automatic 4-spd

The 2004 Mitsubishi Montero Sport 3.5L is an SUV powered by a 3.5-liter engine paired with a four-speed automatic transmission, calling for 4.9 quarts of 10W-30 or 5W-30 API oil and carrying EPA ratings of 15 city/19 highway/17 combined mpg. Within the 1998-2009 Montero Sport complaint record, the 2004 model year sits far below the 2001 peak of 245 owner reports with only 5 total complaints, one recall, and the fuel/propulsion system cited as the top complaint area. That low complaint volume places it near the quieter end of the range before the 2009 low of a single complaint, making the 2004 model a relatively uneventful data point for researchers tracking this generation.

Model year20042003200220001999

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity4.9 qtOEM · verified
Engine oil type10W-30 / 5W-30 APIOEM · verified
Lug nut torque72-87 ft-lbsOEM · verified
EPA fuel economy15/19/17 mpgEPA · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 24 · 585 CCA battery, OE oil filter MZ690116. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 24 · 585 CCAOEM · verified
Tail / brake / turnHEADOEM · verified
Tire sizeP255-70R16OEM · verified
Wheel / rim7-JJ inOEM · verified

OE service part numbers OEM · verified

Engine oil filterMZ690116
Engine air filterMR571473
Fuel filterMR239580
Spark plugMD361067 alt MD372553
Front wiper bladesMR300877 alt MR300876
Serpentine belt4451A104 alt 7814A030
Thermostat1305A239

Full specifications

Engine, drivetrain, dimensions and economy.

Engine & drivetrain NHTSA vPIC

TransmissionAutomatic 4-spd

Dimensions & weight NHTSA vPIC

Overall length183.1 in
Overall width74.8 in
Overall height71.7 in
Wheelbase109.4 in
Curb weight4718 lb
Track (front / rear)61.4 / 61.8 in
Weight distribution (front / rear)47/53

Ratings & economy EPA / vPIC

EPA city / highway / combined15 / 19 / 17 mpg
DrivetrainRear-Wheel Drive
Recommended fuelRegular Gasoline

Performance & power Independent road tests

0–60 mph, quarter-mile, horsepower and torque from independent road tests.

No 2004 road test on record; the results below are same-engine tests from nearby model years, each shown under its own year.

10.1 sec0–60 mph (tested)quickest 10.10 sec — 2000 Limited
200 hpHorsepower (as tested)
230 lb-ftTorque (as tested)
YearTrim / engine0–60¼ mileHPDrivetrain
2000Limited 3.5L V610.10 sec17.50 sec200 hp4x4

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 4.9 qt of 10W-30 / 5W-30 API engine oil. Torque lug nuts to 72-87 ft-lbs, the oil drain plug to 29.0 ft-lbs. The firing order is 1-2-3-4-5-6.

Lubricants & capacities

Automatic Transmission FluidMitsubishi Diamond Queen SP-III
Automatic Transmission Fluid Capacity9.8
Engine Oil10W-30 · API · 5W-30
Engine Oil Capacity4.9 qt
Power Steering FluidGenuine Mitsubishi PS fluid
Power Steering FluidUse Mitsubishi PS fluid

Engine torques

Camshaft Bearing/Carrier Cap Bolts or StudsTighten in 2
Crankshaft Pulley and/or Damper Bolts134 ft-lbs
Cylinder Head Steps3 steps in sequence: Final torque; 80 ft-lbs
Engine Flywheel Bolts54 ft-lbs
Intake Manifold to Engine Bolts16 ft-lbs
Exhaust Manifold to Cylinder Head Bolts33 ft-lbs
Main Bearings54 ft-lbs
Engine Oil Pan Drain Plug29.0 ft-lbs

Chassis torques

Lug Nuts72-87 ft-lbs
Transfer Case Fill Plug21.0-25.0 ft-lbs
Transfer Case Drain Plug21.0-25.0 ft-lbs

Ignition

Cylinder Firing Order1-2-3-4-5-6
Curb Idle Speed (No Load)700 rpm
Curb Idle Speed Variance (No Load)100 rpm
Spark Plug Gap0.039-0.0.043 in
Spark Plug Torque15.0-21.0 ft-lbs
Ignition Timing5, Not adjustable degrees
Ignition Timing Acceptable Variance3 degrees

Battery & A/C

RefrigerantR134a
Refrigerant Capacity1.44-1.50 lbs
Oil GroupPAG
Oil Type46
Oil Capacity5.70 oz
Standard BCI Group Number24
Standard BCI Cranking Performance585 cca

Service checks

Regulated Fuel System Pressure (Without Vacuum)47.0-50.0 psi
Regulated Fuel System Pressure (With Vacuum)38.0 psi
Engine Compression171 minimum PSI. 14 maximum variation PSI.
Engine Compression127-171 psi
Engine Oil Pressure4.2 psi @ Idle, 43-100 psi @ 3500 rpm psi
Intake Valve LashHydraulic in
Exhaust Valve LashHydraulic in

Brakes

Torque Caliper to Bracket32 ft-lbs / 55 ft-lbs
Torque to Knuckle65 ft-lbs
Minimum Pad ThicknessFront: 0.080; Rear: 0.080 in
Minimum Shoe Thickness0.039 in
Rotor Runout Limit0.0031 in / 0.0024 in
Rotor Nominal Thickness From0.709 in / 0.945 in
Rotor Nominal Thickness To0.709 in / 0.945 in
Rotor Discard at or Under0.65 in / 0.88 in

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 7,500 mi; spark plugs every 60,000 mi; coolant at 60,000 mi. The big-interval services (at 60,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

Every 7,500 miEngine Oil (drain & refill) · Engine Oil Filter (replace) · Tire & Wheel Assembly (rotate)
Every 15,000 miAxle Shaft Oil Seal (inspect) · Brake Line (inspect) · Brake System (inspect)
Every 30,000 miAccessory Drive Belt (inspect) · Brake Drum Assembly (inspect) · CV Joint Boot (inspect) · Differential (inspect fluid level) · Drive Axle Assembly (drain & refill) · Driveshaft U-Joint (lubricate)
At 60,000 miEngine Coolant System (drain, flush & refill)
Every 60,000 miFuel Evaporative Emission Control System (inspect) · Fuel System (inspect) · Spark Plug Wires (replace) · Timing Belt (replace)
At 105,000 miSpark Plugs (replace)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

The complaint record shows a low of 35 in 1998, rising to 40 in 1999, 98 in 2000, then spiking to a peak of 245 in 2001 before falling to 61 in 2002, 83 in 2003, and dropping sharply to just 5 complaints in 2004, with only 1 complaint recorded in 2009. Recalls followed a similar arc: 1 in 1998, 3 in 1999, 1 in 2000, a high of 6 in 2001, none in 2002, 2 in 2003, 1 in 2004, and none in 2009. Investigations were absent except for a single investigation in 2002, while TSB counts declined from a high of 162 in 2001 to 24 in 2004. In 2004, the few complaints were concentrated in Fuel/Propulsion System (2), Engine & Engine Cooling (1), Power Train (1), and Air Bags/Seat Belts (1), accompanied by one crash complaint and zero fire complaints. Given the marked reduction in complaints, recalls, and TSBs after the 2001 peak, the 2004 model year presents a comparatively favorable reliability profile, making it a reasonable year to consider for purchase.

1
Open recalls
NHTSA campaigns
24
Service bulletins
Manufacturer communications
0
ODI investigations
Office of Defects Investigation
5
Owner complaints
1 involved a crash · 0 a fire
Owner complaints by model year NHTSA · this generation & adjacent

Owner complaints filed with NHTSA, by component

All 5 complaints on record, top 4 components.

Fuel/Propulsion System2
Engine & Engine Cooling1
Power Train1
Air Bags,Seat Belts1

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 1 of 1 campaigns on record for this vehicle.

04V095000Equipment:Other:LabelsReported 20/02/2004

ON CERTAIN SPORT UTILITY VEHICLES, THE VEHICLE CAPACITY WEIGHTS AS STATED ON THE TIRE AND LOADING INFORMATION LABEL ARE IN ERROR. Remedy: OWNERS WILL BE SENT REPLACEMENT LABELS WITH INSTRUCTIONS ON HOW TO INSTALL THEM. THE RECALL BEGAN ON APRIL 14, 2004. OWNERS SHOULD CONTACT MITSUBISHI AT 1-800-222-0037.

Technical service bulletins NHTSA · verified

Showing 5 of 24 bulletins on record with NHTSA.

BulletinDateComponentSummary
DEALER LETTER2023-07-21EquipmentThis is a Dealer Letter sent to dealers informing that Mitsubishi Technical Training has…
TSB-23-00-0042023-04-24StructureThis Technical Service Bulletin provides instructions and material safety data sheets for…
TSB-23-00-0012023-04-24EquipmentThis Technical Service Bulletin reviews the regulations that require a label showing the…
DEALER LETTER2023-04-21EquipmentThis is a Dealer Letter sent to dealers informing that Mitsubishi Technical Training has…
TSB-22-54-0032022-04-07Exterior LightingThis Technical Service Bulletin was sent to dealers to explain the difference between…

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420
Catalyst system efficiency below threshold — Bank 1
P0300
Random / multiple cylinder misfire detected
P0171
System too lean — Bank 1
P0455
Evaporative emission system leak detected — large leak
P0128
Coolant thermostat below regulating temperature
P0442
Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN
Decode a VIN to confirm the transmission and build data for a specific Montero Sport. OEM
Build data
Plant, GVWR class, engine and body data for any 17-character VIN.
Recalls
Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Reference guides

Cross-vehicle references for the kinds of data on this page.

Frequently asked

How much oil does the 2004 Montero Sport 3.5L take?

4.9 qt of ABOVE 0 degreesF 10W-30 SL API, BELOW 100 degreesF 5W-30 SL API, per the factory manual.

Does the 2004 Montero Sport have open recalls?

NHTSA lists 1 recall campaign(s) for this model year. Check your specific vehicle by VIN.

What gas mileage does the 3.5L get?

EPA figures are 15 city / 19 highway / 17 combined mpg.