Mitsubishi Montero Workshop Service Manual Pack

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🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Codes Internal Model Codes: NH, NJ, NK, NS, NT, NW, NP 👋 Introduction Market Position Segment: Full-size SUV, Off-road capable vehicle Competitive...

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Typ: Car

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Art.-Nr: 39583

Stichworte: Car Cars Misc Mitsubishi Montero

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Beschreibung

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Montero

Codes

Internal Model Codes:

NH, NJ, NK, NS, NT, NW, NP

👋 Introduction

Market Position

Segment:

Full-size SUV, Off-road capable vehicle

Competitive Analysis

Key Competitors:

Toyota Land Cruiser, Jeep Grand Cherokee, Ford Explorer, Chevrolet Blazer

Key Features

Off Road Capability:

Renowned for its robust chassis, advanced 4WD systems (Super Select 4WD), and excellent ground clearance.

Durability Reliability:

Known for its rugged construction and ability to withstand demanding conditions, a favorite among off-road enthusiasts and for heavy-duty use.

Versatility:

Offers comfortable on-road manners combined with serious off-road prowess, suitable for family use and adventure.

📋 Manual Details

Coverage Areas

Years Covered:

1983, 1984, 1989, 2003

Page Count

Aggregate Page Count Estimate:

2000+

Manual Type

Manual Types Included:

Workshop Service Manual, Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine Mechanical, Engine Electrical, Fuel System, Ignition System, Cooling System, Lubrication System, Exhaust System, Emission Control

Drivetrain Systems:

Clutch, Manual Transmission, Automatic Transmission, Transfer Case, Drive Shafts, Axles, Differentials (Front, Rear, Center)

Suspension Steering Brakes:

Front Suspension (Independent, Double Wishbone), Rear Suspension (Multi-link Coil Spring, Leaf Spring), Steering System (Power Steering), Brake System (Front/Rear Disc, ABS)

Body Chassis:

Body Panels, Doors, Windows, Seating, Interior Trim, Exterior Trim, Chassis Frame, Collision Repair

Electrical Electronics:

Battery, Charging System, Starting System, Lighting System, Instrumentation, Wiper/Washer System, Power Windows/Locks, Audio System, HVAC Controls, ECU/ECM Diagnostics

Procedures Included

Maintenance Procedures:

Oil Changes, Filter Replacements, Spark Plug Service, Belt Inspections/Replacement, Fluid Checks/Changes, Tire Rotation, Brake Pad Replacement

Diagnostic Procedures:

Troubleshooting Flowcharts, DTC (Diagnostic Trouble Code) Interpretation, Symptom-Based Diagnostics, Circuit Testing

Repair Procedures:

Engine Rebuilds, Transmission Overhaul, Suspension Component Replacement, Brake System Repairs, Electrical Component Repair, Body Panel Replacement

Special Procedures:

Torque Specifications, Alignment Procedures, A/C System Servicing, Fuel System Cleaning, Diagnostic Tool Usage

Technical Depth

Diagnostic Depth:

Advanced diagnostic procedures for all major vehicle systems, including detailed wiring diagrams and component testing.

Repair Depth:

Comprehensive repair instructions for both routine maintenance and major component overhauls, including disassembly, assembly, and adjustment procedures.

Electrical Diagrams:

Detailed electrical schematics for all circuits, including power distribution, grounds, sensor signals, and actuator controls.

📊 Manual Specifications

File Format

PDF Quality:

High-resolution, searchable PDF for easy navigation and printing.

Print Quality

Printable Pages:

Yes, all pages are designed for clear printing.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper Recommendation:

Standard printer paper recommended for printing.

⚙️ Engine Specifications

Primary Engine

Engine Type 2003:

V6 SOHC (6G72/6G74) and V6 DOHC (6G74/6G75 variants)

Engine Displacement 2003:

3.5L (3497cc) and 3.8L (3799cc)

Engine Type Earlier Years:

Inline-4 SOHC (4G64), V6 SOHC (6G72)

Engine Displacement Earlier Years:

2.0L (1998cc), 2.6L (2600cc), 3.0L (2972cc)

Performance

Horsepower 2003 3.5L:

~197 hp @ 5000 rpm (V6 SOHC)

Torque 2003 3.5L:

~215 lb-ft @ 3500 rpm (V6 SOHC)

Horsepower 2003 3.8L:

~215 hp @ 4500 rpm (V6 SOHC)

Torque 2003 3.8L:

~255 lb-ft @ 3750 rpm (V6 SOHC)

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Recommended Fuel:

Unleaded gasoline (Octane rating varies by engine, refer to manual for specifics)

🔧 Transmission

Standard

Transmission Early Years:

5-Speed Manual Transmission

Transmission 2003:

4-Speed Automatic Transmission (4WD)

Optional

Transmission Early Years Optional:

4-Speed Automatic Transmission

Transmission 2003 Optional:

5-Speed Manual Transmission (rare, typically on base models)

Features

4Wd System:

Super Select 4WD II (electronic control) or conventional 4WD with locking center differential and low-range gearing.

📐 Dimensions

Exterior

Wheelbase 2003:

~107.3 inches (2725 mm)

Length 2003:

~186.4 inches (4735 mm)

Width 2003:

~71.7 inches (1820 mm)

Height 2003:

~71.9 inches (1825 mm)

Weights

Curb Weight 2003:

~4300 - 4700 lbs (1950 - 2130 kg) depending on configuration

Towing Capacity:

Up to 5,000 lbs (2268 kg), refer to specific model year and configuration for exact rating.

🛡️ Safety Features

Ratings

NHTSA Crash Test Ratings:

Varies by year and trim. Frontal impact ratings generally good for its era, but side impact and rollover resistance varied. Consult specific model year documentation.

Active Features

Standard on most models, especially later generations and higher trims.

Traction Control:

Available on select models and trims, particularly those with advanced 4WD systems.

Passive Features

Airbags:

Driver and front passenger airbags standard on later models. Side airbags not common until very late in production or as options.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD systems, often with Rockford Fosgate premium audio option on higher trims in later years.

Navigation:

Optional factory navigation systems available on some later models and trims.

Driver Assistance

Cruise Control:

Standard on most models, especially from the second generation onwards.

Power Features:

Power windows, power door locks, power mirrors are common on most trims.

Connectivity

Aux Input:

Not commonly found on earlier models; later models may have auxiliary audio inputs.

🔧 Maintenance

Service Intervals

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 (refer to manual for specific recommendation).

Transmission Fluid Change Interval:

Automatic transmission fluid typically every 30,000 - 60,000 miles (48,000 - 96,000 km), manual transmission and transfer case fluid vary.

Coolant Change Interval:

Every 30,000 - 50,000 miles (48,000 - 80,000 km) or 2-4 years.

Fluid Specifications

Engine Oil Type 2003:

API SG, SH, SJ or ILSAC GF-2, GF-3 certified oil, viscosity grade SAE 5W-30 or 10W-30 recommended based on ambient temperature (refer to manual).

Automatic Transmission Fluid Type:

Mitsubishi Diaqueen ATF SP-II M or equivalent DEXRON-III H / MERCON compatible fluid (confirm specific type in manual).

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Known Issues

Common Issues General:

Radiator leaks, differential seal leaks, timing belt replacement (on specific engines), occasional ABS sensor issues, front suspension wear (ball joints, bushings) due to off-road use.

Common Issues Electrical:

Window regulator failures, HVAC blower motor issues, intermittent dash light problems.

📚 Vehicle History

Brand Heritage

Mitsubishi Origins:

Mitsubishi Motors Corporation is a Japanese automobile manufacturer with a long history dating back to the early 20th century.

Model Evolution

First Generation:

First generation (1983-1990) based on the Pajero, introduced as a rugged, body-on-frame SUV for off-road capability.

Second Generation:

Second generation (1991-2000) introduced more refined styling, independent front suspension, and advanced 4WD systems (Super Select).

Third Generation:

Third generation (2001-2006) adopted unibody construction for improved ride comfort and handling, though retaining significant off-road capability. This is covered by the 2003 manual.

Later Generations:

Subsequent generations (NS, NT, NW, NP in some markets) continued to evolve, with the Montero name phased out in many markets but retained in others.

Production

Manufacturing Locations:

Primarily Japan, with assembly plants in other countries for various markets.

🏆 Awards & Recognition

Recognitions

Off Road Awards:

The Montero (and its Pajero predecessor) has a strong reputation in off-road communities and has often been praised for its capability in various challenging terrains.

Ratings

Consumer Reports Ratings:

Ratings vary by year. Generally considered average to above average in reliability for its class, with some years performing better than others. Specific model year reviews are key.

Certifications

Emissions Certifications:

Meets U.S. EPA and CARB emissions standards for its respective model years.