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Mitsubishi Montero 2003 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Year: 2003 Codes Chassis Code: V73W, V75W, V77W, V78W 👋 Introduction Market Position Segment: Mid-size SUV, body-on-frame Target Audience: Off-road enthusiasts, families...
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Tipo: Coches
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SKU: 495535
Mitsubishi Montero 2003 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Montero
Year:
2003
Codes
Chassis Code:
V73W, V75W, V77W, V78W
👋 Introduction
Market Position
Segment:
Mid-size SUV, body-on-frame
Target Audience:
Off-road enthusiasts, families requiring utility and ruggedness
Competitive Analysis
Competitors:
Toyota 4Runner, Jeep Grand Cherokee, Ford Explorer, Chevrolet TrailBlazer
Key Features
Platform:
Third-generation Montero (NM/NP platform)
Off Road Capability:
Available Super Select II 4WD system with locking center differential, low-range gearing
📋 Manual Details
Coverage Areas
Countries:
Global (Primarily North America, Europe, Asia)
Trim Levels:
All trim levels (e.g., XLS, Limited, ES, LS)
Page Count
Estimated Pages:
2000+
Manual Type
Type:
Factory Service Manual (FSM)
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical, engine electrical, fuel system, exhaust system, cooling system, lubrication system
Drivetrain:
Transmission (automatic and manual), transfer case, drive shafts, differentials (front, rear, center), axles
Suspension:
Front suspension (independent), rear suspension (multi-link), springs, shock absorbers, bushings
Steering:
Power steering system, steering column, steering gear
Brakes:
Front disc brakes, rear disc brakes, anti-lock braking system (ABS), parking brake
Electrical:
Battery, charging system, starting system, ignition system, lighting system, interior/exterior electronics, body control module (BCM), multiplex communication system
HVAC:
Heating, ventilation, and air conditioning system (manual and automatic climate control)
Body:
Body structure, exterior panels, doors, hood, tailgate, glass, interior trim, seats, airbags
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs), wiring diagrams, connector pinouts
Repair:
Engine overhaul, transmission overhaul, brake system repair, suspension component replacement, electrical component repair, body panel repair
Special Tools:
Identification and usage of special tools required for specific procedures
Specifications:
Torque specifications, clearances, fluid capacities, electrical values
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete engine/transmission rebuilds and complex electrical diagnostics)
📊 Manual Specifications
File Format
File Type:
Searchable PDF
Printability:
Printable pages for workshop use
Print Quality
Image Resolution:
High-resolution images and diagrams
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
6G72
Engine Type 1:
3.5L SOHC V6 MIVEC
Displacement 1:
3497 cc
Horsepower 1:
200 hp @ 5000 rpm (V6 MIVEC)
Torque 1:
235 lb-ft @ 3750 rpm (V6 MIVEC)
Bore X Stroke 1:
91.1 mm x 86.0 mm
Compression Ratio 1:
9.0:1
Fuel Induction 1:
Multi-point Fuel Injection (MPI)
Secondary Engine
Engine Code 2:
6G75
Engine Type 2:
3.8L SOHC V6 MIVEC (some markets/later models)
Displacement 2:
3828 cc
Horsepower 2:
215-220 hp @ 5000-5500 rpm (V6 MIVEC)
Torque 2:
255-260 lb-ft @ 3750-4000 rpm (V6 MIVEC)
Performance
Fuel Type:
Unleaded Gasoline
Fuel System
Fuel Pump Type:
Electric, in-tank
Fuel Pressure:
Approximately 45-58 psi (310-400 kPa)
🔧 Transmission
Standard
Transmission Type:
5-speed Automatic (W5A580)
Optional
Transmission Type:
5-speed Manual (N7M-something, less common)
Features
4Wd System:
Available Super Select II 4WD system
Transfer Case:
2-speed transfer case with lockable center differential
Fluid Type
Automatic Transmission Fluid:
MITSU-SPEC ATF-SP-III (or equivalent DEXRON III/MERCON)
Fluid Capacity
Automatic Transmission Capacity:
Approx. 9.6 US quarts (9.1 liters) for complete refill
📐 Dimensions
Exterior
Length:
186.6 inches (4740 mm)
Width:
73.8 inches (1875 mm)
Height:
72.0 inches (1829 mm) (with roof rails)
Wheelbase:
109.7 inches (2785 mm)
Ground Clearance:
8.4 inches (213 mm)
Weights
Curb Weight:
4,500 - 4,800 lbs (2041 - 2177 kg) depending on configuration
Gross Vehicle Weight Rating:
6,000 - 6,200 lbs (2722 - 2812 kg)
Cargo
Cargo Volume Behind 2Nd Row:
Approx. 45.7 cu ft (1294 liters)
Cargo Volume Max:
Approx. 87.5 cu ft (2478 liters)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4 Stars (Driver and Passenger)
NHTSA Side Impact:
4 Stars (Front and Rear Passenger)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Available Traction Control System (TCL)
Passive Features
Airbags:
Standard front airbags, available side curtain airbags
Seatbelts:
Three-point seatbelts with pretensioners for front seats
💡 Technology Features
Infotainment
Audio System:
Optional Rockford Fosgate premium audio system with subwoofer
Navigation:
Available factory navigation system (early generation)
Driver Assistance
Cruise Control:
Standard cruise control
Connectivity
Phone Integration:
Limited to aftermarket Bluetooth kits for most 2003 models
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles (6,000 km) or 6 months, whichever comes first (severe conditions) or 7,500 miles (12,000 km) or 12 months (normal conditions) - Consult manual for exact recommendation
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months
Spark Plug Replacement:
Every 60,000 miles (96,000 km) for iridium plugs
Timing Belt Replacement:
Refer to specific engine variant and mileage, often around 75,000-105,000 miles (120,000-170,000 km) for 6G72/6G75 engines (check manual for exact interval as it's a belt-driven OHC engine)
Fluid Specifications
Engine Oil Type:
API SL or SM, SAE 5W-30 (check manual for specific viscosity and API rating)
Engine Oil Capacity:
Approx. 4.5 US quarts (4.3 liters) with filter change
Coolant Type:
Ethylene glycol based antifreeze, 50/50 mix with distilled water
Power Steering Fluid:
MITSU-SPEC PSF (or equivalent DEXRON III/MERCON ATF)
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid
Known Issues
Common Problems:
Sunroof drain tube blockages leading to water ingress, front axle CV joint wear (especially with off-road use), ABS sensor issues, occasional transmission solenoid issues
📚 Vehicle History
Brand Heritage
Heritage Summary:
Mitsubishi has a long history in producing robust and capable SUVs, with the Pajero/Montero line being a flagship model known for its off-road prowess and durability since its introduction in 1982.
Model Evolution
Generation Introduction:
The 2003 model year represents the third generation (NM/NP) of the Montero, launched for the 2000 model year, featuring a unibody construction (monocoque chassis) for improved on-road comfort and safety compared to previous body-on-frame designs.
Production
Production Location:
Gifu Prefecture, Japan (Pajero Manufacturing Co., Ltd.)
🏆 Awards & Recognition
Recognitions
Off Road Accolades:
The Montero line is renowned for its consistent performance in demanding off-road competitions and expeditions worldwide, reinforcing its rugged reputation.
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