Mitsubishi Montero 1992 Repair Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Year: 1992 Codes Internal Model Code: V20 Series 👋 Introduction Market Position Vehicle Segment: Compact to Mid-size SUV / Off-roader Key Competitors...

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UGS: 391051

Mots clés: 1992 Car Cars Misc Mitsubishi Montero

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Montero

Year:

Codes

Internal Model Code:

V20 Series

👋 Introduction

Market Position

Vehicle Segment:

Compact to Mid-size SUV / Off-roader

Key Competitors 1992:

Toyota 4Runner, Jeep Cherokee (XJ), Ford Explorer, Nissan Pathfinder, Isuzu Trooper

Key Features

Body Styles:

2-door (short wheelbase), 4-door (long wheelbase), Hardtop, Soft-top (less common)

Drivetrain:

Part-time 4WD (Super Select 4WD optional on some variants), RWD available.

Off Road Capability:

Body-on-frame construction, solid rear axle, low-range transfer case, good ground clearance.

Interior Versatility:

Foldable rear seats, ample cargo space for its class.

📋 Manual Details

Coverage Areas

Regions Covered:

Global (specific focus likely North America, Japan, Europe due to market presence)

Page Count

Estimated Page Count:

Varies significantly by OEM manual, typically 1000+ pages for full repair manuals.

Manual Type

Type:

Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Detailed diagnostics, repair, overhaul procedures for all gasoline and diesel engines offered in 1992 Montero.

Transmission:

Service and repair for manual and automatic transmissions, including clutch, transfer case, and driveline components.

Brakes:

Front disc, rear drum/disc brake systems, ABS (if equipped), hydraulic system diagnostics, caliper/master cylinder repair.

Suspension:

Front independent suspension (torsion bar or coil spring), rear multi-link solid axle, shock absorbers, bushings, alignment specifications.

Steering:

Power steering system diagnostics, pump, rack/gearbox repair, steering column.

Electrical:

Complete wiring diagrams, component testing, diagnostics for lighting, ignition, charging, starting systems, instrument cluster.

Bodywork:

Exterior panel repair, interior trim removal/installation, door mechanisms, glass replacement.

HVAC:

Air conditioning system servicing, heater core, blower motor, climate controls.

Fuel System:

Fuel injection (MPI/EFI) or carburetor systems, fuel pump, injectors, fuel lines, emissions controls.

Cooling System:

Radiator, thermostat, water pump, cooling fan operation, coolant specifications.

Exhaust System:

Muffler, catalytic converter, exhaust manifold, pipe replacement.

Procedures Included

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, spark plug service, lubrication.

Diagnostics:

Troubleshooting flowcharts, symptom-based diagnostics, fault code interpretation (if applicable).

Repair:

Step-by-step repair instructions for all major and minor mechanical and electrical components.

Overhaul:

Complete engine and transmission rebuild procedures with detailed specifications.

Installation:

Procedures for installing replacement parts and accessories.

Specifications:

Torque values, clearances, tolerances, fluid capacities, electrical resistance values.

Technical Depth

Depth:

Comprehensive: Covers routine maintenance to full engine and transmission rebuilds, including advanced diagnostics.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable PDF for efficient information retrieval.

Print Quality

Quality:

High resolution, suitable for printing specific sections or the entire manual.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code Gasoline 1:

4G63 (2.0L SOHC I4)

Engine Code Gasoline 2:

6G72 (3.0L SOHC V6)

Engine Code Diesel:

4D56 (2.5L SOHC I4 Diesel)

Performance Gasoline 1

Horsepower 4G63:

Approx. 108-118 hp (depending on market and tuning)

Torque 4G63:

Approx. 130-135 lb-ft

Performance Gasoline 2

Horsepower 6G72:

Approx. 143-155 hp (depending on market and tuning)

Torque 6G72:

Approx. 165-180 lb-ft

Performance Diesel

Horsepower 4D56:

Approx. 80-95 hp (depending on market and tuning)

Torque 4D56:

Approx. 145-160 lb-ft

Fuel System

Fuel Delivery Gasoline:

Multi-point Fuel Injection (MPI) for most models, some earlier or base models might have Carbureted.

Fuel Type:

Unleaded Gasoline (Regular Octane), Diesel

🔧 Transmission

Standard

Transmission Type Standard:

5-speed Manual Transmission

Optional

Transmission Type Optional:

4-speed Automatic Transmission

Features

Transfer Case Type:

Part-time 4WD with Manual Hubs (standard), optional 'Super Select 4WD' with center differential and electronic controls on some models.

Manual Transmission Fluid:

API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil (verify specific manual for exact spec).

Automatic Transmission Fluid:

Dexron II or equivalent (verify specific manual for exact spec).

📐 Dimensions

Exterior 2Door

Wheelbase 2Door:

Approx. 2450 mm (96.5 in)

Exterior 4Door

Wheelbase 4Door:

Approx. 2725 mm (107.3 in)

Weights

Curb Weight Approx:

1600 - 1900 kg (3500 - 4200 lbs) depending on configuration

🛡️ Safety Features

Ratings

Crash Test Era:

Safety standards and testing were less stringent compared to modern vehicles. Focus on structural integrity and passive restraints of the era.

Active Features

Anti-lock Braking System (ABS) available as an option on some higher trim levels.

Passive Features

Seatbelts:

Front and rear seatbelts, potentially with pretensioners on front seats.

Airbags:

Driver-side airbag became standard in the US for 1992 models. Passenger airbag not common for this generation.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with cassette player. Speaker configurations vary by trim.

Driver Assistance

As mentioned, ABS was an optional feature, not a widespread driver assistance system by modern standards.

Connectivity

Connectivity Features:

None by modern definition (no Bluetooth, USB, or infotainment integration beyond radio).

🔧 Maintenance

Service Intervals Oil

Oil Change Interval Gasoline:

Every 3,000-5,000 miles or 3-6 months (depending on driving conditions, refer to manual for precise interval).

Oil Change Interval Diesel:

Every 3,000-5,000 miles or 3-6 months (diesel engines may require more frequent changes).

Service Intervals Filters

Air Filter Replacement:

Every 15,000-30,000 miles or as needed based on condition.

Fuel Filter Replacement:

Every 20,000-40,000 miles (gasoline), every 20,000 miles (diesel).

Service Intervals Spark Plugs

Spark Plug Replacement Gasoline:

Every 30,000-60,000 miles, depending on plug type (copper, platinum).

Fluid Specifications

Engine Oil Spec Gasoline:

API SG or SH, SAE 10W-30 or 10W-40 (verify specific manual for exact viscosity).

Engine Oil Spec Diesel:

API CD or CE, SAE 15W-40 (verify specific manual for exact viscosity).

Coolant Type:

Ethylene Glycol based coolant, typically a green silicate-inhibited type. 50/50 mix with distilled water.

Known Issues

Rust Corrosion:

Common issue on older SUVs, especially in rust-belt regions. Check frame rails, rocker panels, wheel wells.

Head Gasket Failure:

Can occur on the 6G72 V6 engine, particularly with overheating. The manual will cover diagnosing and replacing.

Transfer Case Actuator:

On 'Super Select' models, the electronic actuator for the transfer case can be a point of failure. Manual will have diagnostic procedures.

Suspension Wear:

Ball joints, tie rod ends, and bushings can wear over time, impacting steering and ride quality. Manual details inspection and replacement.

Cooling System Leaks:

Radiator, hoses, and water pump are common wear items susceptible to leaks.

📚 Vehicle History

Brand Heritage

Mitsubishi SUV Legacy:

Mitsubishi has a long history of producing rugged, capable off-road vehicles, dating back to models like the JEEP (which they licensed production for).

Model Evolution

First Generation Start:

The first generation Pajero/Montero debuted in 1982.

Second Generation Start:

The second generation, which the 1992 model belongs to, was introduced in 1991.

Key Updates 1992:

Introduction of the 3.0L V6 engine, availability of ABS, more refined interior, and optional 'Super Select 4WD'.

Production

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Off Road Reputation:

The Montero (Pajero) is globally recognized for its off-road prowess and durability, often winning or placing highly in events like the Dakar Rally.