🏷️ Basic Information

Make:

Mitsubishi

Model:

Montero

Year:

1994

Platform Code:

Second Generation (2nd Gen) / Second Series

👋 Introduction

Segment:

Mid-size SUV / Sport Utility Vehicle.

Target Audience:

Families, off-road enthusiasts, and those seeking a rugged and versatile vehicle.

Key Competitors:

Jeep Grand Cherokee, Toyota 4Runner, Ford Explorer, Chevrolet Blazer.

Body Styles:

3-door and 5-door configurations.

Drivetrain Options:

Rear-wheel drive (RWD) and part-time 4WD (Super Select 4WD II system on some models).

Off Road Capability:

Body-on-frame construction, robust suspension, available locking differentials enhance off-road prowess.

📋 Manual Details

Primary Coverage:

Complete repair and service procedures for the 1994 Mitsubishi Montero.

Secondary Coverage:

Maintenance, diagnostics, troubleshooting, specifications, wiring diagrams.

Estimated Page Count:

1500+

Type:

Factory Service Manual (FSM) / Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Engine overhaul, cylinder head, block, pistons, crankshaft, camshafts, timing belt/chain, lubrication system.

Engine Fuel System:

Fuel injection system (MPI), fuel pump, injectors, fuel pressure regulator, throttle body.

Engine Cooling System:

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

Engine Ignition System:

Ignition coil, spark plugs, distributor (if applicable), ignition timing.

Transmission Automatic:

Automatic transmission (e.g., KM145, V5A51) overhaul, diagnosis, fluid type and capacity, control systems.

Transmission Manual:

Manual transmission (e.g., W5MG1) overhaul, diagnosis, fluid type and capacity, clutch system.

Drivetrain 4Wd:

Transfer case operation and overhaul, front/rear axle overhaul, differentials, drive shafts, CV joints.

Suspension Front:

Independent front suspension, control arms, ball joints, bushings, shock absorbers, coil springs.

Brakes Front:

Front disc brake system, calipers, rotors, pads, master cylinder.

Steering:

Power steering system, steering gear, tie rods, power steering fluid.

Suspension Rear:

Multi-link rear suspension, trailing arms, shock absorbers, coil springs, bushings.

Brakes Rear:

Rear disc or drum brake system, calipers/wheel cylinders, rotors/drums, pads/shoes.

Electrical Engine:

ECU, sensors (e.g., Crankshaft Position, Camshaft Position, MAP, TPS, O2), actuators, engine wiring harness.

Electrical Chassis:

Lighting, horns, wipers, power windows, power locks, mirrors, seat adjustments.

Electrical Comfort:

HVAC system controls and components, blower motor, climate control module.

Body Exterior:

Body panel removal/installation, doors, hood, tailgate, bumpers, glass replacement, rust prevention.

Body Interior:

Interior trim, dashboard, seats, carpeting, headliner, sound insulation.

Maintenance Schedule:

Detailed recommended maintenance intervals for all major systems.

Diagnostic Troubleshooting:

Step-by-step diagnostic procedures for common and uncommon faults, including DTC (Diagnostic Trouble Code) interpretation where applicable.

Repair Procedures:

Complete step-by-step overhaul and repair instructions for all major vehicle components.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all systems, including component locations and wire color coding.

Specifications Charts:

Torque specifications, clearances, fluid capacities, electrical values, and diagnostic parameters.

Depth Level:

Comprehensive (suitable for professional technicians and advanced DIYers).

📊 Manual Specifications

File Type:

PDF

Searchability:

Searchable text content.

Printability:

Printable pages.

Image Clarity:

High-resolution diagrams and images.

Binding:

Not applicable (digital download).

Paper:

Not applicable (digital download).

⚙️ Engine Specifications

Engine Code:

6G72 (V6 SOHC) or 4D56 (4-cylinder OHC Turbo Diesel - less common in some markets)

Engine Configuration:

3.0L SOHC V6 (Gasoline)

Displacement:

2972 cc (3.0 Liters)

Bore X Stroke:

86.1 mm x 85.0 mm

Horsepower Est:

150-157 hp @ 5000 rpm (depending on market/tune)

Torque Est:

170-175 lb-ft @ 2500-3000 rpm (depending on market/tune)

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 Octane recommended)

Timing Belt Replacement Interval:

Typically 60,000 miles (96,000 km) or 4 years.

Spark Plug Part Number Example:

NGK BKR5ES-11 or equivalent

🔧 Transmission

Transmission Type Standard:

5-speed Manual Transmission (W5MG1)

Transmission Type Optional:

4-speed Automatic Transmission (e.g., KM145, V5A51)

Transfer Case Type:

Part-time 4WD with manual front hub engagement (or optional 'Super Select' system with electronic controls).

Automatic Transmission Fluid:

ATF SP-II, SP-III, or equivalent

Manual Transmission Fluid:

GL-4 75W-90 Gear Oil

Transfer Case Fluid:

GL-4 75W-90 Gear Oil

Automatic Transmission Capacity Approx:

8.5 Liters (17.9 Pints)

Manual Transmission Capacity Approx:

2.2 Liters (4.6 Pints)

📐 Dimensions

Wheelbase:

Approximately 109.4 inches (2780 mm)

Length:

Approximately 177.0 - 182.7 inches (4495 - 4640 mm) depending on body style

Width:

Approximately 69.7 inches (1770 mm)

Height:

Approximately 66.3 - 69.1 inches (1685 - 1755 mm) depending on model/options

Curb Weight Est:

Approximately 3900 - 4300 lbs (1770 - 1950 kg) depending on configuration

Gross Vehicle Weight Rating Gvw:

Approximately 5400 - 5700 lbs (2450 - 2585 kg)

Cargo Volume Behind Rear Seat Est:

Approximately 40-50 cubic feet

Cargo Volume With Rear Seat Folded Est:

Approximately 70-80 cubic feet

🛡️ Safety Features

NHTSA Frontal Crash Rating Driver:

Not rated or 4 stars (depending on specific test year and configuration)

NHTSA Frontal Crash Rating Passenger:

Not rated or 4 stars (depending on specific test year and configuration)

ABS:

Optional Anti-lock Braking System (ABS) on some models.

Airbags:

Driver airbag standard, passenger airbag optional or unavailable on some models.

Seatbelts:

3-point seatbelts front and rear.

Body Construction:

Body-on-frame construction provides inherent structural rigidity.

💡 Technology Features

Audio System:

Factory AM/FM cassette player, optional CD player. Limited speaker configurations.

Cruise Control:

Optional cruise control system.

Connectivity Features:

No modern connectivity features (Bluetooth, USB, etc.) present. Analog systems.

🔧 Maintenance

Oil Change Interval Synthetic:

5,000 - 7,500 miles (8,000 - 12,000 km) or 6 months, whichever comes first.

Oil Filter Replacement:

Replace with every oil change.

Engine Air Filter Replacement:

Every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed based on driving conditions.

Cabin Air Filter Replacement:

Not typically equipped on this model year.

Coolant Flush Interval:

Every 30,000 miles (48,000 km) or 2 years.

Engine Oil Specification:

API SG or SH, SAE 10W-30 or 10W-40 (refer to owner's manual for climate variations).

Engine Oil Capacity Approx:

4.5 - 5.0 Quarts (4.3 - 4.7 Liters) with filter change.

Brake Fluid Type:

DOT 3

Power Steering Fluid:

Dexron II or III ATF

Common Concerns:

Front suspension component wear (ball joints, bushings), rear main seal leaks, potential for timing belt failure if not replaced on schedule, exhaust manifold cracks (especially on V6), automatic transmission shifting issues.

Electrical Quirks:

Corrosion in electrical connectors, power window motor failures, HVAC blower resistor issues.

📚 Vehicle History

Brand Origins:

Mitsubishi Motors is a Japanese multinational automotive manufacturer with a long history dating back to 1917.

First Generation Start:

1976 (as the Mitsubishi Pajero)

Second Generation Start:

1991

Second Generation End:

1999

Manufacturing Locations:

Japan (primarily Mizushima Plant)

Market Regions:

Globally, including North America (as Montero), Europe (as Pajero), Australia (as Pajero), and other markets.

🏆 Awards & Recognition

Off Road Awards General:

The Mitsubishi Pajero/Montero platform has a strong reputation for off-road capability and has won numerous accolades in international rallies, including the Dakar Rally, though specific awards for the 1994 model year may vary.

Consumer Reports Reliability:

Reliability ratings for this era are generally considered average to below average compared to modern vehicles, with a strong emphasis on preventative maintenance being key.