Mitsubishi Montero 2006 2007 2008 2009 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Model Generations: • Third Generation (NM/NS) Covered Years: • 2006 • 2007 • 2008 • 2009 Codes Vehicle Identification Number Vin Prefix:...

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Tags: 2006 2007 2008 2009 Car Cars Misc Mitsubishi Montero

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Montero

Model Generations:

• Third Generation (NM/NS)

Covered Years:

• 2006

• 2007

• 2008

• 2009

Codes

Vehicle Identification Number Vin Prefix:

J-VIN (Japan manufactured)

👋 Introduction

Market Position

Market Position:

The Mitsubishi Montero (known as Pajero in many markets) is a full-size, body-on-frame SUV renowned for its off-road capability, ruggedness, and versatility. This manual caters to owners and technicians servicing the later models of the third generation, which continued to offer robust performance and a comfortable on-road experience while maintaining its legendary off-road prowess.

Target Audience:

Targeted at individuals and families seeking a highly capable SUV for both everyday use and adventurous off-road excursions. It appealed to those who valued ruggedness, durability, and the ability to tackle challenging terrain.

Competitive Analysis

Competitive Analysis:

During the 2006-2009 model years, the Montero competed against other capable full-size SUVs like the Toyota 4Runner, Jeep Grand Cherokee, Ford Explorer (older generation), and Nissan Pathfinder. Its key differentiators were its Super Select II 4WD system, advanced unibody construction (for its class, though still body-on-frame), and strong V6 engine, offering a balance of on-road comfort and extreme off-road capability.

Key Features

Key Features:

• Renowned off-road capability

• Comfortable and spacious interior

• Powerful V6 engine

• Advanced 4WD system

• Durable construction

📋 Manual Details

Coverage

Coverage Areas:

• Mechanical Repair

• Electrical Systems

• Body and Chassis

• Maintenance Procedures

• Diagnostics

• Troubleshooting

• Specifications

• Wiring Diagrams

• Component Location

• Torque Specifications

• Fluid Capacities

Page Count

Page Count:

Manual Type

Manual Type:

Workshop Service Manual / Repair Manual

Manual Type Description:

This is a comprehensive workshop manual designed for professional technicians and experienced DIY mechanics. It provides detailed instructions, diagrams, and specifications necessary for diagnosing, repairing, and maintaining the Mitsubishi Montero from 2006 to 2009.

Language

Language:

English

Format

Format:

PDF (Digital)

Download Information:

Instant download in PDF format, allowing immediate access to repair and maintenance information without waiting for physical delivery.

📖 Manual Coverage

Systems

Systems Covered:

• Engine Mechanical (6G75 V6)

• Engine Control System (ECU/ECM)

• Fuel System (Injection, Pump, Lines)

• Cooling System

• Lubrication System

• Exhaust System

• Ignition System

• Starting System

• Charging System

• Transmission (Automatic INVECS-II 5-Speed)

• Drivetrain (4WD System, Transfer Case, Differentials)

• Braking System (ABS, EBD, Brake Assist)

• Suspension (Front Independent, Rear Multi-link)

• Steering System (Power Steering)

• Wheels and Tires

• Body Electrical Systems (Lighting, Wipers, Horn)

• Climate Control System (HVAC)

• Interior Systems (Seats, Trim, Audio)

• Exterior Systems (Doors, Hood, Tailgate, Bumpers)

• Restraint Systems (Airbags, Seatbelts)

• Body Control Module (BCM)

• Instrument Panel and Gauges

• Cruise Control System

• Remote Keyless Entry

• Immobilizer System

• Diagnostic Trouble Codes (DTCs)

Procedures

Procedures Included:

• Routine Maintenance (Oil Changes, Filter Replacements)

• Component Removal and Installation

• Disassembly and Assembly of Major Components

• Diagnostic Testing and Troubleshooting of Faults

• Adjustment and Calibration Procedures

• Wiring Harness Repair

• Engine Tune-up

• Transmission Fluid and Filter Service

• Brake System Bleeding and Pad Replacement

• Suspension Component Replacement

• Steering System Repair

• Air Conditioning System Servicing

• Body Panel Repair and Replacement

• Electrical Component Testing

• Diagnostic Scan Tool Usage

• Torque Wrench Application

Depth

Technical Depth:

Comprehensive. Covers everything from basic maintenance and fluid changes to in-depth engine and transmission overhauls, detailed electrical system diagnostics, and bodywork repairs. Includes detailed schematics and troubleshooting flowcharts.

Technical Depth

Technical Depth Description:

The manual's 4960 pages signify an extremely high level of detail, covering every aspect of the vehicle. It moves beyond basic 'how-to' guides to include in-depth diagnostic procedures, electrical schematics with component tracing, and internal component repair instructions.

Systems Covered

Chassis And Body:

Includes procedures for body panel removal and installation, door mechanisms, window regulators, sunroof operation, bumper repair, chassis lubrication, frame inspection, and collision repair information.

Procedures Included

Diagnostics:

Detailed troubleshooting guides for common and uncommon issues, including symptom-based diagnostics, use of scan tools for reading Diagnostic Trouble Codes (DTCs), and step-by-step procedures for pinpointing faults in all major systems.

📊 Manual Specifications

File Attributes

File Format Details:

High-resolution PDF, optimized for viewing and printing. Text is searchable, allowing for quick access to specific information. Supports bookmarking for easy navigation.

Print Quality

Print Quality:

Printable. Designed to be easily printed at home or a professional print shop for a physical copy.

Binding Type

Binding Type:

N/A (Digital Download - Printable PDF)

Paper Type

Paper Type:

N/A (Digital Download - Printable PDF)

File Format

File Format:

⚙️ Engine Specifications

Primary Engine

Engine Type:

6G75 MIVEC SOHC V6

Displacement:

3.8 Liters (3828 cc)

Performance

Horsepower:

230 hp @ 6000 rpm (approx.)

Torque:

260 lb-ft @ 3750 rpm (approx.)

Fuel System

Fuel System Type:

Electronic Fuel Injection (EFI)

Recommended Fuel:

Unleaded Regular Gasoline (87 Octane)

Engine Management

Engine Control Unit:

Engine Control Module (ECM)

Ignition System:

Distributorless Ignition System (DIS) with individual coil packs

Mivec System:

Mitsubishi Innovative Valve timing Electronic Control (MIVEC) system for variable valve timing to optimize power and fuel efficiency across the RPM range.

🔧 Transmission

Standard

Transmission Type:

INVECS-II 5-Speed Automatic with Sportronic

Optional

Optional Transmission Type:

5-Speed Manual (Less common in North America)

Features

Transmission Features:

• Electronically controlled shift points

• Sportronic manual shifting mode

• Adaptive shift logic

Fluid Specifications

Automatic Transmission Fluid Type:

Mitsubishi Diaqueen ATF-SP III (or equivalent DEXRON III/MERCON compatible)

Fluid Capacities

Automatic Transmission Fluid Capacity:

Approximately 9.5 - 10.0 Liters (for complete refill, drain and fill is less)

Drivetrain

Drivetrain System:

Full-time 4WD with Electronic Transfer Case and Rear Differential Lock (optional on some trims). Features the Super Select II 4WD system allowing seamless switching between 2WD and 4WD modes, including locking the center differential and engaging low-range gearing.

📐 Dimensions

Exterior

Length:

192.1 inches (4879 mm)

Width:

76.0 inches (1930 mm)

Height:

74.4 inches (1890 mm)

Wheelbase:

109.7 inches (2786 mm)

Cargo

Cargo Volume Behind 3Rd Row:

12.5 cubic feet (approx.)

Cargo Volume Behind 2Nd Row:

48.6 cubic feet (approx.)

Cargo Volume Behind 1St Row:

81.7 cubic feet (approx.)

Weights

Curb Weight:

Approximately 4,700 - 4,900 lbs (2130 - 2220 kg)

Gross Vehicle Weight Rating Gvwr:

Approximately 6,160 lbs (2794 kg)

Towing Capacity:

Up to 5,000 lbs (2268 kg) (when properly equipped)

Wheels Tires

Wheelbase:

109.7 inches (2786 mm)

Wheel Bolt Pattern:

6x139.7 mm (6x5.5 inches)

Standard Wheel Size:

17-inch alloy wheels

Standard Tire Size:

265/65R17

🛡️ Safety Features

Ratings

NHTSA Front Crash Test Rating:

5-Star (Driver and Passenger)

IIHS Side Impact Test Rating:

Active Features

Active Safety Features:

• Anti-lock Braking System (ABS)

• Electronic Brake-force Distribution (EBD)

• Brake Assist (BA)

• Traction Control System (TCL)

• Active Stability Control (ASC) / Electronic Stability Program (ESP)

Passive Features

Passive Safety Features:

• Driver and Front Passenger Airbags

• Side Curtain Airbags (Optional/Standard on higher trims)

• Three-Point Seatbelts with Pretensioners

• LATCH Child Seat Anchors

• Crumple Zones

• Reinforced Body Structure

Child Safety Features:

Rear door child safety locks, LATCH (Lower Anchors and Tethers for CHildren) system for child seat installation.

💡 Technology Features

Infotainment

Infotainment System:

Base models featured a standard AM/FM stereo with CD player. Higher trims offered premium audio systems, often with an in-dash CD changer and Rockford Fosgate branded speakers. Navigation systems were available as an option on some trims.

Premium Audio Details:

Optional Rockford Fosgate premium audio systems typically included a multi-speaker setup with a subwoofer, providing enhanced sound quality for the cabin. The manual covers audio system diagnostics and component replacement.

Driver Assistance

Driver Assistance Features:

• Cruise Control

• Rear Parking Sensors (Optional/Trim dependent)

Connectivity

Connectivity Features:

Limited connectivity by modern standards. Typically featured auxiliary inputs for audio devices on later models. Bluetooth hands-free calling was not a standard feature across the range.

Other Technology

Other Technology:

• Power adjustable front seats (driver and passenger)

• Sunroof (Optional/Trim dependent)

• Heated front seats (Optional/Trim dependent)

• Automatic climate control (Optional/Trim dependent)

🔧 Maintenance

Service Intervals

Engine Oil And Filter Change:

Every 5,000 to 7,500 miles (8,000 to 12,000 km) or 6 months, whichever comes first, depending on driving conditions.

Engine Air Filter Replacement:

Every 30,000 miles (48,000 km) or as needed based on inspection.

Cabin Air Filter Replacement:

Every 15,000 miles (24,000 km) or annually.

Transmission Fluid Change:

Every 60,000 miles (96,000 km) or 4 years for the automatic transmission. Manual transmission service intervals vary.

Spark Plug Replacement:

Typically Iridium spark plugs are rated for 100,000 miles (160,000 km).

Fluid Specifications

Engine Coolant Type:

Mitsubishi Super Long Life Coolant (or equivalent OAT - Organic Acid Technology) Pink/Red

Engine Coolant Capacity:

Approximately 10.5 Liters (11.1 Quarts)

Power Steering Fluid Type:

DEXRON III ATF (or equivalent)

Brake Fluid Type:

DOT 3 or DOT 4

Transfer Case Fluid Type:

Gear Oil API GL-4 or GL-5 SAE 75W-90

Front Differential Fluid Type:

Gear Oil API GL-5 SAE 75W-90

Rear Differential Fluid Type:

Gear Oil API GL-5 SAE 75W-90 (with Limited Slip Additive if equipped with LSD)

Known Issues

Known Issues:

• Rear differential pinion seal leaks

• Catalytic converter failure (less common but possible)

• Minor interior trim rattles

• ABS/TCL/ASC warning lights due to wheel speed sensor issues

• Occasional issues with power window motors

Maintenance Notes:

Regularly inspect the Super Select II 4WD system components and fluid levels. Pay attention to any ABS or traction control warning lights, as these often indicate sensor issues that are critical for safety and performance.

Engine Misfires:

Occasionally reported misfires can be attributed to faulty ignition coils, spark plugs, or fuel injectors. The manual provides detailed diagnostic procedures for these components.

Fluid Capacities

Transfer Case Fluid Capacity:

Approximately 2.0 Liters

Front Differential Fluid Capacity:

Approximately 1.3 Liters

Rear Differential Fluid Capacity:

Approximately 1.5 Liters

📚 Vehicle History

Brand Heritage

Brand Heritage:

Mitsubishi Motors has a long history of producing robust and capable off-road vehicles, with the Pajero (Montero) lineage dating back to 1982. This heritage is built on durability, reliability, and impressive off-road performance, often demonstrated in demanding rally events like the Dakar Rally.

Model Evolution

Model Evolution:

The third generation Montero (NM/NS) introduced a significant shift with its unibody construction, moving away from the traditional body-on-frame design of its predecessors. This provided a more car-like ride and improved handling while retaining strong off-road capabilities due to its integrated frame and sophisticated suspension. The 2006-2009 models represent the latter part of this generation, with updates focusing on refinement and feature enhancements.

Third Gen Chassis:

The unibody structure of the third-generation Montero (NM/NS) integrated a reinforced steel ladder frame into the chassis, a design intended to provide the stiffness and durability of body-on-frame construction with the ride comfort and handling benefits of a unibody. This made it a capable off-roader without the harshness of traditional SUVs.

Production

Production Years For Generation:

2000-2006 (NM), 2007-2009 (NS)

Manufacturing Location:

Japan (Okazaki Plant) and potentially other global assembly plants.

🏆 Awards & Recognition

Recognitions

Awards:

While specific awards for the 2006-2009 Montero might not be as prominent as for earlier or later generations, the Montero platform consistently received praise for its off-road capability and durability from automotive publications specializing in SUVs and off-roading. It was often cited as a benchmark for ruggedness in its class.