Vehicle Class:
Compact/Mid-size SUV, Off-road Vehicle
Key Competitors Era:
Jeep Cherokee (XJ), Toyota 4Runner, Nissan Pathfinder, Ford Bronco II
Vehicle Strengths:
Robust construction, capable off-road performance, reliable powertrains, durable design.
Manual Value Proposition:
Enables DIY maintenance and repairs, reduces reliance on expensive dealership services, extends vehicle lifespan.
Applicable Years:
1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996
Estimated Page Count:
1000+
Manual Type:
Complete Workshop Service Repair Manual
Format:
Downloadable Digital File (likely PDF)
Engine:
All engine types (including gasoline and diesel variants) - repair, overhaul, troubleshooting, diagnostics.
Transmission:
Manual and Automatic transmission systems - repair, overhaul, fluid service, troubleshooting.
Drivetrain:
4WD system (Super Select 4WD), transfer case, differentials, CV joints, driveshafts.
Suspension:
Front and rear suspension components, shocks, struts, bushings, alignment specifications.
Brakes:
Brake system components (discs, calipers, master cylinder, lines), ABS system (if equipped), bleeding procedures, specifications.
Steering:
Power steering system, steering column, linkage, specifications.
Electrical:
Complete electrical system, wiring diagrams, battery, charging system, starting system, lighting, fuses, relays, ECUs.
HVAC:
Heating, Ventilation, and Air Conditioning system diagnosis and repair.
Body Interior:
Body panels, doors, windows, seats, interior trim, door locks, glass replacement.
Body Exterior:
Bumpers, fenders, hood, tailgate, sunroof, exterior trim, paint codes.
Routine Maintenance:
Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt adjustments.
Troubleshooting:
Diagnostic procedures for common and complex issues across all systems.
Engine Repair:
Engine rebuilds, head gasket replacement, piston and ring replacement, valve adjustments.
Transmission Repair:
Clutch replacement, transmission overhaul, torque converter service.
Brake Service:
Brake pad/shoe replacement, rotor resurfacing/replacement, brake line repair, bleeding.
Electrical Diagnostics:
Wiring harness repair, sensor testing, component diagnosis.
Suspension And Steering Repair:
Ball joint replacement, tie rod end replacement, shock absorber replacement, power steering pump service.
Depth:
Comprehensive (from basic maintenance to complete engine and transmission overhauls).
Detail Level:
Detailed step-by-step instructions, exploded diagrams, torque specifications, special tool recommendations.
Engine Options Gasoline:
2.6L 4G54 I4, 3.0L 6G72 V6
Engine Options Diesel:
2.3L 4D55 I4 Diesel, 2.5L 4D56 I4 Diesel (Intercooled Turbo)
Horsepower Range:
Approx. 105-145 HP (Gasoline), 80-115 HP (Diesel)
Torque Range:
Approx. 130-180 lb-ft (Gasoline), 120-170 lb-ft (Diesel)
Fuel Delivery Gasoline:
Carbureted (early models), Electronic Fuel Injection (EFI) (later models)
Fuel Delivery Diesel:
Indirect Injection (IDI), Direct Injection (DI) (Turbo Diesel)
Timing Belt Gasoline:
Yes, typically requires replacement every 60,000-90,000 miles.
Timing Chain Diesel:
Yes, typically chain-driven (requires inspection, less frequent replacement).
Manual Transmission:
5-speed manual (Getrag G360 or similar)
Automatic Transmission:
4-speed automatic (e.g., KM148)
Transfer Case:
Part-time 4WD with low range (e.g., NP233, Super Select 4WD on some later models).
Atf Type:
Dexron III or equivalent for automatic transmissions.
Manual Gear Oil:
GL-4 or GL-5 gear oil, viscosity typically 75W-90.
Wheelbase:
Approx. 104.5 inches (2655 mm)
Length:
Approx. 171.7 inches (4360 mm)
Width:
Approx. 66.1 inches (1680 mm)
Height:
Approx. 64.2 inches (1630 mm) (varies with roof rack)
Curb Weight Range:
Approx. 3,500 - 4,000 lbs (1588 - 1814 kg)
Towing Capacity:
Typically rated around 2000-3500 lbs (907-1588 kg) depending on configuration and market.
Oil Change Interval:
Typically every 3,000-5,000 miles or 6 months, whichever comes first.
Engine Oil Filter:
Replace at every oil change.
Air Filter:
Inspect every 15,000 miles, replace as needed (or every 30,000 miles).
Fuel Filter:
Replace every 30,000-45,000 miles (especially important for diesel models).
Transmission Fluid Change:
Automatic: Every 30,000-60,000 miles. Manual: Inspect periodically, drain/fill as per manual recommendation (often longer intervals).
Engine Oil Viscosity:
SAE 10W-30 or 10W-40 (check manual for specific engine/climate recommendations).
Coolant Type:
Ethylene glycol-based coolant, typically green color. Capacity ~8-10 quarts.
Brake Fluid Type:
DOT 3 or DOT 4.
Common Problem 1:
Head gasket failure on V6 engines, especially if not properly maintained.
Common Problem 2:
Rust and corrosion, particularly in the unibody structure, wheel wells, and frame rails in certain climates.
Common Problem 3:
Worn suspension bushings and ball joints due to off-road use and age.
Common Problem 4:
Electrical issues, such as faulty grounds, worn wiring insulation, and malfunctioning sensors over time.
Common Problem 5:
Diesel engine glow plug system issues and potential fuel injection pump leaks.
Mitsubishi Motors:
Founded in 1970, Mitsubishi Motors is part of the larger Mitsubishi conglomerate, known for its engineering and diverse industrial products.
First Generation Launch:
The first generation Montero (also known as Pajero in many markets) debuted in 1982, with the 1986-1996 models representing a significant portion of this generation's lifecycle.
Mid-Cycle Refresh:
The first generation received a significant update around 1991, which included styling tweaks, updated interior features, and potentially new powertrain options.
Manufacturing Locations:
Primarily Japan (Pajero), with assembly also occurring in other global locations depending on market.
