🏷️ Basic Information

Make:

Mitsubishi

Model:

Montero

Generation:

Second Generation (V20/V40)

Years Covered:

1992, 1993, 1994, 1995

Chassis Codes:

V20 (Short Wheelbase), V40 (Long Wheelbase)

Engine Codes Applicable:

6G72 (3.0L SOHC & DOHC V6), 6G74 (3.5L DOHC V6 - later models)

👋 Introduction

Vehicle Segment:

Mid-size to Full-size SUV (Sport Utility Vehicle), known for off-road capability and ruggedness.

Competitive Landscape:

Competed against vehicles such as the Toyota 4Runner, Jeep Cherokee (XJ), Ford Explorer, Nissan Pathfinder, and Chevrolet/GMC Blazers/Tahoes.

Target Audience:

Adventurous individuals, families, off-road enthusiasts, and those requiring a robust, versatile vehicle.

Key Differentiators:

Optional Super Select II 4WD system (some models), robust body-on-frame construction, powerful V6 engines, comfortable ride for an SUV of its era, good off-road prowess.

Body Styles:

Available in short-wheelbase (2-door) and long-wheelbase (4-door) configurations.

4Wd System:

Available with part-time 4WD or the advanced Super Select II system offering 4H, 4HLc, 4LLc, and selectable 2WD/4WD modes with locking differentials.

📋 Manual Details

Geographic Markets:

North America (primarily), global variations may exist

Vehicle Types:

SUV (Sport Utility Vehicle), including short-wheelbase (SWB) and long-wheelbase (LWB) variants

Estimated Pages:

1500+

Type:

Workshop Service Repair Manual

Language:

English

Format:

Digital Download (PDF)

📖 Manual Coverage

Engine:

Internal combustion engine: diagnostics, repair, overhaul, timing, lubrication, cooling, fuel injection, emissions control systems (e.g., EGR)

Transmission:

Manual and automatic transmissions: inspection, repair, overhaul, clutch, torque converter, gear shift mechanisms

Drivetrain:

Four-wheel drive (4WD) systems: transfer case, front and rear differentials, drive shafts, CV joints, electronic control units (if applicable)

Suspension:

Front independent suspension, rear multi-link solid axle: shock absorbers, springs, control arms, bushings, alignment specifications

Brakes:

Front disc, rear drum or disc (depending on trim/year): hydraulic system, ABS (if equipped), master cylinder, calipers, rotors, pads, parking brake

Steering:

Power assisted steering system: pump, steering rack/gearbox, tie rods, linkages, column

Electrical:

Wiring diagrams, charging system (alternator, battery), starting system (starter motor), ignition system, lighting, gauges, instruments, power accessories, fuses, relays, ECUs

Body:

Body panels, doors, hood, tailgate, glass, mirrors, interior trim, seats, HVAC system (heating, ventilation, air conditioning)

Chassis:

Frame construction, body mounting, corrosion protection

Maintenance:

Routine maintenance: oil changes, filter replacements, fluid checks and top-offs, belt inspections and replacement, spark plug replacement, brake checks

Troubleshooting:

Systematic diagnostic procedures for common and uncommon faults, fault codes (OBD-I in this era), symptom-based troubleshooting

Repair:

Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation

Overhaul:

Complete engine and transmission rebuild procedures, including internal component specifications and tolerances

Installation:

Procedures for installing replacement parts and accessories

Specifications:

Torque values, clearances, fluid capacities, electrical resistance values, diagnostic parameters

Depth:

Comprehensive coverage suitable for professional technicians, including detailed disassembly, reassembly, and diagnostic procedures. Also provides adequate detail for advanced DIY mechanics.

📊 Manual Specifications

Format Type:

PDF

Searchable:

Yes (text-searchable)

Quality:

High-resolution scans with clear text and legible diagrams

Illustrations:

Includes detailed diagrams, schematics, and photographic guides

Binding:

N/A (Digital)

Paper:

N/A (Digital)

⚙️ Engine Specifications

Engine Code 1:

6G72

Engine Description 1:

3.0L (2972cc) SOHC V6 and DOHC V6

Displacement 1:

3.0 Liters

Horsepower 1:

Approximately 143 hp (SOHC) to 177 hp (DOHC - early '92), up to 186 hp (later DOHC)

Torque 1:

Approximately 173 lb-ft (SOHC) to 195 lb-ft (DOHC - early '92), up to 203 lb-ft (later DOHC)

Engine Code 2:

6G74 (Optional for later models in this range)

Engine Description 2:

3.5L (3497cc) DOHC V6

Displacement 2:

3.5 Liters

Horsepower 2:

Approximately 206-210 hp

Torque 2:

Approximately 225-230 lb-ft

Valvetrain:

SOHC (2 valves per cylinder) or DOHC (4 valves per cylinder)

Induction:

Multi-point fuel injection (MPI)

Fuel Type:

Unleaded Gasoline

Fuel Octane Rating:

87 Octane (Minimum - check owner's manual for specific recommendations)

🔧 Transmission

Transmission Type Standard:

5-speed Manual Transmission

Transmission Type Optional:

4-speed Automatic Transmission (with electronic control in later models)

4Wd Modes:

Available with part-time 4WD or full-time 4WD (Super Select II) with electronic engagement and locking capabilities.

Transfer Case:

Two-speed transfer case with neutral and locked low-range gearing (standard on most models).

Automatic Transmission Fluid:

Dexron-II or equivalent (check manual for exact specification)

Manual Transmission Fluid:

GL-4 gear oil (e.g., 75W-90, check manual for exact specification)

📐 Dimensions

Wheelbase Swb:

Approx. 97.2 inches (2469 mm)

Wheelbase Lwb:

Approx. 109.5 inches (2781 mm)

Length Lwb:

Approx. 180.7 inches (4590 mm)

Width Lwb:

Approx. 69.5 inches (1765 mm)

Height Lwb:

Approx. 66.3 inches (1684 mm)

Curb Weight Lwb Approx:

4,000 - 4,500 lbs (1814 - 2041 kg), varies by trim and options

Towing Capacity Approx:

Up to 5,000 lbs (2268 kg), consult manual for specifics

🛡️ Safety Features

NHTSA Ratings:

Not extensively rated by modern standards; body-on-frame construction and older safety features.

ABS:

Anti-lock Braking System (ABS) available on some models, typically front wheels only or 4-wheel depending on year/trim.

Airbags:

Driver-side airbag became standard by mid-period; passenger airbag not typically available in this generation.

Seatbelts:

Three-point seatbelts with pretensioners for front occupants (standard).

Rollover Protection:

Body-on-frame construction offers inherent structural rigidity; potential for rollover in high-speed maneuvers due to higher center of gravity. Roll bar often integrated into roof structure.

💡 Technology Features

Audio System:

Factory AM/FM stereo with cassette player. Optional CD player became available in later years. Speaker count and quality vary by trim level.

Climate Control:

Manual or automatic climate control systems, depending on trim. HVAC blower motor failures are a common point of repair.

Cruise Control:

Standard on most higher trims.

ABS:

Anti-lock braking system (mentioned in safety) provided a key driver assistance feature for its time.

OBD System:

OBD-I diagnostic port. The manual will detail diagnostic procedures and potentially some fault code retrieval methods specific to this system.

🔧 Maintenance

Oil Change Interval:

Every 3,000-5,000 miles or 3-6 months (depending on driving conditions and oil type used; consult manual for specific recommendations).

Engine Oil Filter Replacement:

Replace with every oil change.

Air Filter Replacement:

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

Spark Plug Replacement:

Every 30,000-60,000 miles (depending on plug type; Platinum/Iridium plugs will have longer intervals).

Timing Belt Replacement:

Crucial item for 6G7x engines. Typically every 60,000-90,000 miles or 5-7 years due to potential for catastrophic engine damage if it breaks. Manual will specify the exact interval and replacement procedure for timing belt, tensioner, and idler pulleys.

Coolant Flush:

Every 30,000-50,000 miles or 2-3 years.

Transmission Fluid Change Auto:

Every 30,000-60,000 miles or 2-3 years.

Engine Oil Type:

API SG or higher, SAE 10W-30 or 10W-40 (check manual for specific viscosity based on temperature).

Engine Oil Capacity:

Approx. 4.8 quarts (4.5 liters) for 3.0L V6 with filter. Approx. 5.2 quarts (4.9 liters) for 3.5L V6 with filter. Consult manual.

Coolant Type:

Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Consult manual for specific type (e.g., Asian vehicle specific coolant might be recommended).

Engine:

Timing belt failure if not replaced on schedule (interference engine). Valve stem seals can wear, causing oil consumption. Early DOHC engines could have head gasket issues if overheated.

Transmission:

Automatic transmission torque converter lock-up solenoid issues. Manual transmission synchro wear.

Suspension:

Wear in bushings, ball joints, and tie rod ends is common with age and mileage, affecting steering and ride quality. Leaks from shock absorbers.

Electrical:

Corrosion in electrical connectors, especially ground points and connections exposed to moisture. Power window regulators can fail. Alternator and starter motor reliability can vary.

Exhaust:

Corrosion and leaks in exhaust system components due to environmental exposure.

4Wd System:

Actuator issues with the automatic front hub locking system (if equipped). Transfer case seal leaks.

📚 Vehicle History

Mitsubishi SUV Legacy:

Mitsubishi has a long history of producing capable off-road vehicles, dating back to models like the Jeep CJ-3B (licensed production) and the Pajero line (the Montero is a rebadged Pajero for export markets).

Generation 2 Introduction:

The second generation Pajero/Montero was introduced in late 1991 for the 1992 model year, marking a significant redesign with more refined styling and improved on-road manners while retaining its off-road prowess.

Key Updates 1992-1995:

Engine options evolved, with the 3.0L V6 being joined by the larger 3.5L V6 in later years. Minor interior and exterior styling tweaks and feature updates occurred throughout this period.

Manufacturing Location:

Primarily manufactured in Japan.

🏆 Awards & Recognition

Off Road Awards:

While specific awards for the 1992-1995 model aren't as readily documented as later generations, the Mitsubishi Pajero/Montero line consistently received accolades for its off-road performance and durability in various international publications and events, including Dakar Rally successes for the Pajero.

Consumer Reports:

Historically, this generation often received mixed reviews from consumer publications, with praise for its off-road capability and durability but sometimes criticism for fuel economy and interior refinement compared to some competitors.