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Mitsubishi Montero 2006 Workshop Service Manual Repair

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The Mitsubishi Montero, specifically the V80/V90 Series chassis, is a robust and capable full-size SUV that has earned a reputation for its durability and off-road prowess. Produced in 2006, this...
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Mitsubishi Montero 2006 Workshop Service Manual RepairMitsubishi Montero 2006 Workshop Service Manual RepairMitsubishi Montero 2006 Workshop Service Manual RepairMitsubishi Montero 2006 Workshop Service Manual Repair
The Mitsubishi Montero, specifically the V80/V90 Series chassis, is a robust and capable full-size SUV that has earned a reputation for its durability and off-road prowess. Produced in 2006, this generation of the Montero builds upon Mitsubishi's heritage of creating reliable vehicles, offering a blend of family-friendly practicality and adventure-ready performance. With available 3-door and 5-door body styles and the advanced Super Select II 4WD system, it is engineered to tackle challenging terrains while providing comfortable transportation for families and enthusiasts alike. Its engineering quality is reflected in its strong safety ratings and its consistent praise for off-road capability, making it a dependable choice for various driving needs. This comprehensive workshop service and repair manual is designed to be an indispensable resource for maintaining and repairing your 2006 Mitsubishi Montero. It covers all major mechanical and electrical systems, including detailed engine diagnostics and overhaul procedures, transmission service for both automatic and manual variants, drivetrain components, suspension, steering, brakes, and the complete electrical system with extensive wiring diagrams. Furthermore, the manual provides essential information on scheduled maintenance, troubleshooting common issues, and specific repair instructions, ensuring that both professional technicians and enthusiast DIYers have the knowledge needed to keep their Montero in optimal condition.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Montero
Year:
2006
Codes
Chassis Code:
V80/V90 Series
👋 Introduction
Market Position
Segment:
Full-size SUV / Off-road capable vehicle
Target Demographic:
Families, adventure enthusiasts, off-roaders
Competitive Analysis
Key Competitors 2006:
Toyota 4Runner, Ford Explorer, Chevrolet TrailBlazer, Jeep Grand Cherokee, Nissan Pathfinder
Key Features Vehicle
Body Styles:
3-door (short wheelbase), 5-door (long wheelbase)
Drivetrain Options:
Rear-wheel drive (RWD), Super Select II 4WD system
Key Features Manual
Utility:
Essential for diagnosing and repairing complex issues, performing routine maintenance, and understanding vehicle systems.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Manual / Repair Manual
Language:
English
Format:
PDF Download
Intended Audience:
Professional Technicians, Enthusiast DIYers
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, overhaul procedures, component testing, timing specifications, lubrication systems, cooling systems, fuel delivery and injection systems, emission control systems, ignition systems, engine mechanical components (cylinder head, block, pistons, crankshaft, camshafts), turbocharger systems (if applicable).
Transmission:
Automatic and Manual transmission overhaul, operation, diagnosis, removal/installation, fluid specifications, torque converter, gear selection mechanisms, shift solenoids, electronic controls.
Drivetrain:
Four-Wheel Drive (4WD) system operation and diagnosis, transfer case overhaul, differential service (front and rear), driveshaft inspection and replacement, CV joints, propeller shafts.
Suspension And Steering:
Front and rear suspension component identification and replacement (struts, shocks, control arms, bushings, ball joints, springs), steering system diagnosis, power steering pump and rack repair, wheel alignment specifications.
Brakes:
Brake system diagnosis, hydraulic components (master cylinder, calipers, wheel cylinders, brake lines), ABS system operation and troubleshooting, brake pad and rotor replacement, parking brake adjustment.
Electrical System:
Complete wiring diagrams, fuse box locations and function, lighting systems, starting and charging systems, battery service, power windows, door locks, mirrors, wiper systems, horn, instrument cluster troubleshooting, body control module (BCM) diagnostics.
HVAC:
Air conditioning system service, refrigerant handling, compressor diagnosis, blower motor, heater core, climate control module troubleshooting.
Body And Chassis:
Body panel removal and installation, door mechanisms, tailgate, hood, interior trim, chassis lubrication, corrosion protection.
Safety Systems:
Airbag system diagnosis and service, seatbelt mechanisms, SRS control module.
Procedures Included
Maintenance:
Scheduled maintenance intervals, oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, belt inspection and replacement, fluid level checks and top-offs.
Troubleshooting:
Diagnostic charts, symptom-based troubleshooting guides, common problem diagnosis and repair.
Repair:
Step-by-step repair instructions for all major vehicle components, including engine teardown, transmission rebuilds, suspension component replacement, brake caliper overhaul, electrical component repair.
Diagnostics:
OBD-II (On-Board Diagnostics II) procedures, scan tool usage, trouble code interpretation, sensor testing, actuator testing, circuit testing.
Technical Depth
Completeness:
Comprehensive coverage for all mechanical and electrical systems, suitable for complete vehicle overhaul and restoration.
Detail Level:
Includes torque specifications, clearances, special tool requirements, exploded views of components, wiring schematics, diagnostic flowcharts.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text for quick information retrieval.
Printability:
Printable pages for on-site workshop use.
Quality:
High-resolution scans ensuring clarity of diagrams and text.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
6G74 (V6) / 6G75 (V6 MIVEC)
Engine Type:
SOHC V6 (6G74) / SOHC MIVEC V6 (6G75)
Displacement:
3.5L (3497cc) for 6G74 / 3.8L (3828cc) for 6G75
Bore X Stroke:
91.1 mm x 89.7 mm (6G74) / 95.0 mm x 89.7 mm (6G75)
Compression Ratio:
8.8:1 (6G74) / 9.5:1 (6G75)
Performance
Horsepower:
Approx. 197 hp @ 5000 rpm (6G74) / Approx. 230 hp @ 5000 rpm (6G75)
Torque:
Approx. 215 lb-ft @ 3750 rpm (6G74) / Approx. 260 lb-ft @ 3750 rpm (6G75)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Multi-Point Injection (MPI)
Fuel Type:
Unleaded Gasoline
Fuel Recommendation:
87 Octane Minimum
🔧 Transmission
Standard
Transmission Type:
4-speed Automatic (4WD models)
Optional
Transmission Type Alternative:
5-speed Manual (less common on some markets/trims)
Features
4Wd System:
Super Select II 4WD system with Electronic Transfer Case (4H, 4HLc, 4LLc modes), locking center differential.
Automatic Transmission Features:
Electronically controlled with Overdrive, adaptive shift logic.
📐 Dimensions
Exterior
Wheelbase:
2780 mm (109.4 in) for 5-door / 2220 mm (87.4 in) for 3-door
Length:
4695 mm (184.8 in) for 5-door / 4065 mm (159.9 in) for 3-door
Width:
1895 mm (74.6 in)
Height:
1890 mm (74.4 in) for 5-door / 1915 mm (75.4 in) for 3-door
Weights
Curb Weight:
Approx. 2000-2200 kg (4400-4850 lbs) depending on configuration
Gross Vehicle Weight Rating:
Approx. 2700-2800 kg (5950-6170 lbs)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5-Star (for models equipped with side airbags)
NHTSA Front Impact Passenger:
5-Star (for models equipped with side airbags)
IIHS Front Crash Rating:
Good
Active Features
ABS:
Anti-lock Braking System (ABS) standard
Traction Control:
Electronic Traction Control System (TCL)
Stability Control:
Active Stability Control (ASC)
Passive Features
Airbags:
Front airbags, optional front side-impact airbags, optional side-curtain airbags.
Seatbelts:
3-point seatbelts with pretensioners for front seats, three-point seatbelts for rear seats.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM CD player with optional premium audio system (e.g., Rockford Fosgate), auxiliary input may be available.
Navigation:
Optional factory navigation system available on higher trim levels.
Driver Assistance
Cruise Control:
Standard cruise control system.
Connectivity
Power Accessories:
Power windows, power door locks, power mirrors.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first. Consult manual for severe driving conditions.
Air Filter Replacement:
Every 30,000 miles (48,000 km) or as needed based on driving environment.
Spark Plug Replacement:
Every 105,000 miles (168,000 km) for Iridium spark plugs (standard on some engines).
Transmission Fluid Change:
Every 60,000 miles (96,000 km) or every 4 years for automatic transmission fluid. Manual transmission fluid inspection every 30,000 miles, replacement at 100,000 miles.
Fluid Specifications
Engine Oil Type:
API SN or SP, ILSAC GF-6A, SAE 5W-30
Engine Oil Capacity:
Approx. 4.5 Liters (4.8 US Quarts) with filter change (V6 engines)
Coolant Type:
Mitsubishi DiaQueen Super Long Life Coolant (Green) or equivalent OAT/HOAT coolant
Transmission Fluid Type Auto:
DIA QUEEN ATF-PA (or equivalent Mercon V or Dexron III)
Transmission Fluid Type Manual:
API GL-4 SAE 75W-85 or SAE 75W-90
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Common Problems And Fixes:
Potential for ABS sensor failures, catalytic converter issues, exhaust manifold leaks, minor electrical glitches (e.g., window regulators), fuel pump failures. The manual provides diagnostic steps for all these.
📚 Vehicle History
Brand Heritage
Mitsubishi Heritage:
Mitsubishi Motors, a Japanese automotive manufacturer with a long history in producing rugged and reliable vehicles, including off-road focused models.
Model Evolution
Montero Lineage:
The 2006 model year represents the third generation (NM/NP series, with V80/V90 being the internal codes for this generation's later iterations). This generation evolved from its robust, body-on-frame predecessors, offering improved on-road manners while retaining strong off-road capabilities.
Production
Production Period:
Third generation: 2000-2006 (globally), though specific market availability and face-lifts may vary. The 2006 model is typically the final year of this generation before a significant redesign or replacement in many markets.
Manufacturing Locations:
Japan (Okazaki Plant), also assembled in other locations depending on market.
🏆 Awards & Recognition
Recognitions
Off Road Capability:
Consistently praised for its off-road prowess, often cited as a capable competitor in its segment for tackling difficult terrain.
Durability:
Generally considered a durable and long-lasting SUV when properly maintained.
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