Mitsubishi Montero 1992 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Year: 1992 Chassis Code: V20, V30, V40 Series Codes Engine Code Primary: 6G72 👋 Introduction Market Position Segment: Mid-size SUV / Off-road...

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标签: 1992 Car Cars Misc Mitsubishi Montero

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Montero

Year:

Chassis Code:

V20, V30, V40 Series

Codes

Engine Code Primary:

👋 Introduction

Market Position

Segment:

Mid-size SUV / Off-road vehicle

Target Audience:

Off-road enthusiasts, families, those seeking rugged utility and capability.

Competitive Analysis

Competitors:

Jeep Cherokee (XJ), Toyota 4Runner, Ford Bronco, Nissan Pathfinder.

Key Features

Body Styles:

2-door, 4-door, Long Wheelbase (Exceed)

Drivetrain:

Available 2WD and 4WD (including Super Select 4WD system).

Off Road Capability:

Body-on-frame construction, high ground clearance, robust suspension, selectable 4WD modes.

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive service and repair for all systems.

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Full Service and Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, overhaul, timing, lubrication, cooling.

Fuel System:

Fuel injection system (MPI/ECI), fuel pump, injectors, lines, tank, diagnostics.

Ignition System:

Spark plugs, coils, distributor (if applicable), timing, ignition control module.

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, pipes, O2 sensors.

Transmission Manual:

Clutch, gearbox overhaul, shifting mechanisms, gear ratios, maintenance.

Transmission Automatic:

Torque converter, valve body, internal components, maintenance, fluid specifications, diagnostics.

Drivetrain 4Wd:

Transfer case operation, front and rear differentials, driveshafts, CV joints, Super Select 4WD system.

Suspension Front:

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

Suspension Rear:

Multi-link rear suspension, control arms, coil springs, shock absorbers, sway bar.

Steering System:

Power steering pump, rack and pinion, steering column, linkage, fluid specifications.

Brake System:

Front disc brakes, rear drum/disc brakes, master cylinder, brake booster, ABS (if equipped), lines, bleeding procedures.

Electrical System:

Battery, alternator, starter, wiring diagrams, lighting, fuses, relays, ignition switch.

Body And Interior:

Body panels, doors, windows, locks, seats, trim, HVAC controls, dashboard.

HVAC System:

Air conditioning compressor, condenser, evaporator, heater core, blower motor, refrigerant.

Safety Systems:

Seat belts, airbags (if equipped), SRS system diagnostics.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks, tire rotation, lubrication.

Engine Repair:

Head gasket replacement, piston ring installation, bearing replacement, complete engine rebuild.

Transmission Repair:

Clutch replacement, transmission overhaul (auto and manual), seal replacement.

Brake Service:

Brake pad/shoe replacement, rotor/drum resurfacing, caliper/wheel cylinder repair, brake bleeding.

Suspension Repair:

Shock/strut replacement, ball joint/tie rod end replacement, bushing replacement, alignment specifications.

Electrical Diagnostics:

Troubleshooting circuits, component testing, wiring harness repair.

Body Repair:

Panel replacement, door hinge adjustment, glass replacement, rust repair techniques.

HVAC Service:

Refrigerant charging, leak detection, component replacement, blower motor repair.

Troubleshooting:

Diagnostic charts, common problems and solutions, symptom-based diagnosis.

Special Tools:

Identification and usage of specialized tools for specific procedures.

Technical Depth

Depth:

In-depth mechanical, electrical, and diagnostic procedures suitable for professional technicians and advanced DIYers.

📊 Manual Specifications

File Format

Format:

Searchability:

Text-searchable PDF for quick information retrieval.

Print Quality

Quality:

High-resolution scans for clear diagrams and text.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

V6, SOHC

Displacement:

3.0 L (2972 cc)

Bore X Stroke:

91.1 mm x 76.0 mm

Compression Ratio:

8.3:1

Horsepower:

Approx. 145-155 hp @ 5000 rpm (depending on market/spec)

Torque:

Approx. 170-180 lb-ft @ 3500 rpm (depending on market/spec)

Fuel System

Induction:

Multi-point Fuel Injection (MPI) / Electronic Controlled Injection (ECI)

Fuel Type:

Unleaded Gasoline

🔧 Transmission

Standard

Type:

5-speed manual transmission

Optional

Type:

4-speed automatic transmission

Features

Transfer Case:

2-speed transfer case with manual or automatic (Super Select) engagement.

📐 Dimensions

Exterior

Wheelbase Short Wheelbase:

Approx. 100.4 inches (2550 mm)

Wheelbase Long Wheelbase:

Approx. 109.4 inches (2780 mm)

Length Short Wheelbase:

Approx. 168.9 inches (4300 mm)

Length Long Wheelbase:

Approx. 177.0 inches (4500 mm)

Width:

Approx. 66.5 inches (1690 mm)

Height:

Approx. 65.2 inches (1655 mm)

Weights

Curb Weight Min:

Approx. 3700 lbs (1678 kg)

Curb Weight Max:

Approx. 4200 lbs (1905 kg)

🛡️ Safety Features

Ratings

NHTSA Rollover Resistance:

Considered good for its class and era, though specific ratings may vary.

Active Features

Available Anti-lock Braking System (ABS) on select models/trims.

Passive Features

Airbags:

Driver-side airbag standard on most models from 1992.

Seatbelts:

3-point front seatbelts, 2-point or 3-point rear seatbelts depending on seating position.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM cassette player with optional CD player. Basic speaker configurations.

Driver Assistance

Cruise Control:

Standard on many trims, operated via steering column stalk.

4Wd System:

Super Select 4WD system allowing on-the-fly selection of 2WD, 4WD Full-Time, 4WD High-Lock, and 4WD Low-Lock.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 3,000-5,000 miles (5,000-8,000 km) or 6 months, depending on driving conditions.

Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or annually.

Spark Plug Replacement:

Every 30,000-60,000 miles (48,000-96,000 km) depending on plug type.

Timing Belt Replacement:

Critical: Every 60,000 miles (96,000 km) or 5 years, as the 6G72 is an interference engine.

Fluid Specifications

Engine Oil:

API SG or higher, SAE 10W-30 or 10W-40 recommended (refer to manual for exact spec).

Coolant:

Ethylene glycol-based coolant (e.g., Mitsubishi DiaQueen Super Long Life Coolant or equivalent).

Transmission Fluid Auto:

Dexron II or equivalent (e.g., Mopar ATF+2).

Transmission Fluid Manual:

API GL-4, SAE 75W-90 or 80W-90 gear oil.

Brake Fluid:

DOT 3 or DOT 4, glycol-based.

Power Steering Fluid:

ATF Dexron II or equivalent.

Known Issues

Engine:

Timing belt failure (if not replaced on schedule), head gasket leaks, oil leaks from seals.

Drivetrain:

Transfer case actuator issues (Super Select), worn CV joints, differential seals.

Suspension:

Wear in bushings, ball joints, and tie rod ends due to off-road use and age.

Electrical:

Corrosion in connectors, aging wiring harness, power window regulator failures.

Body:

Rust, especially in wheel wells, rocker panels, and tailgate.

📚 Vehicle History

Brand Heritage

Parent Company:

Mitsubishi Motors

Model Evolution

Generation:

First Generation (1982-1990), Second Generation (1991-2000). 1992 falls into the second generation's initial phase.

Design Changes:

The 1991+ generation adopted a more rounded, aerodynamic design compared to the boxier first generation.

Production

Manufacturing Plant:

Often produced in Japan (e.g., Nagoya Plant).

Market Availability:

Global market availability, including North America (as Montero), Europe (as Pajero), and other regions.

🏆 Awards & Recognition

Recognitions

Off Road Awards:

Consistently praised in automotive media for its off-road prowess and durability, often winning comparisons against competitors in its segment.

Ratings

Customer Satisfaction:

Generally high ratings for durability and reliability, especially for the powertrain and chassis when properly maintained.