🏷️ Basic Information

Make:

Mitsubishi

Model:

Montero

Generation Designation:

Second Generation (V20/V40 Series)

Chassis Codes:

V21W, V23W, V24W, V25W, V26W, V41W, V43W, V44W, V45W, V46W

👋 Introduction

Segment:

Mid-size SUV, Body-on-frame construction, focused on off-road capability and ruggedness.

Competitors:

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

Distinguishing Factors:

Robust 4WD system (Super Select 4WD-II), comfortable ride for an SUV of its era, capable off-road performance, available larger V6 engine, durable construction.

Body Styles:

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

📋 Manual Details

Years Covered:

1992, 1993, 1994, 1995

Estimated Pages:

Over 2000 (typical for comprehensive factory service manuals)

Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Powertrain:

Engine mechanical, engine control systems (EFI), fuel system, exhaust system, cooling system, lubrication system, ignition system, transmission (manual and automatic), transfer case, driveline, axles, differentials.

Chassis And Suspension:

Front suspension (independent double wishbone with torsion bars), rear suspension (multi-link beam axle with coil springs), steering system (power assisted recirculating ball), brakes (front ventilated discs, rear drums or discs), wheels and tires.

Electrical And Electronics:

12V electrical system, battery, charging system (alternator), starting system, lighting (headlights, taillights, interior), instrumentation, wiring diagrams for all circuits, fuses and relays, power windows, power locks, mirrors, horn, audio system, optional accessories.

Body And Interior:

Body construction, exterior panels, doors, hood, tailgate, bumpers, glass, interior trim, seats, HVAC system (heating, ventilation, air conditioning), dashboard, controls, safety belts, SRS airbags (if equipped).

Diagnostic Troubleshooting:

Trouble shooting charts based on symptoms (e.g., 'engine won't start', 'brake pedal is soft') with step-by-step diagnostic procedures.

Safety Systems:

Seat belt operation and adjustment, SRS airbag system component identification and diagnostics (if equipped).

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection/replacement, brake fluid flush, coolant flush.

Repair And Rebuild:

Engine overhaul, transmission service and repair, brake component replacement (pads, rotors, calipers, drums, shoes), suspension component replacement (shocks, struts, ball joints, tie rods), steering system repair, HVAC system servicing, electrical component diagnosis and replacement.

Diagnostics And Troubleshooting:

Diagnostic trouble codes (DTCs) for engine control, symptoms-based troubleshooting guides, diagnostic procedures for electrical systems, fuel system testing, ignition system testing.

Body And Frame:

Body panel alignment, rust repair considerations, door/window mechanisms, bumper replacement, chassis maintenance.

Special Tools:

Lists required special tools for specific repair procedures, torque wrenches, diagnostic equipment.

Depth:

Comprehensive, covering everything from basic fluid checks to full engine and transmission rebuilds. Includes detailed diagnostic procedures, torque specifications, component removal and installation instructions, and wiring diagrams.

Wiring Diagrams:

Detailed, system-specific wiring diagrams covering engine, transmission, lighting, interior electronics, power accessories, and safety systems.

📊 Manual Specifications

File Type:

PDF

Searchability:

PDF files often include searchable text, allowing users to quickly find specific topics or keywords.

Digital Features:

Hyperlinked table of contents and cross-references for easier navigation within the digital document.

Quality:

High-resolution, enabling clear viewing of diagrams and text. Typically designed for digital viewing and printing.

Binding:

N/A (Digital Download)

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Code And Type:

6G72: 3.0L V6 SOHC MPI

Engine Displacement:

2972 cc (3.0 Liters)

Engine Block Material:

Cast Iron

Cylinder Head Material:

Aluminum Alloy

Horsepower:

Approx. 155 hp @ 5000 rpm (for 6G72 V6)

Torque:

Approx. 175 lb-ft @ 3000 rpm (for 6G72 V6)

Fuel Delivery:

Multi-Point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 octane recommended)

Other Engines:

4G63: 2.4L I4 SOHC MPI (less common in North American market during these years, more prevalent in other regions or base models).

🔧 Transmission

Transmission Type:

5-speed Manual Transmission (e.g., KM201)

Transmission Type:

4-speed Automatic Transmission (e.g., KM221)

Drivetrain Options:

Part-time 4WD, Full-time 4WD (optional, with locking center differential on some models).

Transfer Case Type:

Super Select 4WD-II (SS4-II) - allows shifting between 2H, 4H, 4H Lock, 4L Lock via electronic or manual controls depending on trim.

Manual Transmission Fluid:

API GL-4 or GL-5, SAE 75W-90 (consult manual for exact spec)

Automatic Transmission Fluid:

Dia Queen ATF-SP II (or equivalent MERCON/Dexron II/III)

📐 Dimensions

Wheelbase:

Approx. 109.4 inches (2780 mm)

Length:

Approx. 180.7 inches (4590 mm)

Width:

Approx. 69.5 inches (1765 mm)

Height:

Approx. 67.7 inches (1720 mm)

Ground Clearance:

Approx. 8.1-8.9 inches (205-225 mm), depending on tire size and suspension setup.

Curb Weight:

Approx. 4000-4500 lbs (1815-2040 kg), depending on configuration.

Towing Capacity:

Typically rated for 5,000 lbs (2268 kg) when properly equipped, but consult specific model year and local regulations.

🛡️ Safety Features

NHTSA Front Crash Test:

Not extensively tested by modern NHTSA standards; early SUVs often had fewer safety features.

ABS:

Optional on some models, standard on higher trims later in the generation.

Airbags:

Driver-side airbag standard on most 1994+ models. Passenger airbag typically not available.

Seatbelts:

Front 3-point height-adjustable seatbelts, rear lap and shoulder belts.

💡 Technology Features

Audio System:

Factory AM/FM cassette player with optional CD changer. Speakers typically 4-6.

Cruise Control:

Standard on most V6 models, optional on others.

Antenna:

Power antenna (on higher trims).

Climate Control:

Manual HVAC system with A/C as standard or optional depending on trim. Some later models may feature automatic climate control.

🔧 Maintenance

Oil Change Interval:

Every 3,750 - 7,500 miles or 6 months, depending on driving conditions and oil type used (consult manual for specific recommendation).

Transmission Fluid Change:

Automatic: Every 30,000 - 60,000 miles. Manual: Inspect periodically, change if contaminated or upon major repairs.

Coolant Change Interval:

Every 30,000 - 50,000 miles or 2-3 years (using ethylene glycol coolant).

Spark Plug Replacement:

Approx. 60,000 - 100,000 miles for platinum-tipped plugs, depending on type.

Engine Oil Type:

API SJ or higher, SAE 5W-30 or 10W-30 (check manual for climate-specific recommendations).

Coolant Type:

Ethylene Glycol based coolant (green or orange depending on formulation), typically a 50/50 mix with distilled water.

Brake Fluid Type:

DOT 3 or DOT 4

Power Steering Fluid Type:

Dexron II/III ATF or dedicated power steering fluid (consult manual).

Differential Fluid Type:

API GL-5, SAE 80W-90 for front and rear differentials.

Common Wear Items:

Idler arm and pitman arm wear (steering looseness), exhaust manifold cracks (especially on V6), starter motor contacts, rear main seal leaks, cooling system components (radiator, hoses), CV joint boots.

Electrical Quirks:

Failing power window regulators, intermittent wiper function, gauge cluster issues (less common but possible).

Engine Maintenance:

Timing belt inspection and replacement on 2.4L 4-cyl engines (if equipped); the 3.0L V6 uses a timing chain, generally more durable but requires inspection.

📚 Vehicle History

Mitsubishi History:

Mitsubishi Motors, a division of the Mitsubishi Group, has a long history in automotive manufacturing, known for ruggedness and innovative technologies, especially in 4WD systems.

Montero Evolution:

The Montero (known as Pajero in most global markets) transitioned to its second generation in 1991. This generation saw significant styling updates, improved comfort, and enhanced off-road capabilities, including the advanced Super Select 4WD system. It was a key model for Mitsubishi in establishing its SUV presence.

Manufacturing Locations:

Primarily manufactured in Japan (Pajeros), with some assembly potentially in other global locations for specific markets.

🏆 Awards & Recognition

Off Road Accolades:

The Montero/Pajero lineage is renowned for its off-road prowess, often winning or placing highly in events like the Dakar Rally, contributing to its rugged image.

Consumer Reports Rating:

Often rated as average to good for reliability in its class during its production years, with some specific components noted for potential issues (see known_issues).