Mitsubishi Montero 1992-1995 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Model Alias: Pajero (International Markets) Generation: Second Generation (1991-2000) Codes Chassis Code Prefix: V20/V30 Series 👋 Introduction Market Position Segment: Compact/Mid-size SUV,...

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类型: Car

斯库: 414446

标签: 1992 1993 1994 1995 Car Cars Misc Mitsubishi Montero

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Montero

Model Alias:

Pajero (International Markets)

Generation:

Second Generation (1991-2000)

Codes

Chassis Code Prefix:

V20/V30 Series

👋 Introduction

Market Position

Segment:

Compact/Mid-size SUV, known for its off-road capability and ruggedness.

Competitive Analysis

Competitors:

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

Key Features

Off Road Capability:

Renowned for its robust chassis, available Super Select 4WD system, and impressive ground clearance.

Durability:

Built with a body-on-frame construction for enhanced durability and towing capacity.

📋 Manual Details

Coverage Areas

Years Covered:

1992, 1993, 1994, 1995

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete engine systems, including teardown, assembly, diagnostics, specifications, and troubleshooting for all applicable engine variants.

Transmission:

Detailed coverage of manual and automatic transmissions, including gear train, clutch, torque converter, hydraulic systems, and shift mechanisms.

Drivetrain:

Includes front and rear axles, differentials, drive shafts, CV joints, transfer case (4WD systems), and related components.

Suspension:

Front and rear suspension systems, including independent front suspension (IFS) or solid front axle (depending on variant), coil springs, shock absorbers, control arms, bushings, and alignment procedures.

Brakes:

Hydraulic brake system, including front disc brakes, rear drum or disc brakes, ABS system (if equipped), brake lines, calipers, master cylinder, and bleeding procedures.

Steering:

Power steering system, steering gear, steering column, tie rods, and related components.

Fuel System:

Fuel tank, fuel pump, fuel lines, fuel injectors, fuel pressure regulator, and emissions control systems.

Cooling System:

Radiator, water pump, thermostat, coolant hoses, and heater core.

Exhaust System:

Exhaust manifold, catalytic converter, mufflers, and pipes.

Electrical System:

Battery, alternator, starter motor, ignition system, lighting, instrumentation, fuses, relays, and wiring diagrams.

Body And Chassis:

Frame construction, body panels, doors, windows, latches, hinges, interior trim, and exterior trim.

HVAC System:

Heating, ventilation, and air conditioning (HVAC) system, including compressor, condenser, evaporator, blower motor, and climate control.

Procedures Included

Maintenance:

Routine maintenance procedures, including oil changes, filter replacements, fluid checks and top-offs, belt inspections, and tire rotations.

Troubleshooting:

Diagnostic procedures and flowcharts for identifying and resolving common and complex vehicle issues.

Repair:

Step-by-step repair instructions for major component overhauls, replacements, and adjustments.

Disassembly Assembly:

Detailed procedures for the removal and installation of virtually all vehicle components.

Wiring Diagrams:

Comprehensive electrical wiring schematics for all vehicle systems.

Technical Depth

Depth:

Comprehensive, covering everything from basic scheduled maintenance and fluid changes to complete engine and transmission rebuilds, advanced diagnostics, and bodywork repairs.

📊 Manual Specifications

File Format

Format:

Print Quality

Quality:

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

Binding Type

Type:

N/A (Digital PDF)

Paper Type

Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code:

Engine Type:

SOHC V6, naturally aspirated

Displacement Liters:

Displacement Cc:

Bore X Stroke Mm:

86.0 x 86.0

Compression Ratio:

8.8:1

Horsepower Hp At Rpm:

144-151 hp @ 5000-5500 RPM (varies by market and year)

Torque Lb-Ft At Rpm:

170-174 lb-ft @ 3500-4000 RPM (varies by market and year)

Performance

0 60 Mph Seconds:

11.0 - 13.0 (approximate)

Fuel System

Fuel Delivery:

Multi-Point Fuel Injection (MPI)

Recommended Fuel:

87 Octane (Regular Unleaded)

Engine Oil

Capacity Quarts:

Recommended Viscosity:

10W-30 or 10W-40 (check owner's manual for ambient temperature variations)

Oil Filter Part Number Example:

Mitsubishi MD069783 or equivalent (e.g., Fram PH8A, Purolator L30001)

🔧 Transmission

Standard

Type:

5-speed Manual Transmission

Optional

Type:

4-speed Automatic Transmission with Overdrive

Features

4Wd System:

Available with Mitsubishi's 'Super Select' 4WD system, offering 2WD, 4H, 4HLC (with locked center differential), and 4LLC (with locked center and low range).

Transmission Fluid Automatic

Type:

Dexron-III ATF or equivalent

Transmission Fluid Manual

Type:

API GL-4 (75W-90 or 75W-85) Manual Transmission Fluid

📐 Dimensions

Exterior

Wheelbase Inches:

102.4 (Short Wheelbase), 112.6 (Long Wheelbase)

Length Inches:

169.1 (SWB), 184.4 (LWB)

Width Inches:

Height Inches:

Weights

Curb Weight Lbs:

3800 - 4300 lbs (approximate, depending on configuration)

Towing Capacity Lbs:

Up to 5,000 lbs (verify specific configuration)

Suspension Specs

Front Suspension Type:

Independent Torsion Bar or Coil Spring (depending on specific model/trim)

Rear Suspension Type:

Multi-link with Coil Springs or Leaf Springs (depending on specific model/trim)

Wheel Tire Specs

Bolt Pattern:

6x139.7mm (6x5.5 inches)

Standard Tire Size:

265/70R15 or 31x10.50R15 (common)

Wheel Size:

15 x 7J or 15 x 7.5J

🛡️ Safety Features

Ratings

NHTSA Front Impact Rating:

Not rated in available data for this period, but generally considered robust for its era.

IIHS Crash Test Ratings:

Information not readily available for this specific model and period.

Active Features

Available on some models/trims, typically 4-wheel ABS.

Passive Features

Airbags:

Driver-side airbag standard on most models from 1994 onwards; passenger airbag not typically available.

Seatbelts:

Three-point front seatbelts with pretensioners, three-point rear seatbelts (outboard), lap belts (center rear).

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/Cassette player, often with optional CD player or external amplifier. Speaker configurations varied by trim.

Driver Assistance

Cruise Control:

Standard on higher trim levels, an electronic cruise control system.

Connectivity

Connectivity Options:

Limited by modern standards. Primarily focused on basic audio and power features. Aftermarket solutions for modern connectivity are common.

🔧 Maintenance

Service Intervals

Oil Change Interval Miles Km:

3,750 - 5,000 miles (6,000 - 8,000 km) or 6 months, whichever comes first (use synthetic oil for extended intervals).

Air Filter Replacement Interval Miles Km:

15,000 - 30,000 miles (24,000 - 48,000 km), inspect every oil change.

Spark Plug Replacement Interval Miles Km:

30,000 - 60,000 miles (48,000 - 96,000 km) depending on spark plug type (copper vs. platinum).

Coolant Flush Interval Miles Km:

30,000 - 50,000 miles (48,000 - 80,000 km) or 2-3 years.

Timing Belt Replacement Interval Miles Km:

60,000 - 90,000 miles (96,000 - 144,000 km) for the 6G72 V6 engine. CRITICAL item to replace due to interference design.

Fluid Specifications

Brake Fluid Type:

DOT 3 or DOT 4 (check reservoir cap)

Power Steering Fluid Type:

ATF Dexron-III or equivalent

Transfer Case Fluid Type:

API GL-4 75W-90 Gear Oil

Differential Fluid Type Front:

API GL-5 80W-90 Gear Oil (or consult manual for specific diffs)

Differential Fluid Type Rear:

API GL-5 80W-90 Gear Oil (or consult manual for specific diffs)

Known Issues

Ignition System:

Premature failure of ignition coils and spark plug wires can occur, especially with higher mileage vehicles. Distributor cap and rotor wear.

Cooling System:

Overheating due to clogged radiators, failing water pumps, or thermostat issues. Leaks from hoses or the reservoir tank.

Suspension:

Worn ball joints, tie rod ends, and bushings leading to steering wander and tire wear. Torsion bar adjustments can sag over time.

Transmission Automatic:

Some units may experience issues with solenoids or clutch packs, particularly if fluid maintenance has been neglected.

Rust Corrosion:

Common issue in certain climates, especially on the frame rails, rocker panels, and wheel arches. Early prevention and treatment are key.

Power Windows:

Window regulators and motors can wear out, causing slow or inoperable power windows.

📚 Vehicle History

Brand Heritage

Manufacturer Origins:

Mitsubishi Motors Corporation, a Japanese multinational automotive manufacturer.

Model Evolution

First Generation Debut:

1976 (as the Mitsubishi Jeep), 1982 (as the Pajero in Japan)

Second Generation Debut:

Design Philosophy:

The second generation introduced a more car-like ride with independent front suspension on many models, while retaining robust off-road credentials.

Production

Manufacturing Plant:

Japan (Okazaki Plant)

Production Span For Model Years:

1991 - 2000

🏆 Awards & Recognition

Recognitions

Off Road Magazine Awards:

The Mitsubishi Pajero (Montero's international name) has a strong history of success in off-road endurance events like the Paris-Dakar Rally, reflecting its inherent capabilities.

Ratings

Consumer Reports Reliability:

Reliability ratings varied by year and specific components, but generally seen as a durable vehicle with proper maintenance.

Certifications

Emissions Compliance:

Designed to meet US EPA emissions standards for the respective model years, covered in detail within the manual.