Mitsubishi Montero 2003 Repair Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Year: 2003 Chassis Code: V73W, V75W, V78W Codes Engine Code Primary: 6G72 (3.0L V6 SOHC) Engine Code Optional: 6G75 (3.8L V6 SOHC) Engine Code Diesel: 4M41 (3.2L DOHC Intercooled Turbo Diesel) 👋 Introduction Market Position Segment: Body-on-frame Mid-size SUV Target Audience: Families, off-road enthusiasts, general consumers seeking robust utility Competitive Analysis Key Competitors: Toyota 4Runner, Ford Explorer, Nissan Pathfinder, Chevrolet TrailBlazer, Jeep Grand Cherokee Key Features Strengths: Renowned off-road capability, durable construction, spacious interior, available V8 engine, available Super Select II 4WD system. Model Positioning: Represents Mitsubishi's commitment to robust SUVs with a blend of on-road comfort and significant off-road prowess. 📋 Manual Details Coverage Areas Regions Covered: Global (specific regional variations may apply, primarily North America based on typical distribution) Page Count Estimated Pages: 1500+ Manual Type Type: Repair Service Manual Language Language: English Format Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine control systems (ECU/ECM diagnostics and programming), manual transmission, automatic transmission, transfer case, front axle, rear axle, drive shafts, CV joints. Chassis: Suspension (front and rear independent, multi-link rear), steering system (hydraulic power steering), braking system (ABS, EBD, brake component replacement, hydraulic system bleeding), wheels and tires, chassis and frame. Electrical: 12V electrical system, battery, charging system (alternator), starting system (starter motor), lighting (headlamps, taillamps, interior), instrument panel and gauges, power windows, power locks, mirrors, wipers and washers, horn, audio system wiring, remote keyless entry, immobilizer system, body control module (BCM) diagnostics, fuse and relay locations. Body: Body panels (doors, hood, tailgate), interior trim, seats, glass and seals, bumpers, exterior trim, door hardware, convertible top mechanisms (if applicable to specific trims), structural components. HVAC: Heating, ventilation, and air conditioning (HVAC) system operation, refrigerant handling, component replacement (compressor, condenser, evaporator), blower motor, control panels. Procedures Included Maintenance: Oil change, filter replacement (oil, air, fuel, cabin), spark plug replacement, coolant flush and replacement, brake fluid replacement, power steering fluid replacement, transmission fluid change, differential fluid change, transfer case fluid change, belt inspection and replacement, battery service, tire rotation, wheel alignment checks. Diagnostics: Troubleshooting charts for common symptoms, diagnostic trouble codes (DTCs) interpretation for OBD-II system, electrical system diagnostics using multimeter and oscilloscope, fuel system pressure testing, ignition system testing, emissions system diagnostics. Repair: Engine component repair (e.g., cylinder head removal/installation, piston ring replacement), transmission overhaul and repair, clutch replacement (manual transmission), brake caliper and rotor replacement, suspension component replacement (shocks, struts, ball joints, control arms), steering rack repair, CV axle replacement, exhaust system repair/replacement, starter/alternator replacement, door lock actuator replacement, power window motor replacement. Installation: Accessory installation (e.g., tow hitch wiring), minor component upgrades, sensor replacement. Technical Depth Depth: Comprehensive from basic maintenance to advanced diagnostics and complete overhaul procedures. Includes detailed torque specifications, wiring diagrams, exploded views, and diagnostic flowcharts. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content Print Quality Resolution: High-resolution, suitable for printing Binding Type Binding: N/A (Digital) Paper Type Paper Quality: N/A (Digital) ⚙️ Engine Specifications Primary Engine Engine 1 Displacement: 3.0 Liters (2972 cc) Engine 1 Configuration: V6, SOHC, 24-valve Engine 1 Fuel Delivery: Multi-point Fuel Injection (MPI) Engine 1 Horsepower: 177 hp @ 5500 rpm (approx.) Engine 1 Torque: 207 lb-ft @ 4500 rpm (approx.) Optional Engine Engine 2 Displacement: 3.8 Liters (3798 cc) Engine 2 Configuration: V6, SOHC, 24-valve Engine 2 Fuel Delivery: Multi-point Fuel Injection (MPI) Engine 2 Horsepower: 200 hp @ 5500 rpm (approx.) Engine 2 Torque: 235 lb-ft @ 3750 rpm (approx.) Diesel Engine Engine 3 Displacement: 3.2 Liters (3200 cc) Engine 3 Configuration: Inline 4-cylinder, DOHC, Turbocharged, Intercooled Engine 3 Fuel Delivery: Direct Injection (Common Rail in later revisions, likely DI for 2003) Engine 3 Horsepower: 165 hp @ 4000 rpm (approx.) Engine 3 Torque: 260 lb-ft @ 2000 rpm (approx.) Fuel System Fuel Type: Unleaded Gasoline (3.0L, 3.8L), Diesel Fuel (3.2L DI-D) Cooling System Coolant Type: Mitsubishi DiaQueen Super Long Life Coolant (LLC) or equivalent (Green) Lubrication System Oil Type 3.0L: SAE 5W-30 or 10W-30 API SG or higher Oil Capacity 3.0L: 4.5 Liters (4.8 US Quarts) with filter Oil Type 3.8L: SAE 5W-30 API SG or higher Oil Capacity 3.8L: 4.7 Liters (5.0 US Quarts) with filter Oil Type 3.2L Diesel: SAE 5W-40 API CF-4 or higher Oil Capacity 3.2L Diesel: 7.4 Liters (7.8 US Quarts) with filter 🔧 Transmission Standard Transmission 1 Type: 5-Speed Manual Optional Transmission 2 Type: 4-Speed Automatic (INVECS-II) Features 4Wd System: Available with Super Select II 4WD system (electronic control with lockable center differential and low-range gearing) or standard 4WD. Fluid Specs Auto Automatic Transmission Fluid: DIAQueen ATF-SPII or equivalent Fluid Capacity Auto Automatic Transmission Capacity: Approx. 7.7 Liters (8.1 US Quarts) for fluid change Fluid Specs Manual Manual Transmission Fluid: API GL-3 or...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Montero

Year:

Chassis Code:

V73W, V75W, V78W

Codes

Engine Code Primary:

6G72 (3.0L V6 SOHC)

Engine Code Optional:

6G75 (3.8L V6 SOHC)

Engine Code Diesel:

4M41 (3.2L DOHC Intercooled Turbo Diesel)

👋 Introduction

Market Position

Segment:

Body-on-frame Mid-size SUV

Target Audience:

Families, off-road enthusiasts, general consumers seeking robust utility

Competitive Analysis

Key Competitors:

Toyota 4Runner, Ford Explorer, Nissan Pathfinder, Chevrolet TrailBlazer, Jeep Grand Cherokee

Key Features

Strengths:

Renowned off-road capability, durable construction, spacious interior, available V8 engine, available Super Select II 4WD system.

Model Positioning:

Represents Mitsubishi's commitment to robust SUVs with a blend of on-road comfort and significant off-road prowess.

📋 Manual Details

Coverage Areas

Regions Covered:

Global (specific regional variations may apply, primarily North America based on typical distribution)

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Repair Service Manual

Language

Language:

English

Format

Format:

PDF (Digital Download)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine control systems (ECU/ECM diagnostics and programming), manual transmission, automatic transmission, transfer case, front axle, rear axle, drive shafts, CV joints.

Chassis:

Suspension (front and rear independent, multi-link rear), steering system (hydraulic power steering), braking system (ABS, EBD, brake component replacement, hydraulic system bleeding), wheels and tires, chassis and frame.

Electrical:

12V electrical system, battery, charging system (alternator), starting system (starter motor), lighting (headlamps, taillamps, interior), instrument panel and gauges, power windows, power locks, mirrors, wipers and washers, horn, audio system wiring, remote keyless entry, immobilizer system, body control module (BCM) diagnostics, fuse and relay locations.

Body:

Body panels (doors, hood, tailgate), interior trim, seats, glass and seals, bumpers, exterior trim, door hardware, convertible top mechanisms (if applicable to specific trims), structural components.

HVAC:

Heating, ventilation, and air conditioning (HVAC) system operation, refrigerant handling, component replacement (compressor, condenser, evaporator), blower motor, control panels.

Procedures Included

Maintenance:

Oil change, filter replacement (oil, air, fuel, cabin), spark plug replacement, coolant flush and replacement, brake fluid replacement, power steering fluid replacement, transmission fluid change, differential fluid change, transfer case fluid change, belt inspection and replacement, battery service, tire rotation, wheel alignment checks.

Diagnostics:

Troubleshooting charts for common symptoms, diagnostic trouble codes (DTCs) interpretation for OBD-II system, electrical system diagnostics using multimeter and oscilloscope, fuel system pressure testing, ignition system testing, emissions system diagnostics.

Repair:

Engine component repair (e.g., cylinder head removal/installation, piston ring replacement), transmission overhaul and repair, clutch replacement (manual transmission), brake caliper and rotor replacement, suspension component replacement (shocks, struts, ball joints, control arms), steering rack repair, CV axle replacement, exhaust system repair/replacement, starter/alternator replacement, door lock actuator replacement, power window motor replacement.

Installation:

Accessory installation (e.g., tow hitch wiring), minor component upgrades, sensor replacement.

Technical Depth

Depth:

Comprehensive from basic maintenance to advanced diagnostics and complete overhaul procedures. Includes detailed torque specifications, wiring diagrams, exploded views, and diagnostic flowcharts.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content

Print Quality

Resolution:

High-resolution, suitable for printing

Binding Type

Binding:

N/A (Digital)

Paper Type

Paper Quality:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Engine 1 Displacement:

3.0 Liters (2972 cc)

Engine 1 Configuration:

V6, SOHC, 24-valve

Engine 1 Fuel Delivery:

Multi-point Fuel Injection (MPI)

Engine 1 Horsepower:

177 hp @ 5500 rpm (approx.)

Engine 1 Torque:

207 lb-ft @ 4500 rpm (approx.)

Optional Engine

Engine 2 Displacement:

3.8 Liters (3798 cc)

Engine 2 Configuration:

V6, SOHC, 24-valve

Engine 2 Fuel Delivery:

Multi-point Fuel Injection (MPI)

Engine 2 Horsepower:

200 hp @ 5500 rpm (approx.)

Engine 2 Torque:

235 lb-ft @ 3750 rpm (approx.)

Diesel Engine

Engine 3 Displacement:

3.2 Liters (3200 cc)

Engine 3 Configuration:

Inline 4-cylinder, DOHC, Turbocharged, Intercooled

Engine 3 Fuel Delivery:

Direct Injection (Common Rail in later revisions, likely DI for 2003)

Engine 3 Horsepower:

165 hp @ 4000 rpm (approx.)

Engine 3 Torque:

260 lb-ft @ 2000 rpm (approx.)

Fuel System

Fuel Type:

Unleaded Gasoline (3.0L, 3.8L), Diesel Fuel (3.2L DI-D)

Cooling System

Coolant Type:

Mitsubishi DiaQueen Super Long Life Coolant (LLC) or equivalent (Green)

Lubrication System

Oil Type 3.0L:

SAE 5W-30 or 10W-30 API SG or higher

Oil Capacity 3.0L:

4.5 Liters (4.8 US Quarts) with filter

Oil Type 3.8L:

SAE 5W-30 API SG or higher

Oil Capacity 3.8L:

4.7 Liters (5.0 US Quarts) with filter

Oil Type 3.2L Diesel:

SAE 5W-40 API CF-4 or higher

Oil Capacity 3.2L Diesel:

7.4 Liters (7.8 US Quarts) with filter

🔧 Transmission

Standard

Transmission 1 Type:

5-Speed Manual

Optional

Transmission 2 Type:

4-Speed Automatic (INVECS-II)

Features

4Wd System:

Available with Super Select II 4WD system (electronic control with lockable center differential and low-range gearing) or standard 4WD.

Fluid Specs Auto

Automatic Transmission Fluid:

DIAQueen ATF-SPII or equivalent

Fluid Capacity Auto

Automatic Transmission Capacity:

Approx. 7.7 Liters (8.1 US Quarts) for fluid change

Fluid Specs Manual

Manual Transmission Fluid:

API GL-3 or GL-4, SAE 75W-90

Fluid Capacity Manual

Manual Transmission Capacity:

Approx. 2.8 Liters (3.0 US Quarts)

Fluid Specs Transfer Case

Transfer Case Fluid:

API GL-4, SAE 75W-90

Fluid Capacity Transfer Case

Transfer Case Capacity:

Approx. 1.8 Liters (1.9 US Quarts)

Fluid Specs Front Diff

Front Differential Fluid:

API GL-5, SAE 80W-90

Fluid Capacity Front Diff

Front Differential Capacity:

Approx. 1.2 Liters (1.3 US Quarts)

Fluid Specs Rear Diff

Rear Differential Fluid:

API GL-5, SAE 80W-90

Fluid Capacity Rear Diff

Rear Differential Capacity:

Approx. 1.7 Liters (1.8 US Quarts)

📐 Dimensions

Exterior

Length:

Approx. 186.6 inches (4740 mm)

Width:

Approx. 75.4 inches (1915 mm)

Height:

Approx. 72.4 inches (1839 mm)

Wheelbase:

Approx. 109.4 inches (2780 mm)

Ground Clearance:

Approx. 8.0 - 9.1 inches (203 - 231 mm) depending on suspension/tire

Interior

Seating Capacity:

5-7 passengers (depending on configuration)

Cargo

Cargo Volume Behind 3Rd Row:

Approx. 11.5 cu ft (257 cu L)

Cargo Volume Behind 2Nd Row:

Approx. 47.0 cu ft (1330 cu L)

Weights

Curb Weight:

Approx. 4,300 - 4,900 lbs (1950 - 2220 kg) depending on engine/trim

Gross Vehicle Weight Rating:

Approx. 5,700 - 6,200 lbs (2585 - 2812 kg)

Towing Capacity:

Up to 5,000 lbs (2268 kg) with proper equipment

🛡️ Safety Features

Ratings

NHTSA Rollover Rating:

4/5 stars (for specific configurations, consult NHTSA archives)

Active Features

Standard Anti-lock Braking System (ABS)

Electronic Brake-force Distribution (EBD)

Traction Control:

Available Active Traction Control (Active Stability Control also available on some trims)

Passive Features

Airbags Front:

Dual front airbags

Airbags Side:

Available front-seat side-impact airbags

Seatbelts:

Three-point seatbelts with pretensioners for front seats

Child Anchors:

LATCH (Lower Anchors and Tethers for CHildren) system

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with CD player, optional premium audio systems (e.g., Rockford Fosgate) may be available on higher trims.

Navigation:

Optional factory navigation system available on some trim levels.

Driver Assistance

Cruise Control:

Standard cruise control

Parking Sensors:

Not typically standard, may be an optional dealer-installed accessory.

Connectivity

Keyless Entry:

Remote keyless entry system standard on most trims.

Power Features:

Power windows, power door locks, power mirrors standard on most models.

🔧 Maintenance

Service Intervals

Oil Change Interval Gasoline:

Every 3,750 miles (6,000 km) or 6 months, whichever comes first, under normal driving conditions. Severe conditions may require more frequent changes.

Air Filter Replacement:

Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).

Spark Plug Replacement 3.0L:

Every 60,000 miles (96,000 km) with iridium-tip plugs.

Spark Plug Replacement 3.8L:

Every 60,000 miles (96,000 km) with iridium-tip plugs.

Coolant Replacement:

Initial replacement at 30,000 miles (48,000 km) or 24 months, then every 30,000 miles (48,000 km) or 24 months thereafter.

Transmission Fluid Change Auto:

Inspect every 30,000 miles (48,000 km), change if fluid is discolored or contaminated. Typically recommended every 45,000 - 60,000 miles (72,000 - 96,000 km).

Brake Fluid Replacement:

Every 24 months or 30,000 miles (48,000 km) for optimal performance.

Fluid Specifications

Power Steering Fluid:

Power Steering Fluid (Dexron III/Mercon compatible)

Fluid Capacities

Fuel Tank Capacity:

Approx. 17.5 gallons (66 Liters)

Known Issues

Common Problems:

Minor oil leaks from valve cover gaskets, occasional HVAC blower motor issues, potential for ABS sensor failure, rear differential pinion seal leaks, automatic transmission shift quality degradation with age/mileage.

Diesel Specific Concerns:

Check for injector seal leaks, glow plug issues, and potential turbocharger wear if maintenance is neglected.

📚 Vehicle History

Brand Heritage

Brand Focus:

Mitsubishi Motors has a long history in vehicle manufacturing, with a significant focus on durable and capable SUVs and off-road vehicles, tracing roots back to the Pajero lineage.

Model Evolution

Generation:

Second Generation (1991-2000) followed by the Third Generation (2001-2006), this manual covers the early part of the Third Gen.

Third Gen Design:

Introduced a radical redesign with a unibody construction (monocoque chassis) for improved ride comfort and handling, moving away from the previous body-on-frame design.

Production

Manufacturing Location:

Japan (Okazaki Plant)

Production Period:

2000 - 2006 (Third Generation)

🏆 Awards & Recognition

Recognitions

Off Road Acclaim:

The Montero (Pajero globally) has a strong heritage in off-road racing, including multiple victories in the Dakar Rally, underscoring its inherent capability.

Ratings

Consumer Reports:

While specific year ratings vary, the Third Generation Montero was generally rated well for its off-road prowess and durability, though some reported average fuel economy.