2006 Mitsubishi Montero Factory Service & Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Year: 2006 Trim Level: Limited Generation Generation Code: Third Generation (V70/V80) Generation Years: 1999-2006 (International), 2000-2006 (North America) 👋 Introduction Market Position Vehicle Segment: Full-size SUV, body-on-frame, known for off-road capability and spacious interior. Competitive Analysis Key Competitors: Toyota 4Runner, Nissan Pathfinder, Ford Explorer, Jeep Grand Cherokee. Key Features Vehicle Highlights: Robust construction, available 4WD system (SS4-II), powerful V6 engine, comfortable ride for its class, significant updates in 2003. Manual Value Proposition Diy Benefits: Empowers owners to perform routine maintenance and repairs, saving money and gaining practical skills. 📋 Manual Details Coverage Areas Models Covered: 2006 Mitsubishi Montero Limited Page Count Estimated Page Count: 1500-2000 pages (estimated for comprehensive factory service manuals) Manual Type Manual Type: Factory Service & Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, overhaul procedures, specifications for the 3.8L V6 engine. Transmission: Service and repair for the INVECS-II 5-speed automatic transmission, including troubleshooting and component replacement. Drivetrain: Procedures for front and rear differentials, driveshafts, CV joints, and the SS4-II electronic 4WD system. Suspension: Front independent double-wishbone, rear multi-link suspension diagnostics, alignment, component replacement (shocks, springs, bushings). Brakes: Front vented disc, rear solid disc brake system repair, ABS system diagnosis, hydraulic components. Steering: Power steering system diagnosis, repair, components, steering column. Electrical System: Comprehensive wiring diagrams, component testing, charging system, starting system, lighting, accessories. HVAC: Heating, ventilation, and air conditioning system service, refrigerant handling, component repair. Body And Interior: Panel removal, door mechanisms, seat adjustments, interior trim, glass replacement, exterior moldings. Chassis: Frame, body mounts, exhaust system, fuel tank, and related components. Procedures Included Maintenance: Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, lubrication. Troubleshooting: Diagnostic charts, symptom-based troubleshooting for various systems (engine, electrical, HVAC, etc.). Repair: Detailed step-by-step instructions for component replacement, assembly, and disassembly. Diagnostics: OBD-II diagnostics, reading trouble codes, specific system diagnostic procedures. Specifications: Torque specifications, clearances, fluid capacities, electrical resistance values, diagnostic parameters. Engine Repair: Detailed instructions for cylinder head removal/installation, piston and connecting rod service, crankshaft removal/installation, timing belt/chain service (if applicable). Drivetrain Service: Front and rear differential fluid changes, seal replacement, axle shaft removal/installation, propeller shaft service, SS4-II 4WD system calibration and troubleshooting. Suspension Wheel Alignment: Specifications for camber, caster, toe, and steering axis inclination (SAI) for both front and rear suspension. Technical Depth Depth: Comprehensive, covering from basic maintenance to major overhauls and advanced diagnostics. Wiring Diagrams: Comprehensive, color-coded wiring diagrams for all major electrical systems, including engine control, body electronics, and lighting. 📊 Manual Specifications File Format Compatibility: All Versions of Windows & Mac Software Requirements: Adobe PDF Reader Print Quality Digital Format Quality: High-resolution PDFs with clear text and diagrams. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code: 6G75 Engine Displacement: 3.8 Liters (3828 cc) Engine Configuration: SOHC V6 (Single Overhead Camshaft, V-configuration) Bore X Stroke: 95.0 mm x 89.0 mm (3.74 in x 3.50 in) Compression Ratio: 9.5:1 Performance Horsepower: 215 hp @ 5500 rpm (estimated) Torque: 280 lb-ft @ 3750 rpm (estimated) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Ignition System Ignition Type: Electronic Ignition with Distributorless Ignition System (DIS) / Coil-on-Plug (COP) 🔧 Transmission Standard Transmission Type: INVECS-II 5-Speed Automatic Transmission Optional Optional Transmission: N/A for 2006 Limited model in North America Features Transmission Features: Sportronic Shifting (manual mode), adaptive shift control. Fluid Specification Transmission Fluid Type: Diamond ATF SP-III or equivalent 📐 Dimensions Exterior Wheelbase: 109.7 inches (2785 mm) Length: 186.5 inches (4737 mm) Width: 73.7 inches (1872 mm) Height: 70.3 inches (1786 mm) Weights Curb Weight: Approx. 4600-4700 lbs (2087-2132 kg) depending on configuration. Gross Vehicle Weight Rating: Approx. 6150 lbs (2790 kg) Cargo Cargo Volume Behind 3Rd Row: N/A (3rd row not standard on 2006 Limited in US market, typically 7-seater configuration was optional) Cargo Volume Behind 2Nd Row: Approx. 46.6 cubic feet (1319 liters) Towing Towing Capacity: Up to 5000 lbs (2268 kg) with towing package. 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 5 Stars (2005 model year data, applicable to 2006) NHTSA Front Impact Passenger: 5 Stars (2005 model year data, applicable to 2006) NHTSA Side Impact Front Seat: 5 Stars (2005 model year data, applicable to 2006) NHTSA Side Impact Rear Seat: 4 Stars (2005 model year data, applicable to 2006) IIHS Roof Strength: Good (2005 model year data, applicable to 2006) Active Features Active Safety Features: ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution), Traction Control System (TCS), Electronic Stability Control (ESC) / Active Stability Control (ASC). Passive Features Passive Safety Features: Front airbags, front side-impact airbags, 3-point seatbelts with pretensioners, LATCH child seat anchors. 💡 Technology Features Infotainment Infotainment Features: AM/FM stereo with CD player, optional...
Detailed instructions for cylinder head removal/installation, piston and connecting rod service, crankshaft removal/installation, timing belt/chain service (if applicable).
Drivetrain Service:
Front and rear differential fluid changes, seal replacement, axle shaft removal/installation, propeller shaft service, SS4-II 4WD system calibration and troubleshooting.
Suspension Wheel Alignment:
Specifications for camber, caster, toe, and steering axis inclination (SAI) for both front and rear suspension.
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to major overhauls and advanced diagnostics.
Wiring Diagrams:
Comprehensive, color-coded wiring diagrams for all major electrical systems, including engine control, body electronics, and lighting.
📊 Manual Specifications
File Format
Compatibility:
All Versions of Windows & Mac
Software Requirements:
Adobe PDF Reader
Print Quality
Digital Format Quality:
High-resolution PDFs with clear text and diagrams.
Approx. 4600-4700 lbs (2087-2132 kg) depending on configuration.
Gross Vehicle Weight Rating:
Approx. 6150 lbs (2790 kg)
Cargo
Cargo Volume Behind 3Rd Row:
N/A (3rd row not standard on 2006 Limited in US market, typically 7-seater configuration was optional)
Cargo Volume Behind 2Nd Row:
Approx. 46.6 cubic feet (1319 liters)
Towing
Towing Capacity:
Up to 5000 lbs (2268 kg) with towing package.
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5 Stars (2005 model year data, applicable to 2006)
NHTSA Front Impact Passenger:
5 Stars (2005 model year data, applicable to 2006)
NHTSA Side Impact Front Seat:
5 Stars (2005 model year data, applicable to 2006)
NHTSA Side Impact Rear Seat:
4 Stars (2005 model year data, applicable to 2006)
IIHS Roof Strength:
Good (2005 model year data, applicable to 2006)
Active Features
Active Safety Features:
ABS (Anti-lock Braking System), EBD (Electronic Brake-force Distribution), Traction Control System (TCS), Electronic Stability Control (ESC) / Active Stability Control (ASC).
Passive Features
Passive Safety Features:
Front airbags, front side-impact airbags, 3-point seatbelts with pretensioners, LATCH child seat anchors.
💡 Technology Features
Infotainment
Infotainment Features:
AM/FM stereo with CD player, optional navigation system, premium audio systems were available on Limited trim.
Driver Assistance
Driver Assistance Features:
Traction Control, Stability Control, ABS, EBD.
Connectivity
Connectivity Options:
Power windows, power door locks, remote keyless entry, cruise control.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 to 7,500 miles (8,000 to 12,000 km) or 6 months, whichever comes first, depending on driving conditions.
Engine Air Filter Replacement:
Every 30,000 miles (48,000 km) or as needed based on inspection.
Cabin Air Filter Replacement:
Every 15,000 miles (24,000 km) or annually.
Spark Plug Replacement:
Refer to manual for specific type (e.g., iridium), typically 60,000-100,000 miles.
Fluid Specifications
Engine Oil Specification:
SAE 5W-30 (API SM or ILSAC GF-4 certified)
Engine Oil Capacity:
Approx. 4.5 quarts (4.3 liters) with filter change.
Coolant Type:
Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol based coolant with long-life additives, typically pink or red).
Brake Fluid Specification:
DOT 3
Known Issues
Common Issues:
Rear differential breather clog (can cause seal leaks), occasional HVAC blower motor failures, potential for ABS sensor issues, front axle seal leaks.
📚 Vehicle History
Brand Heritage
Mitsubishi Brand History:
Mitsubishi Motors Corporation, a Japanese multinational automotive manufacturer with a long history dating back to 1917.
Model Evolution
Montero History:
The Montero (known as Pajero outside North America) has been a flagship SUV for Mitsubishi, evolving through three generations, known for its off-road prowess and ruggedness.
Production
Production Location:
Japan (main manufacturing)
Model Year Updates
2006 Updates:
Minimal changes from the 2005 model year. Primarily offered in the 'Limited' trim. Exterior styling retained from the 2003 refresh which included a restyled grille, integrated side steps, and updated bodyside cladding.
🏆 Awards & Recognition
Recognitions
Safety Awards:
Consistent good safety ratings from NHTSA and IIHS during its generation.