Mitsubushi MONTERO SHOGUN PAJERO Service Repair Workshop Manual 1992
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🏷️ Basic Information Identification Make: Mitsubishi Model: Montero / Shogun / Pajero Year: 1992 Generation Generation Designation: Second Generation (NJ/NK/NL/NM/NP) Codes Chassis Codes: V20 series (short wheelbase), V30 series (long wheelbase), V40 series (short wheelbase SWB), V55 (short wheelbase, V6 3000cc), V60 series (long wheelbase LWB) 👋 Introduction Market Position Vehicle Segment: Robust mid-size SUV, known for its off-road capability and durability. Positioned as a versatile vehicle for both on-road comfort and extreme off-road adventure. Competitive Analysis Key Competitors 1992: Jeep Cherokee (XJ), Toyota 4Runner (N130), Ford Explorer, Nissan Pathfinder (WD21), Land Rover Discovery. Key Features Manual Advantage: Provides dealer-level repair information, enabling owners to perform maintenance and repairs themselves, saving significant costs on labor. Highly detailed with diagrams and schematics specific to the 1992 model year. Vehicle Attributes: Known for its rugged construction, available V6 engines, advanced 4WD systems (like Super Select), and comfortable interior for its class. 📋 Manual Details Coverage Areas Global Market Coverage: Covers all models and regions where the Montero/Shogun/Pajero was sold for the 1992 model year, including North America, Europe, Australia, and other international markets. Page Count Estimated Page Count: Extremely comprehensive, typically over 1000 pages for a full factory service manual covering all aspects. Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul, assembly, disassembly, cylinder head, block, crankshaft, camshafts, timing belts/chains, pistons, connecting rods, lubrication system, cooling system, fuel system components (injectors, pumps, lines), intake manifold, exhaust manifold. Engine Performance: Engine tuning, idle speed control, emission control systems, diagnosis of performance issues, sensor operation and testing (MAP, TPS, O2, etc.). Transmission Manual: Manual transmission overhaul, disassembly, assembly, clutch system, shift linkage, transfer case (Super Select 4WD) operation and repair. Transmission Automatic: Automatic transmission overhaul, disassembly, assembly, torque converter, valve body, planetary gear sets, hydraulic control systems, transmission fluid cooler. Drivetrain: Front and rear differentials, axles, CV joints, driveshafts, U-joints, wheel bearings, hub assemblies. Suspension System: Front suspension (independent, coil springs, torsion bars or double wishbone depending on variant), rear suspension (multi-link, coil springs), shock absorbers, struts, bushings, ball joints, control arms, anti-roll bars. Steering System: Power steering pump, steering gear or rack and pinion, steering column, tie rod ends, power steering fluid specifications. Brake System: Front disc brakes, rear drum or disc brakes (depending on model), ABS system (if equipped), brake calipers, rotors, pads, brake lines, master cylinder, brake fluid specifications, parking brake. Electrical System Engine: Starter motor, alternator, battery, ignition system (coil, distributor or electronic ignition), engine control unit (ECU) operation and diagnosis, sensor inputs and outputs. Electrical System Accessories: Lighting system (headlights, taillights, interior lights), horn, wipers and washer system, power windows, power locks, mirrors, seat adjustment, HVAC blower motor, radio, antenna. Body And Chassis: Body panel removal and installation, door mechanisms, hood, tailgate, bumpers, glass replacement, interior trim, chassis lubrication points, frame repair. Climate Control HVAC: Air conditioning system diagnosis and repair, refrigerant types and capacities, heater core, blower motor, control panels, ducting, evaporative emissions system (if applicable). Manual Coverage Procedures Included: Step-by-step repair procedures for all major mechanical and electrical components, including detailed disassembly and reassembly instructions. Procedures Included Troubleshooting Guides: Comprehensive diagnostic charts and troubleshooting procedures for common and uncommon problems, symptom-based diagnosis. Maintenance Tasks: Scheduled maintenance, fluid changes, filter replacements, tune-ups, lubrication, belt inspection and replacement. Wiring Schematics: Full color or black and white wiring diagrams for all electrical systems, including power distribution, lighting, engine controls, ABS, and accessories. Diagnostic Procedures: Methods for diagnosing faults using onboard diagnostic systems (OBD-I for this era), multimeter testing, and specialized tools. Component Replacement: Detailed instructions for replacing specific parts such as alternators, starter motors, fuel pumps, brake calipers, ball joints, etc. Torque Specifications: Precise torque values for all critical fasteners, including cylinder head bolts, main bearing caps, connecting rod bolts, wheel nuts, etc. Special Tools: Identification and usage instructions for any specialized tools required for specific repairs or adjustments. Technical Depth Depth: Factory-level technical detail, suitable for professional technicians and advanced DIY enthusiasts. Covers everything from basic maintenance to full engine and transmission rebuilds. 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Print Quality Printable Pages: All pages are fully printable, allowing users to print specific sections or the entire manual as needed. Image Enhancement: Supports zooming in on images and diagrams for detailed viewing and printing enlarged copies. Binding Type Binding: Digital Download (no physical binding) Paper Type Paper Type Digital: N/A (Digital format) Compatibility Operating Systems: Compatible with all versions of Windows (7, Vista 32/64, XP, ME, 98, NT, 2000) and Mac computers. Requirements Software Requirement: Adobe PDF Reader (free download available). ⚙️ Engine Specifications Primary Engine Engine Options 1992: 2.6L 4G64 I4, 3.0L 6G72 V6 SOHC, 3.0L 6G72 V6 SOHC Twin-Turbo (JDM specific, less common globally for 1992). The...
V20 series (short wheelbase), V30 series (long wheelbase), V40 series (short wheelbase SWB), V55 (short wheelbase, V6 3000cc), V60 series (long wheelbase LWB)
👋 Introduction
Market Position
Vehicle Segment:
Robust mid-size SUV, known for its off-road capability and durability. Positioned as a versatile vehicle for both on-road comfort and extreme off-road adventure.
Competitive Analysis
Key Competitors 1992:
Jeep Cherokee (XJ), Toyota 4Runner (N130), Ford Explorer, Nissan Pathfinder (WD21), Land Rover Discovery.
Key Features
Manual Advantage:
Provides dealer-level repair information, enabling owners to perform maintenance and repairs themselves, saving significant costs on labor. Highly detailed with diagrams and schematics specific to the 1992 model year.
Vehicle Attributes:
Known for its rugged construction, available V6 engines, advanced 4WD systems (like Super Select), and comfortable interior for its class.
📋 Manual Details
Coverage Areas
Global Market Coverage:
Covers all models and regions where the Montero/Shogun/Pajero was sold for the 1992 model year, including North America, Europe, Australia, and other international markets.
Page Count
Estimated Page Count:
Extremely comprehensive, typically over 1000 pages for a full factory service manual covering all aspects.
Front and rear differentials, axles, CV joints, driveshafts, U-joints, wheel bearings, hub assemblies.
Suspension System:
Front suspension (independent, coil springs, torsion bars or double wishbone depending on variant), rear suspension (multi-link, coil springs), shock absorbers, struts, bushings, ball joints, control arms, anti-roll bars.
Steering System:
Power steering pump, steering gear or rack and pinion, steering column, tie rod ends, power steering fluid specifications.
Brake System:
Front disc brakes, rear drum or disc brakes (depending on model), ABS system (if equipped), brake calipers, rotors, pads, brake lines, master cylinder, brake fluid specifications, parking brake.
Electrical System Engine:
Starter motor, alternator, battery, ignition system (coil, distributor or electronic ignition), engine control unit (ECU) operation and diagnosis, sensor inputs and outputs.
Electrical System Accessories:
Lighting system (headlights, taillights, interior lights), horn, wipers and washer system, power windows, power locks, mirrors, seat adjustment, HVAC blower motor, radio, antenna.
Body And Chassis:
Body panel removal and installation, door mechanisms, hood, tailgate, bumpers, glass replacement, interior trim, chassis lubrication points, frame repair.
Climate Control HVAC:
Air conditioning system diagnosis and repair, refrigerant types and capacities, heater core, blower motor, control panels, ducting, evaporative emissions system (if applicable).
Manual Coverage
Procedures Included:
Step-by-step repair procedures for all major mechanical and electrical components, including detailed disassembly and reassembly instructions.
Procedures Included
Troubleshooting Guides:
Comprehensive diagnostic charts and troubleshooting procedures for common and uncommon problems, symptom-based diagnosis.
Maintenance Tasks:
Scheduled maintenance, fluid changes, filter replacements, tune-ups, lubrication, belt inspection and replacement.
Wiring Schematics:
Full color or black and white wiring diagrams for all electrical systems, including power distribution, lighting, engine controls, ABS, and accessories.
Diagnostic Procedures:
Methods for diagnosing faults using onboard diagnostic systems (OBD-I for this era), multimeter testing, and specialized tools.
Component Replacement:
Detailed instructions for replacing specific parts such as alternators, starter motors, fuel pumps, brake calipers, ball joints, etc.
Torque Specifications:
Precise torque values for all critical fasteners, including cylinder head bolts, main bearing caps, connecting rod bolts, wheel nuts, etc.
Special Tools:
Identification and usage instructions for any specialized tools required for specific repairs or adjustments.
Technical Depth
Depth:
Factory-level technical detail, suitable for professional technicians and advanced DIY enthusiasts. Covers everything from basic maintenance to full engine and transmission rebuilds.
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Print Quality
Printable Pages:
All pages are fully printable, allowing users to print specific sections or the entire manual as needed.
Image Enhancement:
Supports zooming in on images and diagrams for detailed viewing and printing enlarged copies.
Binding Type
Binding:
Digital Download (no physical binding)
Paper Type
Paper Type Digital:
N/A (Digital format)
Compatibility
Operating Systems:
Compatible with all versions of Windows (7, Vista 32/64, XP, ME, 98, NT, 2000) and Mac computers.
Requirements
Software Requirement:
Adobe PDF Reader (free download available).
⚙️ Engine Specifications
Primary Engine
Engine Options 1992:
2.6L 4G64 I4, 3.0L 6G72 V6 SOHC, 3.0L 6G72 V6 SOHC Twin-Turbo (JDM specific, less common globally for 1992). The 3.0L V6 was the most prevalent in many markets.
Performance
3.0L V6 Sohc Horsepower Torque:
Approx. 140-150 hp (Varies by market and tuning); Torque approx. 170-180 lb-ft.
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Engine Codes
Common Engine Codes:
6G72 (3.0L V6), 4G64 (2.6L I4)
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual Transmission
Optional
Optional Transmission:
4-speed Automatic Transmission
Features
4Wd System:
Super Select 4WD (SS4) system, offering 2H, 4H, 4HLC (with locked center differential), and 4LLC (with locked center and low range) modes. Some base models may have simpler part-time 4WD systems.
📐 Dimensions
Exterior
Wheelbase Swb:
Approx. 2,450 mm (96.5 in) for Short Wheelbase (SWB) models (e.g., V20 series)
Wheelbase Lwb:
Approx. 2,725 mm (107.3 in) for Long Wheelbase (LWB) models (e.g., V30/V60 series)
Weights
Curb Weight Range:
Approx. 1,700 kg to 2,000 kg (3,750 lbs to 4,400 lbs), depending on configuration.
🛡️ Safety Features
Ratings
Safety Features Availability:
Availability of features like ABS (Anti-lock Braking System) varied by trim level and market. Airbags were not standard on all models for 1992.
Active Features
ABS:
Available on higher trim levels, typically for front wheels or all four wheels depending on the specific system.
Passive Features
Seatbelts:
Standard three-point seatbelts in the front, lap belts in the rear. Child seat anchor points (LATCH/ISOFIX) were not standard in this era.
💡 Technology Features
Infotainment
Audio System:
Typically an AM/FM stereo with cassette player. Optional CD player was available on higher trims. Speaker configurations varied.
Driver Assistance
Cruise Control:
Available as an option or standard on higher trim levels.
Connectivity
Connectivity Options:
Limited by era; primarily focused on basic automotive functions. No integrated Bluetooth, USB, or advanced smartphone connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000 miles (8,000 km) or 6 months, whichever comes first. Refer to the manual for specific engine and oil type recommendations.
Transmission Fluid Change Interval:
Automatic transmission fluid: approximately every 30,000 miles (48,000 km). Manual transmission fluid: approximately every 60,000 miles (96,000 km). Check manual for specific intervals and fluid types.
Fluid Specifications
Engine Oil Viscosity:
Commonly 10W-30 or 10W-40, depending on climate. Check manual for specific API service classification and exact viscosity recommendations for the fitted engine.
Coolant Type:
Ethylene glycol-based antifreeze coolant, typically a 50/50 mix with distilled water. Check manual for specific color and type.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. Always use fresh, sealed fluid.
Power Steering Fluid:
Specific power steering fluid or Dexron II/III ATF, as specified by Mitsubishi. Refer to manual for precise specification.
Known Issues
Common Wear Items:
Worn ball joints, tie rod ends, wheel bearings, transfer case seals, starter motor brushes, alternator wear, exhaust manifold gaskets, and potential for radiator leaks with age.
Engine Minor Issues:
Minor oil leaks from valve cover gaskets or oil pan gaskets, ignition system component failures (spark plug wires, distributor cap/rotor). Timing belt replacement is critical on non-interference engines with belts.
4Wd System Maintenance:
Regular lubrication of transfer case and propeller shaft U-joints is crucial. Proper functioning of the Super Select 4WD hubs and engagement mechanisms should be periodically checked.
📚 Vehicle History
Brand Heritage
Mitsubishi SUV Legacy:
Mitsubishi has a long history of producing capable off-road vehicles, dating back to the original Pajero in 1976, which established its reputation for ruggedness and off-road prowess.
Model Evolution
Second Gen Introduction:
The second generation Pajero/Montero, introduced in 1991 for the 1992 model year, featured a significant redesign with a more modern exterior, improved interior comfort, and advanced features like the Super Select 4WD system.
Production
Production Locations:
Primarily manufactured in Japan, with some assembly in other countries depending on the market.
🏆 Awards & Recognition
Recognitions
Off Road Acclaim:
The Pajero/Montero has a strong legacy in off-road motorsports, including numerous victories in the Dakar Rally, highlighting its inherent capability and durability.
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