🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Model Nickname: Pajero (International Markets) Generation: Second Generation (1991-2000) Codes Chassis Code: V20 Series (Short Wheelbase), V30 Series (Long Wheelbase) 👋 Introduction Market Position Positioning: The Mitsubishi Montero (Pajero) was positioned as a highly capable, rugged, and versatile SUV, often competing in the premium segment of the off-road market against vehicles like the Toyota Land Cruiser and Jeep Cherokee. Competitive Analysis Competitors: Toyota Land Cruiser (80 Series), Jeep Grand Cherokee (ZJ), Ford Explorer, Land Rover Discovery. Key Features Off Road Capability: Renowned for its robust chassis, advanced Super Select 4WD system (optional), and excellent suspension articulation. Durability: Known for its bulletproof engineering and durability, making it a popular choice for overlanding and demanding conditions. Engine Options: Offered with powerful V6 gasoline engines and efficient diesel engines (market dependent). 📋 Manual Details Coverage Areas Years Covered: 1992, 1993, 1994, 1995 Regions Covered: Primarily North America, but likely covers global variations for core mechanicals. Page Count Total Pages: 1130 Manual Type Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed diagnostics, repair procedures, component specifications, and overhaul for all applicable engine variants. Engine Management Electronics: EFI system, ignition system, sensors, actuators, ECU diagnostics, wiring diagrams. Transmission Manual: Repair and overhaul of manual transmissions (likely 5-speed). Transmission Automatic: Repair and overhaul of automatic transmissions (likely 4-speed). Transfer Case And 4Wd System: Operation, diagnostics, and repair of the Super Select 4WD system (if equipped) and transfer case components. Suspension Front: Independent front suspension, diagnostics, alignment, component replacement (ball joints, tie rods, control arms). Suspension Rear: Solid rear axle, coil springs, shock absorbers, diagnostics, component replacement. Brakes: Front disc, rear drum/disc configurations, ABS (if equipped), hydraulic system, component replacement, bleeding procedures. Steering: Power steering system, steering gearbox/rack and pinion, component diagnostics and replacement. Electrical System: Battery, charging system, starting system, lighting, horns, wipers, power windows, mirrors, central locking. Body And Chassis: Body panel removal/installation, interior trim, glass replacement, structural components, anti-corrosion measures. HVAC: Air conditioning system diagnosis and repair, heater core, blower motor, controls. Fuel System: Fuel pump, injectors, fuel filter, fuel tank, evaporative emission control system (EVAP). Exhaust System: Catalytic converter, mufflers, pipes, heat shields, oxygen sensors. Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections/replacements. Diagnostic Procedures: Troubleshooting flowcharts, symptom-based diagnostics, OBD-I code retrieval and interpretation. Component Repair And Rebuild: Detailed instructions for disassembling, cleaning, inspecting, repairing, and reassembling major components. Wheel Alignment: Specifications for camber, caster, toe, and procedures for adjustment. Brake Service: Pad and rotor replacement, caliper overhaul, brake bleeding, drum brake adjustments. Electrical Troubleshooting: Wiring diagrams, circuit tracing, voltage drop testing, connector diagnostics. Engine Timing Adjustment: Belt/chain replacement, tensioner adjustment, ignition timing verification. Fluid And Filter Replacement: Precise capacities and recommended replacement intervals for all vehicle fluids. Technical Depth Depth: Comprehensive: Covers everything from basic maintenance to full engine and transmission rebuilds, including advanced electrical diagnostics. Diagnostic Tools: Details on required specialty tools and common diagnostic procedures for the era. Torque Specifications: Extensive list of torque values for all fasteners and critical components. Clearances And Tolerances: Precise measurements for engine internal clearances (e.g., bearing clearances, piston ring gap). 📊 Manual Specifications File Format Format: PDF Searchability: Likely text-searchable if OCR'd correctly, enabling quick information retrieval. Print Quality Quality: Dependent on original source and scanning quality; typically good for factory manuals. Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code Gasoline: 6G72 (3.0L SOHC V6) Engine Code Diesel: 4D56 (2.5L I4 Turbo Diesel) - Common in non-US markets. Engine Displacement Gasoline: 2972 cc (3.0 Liters) Engine Displacement Diesel: 2477 cc (2.5 Liters) Performance Gasoline Horsepower 6G72: Approximately 155-165 hp (varies by market and tuning) Torque 6G72: Approximately 180-185 lb-ft (varies by market and tuning) Performance Diesel Horsepower 4D56: Approximately 95-118 hp (varies by market and tuning) Torque 4D56: Approximately 160-185 lb-ft (varies by market and tuning) Fuel System Fuel Delivery Gasoline: Electronic Fuel Injection (EFI) Fuel Delivery Diesel: Indirect injection or Common Rail (depending on specific 4D56 variant, though early ones were indirect). Engine Management Ignition Type Gasoline: Distributorless Ignition System (DIS) or traditional distributor, depending on specific model year/market. ECM: Engine Control Module (ECM) responsible for fuel and ignition timing. 🔧 Transmission Standard Gasoline Type: 5-speed Manual Transmission (W5MG1) Optional Gasoline Type: 4-speed Automatic Transmission (V4A51) Standard Diesel Type: 5-speed Manual Transmission (W5MG1) Optional Diesel Type: 4-speed Automatic Transmission (V4A51) Features 4Wd System: Super Select 4WD (SS4) with modes: 2H, 4H, 4HLC (Locking Center Diff), 4LLC (Locking Center and Low Range). Fluid Specifications Manual Transmission Fluid: API GL-3 or GL-4, SAE 75W-90 (Refer to manual for exact spec). Automatic Transmission Fluid: DIA-Queen ATF-SP III or equivalent (Refer to manual for exact spec)....