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Mitsubushi MONTERO SHOGUN PAJERO Service Repair Workshop Manual 1989-1991

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🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Model Aliases: Shogun, Pajero Years Covered: 1989-1991 Codes Chassis Codes: NH Series (e.g., NH15W, NH25W, NH35W) 👋 Introduction Market Position Positioning: A robust, reliable SUV known for its off-road capability and durability in its era. Competitive Analysis Competitors: Jeep Cherokee (XJ), Toyota 4Runner (N80/N90), Nissan Pathfinder (WD21), Ford Bronco II. Key Features Distinction: Renowned for its Super Select 4WD system (on some models), solid axles, and powerful V6 engines, making it a capable off-roader. Manual Value Unique Selling Proposition: Provides comprehensive, dealer-level repair information crucial for maintaining and restoring these capable vehicles, especially given their age and specialized nature. 📋 Manual Details Coverage Areas Coverage Scope: All models and all repairs A-Z Page Count Estimated Pages: Extensive (Typically 1000+ pages for full factory service manuals of this era) Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical (including disassembly/assembly), fuel system, ignition system, cooling system, lubrication system, exhaust system, engine electrical. Drivetrain: Manual transmission, automatic transmission, transfer case, front axle, rear axle, drive shafts, differentials. Chassis: Suspension (front and rear), steering system, braking system (including ABS if equipped). Electrical: Battery, charging system, starting system, lighting, instruments and gauges, power accessories, body electrical, engine control module (ECM), diagnostic trouble codes (DTCs). Body: Body panels, doors, glass, interior trim, HVAC system, collision repair procedures. Procedures Included Maintenance: Routine maintenance, fluid changes, filter replacements, lubrication, adjustments. Diagnostics: Step-by-step troubleshooting guides for common and complex issues, diagnostic trouble code interpretation. Repair: Detailed instructions for component removal, installation, overhaul, and replacement for all major systems. Specifications: Torque specifications, clearances, tolerances, fluid capacities, wiring diagrams, technical data for all components. Schematics: Complete electrical wiring schematics for all circuits and systems. Technical Depth Depth: Factory-level, highly detailed, suitable for professional technicians and advanced DIY enthusiasts. 📊 Manual Specifications File Format Digital Format: PDF Print Quality Printable: All pages are printable Image Scaling: Images can be blown up and printed enlarged Binding Type Binding: Digital (N/A for printed) Paper Type Paper Type: Digital (N/A for printed) Compatibility Os Compatibility: Windows (7, Vista 32/64, XP, ME, 98, NT, 2000), Mac OS Device Compatibility: PC, Tablet, Mac Requirements Software Requirements: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Code And Type 1: 4G63 (2.0L SOHC I4, naturally aspirated/turbocharged, depending on market/trim) Engine Code And Type 2: 6G72 (3.0L SOHC V6, naturally aspirated) Performance Horsepower Range: Approx. 114 HP (2.0L I4) to 145 HP (3.0L V6) and higher for turbo models. Torque Range: Approx. 133 lb-ft (2.0L I4) to 170 lb-ft (3.0L V6) and higher for turbo models. Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) for most variants. Cooling System Coolant Capacity: Approx. 7.8 liters (1.8L) for 3.0L V6 (consult manual for exact spec). Lubrication System Oil Type: API SG or SH rated, SAE 10W-30 or 10W-40 recommended (consult manual for exact spec and temperature ranges). Engine Management ECU Type: Engine Control Unit (ECU) for fuel injection and ignition timing. 🔧 Transmission Standard Type 1: 5-speed Manual Transmission Optional Type 2: 4-speed Automatic Transmission Features 4Wd System: Part-time 4WD with selectable 2WD/4WD High/4WD Low. Some models feature the 'Super Select' 4WD system allowing for full-time 4WD operation. Fluid Specifications Manual Transmission Fluid: API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil (consult manual for specific type and capacity). Automatic Transmission Fluid: DIAQueen ATF-SP II (or equivalent, e.g., Dexron II/III) (consult manual for specific type and capacity). 📐 Dimensions Exterior Wheelbase: Approx. 2,500 mm (98.4 inches) for short-wheelbase, longer for long-wheelbase variants. Weights Curb Weight: Varies by model and trim, generally between 1,700 kg to 1,950 kg (3,748 lbs to 4,299 lbs). 🛡️ Safety Features Ratings Safety Standards: Designed to meet safety standards of the late 1980s/early 1990s. Features include seat belts, crumple zones, and reinforced passenger cage. Active Features ABS: Anti-lock Braking System (ABS) available on some higher trims or as an option. Passive Features Airbags: Driver-side airbag may be present on later models of this range, but not standard across all trims. 💡 Technology Features Infotainment Audio System: Basic AM/FM radio with cassette player, potentially CD player on later models. Speaker configurations vary by trim. Driver Assistance Cruise Control: Optional or standard on higher trims. Connectivity No Advanced Connectivity: No factory-integrated Bluetooth, USB, or smartphone connectivity available in this era. Aftermarket solutions are common. 🔧 Maintenance Service Intervals Oil Change: Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions (consult manual for exact intervals). Engine Coolant Flush: Every 2-3 years or 30,000 miles (48,000 km). Transmission Fluid Change: Manual: Every 30,000-50,000 miles (48,000-80,000 km). Automatic: Every 30,000-40,000 miles (48,000-64,000 km). Fluid Specifications Brake Fluid: DOT 3 or DOT 4 (consult manual for specific type). Power Steering Fluid: Dexron II or equivalent (consult...
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Mitsubushi MONTERO SHOGUN PAJERO Service Repair Workshop Manual 1989-1991Mitsubushi MONTERO SHOGUN PAJERO Service Repair Workshop Manual 1989-1991Mitsubushi MONTERO SHOGUN PAJERO Service Repair Workshop Manual 1989-1991Mitsubushi MONTERO SHOGUN PAJERO Service Repair Workshop Manual 1989-1991
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Montero
Model Aliases:
Shogun, Pajero
Years Covered:
1989-1991
Codes
Chassis Codes:
NH Series (e.g., NH15W, NH25W, NH35W)
👋 Introduction
Market Position
Positioning:
A robust, reliable SUV known for its off-road capability and durability in its era.
Competitive Analysis
Competitors:
Jeep Cherokee (XJ), Toyota 4Runner (N80/N90), Nissan Pathfinder (WD21), Ford Bronco II.
Key Features
Distinction:
Renowned for its Super Select 4WD system (on some models), solid axles, and powerful V6 engines, making it a capable off-roader.
Manual Value
Unique Selling Proposition:
Provides comprehensive, dealer-level repair information crucial for maintaining and restoring these capable vehicles, especially given their age and specialized nature.
📋 Manual Details
Coverage Areas
Coverage Scope:
All models and all repairs A-Z
Page Count
Estimated Pages:
Extensive (Typically 1000+ pages for full factory service manuals of this era)
Manual Type
Type:
Factory Service Repair Workshop Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanical (including disassembly/assembly), fuel system, ignition system, cooling system, lubrication system, exhaust system, engine electrical.
Drivetrain:
Manual transmission, automatic transmission, transfer case, front axle, rear axle, drive shafts, differentials.
Chassis:
Suspension (front and rear), steering system, braking system (including ABS if equipped).
Electrical:
Battery, charging system, starting system, lighting, instruments and gauges, power accessories, body electrical, engine control module (ECM), diagnostic trouble codes (DTCs).
Body:
Body panels, doors, glass, interior trim, HVAC system, collision repair procedures.
Procedures Included
Maintenance:
Routine maintenance, fluid changes, filter replacements, lubrication, adjustments.
Diagnostics:
Step-by-step troubleshooting guides for common and complex issues, diagnostic trouble code interpretation.
Repair:
Detailed instructions for component removal, installation, overhaul, and replacement for all major systems.
Specifications:
Torque specifications, clearances, tolerances, fluid capacities, wiring diagrams, technical data for all components.
Schematics:
Complete electrical wiring schematics for all circuits and systems.
Technical Depth
Depth:
Factory-level, highly detailed, suitable for professional technicians and advanced DIY enthusiasts.
📊 Manual Specifications
File Format
Digital Format:
PDF
Print Quality
Printable:
All pages are printable
Image Scaling:
Images can be blown up and printed enlarged
Binding Type
Binding:
Digital (N/A for printed)
Paper Type
Paper Type:
Digital (N/A for printed)
Compatibility
Os Compatibility:
Windows (7, Vista 32/64, XP, ME, 98, NT, 2000), Mac OS
Device Compatibility:
PC, Tablet, Mac
Requirements
Software Requirements:
Adobe PDF Reader
⚙️ Engine Specifications
Primary Engine
Engine Code And Type 1:
4G63 (2.0L SOHC I4, naturally aspirated/turbocharged, depending on market/trim)
Engine Code And Type 2:
6G72 (3.0L SOHC V6, naturally aspirated)
Performance
Horsepower Range:
Approx. 114 HP (2.0L I4) to 145 HP (3.0L V6) and higher for turbo models.
Torque Range:
Approx. 133 lb-ft (2.0L I4) to 170 lb-ft (3.0L V6) and higher for turbo models.
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI) for most variants.
Cooling System
Coolant Capacity:
Approx. 7.8 liters (1.8L) for 3.0L V6 (consult manual for exact spec).
Lubrication System
Oil Type:
API SG or SH rated, SAE 10W-30 or 10W-40 recommended (consult manual for exact spec and temperature ranges).
Engine Management
ECU Type:
Engine Control Unit (ECU) for fuel injection and ignition timing.
🔧 Transmission
Standard
Type 1:
5-speed Manual Transmission
Optional
Type 2:
4-speed Automatic Transmission
Features
4Wd System:
Part-time 4WD with selectable 2WD/4WD High/4WD Low. Some models feature the 'Super Select' 4WD system allowing for full-time 4WD operation.
Fluid Specifications
Manual Transmission Fluid:
API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil (consult manual for specific type and capacity).
Automatic Transmission Fluid:
DIAQueen ATF-SP II (or equivalent, e.g., Dexron II/III) (consult manual for specific type and capacity).
📐 Dimensions
Exterior
Wheelbase:
Approx. 2,500 mm (98.4 inches) for short-wheelbase, longer for long-wheelbase variants.
Weights
Curb Weight:
Varies by model and trim, generally between 1,700 kg to 1,950 kg (3,748 lbs to 4,299 lbs).
🛡️ Safety Features
Ratings
Safety Standards:
Designed to meet safety standards of the late 1980s/early 1990s. Features include seat belts, crumple zones, and reinforced passenger cage.
Active Features
ABS:
Anti-lock Braking System (ABS) available on some higher trims or as an option.
Passive Features
Airbags:
Driver-side airbag may be present on later models of this range, but not standard across all trims.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with cassette player, potentially CD player on later models. Speaker configurations vary by trim.
Driver Assistance
Cruise Control:
Optional or standard on higher trims.
Connectivity
No Advanced Connectivity:
No factory-integrated Bluetooth, USB, or smartphone connectivity available in this era. Aftermarket solutions are common.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions (consult manual for exact intervals).
Engine Coolant Flush:
Every 2-3 years or 30,000 miles (48,000 km).
Transmission Fluid Change:
Manual: Every 30,000-50,000 miles (48,000-80,000 km). Automatic: Every 30,000-40,000 miles (48,000-64,000 km).
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4 (consult manual for specific type).
Power Steering Fluid:
Dexron II or equivalent (consult manual for specific type and capacity).
Known Issues
Common Wear Items:
Suspension bushings, ball joints, tie rod ends, exhaust system components, timing belt (if applicable to specific engine variant), starter motor, alternator.
Electrical Gremlins:
Age-related issues with wiring harnesses, connectors, and control modules are not uncommon.
Rust And Corrosion:
Body rust, especially on frame rails, rocker panels, and around wheel arches, is a significant concern for vehicles of this age and should be inspected.
📚 Vehicle History
Brand Heritage
Mitsubishi 4X4 Legacy:
Mitsubishi has a long history in off-road vehicles, dating back to the PX300 'J-Top' in 1936 and the original Pajero in 1973.
Model Evolution
Second Generation:
The 1989-1991 models represent the latter part of the second generation (1983-1991) Pajero/Montero, which saw significant updates including more refined engines and the introduction of advanced features like the Super Select 4WD.
Production
Manufacturing Locations:
Primarily Japan, with assembly in other countries for specific markets.
🏆 Awards & Recognition
Recognitions
Offroad Acclaim:
The Pajero/Montero platform has a strong heritage in rally raid events, most notably winning the Dakar Rally multiple times (though specific wins for this generation might be post-1991, the platform's reputation was built).
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