1992–1995 Mitsubishi Montero Chassis & Body Service Manual, Volume 1 (P/N MSSP-004B-95 (1/2))

This Mitsubishi Montero Volume 1: Chassis & Body service manual, Publication No. MSSP-004B-95 (1/2), covers the V43/6G72 and V45/6G74 configurations, with separate Federal and California fuel-system information.

Coverage boundary: This volume contains system-specific electrical diagnostics. The paired Volume 2 Electrical and the separate engine and transmission overhaul manuals are not included.

• Engine repair: Timing-belt replacement, cylinder-head-gasket service, camshaft and crankshaft oil seals, engine removal and installation, and lash-adjuster checks.

• Fuel and emissions: Multiport fuel injection diagnosis, fuel-pressure testing, sensor and injector checks, cruise control, EGR, PCV, and evaporative-emission systems.

• Transmission and axles: Transmission/transfer removal, automatic-transmission pressure and stall tests, propeller-shaft service, free-wheeling clutch repair, and differential adjustment.

• Brakes and steering: Disc-brake pad replacement, caliper service, parking-brake adjustment, ABS fault diagnosis, wheel-speed-sensor testing, and power-steering pressure checks.

• Suspension and body: Front and rear suspension service, alignment checks, remotely controlled shock absorbers, door and window mechanisms, and interior/exterior trim.

• Heating and air conditioning: Heater and blower service, refrigerant-circuit diagnosis, compressor work, and separate specifications for R-12 and R-134a systems.

This manual suits technicians familiar with automotive diagnosis, electrical measurements, and workshop lifting equipment; its SRS instructions reserve that work for authorized Mitsubishi service personnel.

Engine Service and Fuel-System Diagnosis

The engine chapters distinguish the SOHC 6G72 configurations from the DOHC 6G74. Timing-mark illustrations and tool references, including tension pulley socket wrench MD998767, accompany the belt procedures. The 6G74 instructions warn that incorrect camshaft positioning can cause valve-to-piston or valve-to-valve contact.

Lash-adjuster noise: The manual explains how oil aeration and extended parking can produce valve noise without establishing that an adjuster has failed. Its inspection guidance helps separate these conditions from component faults; detailed leak-down testing and adjuster bleeding are referred to the separate Engine Service Manual.

MFI system diagrams, diagnostic-code charts, ECU terminal-voltage tables, and connector inspection workflows support fault tracing. MUT-II scan tool MB991502 is identified in the tool lists. The distinction between code-based checks and symptom checks is useful when a running problem produces no diagnostic code.

Cooling-system coverage includes radiator-cap testing, thermostat inspection, water-pump replacement, and coolant-leak checks. Exhaust-manifold and catalytic-converter procedures sit alongside emission-control vacuum-routing diagrams and the scheduled-maintenance tables.

Transmission Tests and Differential Repair

The V5MT1 section addresses shift controls, transfer seals, drive-mode detection switches, and assembly removal. V4AW2 and V4AW3 coverage adds road-test interpretation, hydraulic-pressure checks, and converter stall testing, supported by transmission sectional views and gear-specific hydraulic circuit diagrams.

Front-axle procedures cover the free-wheeling clutch and differential carrier. Rear-axle sections distinguish conventional, limited-slip, and locking differentials, with bearing-preload, backlash, and tooth-contact checks. These distinctions help select the appropriate inspection and assembly information before differential work begins.

Chassis, Cabin, and SRS Service

Steering coverage extends to gear-box and pump disassembly, reassembly, and hydraulic bleeding. Brake chapters add master-cylinder and booster checks, rotor inspection, ABS actuator tests, and wheel-speed-sensor waveform checks. Wheel/tire specifications and suspension adjustment data support the chassis work.

Body procedures address glazing, door regulators, sunroof mechanisms, seats, and trim. The HVAC section separates the refrigerant and lubricant requirements of the two A/C systems and covers performance testing, leak diagnosis, and component removal.

SRS and clock spring: Circuit diagrams and post-collision inspection criteria accompany component service. The clock-spring warning explains that incorrect alignment can sever its flat cable and interfere with normal SRS operation. Follow the manual's component-specific precautions for airbag, torsion-bar, brake, and refrigerant work.

Examples of Thermostat and Injector Test Data

Thermostat opening temperature is specified as 88°C (190°F) for the 6G72 SOHC-12-valve engine and 82°C (180°F) for the 6G72 SOHC-24-valve and 6G74 engines. The cooling tables also distinguish opening temperature from full-opening temperature.

The MFI service specifications list injector coil resistance of 13–16 Ω at 20°C (68°F), alongside separate component-inspection sections for the SOHC-12-valve and SOHC-24-valve/DOHC configurations.

PDF Bookmarks, Diagram Detail, and Included Pages

Navigation and small labels: PDF text search is unavailable. Embedded bookmarks provide access to major chapters and selected subsections. Small wiring labels require zooming; some dense SRS circuit and connector labels remain difficult to read even when enlarged.

Supplied as one printable PDF in English, this 1,134-page manual includes the front cover, rear publication page, and 18 blank or notes pages within the total.