Thinking about buying a used Mitsubishi Montero (1991–2019) in New Zealand? We've documented 30 known faults for this model spanning engine, suspension, transmission, and cooling. Each researched and verified before it's published. The most serious issues here are rated critical. Two are set out in full below — the rest, with the symptoms, repair costs and checks for each, are free with an account.
30
Documented faults
Critical
Most serious
$600–$2,500
Typical repair
7
Systems covered
Known Mitsubishi Montero faults
Every fault below is documented specifically for this model — researched and verified before it’s published.
016G74 3.5L V6 Balance Shaft Belt Failure and Engine Destruction
CriticalCommonEngine $8,000–$20,000 to fix
The 6G74 3.5-litre V6 petrol engine uses a secondary inner belt to drive the balance shafts, running in the same timing chest as the main cambelt. This inner balance shaft belt is prone to delamination and shedding at high mileage, particularly past 100,000 km if the engine has not had the full belt kit (including inner belt) replaced. When the inner belt sheds, rubber debris can jam the timing belt, causing it to skip or snap and resulting in piston-to-valve contact and catastrophic engine damage. The failure is silent and gives no prior warning.
Symptoms to notice
Sudden catastrophic engine failure with no prior warning (belt shed event)
Loud mechanical bang followed by immediate engine stall
No compression on multiple cylinders after failure
Timing belt cover showing rubber debris or shredded belt material
Engine cranks but will not start after over-rev or sustained high-speed run
What to check
Ask for full service history showing the cambelt was replaced with a complete OEM or quality aftermarket belt kit — verify the invoice specifies the balance shaft belt was also replaced, not just the main cambelt. Be extremely wary of any 6G74 with unknown belt history or mileage over 100,000 km without documented belt service. Have a mechanic remove the timing cover to inspect belt condition before purchase.
Where to look: Timing belt cover, front of engine
Ask the seller
“Do you have a workshop invoice confirming both the main cambelt and the inner balance shaft belt were replaced, and when?”
“What is the current mileage and when was the last timing belt service performed?”
“Has the engine ever been rebuilt or replaced due to a belt failure?”
024M41 and 4D56 Diesel EGR Valve and Inlet Manifold Carbon Fouling
MinorVery commonEngine $300–$1,200 to fix
Recirculated exhaust gases deposit a thick, oily carbon sludge in the EGR valve passages and inlet manifold runners of the 4M41 3.2D and 4D56 2.5D engines. Over time, this buildup restricts airflow into the cylinders, reducing combustion efficiency and power output. The EGR valve can stick open (causing rough idle and smoke) or closed (triggering an EGR fault code and check engine light). Vehicles used predominantly for short urban trips accumulate deposits fastest.
Symptoms to notice
Black or blue smoke at idle that clears during highway driving
Progressive loss of power and throttle response over months
Rough or lumpy idle, especially when the engine is fully warm
Check engine light with EGR-related fault codes (P0401, P0404)
Visible black sludge inside intake hose or intercooler pipe
What to check
If accessible, inspect the EGR valve for carbon buildup or a stuck-open position. Scan for fault codes: P0401 (insufficient EGR flow) or P0404 (EGR valve range/performance) are common. A smoky idle that clears on the highway is a classic symptom. If a workshop inspection is possible: Remove the intake hose between the air filter and turbo and inspect for thick black sludge coating — heavy fouling indicates EGR deposits throughout the intake tract.
Where to look: EGR valve on intake manifold, driver's side of engine
Ask the seller
“Has the EGR valve and inlet manifold ever been cleaned or replaced?”
“Does the engine produce any smoke at idle or under light load?”
“Has there ever been a check engine light related to the EGR or emissions system?”
EngineCritical
EngineCritical
EngineCritical
EngineCritical
EngineCritical
EngineCritical
EngineCritical
SuspensionCritical
TransmissionMajor
EngineMajor
TransmissionMajor
CoolingMajor
Body & RustMajor
EngineMajor
CoolingMajor
TransmissionMajor
SuspensionMajor
TransmissionMajor
EngineMajor
EngineMajor
EngineMajor
TransmissionMajor
SuspensionMajor
EngineMajor
Fluid LeaksMajor
BrakesMajor
EngineMajor
SuspensionMinor
28 more documented faults on the Mitsubishi Montero
Symptoms, what to check, where to look and what to ask the seller — for every fault above. Free with an account, no card needed. One account covers one vehicle, so make it the car you’re actually looking at.
This page covers the model. Enter the plate of the actual car you’re looking at and see its year, engine, safety rating and register flags — free, no account needed.
Like any used car, it depends on the specific example and its service history. Across the 30 documented faults for the Mitsubishi Montero, the recurring problem areas are engine, suspension, and transmission. A Mitsubishi Montero with a full service history and no signs of the issues listed on this page can be a sound buy but each one needs to be checked individually before you commit.
What are the most common problems with a used Mitsubishi Montero?
+
We've catalogued 30 known faults for the Mitsubishi Montero, covering engine, suspension, and transmission. Two are written out in full on this page. The rest — with the symptoms to notice, what to inspect, and typical repair costs for each — are free once you create an account.
How much do repairs cost on a Mitsubishi Montero?
+
Most single repairs on the Mitsubishi Montero fall between $600–$2,500 at NZ independent-workshop rates. Some of the 30 documented faults cost less and a few cost considerably more, and no one car needs them all. Knowing which ones to look for before you view is what lets you negotiate the price down or walk away.
Should I get a pre-purchase inspection on a Mitsubishi Montero?
+
Yes. A Mitsubishi Montero inspection focused on its known weak points is the single best way to avoid an expensive mistake. KickTyres gives you a guided, model-specific inspection plus a market valuation and negotiation figure for $17.90 far less than the cost of missing one of the faults on this page.