Mitsubushi MONTERO 1983-1991 Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Generation: First Generation Production Years Covered: 1983-1991 Codes Chassis Codes: L040 Series (L043, L044, L047, L048, L049, L040G, L043G, L044G, L048G, L049G) 👋 Introduction Market Position Vehicle Segment: Compact/Mid-size SUV / Off-road Vehicle Competitive Analysis Key Competitors Era: Toyota 4Runner, Nissan Patrol/Pathfinder, Jeep Cherokee XJ, Ford Bronco II, Chevrolet S-10 Blazer Key Features Vehicle Usp: Rugged construction, reliable powertrains, excellent off-road capability for its time, practical utility Manual Value Proposition Diy Benefit: Empowers owners to perform extensive repairs and maintenance, saving significant workshop costs and ensuring vehicle longevity. Manual Professionalism Professional Standard: Developed to the same standards and detail used by authorized Mitsubishi service centers. 📋 Manual Details Coverage Areas Manual Coverage Scope: Comprehensive front-to-back repair and maintenance Page Count Estimated Page Count: High (Detailed coverage implies several hundred pages) Manual Type Manual Classification: Factory Service Manual / Workshop Manual Language Language Of Manual: English (Assumed based on typical market availability) Format Delivery Format: Physical Print (Implied by sales context, could also be digital) 📖 Manual Coverage Systems Covered Engine Systems: Overhaul, rebuilding, performance tuning, diagnostics, troubleshooting, timing belt service, firing orders Chassis Systems: Front end alignment, suspension (front and rear), brakes (servicing procedures, torque specifications), U-joints, CV-joints Transmission Systems: Removal and installation, in-car servicing Electrical Systems: Complete wiring diagrams Fuel And Emission Systems: Vacuum diagrams HVAC Systems: Air conditioning service and capacities Procedures Included Diagnostic Procedures: Troubleshooting, diagnostic trouble tree charts, computer diagnostic (where applicable for the era) Repair Procedures: Step-by-step explanations for all major repair operations Maintenance Procedures: Routine servicing, fluid checks, component replacement Technical Depth Diagnostic Depth: Advanced diagnostics with specific trouble trees and charts Repair Depth: Complete overhaul and rebuilding procedures for major components Specification Detail: Detailed technical specifications, including torque values, clearances, and capacities Visual Aid Quality: Illustrations, diagrams, and depth illustrations for clarity 📊 Manual Specifications File Format Digital Format Details: Searchable PDF (if digital), high-resolution scans (if physical) Print Quality Print Resolution: High-resolution, clear print for diagrams and text Binding Type Physical Binding: Durable binding (e.g., spiral-bound, perfect bound) suitable for workshop use Paper Type Paper Stock: Heavy-duty, grease-resistant paper stock for workshop durability ⚙️ Engine Specifications Primary Engine Engine Family: Mitsubishi Sirius/4G6 Engine Family Engine Displacement Options: 2.6L (G54B) SOHC I4; 2.5L Turbo Diesel (4D56) (for select markets) Performance 2.6L Horsepower: Approx. 105-114 hp (varies by year and specific tuning) 2.6L Torque: Approx. 140-145 lb-ft (varies by year and specific tuning) Fuel System 2.6L Fuel Delivery: Carbureted (early models) or Electronic Fuel Injection (EFI) (later models) Maintenance Highlights Timing Belt Replacement Interval: Recommended every 60,000 - 90,000 miles or 4-6 years (refer to specific vehicle maintenance schedule) 🔧 Transmission Standard Standard Transmission Type: 5-speed Manual Transmission Optional Optional Transmission Type: 4-speed Automatic Transmission Features Drivetrain Options: Part-time 4WD (with optional 2WD/4WD selector), optional Super Select 4WD (in later iterations/markets) Fluid Specifications Manual Transmission Fluid: API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil (check manual for exact spec) Automatic Transmission Fluid: Dexron III/Mercon equivalent (check manual for exact spec) 📐 Dimensions Exterior Wheelbase Short Wheelbase: Approx. 92.1 inches (2340 mm) Wheelbase Long Wheelbase: Approx. 100.4 inches (2550 mm) Weights Curb Weight Range: Approx. 3,500 - 4,200 lbs (1588 - 1905 kg) Towing Capacity: Varies significantly by configuration and market, consult specific vehicle data 🛡️ Safety Features Ratings Crash Test Availability: Limited official crash test data readily available for this era, emphasis on structural integrity for off-road use. Active Features Braking System: Front disc, rear drum brakes (often with optional rear disc upgrade on higher trims/later years) Off Road Systems: Part-time 4WD system with 2-speed transfer case, available locking rear differential (on some models) Passive Features Seat Belts: Three-point front seat belts, lap belts in rear (standard) Rollover Protection: Reinforced body structure for off-road conditions; convertible/removable top options (on early models) may reduce rollover protection compared to fixed-roof versions. 💡 Technology Features Infotainment Audio System: Basic AM/FM radio with cassette player, optional upgraded systems with more speakers. Driver Assistance ABS: Anti-lock Braking System (ABS) was an optional feature on some later models. Connectivity Connectivity Features: Minimal; focus on mechanical systems rather than electronic integration. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,000 - 5,000 miles or 6 months (depending on driving conditions and oil type) Transmission Fluid Change: Every 30,000 - 50,000 miles (manual and automatic, consult manual for specific intervals) Coolant Flush: Every 30,000 - 50,000 miles or 2-3 years Fluid Specifications Engine Oil Specification: API SG/SH or higher, viscosity SAE 10W-30 or 10W-40 (check owner's manual for exact recommendation) Engine Coolant Type: Ethylene glycol-based coolant, typically a green or long-life orange/pink (check manual for compatibility) Power Steering Fluid: Dexron II/III or equivalent (check manual for exact specification) Brake Fluid Type: DOT 3 or DOT 4 (check manual for exact specification) Known...
Approx. 105-114 hp (varies by year and specific tuning)
2.6L Torque:
Approx. 140-145 lb-ft (varies by year and specific tuning)
Fuel System
2.6L Fuel Delivery:
Carbureted (early models) or Electronic Fuel Injection (EFI) (later models)
Maintenance Highlights
Timing Belt Replacement Interval:
Recommended every 60,000 - 90,000 miles or 4-6 years (refer to specific vehicle maintenance schedule)
🔧 Transmission
Standard
Standard Transmission Type:
5-speed Manual Transmission
Optional
Optional Transmission Type:
4-speed Automatic Transmission
Features
Drivetrain Options:
Part-time 4WD (with optional 2WD/4WD selector), optional Super Select 4WD (in later iterations/markets)
Fluid Specifications
Manual Transmission Fluid:
API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil (check manual for exact spec)
Automatic Transmission Fluid:
Dexron III/Mercon equivalent (check manual for exact spec)
📐 Dimensions
Exterior
Wheelbase Short Wheelbase:
Approx. 92.1 inches (2340 mm)
Wheelbase Long Wheelbase:
Approx. 100.4 inches (2550 mm)
Weights
Curb Weight Range:
Approx. 3,500 - 4,200 lbs (1588 - 1905 kg)
Towing Capacity:
Varies significantly by configuration and market, consult specific vehicle data
🛡️ Safety Features
Ratings
Crash Test Availability:
Limited official crash test data readily available for this era, emphasis on structural integrity for off-road use.
Active Features
Braking System:
Front disc, rear drum brakes (often with optional rear disc upgrade on higher trims/later years)
Off Road Systems:
Part-time 4WD system with 2-speed transfer case, available locking rear differential (on some models)
Passive Features
Seat Belts:
Three-point front seat belts, lap belts in rear (standard)
Rollover Protection:
Reinforced body structure for off-road conditions; convertible/removable top options (on early models) may reduce rollover protection compared to fixed-roof versions.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with cassette player, optional upgraded systems with more speakers.
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was an optional feature on some later models.
Connectivity
Connectivity Features:
Minimal; focus on mechanical systems rather than electronic integration.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 - 5,000 miles or 6 months (depending on driving conditions and oil type)
Transmission Fluid Change:
Every 30,000 - 50,000 miles (manual and automatic, consult manual for specific intervals)
Coolant Flush:
Every 30,000 - 50,000 miles or 2-3 years
Fluid Specifications
Engine Oil Specification:
API SG/SH or higher, viscosity SAE 10W-30 or 10W-40 (check owner's manual for exact recommendation)
Engine Coolant Type:
Ethylene glycol-based coolant, typically a green or long-life orange/pink (check manual for compatibility)
Power Steering Fluid:
Dexron II/III or equivalent (check manual for exact specification)
Brake Fluid Type:
DOT 3 or DOT 4 (check manual for exact specification)
Known Issues
Common Engine Issues:
Head gasket leaks (G54B), timing belt failure if not replaced on schedule, carburetor issues (early models), oil leaks from seals and gaskets.
Common Chassis Issues:
Rust (particularly on frame, body panels, and exhaust system), wear in suspension bushings, U-joint and CV-joint wear, brake component wear.
Common Electrical Issues:
Degradation of wiring insulation over time, alternator and starter issues, corrosion in connectors.
Common 4Wd Issues:
Transfer case and hub actuator issues (if equipped with automatic hubs), worn drive shaft U-joints.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors Origins:
Founded in 1870, entered automotive manufacturing in the early 20th century.
Model Evolution
Montero Introduction:
Originally introduced as the 'Pajero' in Japan in 1982, the Montero nameplate was used for export markets, including North America.
First Generation Design:
Body-on-frame construction, rugged chassis, available in short-wheelbase (2-door) and long-wheelbase (3-door) variants.
Production
Manufacturing Locations:
Primarily Japan (Okazaki Plant), with some assembly in other global locations.
Market Impact
Off Road Segment Contribution:
Contributed significantly to the rise of the SUV segment, offering a more refined alternative to traditional utilitarian off-roaders while retaining strong capability.
🏆 Awards & Recognition
Recognitions
Off Road Capability Recognition:
Frequently lauded for its off-road prowess and reliability in challenging conditions, earning a strong reputation among outdoor enthusiasts and off-roaders.
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