🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Generation Codes: First Generation (L040 Series) Model Years Covered: 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991 👋 Introduction Market Position Vehicle Segment: Compact/Mid-size SUV, Sport Utility Vehicle Initial Purpose: Designed as a robust and capable off-road vehicle with comfortable on-road manners. Competitive Analysis Key Competitors: Jeep Cherokee (XJ), Toyota 4Runner, Ford Bronco II, Nissan Pathfinder. Distinguishing Features: Ladder-frame chassis, available coil-spring front suspension (later models), robust 4WD system, often more affordable than some Japanese rivals. Key Features Body Styles: 2-door (short wheelbase) and 4-door (long wheelbase) configurations. Powertrain Options: Durable 4-cylinder and V6 gasoline engines, available diesel engines in some markets. Off Road Capability: High ground clearance, available locking differentials, low-range gearing in the transfer case. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Language: English Format: Digital Download (PDF) Page Count: Extensive (estimated 1000+ pages) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine removal/installation, cylinder head, crankshaft, pistons, connecting rods, camshaft, timing belt/chain, lubrication system, cooling system. Engine Electrical: Ignition system, starting system, charging system, fuel injection system (ECI), engine control unit (ECU) diagnostics, sensors, actuators. Transmission Manual: Clutch system, gearbox overhaul, shift linkage, component testing. Transmission Automatic: Automatic transmission diagnosis, overhaul, torque converter, shift control, fluid and filter replacement. Drivetrain 4Wd: Transfer case operation and repair, front/rear propeller shafts, universal joints, differential overhaul (front and rear), axle shafts, hub locking mechanisms. Suspension: Front independent suspension (torsion bar, A-arms, ball joints), rear leaf spring suspension, shock absorbers, steering knuckle, wheel bearings. Steering: Power steering system diagnosis and repair, steering gear, steering column, tie rods, steering links. Brakes: Front disc brakes, rear drum brakes (or optional rear discs on some models), hydraulic system, brake booster, master cylinder, ABS (if equipped), parking brake system. Electrical Chassis: Lighting system (headlights, taillights, signals), wiring diagrams, fuse box, relays, power windows, door locks, horn, wiper/washer system. Body Exterior: Body panel removal/installation, door mechanisms, hood, tailgate, bumpers, glass replacement, trim. Body Interior: Seat removal, dashboard components, interior trim panels, carpeting, headliner. Heating Ventilation Ac: HVAC system diagnosis, blower motor, heater core, evaporator, refrigerant system (if equipped). Procedures Included Routine Maintenance: Oil and filter changes, fluid level checks and top-offs (coolant, brake fluid, power steering fluid, transmission fluid, differential fluid), spark plug replacement, air filter replacement, fuel filter replacement. Troubleshooting: Diagnostic procedures for common drivability issues, starting problems, electrical faults, braking issues, and suspension noise. Component Repair: Step-by-step instructions for disassembling, inspecting, repairing, and reassembling major vehicle components. Timing Belt Replacement: Detailed procedures for timing belt replacement on applicable engine variants, including critical timing mark alignment. Brake System Service: Brake pad/shoe replacement, rotor/drum resurfacing or replacement, brake fluid bleeding, caliper/wheel cylinder overhaul. 4Wd System Service: Transfer case fluid change, hub maintenance, propeller shaft U-joint lubrication and replacement. Electrical Diagnostics: Wiring harness testing, sensor testing, troubleshooting common electrical system faults using multimeter and diagnostic charts. Technical Depth Diagnostic Information: Includes diagnostic trouble codes (DTCs) for EFI systems, symptom-based troubleshooting guides, and component testing specifications. Repair Procedures: Comprehensive, step-by-step repair instructions with detailed diagrams and torque specifications. Specifications Data: Includes all essential technical data: clearances, tolerances, fluid capacities, torque values, electrical resistance, and pressure readings. Wiring Diagrams: Detailed and often color-coded wiring diagrams for various electrical systems, crucial for diagnostics and repairs. Special Tools: Lists and descriptions of special tools required for specific repair procedures, often with Mopar part numbers. 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchability: Fully searchable text content for quick information retrieval. Print Quality: High-resolution scans suitable for printing individual pages or the entire manual. Binding Type Digital Format: Downloadable digital file Paper Type Digital Medium: N/A (Digital Delivery) ⚙️ Engine Specifications Primary Engine Engine Code Common Gasoline 1: 4G63 (2.0L SOHC I4) Engine Code Common Gasoline 2: 6G72 (3.0L SOHC V6) Performance 1 4G63 Horsepower Approx: 95-114 hp 4G63 Torque Approx: 120-130 lb-ft Performance 2 6G72 Horsepower Approx: 143-155 hp 6G72 Torque Approx: 160-175 lb-ft Fuel System Fuel Delivery: Electronic Multi-point Fuel Injection (MPI) or Carburetor (early models). Recommended Fuel: Unleaded gasoline (Octane rating varies by engine, typically 87 or higher). 🔧 Transmission Standard Transmission Type Early: 4-speed Manual Optional Transmission Type Late: 4-speed Automatic Features Transfer Case: 2-speed transfer case with selectable 2WD, 4WD High, and 4WD Low ranges. Gear Ratios Manual Approx: Typical ratios: 1st: 3.5-4.0, 2nd: 2.0-2.5, 3rd: 1.3-1.6, 4th: 1.0, Reverse: 3.5-4.0 Transmission Fluid Spec: Refer to manual for specific OEM fluid or equivalent (e.g., Mitsubishi DiaQueen ATF SP-III for automatic, GL-4/GL-5 gear oil for manual and transfer case). 📐 Dimensions Exterior 2Door Approx Length: 155-160 inches Width: 66-67 inches Height: 64-66 inches Exterior 4Door Approx Length: 177-180 inches Width: 67-68 inches Height: 65-67 inches Weights Approx Curb Weight: 3300-3800 lbs Gross Vehicle Weight Rating: 4800-5200 lbs Towing Capacity: Up to...