The Mitsubishi Montero, also known globally as the Pajero, Dodge Raider, or Colt Shogun, represents the first generation (L040 Series) of a capable and rugged sport utility vehicle produced from 1982 through 1991. This robust body-on-frame vehicle was engineered for versatility, offering strong off-road performance complemented by comfortable on-road manners, making it a popular choice for adventure and daily use. Key features include a selectable four-wheel-drive system, durable engine options available in both gasoline and diesel configurations, and a practical interior. Its engineering quality and reliability have cemented its reputation among enthusiasts for durability and off-road prowess. This comprehensive service repair workshop manual provides essential information for maintaining and repairing the Mitsubishi Montero (L040 Series) from 1982 to 1991. It covers a wide array of systems, including engine mechanicals, fuel, cooling, lubrication, emissions, electrical systems, transmission, drivetrain, suspension, steering, brakes, and body/chassis components. Detailed procedures for routine maintenance, such as oil changes and filter replacements, as well as in-depth repair processes for engine overhauls and component replacements, are included. Furthermore, the manual offers valuable troubleshooting guides, diagnostic charts, and technical specifications like torque values and fluid capacities, empowering owners and technicians to ensure the optimal performance and longevity of their vehicle. 🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Generation: First Generation (L040 Series) Market Name Variations: Pajero (Japan/Australia), Dodge Raider (North America), Colt Shogun (UK) Codes Chassis Code Prefix: L040 👋 Introduction Market Position Market Position: Rugged, capable off-road vehicle with comfortable on-road manners. Positioned as a versatile SUV/4x4 for adventure and daily use. Competitive Analysis Competitors: Toyota Land Cruiser Prado, Nissan Patrol, Jeep Cherokee (XJ), Ford Bronco Key Features Key Features Vehicle: Body-on-frame construction, selectable 4WD system, robust engine options, versatile interior, capable off-road performance 📋 Manual Details Coverage Areas Years Covered: 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991 Page Count Estimated Page Count: 1000+ Manual Type Manual Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, lubrication, cooling, fuel, ignition, emissions control, engine electrical Transmission Drivetrain: Manual transmission, automatic transmission, transfer case, front axle, rear axle, driveshafts Suspension Steering: Front suspension (independent), rear suspension (leaf spring), steering system, power steering Brakes: Front disc brakes, rear drum brakes, parking brake, hydraulic system, anti-lock braking system (ABS) for applicable models Electrical Lighting: Battery, charging system, starting system, lighting, instrument panel, body electrical, wiring diagrams Body Chassis: Body construction, interior trim, exterior trim, doors, windows, bumpers, frame Procedures Included Maintenance Procedures: Oil changes, filter replacements, fluid checks and changes, belt inspections and replacements, spark plug replacement, brake service, lubrication Repair Procedures: Engine rebuild, transmission overhaul, suspension component replacement, brake caliper/rotor replacement, steering rack repair, electrical component diagnostics and replacement Troubleshooting: Diagnostic charts, symptom-based troubleshooting, fault code interpretation Specifications: Torque specifications, clearances, tolerances, fluid capacities, electrical specifications Technical Depth Technical Depth: Comprehensive, covering basic maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and wiring diagrams 📊 Manual Specifications File Format File Format: Searchable PDF Print Quality Print Quality: High-resolution, suitable for printing Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code Gasoline: 4G54, 4G63, 4G64 Engine Displacement Gasoline: 2.6L (4G54), 2.0L (4G63), 2.4L (4G64) Engine Type Gasoline: Inline-4 Cylinder, SOHC (some variants) Horsepower Gasoline: Approx. 103-114 hp (2.6L), 97 hp (2.0L), 114 hp (2.4L) Torque Gasoline: Approx. 138-145 lb-ft (2.6L), 119 lb-ft (2.0L), 135 lb-ft (2.4L) Engine Code Diesel: 4D55, 4D56 Engine Displacement Diesel: 2.3L (4D55), 2.5L (4D56) Engine Type Diesel: Inline-4 Cylinder, Naturally Aspirated or Turbocharged Diesel Horsepower Diesel: Approx. 80-84 hp (NA), 95-105 hp (Turbo) Torque Diesel: Approx. 125-130 lb-ft (NA), 145-160 lb-ft (Turbo) Fuel System Fuel System Gasoline: Carburetor (early models) or Electronic Fuel Injection (EFI, later models) Fuel System Diesel: Indirect Injection (IDI) diesel injection pump Fuel Requirements Fuel Type Gasoline: Unleaded Gasoline Fuel Type Diesel: Diesel Fuel 🔧 Transmission Standard Standard Transmission Type: 4-speed or 5-speed Manual Transmission Optional Optional Transmission Type: 3-speed or 4-speed Automatic Transmission Features Transfer Case Type: Part-time, 2-speed transfer case with manual 4WD engagement (2H, 4H, 4L) 📐 Dimensions Exterior Wheelbase: Approx. 104.7 inches (2660 mm) Length: Approx. 167.5 - 171.7 inches (4255 - 4360 mm) Width: Approx. 66.1 - 66.9 inches (1680 - 1700 mm) Height: Approx. 65.0 - 71.1 inches (1650 - 1805 mm) Weights Curb Weight: Approx. 3,500 - 4,200 lbs (1588 - 1905 kg) Gross Vehicle Weight Rating: Varies by configuration, typically around 5,000-5,500 lbs 🛡️ Safety Features Ratings Crash Test Ratings: Limited official crash test data available for this era, generally considered robust for its time due to body-on-frame construction. Active Features Active Safety Features: Four-wheel drive (selectable), power-assisted brakes Passive Features Passive Safety Features: Seat belts, reinforced chassis and body structure 💡 Technology Features Infotainment...