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1984 Mitsubishi Montero Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Year: 1984 Codes Chassis Code Family: L040 Series 👋 Introduction Market Position Market Segment: Compact SUV / Off-Road Vehicle Competitive Analysis Key Competitors 1984: Jeep Cherokee (XJ), Ford Bronco II, Chevrolet S-10 Blazer, Toyota 4Runner, Nissan Pathfinder. Key Features Initial Features: Body-on-frame construction, available 4WD (Part-time 'Easy Select' or Full-time Super Select later), rugged styling, capable off-road performance, practical interior. Model Significance Brand Introduction: The 1984 Montero (also known as Pajero in many markets) marked Mitsubishi's significant entry into the burgeoning SUV segment, emphasizing utility and off-road prowess. 📋 Manual Details Coverage Areas Primary Coverage: Mechanical, Electrical, Bodywork, Maintenance, Diagnostics, Repair Specific Systems Covered: Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Fuel System, Cooling System, Ignition System, Electrical System, HVAC, Body, Chassis Page Count Estimated Page Count: Approximately 700-900 pages (typical for comprehensive service manuals of this era) Manual Type Manual Type: Factory Service Manual / Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical (disassembly, assembly, inspection), fuel injection system (MPI/carburetor depending on variant), ignition system, cooling system, lubrication system, exhaust system, emission controls. Transmission Drivetrain: Manual transmission (5-speed), automatic transmission (4-speed), transfer case operation and repair, front axle, rear axle, driveshafts, CV joints, propeller shafts. Suspension Steering Brakes: Front independent suspension (torsion bar), rear leaf spring suspension, power steering system, brake system (front discs, rear drums), parking brake, ABS (if equipped). Electrical Body: Chassis electrical systems, lighting, instrumentation, charging system, starting system, wiring diagrams, body panel removal and installation, interior trim, glass, locks, wipers. Procedures Included Maintenance Procedures: Scheduled maintenance intervals, oil changes, filter replacements, fluid level checks and replenishment, spark plug replacement, belt tensioning, chassis lubrication. Repair Procedures: Engine overhaul, cylinder head repair, transmission overhaul, clutch replacement, brake caliper and master cylinder repair, suspension component replacement, steering gear repair, electrical component diagnosis and repair. Diagnostics Troubleshooting: Systematic troubleshooting guides for common drivability issues, electrical faults, and mechanical failures. Includes symptom-based diagnostics and component testing procedures. Technical Depth Depth Of Information: Comprehensive: Covers routine maintenance, component-level repair, full system overhauls, and detailed diagnostic procedures. Includes specifications, tolerances, and torque values. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Print Quality: High-resolution scans of original factory documentation, ensuring clarity of diagrams and text. Binding Type Binding Type: N/A (Digital Product) Paper Type Paper Type: N/A (Digital Product) ⚙️ Engine Specifications Primary Engine Engine Code And Type 1984: 4G54 (2.6L SOHC Inline-4, naturally aspirated) Performance Horsepower 1984: Approximately 105-116 hp @ 4500 rpm (depending on market and specific tuning) Torque 1984: Approximately 145-154 lb-ft @ 2500-3000 rpm Fuel System Fuel Delivery 1984: Multi-Point Fuel Injection (MPI) or Carburetor depending on market and trim (MPI more common in US spec). Engine Components Bore X Stroke: 91.1 mm x 98.0 mm Compression Ratio: 8.5:1 Cooling System Cooling Capacity: Approx. 8.5 liters (coolant capacity) Lubrication System Oil Capacity: Approx. 4.7 liters (with filter) 🔧 Transmission Standard Standard Transmission Type: 5-Speed Manual Optional Optional Transmission Type: 4-Speed Automatic Features Drivetrain Options: 2WD (RWD) or 4WD (Part-time 'Easy Select' with manual or automatic locking hubs) Fluid Specifications Manual Transmission Fluid: API GL-4 or GL-5, SAE 75W-90 or 80W-90 Automatic Transmission Fluid: Dexron II or equivalent Transfer Case Fluid Transfer Case Fluid Spec: API GL-4 or GL-5, SAE 75W-90 or 80W-90 📐 Dimensions Exterior Wheelbase Short Wheelbase: 2220 mm (87.4 in) Wheelbase Long Wheelbase: 2440 mm (96.1 in) (for 4-door variants) Overall Length Short Wheelbase: 3745 mm (147.4 in) Overall Width: 1690 mm (66.5 in) Overall Height: 1730 mm (68.1 in) Weights Curb Weight Typical: 1550 - 1800 kg (3417 - 3968 lbs) (depending on configuration) Gross Vehicle Weight Rating Gvwr: Approx. 2100 - 2300 kg (4630 - 5070 lbs) Tires Wheels Standard Tire Size: 215/80R15 or 235/75R15 Wheel Bolt Pattern: 5x139.7 mm (5x5.5 inches) 🛡️ Safety Features Ratings Crash Test Standards: Not extensively tested by modern standards; primarily relied on robust body-on-frame construction for passive safety. Specific ratings not readily available for this era. Active Features Active Safety Features Available: Limited. Basic braking systems. ABS was optional on later models of this generation, not standard on 1984. Passive Features Passive Safety Features: Reinforced chassis, crumple zones (limited by era), three-point front seatbelts, lap belts in rear. 💡 Technology Features Infotainment Infotainment System 1984: Basic AM/FM radio with cassette player or optional CB radio, manual climate controls. Driver Assistance Driver Assistance Features: None by modern standards. Focus on mechanical engagement for 4WD. Connectivity Connectivity Features: None. Engine Management Engine Control Unit ECU Type: Basic electronic fuel injection controller or points-based ignition system (depending on market/specific engine). 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000-7,500 km (3,000-4,500 miles) or 6 months, whichever comes first. Transmission Fluid Change: Manual: Every 40,000-60,000 km (25,000-37,000 miles); Automatic: Every...
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1984 Mitsubishi Montero Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Montero
Year:
1984
Codes
Chassis Code Family:
L040 Series
👋 Introduction
Market Position
Market Segment:
Compact SUV / Off-Road Vehicle
Competitive Analysis
Key Competitors 1984:
Jeep Cherokee (XJ), Ford Bronco II, Chevrolet S-10 Blazer, Toyota 4Runner, Nissan Pathfinder.
Key Features
Initial Features:
Body-on-frame construction, available 4WD (Part-time 'Easy Select' or Full-time Super Select later), rugged styling, capable off-road performance, practical interior.
Model Significance
Brand Introduction:
The 1984 Montero (also known as Pajero in many markets) marked Mitsubishi's significant entry into the burgeoning SUV segment, emphasizing utility and off-road prowess.
📋 Manual Details
Coverage Areas
Primary Coverage:
Mechanical, Electrical, Bodywork, Maintenance, Diagnostics, Repair
Specific Systems Covered:
Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, Fuel System, Cooling System, Ignition System, Electrical System, HVAC, Body, Chassis
Page Count
Estimated Page Count:
Approximately 700-900 pages (typical for comprehensive service manuals of this era)
Manual Type
Manual Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical (disassembly, assembly, inspection), fuel injection system (MPI/carburetor depending on variant), ignition system, cooling system, lubrication system, exhaust system, emission controls.
Transmission Drivetrain:
Manual transmission (5-speed), automatic transmission (4-speed), transfer case operation and repair, front axle, rear axle, driveshafts, CV joints, propeller shafts.
Suspension Steering Brakes:
Front independent suspension (torsion bar), rear leaf spring suspension, power steering system, brake system (front discs, rear drums), parking brake, ABS (if equipped).
Electrical Body:
Chassis electrical systems, lighting, instrumentation, charging system, starting system, wiring diagrams, body panel removal and installation, interior trim, glass, locks, wipers.
Procedures Included
Maintenance Procedures:
Scheduled maintenance intervals, oil changes, filter replacements, fluid level checks and replenishment, spark plug replacement, belt tensioning, chassis lubrication.
Repair Procedures:
Engine overhaul, cylinder head repair, transmission overhaul, clutch replacement, brake caliper and master cylinder repair, suspension component replacement, steering gear repair, electrical component diagnosis and repair.
Diagnostics Troubleshooting:
Systematic troubleshooting guides for common drivability issues, electrical faults, and mechanical failures. Includes symptom-based diagnostics and component testing procedures.
Technical Depth
Depth Of Information:
Comprehensive: Covers routine maintenance, component-level repair, full system overhauls, and detailed diagnostic procedures. Includes specifications, tolerances, and torque values.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Print Quality
Print Quality:
High-resolution scans of original factory documentation, ensuring clarity of diagrams and text.
Binding Type
Binding Type:
N/A (Digital Product)
Paper Type
Paper Type:
N/A (Digital Product)
⚙️ Engine Specifications
Primary Engine
Engine Code And Type 1984:
4G54 (2.6L SOHC Inline-4, naturally aspirated)
Performance
Horsepower 1984:
Approximately 105-116 hp @ 4500 rpm (depending on market and specific tuning)
Torque 1984:
Approximately 145-154 lb-ft @ 2500-3000 rpm
Fuel System
Fuel Delivery 1984:
Multi-Point Fuel Injection (MPI) or Carburetor depending on market and trim (MPI more common in US spec).
Engine Components
Bore X Stroke:
91.1 mm x 98.0 mm
Compression Ratio:
8.5:1
Cooling System
Cooling Capacity:
Approx. 8.5 liters (coolant capacity)
Lubrication System
Oil Capacity:
Approx. 4.7 liters (with filter)
🔧 Transmission
Standard
Standard Transmission Type:
5-Speed Manual
Optional
Optional Transmission Type:
4-Speed Automatic
Features
Drivetrain Options:
2WD (RWD) or 4WD (Part-time 'Easy Select' with manual or automatic locking hubs)
Fluid Specifications
Manual Transmission Fluid:
API GL-4 or GL-5, SAE 75W-90 or 80W-90
Automatic Transmission Fluid:
Dexron II or equivalent
Transfer Case Fluid
Transfer Case Fluid Spec:
API GL-4 or GL-5, SAE 75W-90 or 80W-90
📐 Dimensions
Exterior
Wheelbase Short Wheelbase:
2220 mm (87.4 in)
Wheelbase Long Wheelbase:
2440 mm (96.1 in) (for 4-door variants)
Overall Length Short Wheelbase:
3745 mm (147.4 in)
Overall Width:
1690 mm (66.5 in)
Overall Height:
1730 mm (68.1 in)
Weights
Curb Weight Typical:
1550 - 1800 kg (3417 - 3968 lbs) (depending on configuration)
Gross Vehicle Weight Rating Gvwr:
Approx. 2100 - 2300 kg (4630 - 5070 lbs)
Tires Wheels
Standard Tire Size:
215/80R15 or 235/75R15
Wheel Bolt Pattern:
5x139.7 mm (5x5.5 inches)
🛡️ Safety Features
Ratings
Crash Test Standards:
Not extensively tested by modern standards; primarily relied on robust body-on-frame construction for passive safety. Specific ratings not readily available for this era.
Active Features
Active Safety Features Available:
Limited. Basic braking systems. ABS was optional on later models of this generation, not standard on 1984.
Passive Features
Passive Safety Features:
Reinforced chassis, crumple zones (limited by era), three-point front seatbelts, lap belts in rear.
💡 Technology Features
Infotainment
Infotainment System 1984:
Basic AM/FM radio with cassette player or optional CB radio, manual climate controls.
Driver Assistance
Driver Assistance Features:
None by modern standards. Focus on mechanical engagement for 4WD.
Connectivity
Connectivity Features:
None.
Engine Management
Engine Control Unit ECU Type:
Basic electronic fuel injection controller or points-based ignition system (depending on market/specific engine).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 km (3,000-4,500 miles) or 6 months, whichever comes first.
Transmission Fluid Change:
Manual: Every 40,000-60,000 km (25,000-37,000 miles); Automatic: Every 40,000 km (25,000 miles).
Spark Plug Replacement:
Every 30,000-50,000 km (18,000-30,000 miles).
Fluid Specifications
Engine Oil Specification:
API SF or SG, SAE 10W-30 or 10W-40 (depending on climate).
Coolant Specification:
Ethylene glycol-based coolant (e.g., Prestone) mixed 50/50 with distilled water.
Brake Fluid Specification:
DOT 3 or DOT 4.
Known Issues
Common Wear Items 1984:
Torsion bar bushings, leaf spring bushings, CV joint boots, exhaust system corrosion, fuel pump (early models), aging electrical connectors/grounds, carburetor issues (if equipped).
Filter Part Numbers
Oil Filter Part Number Example:
Mitsubishi MD069780 or equivalent (e.g., Fram PH5000, Wix 51515)
Air Filter Part Number Example:
Mitsubishi MR188257 or equivalent (e.g., Fram CA2775)
Diagnostics Tips
Key Diagnostic Areas:
Checking ignition timing, fuel pressure, vacuum leaks, spark plug condition, and proper operation of the 4WD engagement system.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors Heritage:
Mitsubishi Motors, part of the Mitsubishi keiretsu, has a long history in automotive manufacturing dating back to the early 20th century. Known for rugged and reliable vehicles.
Model Evolution
First Generation Pajero Launch:
The Mitsubishi Pajero (Montero in North America and some other markets) was first introduced in Japan in 1982. The 1984 model year represents an early phase of the first generation (L040 series).
Production
Manufacturing Locations:
Primarily Japan (Nagoya Plant).
Model Significance
Off Road Acclaim:
The Pajero/Montero quickly gained a reputation for its off-road capability, famously winning the Dakar Rally in 1985, solidifying its 'go-anywhere' image.
🏆 Awards & Recognition
Recognitions
Dakar Rally Win:
The Pajero/Montero platform achieved significant recognition by winning the 1985 Dakar Rally in the T2 production category, a testament to its off-road prowess.
Ratings
Consumer Reviews Era:
Generally praised for ruggedness, off-road capability, and durability, though often criticized for a less refined ride compared to later models and competitors.
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