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Mitsubushi PAJERO MONTERO 1987 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Pajero / Montero Year: 1987 Generation Generation: First Generation (L040 Series) 👋 Introduction Market Position Market Position: Positioned as a capable and durable off-road vehicle with a comfortable and practical interior, making it suitable for both recreational use and daily driving. Competitive Analysis Competitive Analysis: Competed with vehicles like the Toyota Land Cruiser, Nissan Patrol, Jeep Cherokee, and Ford Bronco. The Pajero/Montero distinguished itself with its sophisticated suspension, powerful engine options (for the era), and advanced features, often perceived as a more refined yet still highly capable off-road option. Key Features Key Features: Durable chassis, robust 4WD system (Super Select 4WD on some later models, but early models had robust part-time 4WD), comfortable interior for its class, good cargo capacity, and a reputation for reliability and off-road prowess. The 1987 model year was part of a significant update for the first generation. 📋 Manual Details Coverage Areas Coverage Areas: Front to back of the car, engine overhaul and rebuilding, troubleshooting, diagnostics, engine performance, front end alignment, suspension, transmission removal/installation, in-car transmission servicing, air conditioning, firing orders, timing belt service, brake servicing, U-joint and CV-joint service, repair procedures, wiring diagrams, vacuum diagrams. Page Count Page Count: Estimated 1000+ pages (typical for a comprehensive factory service manual of this era) Manual Type Manual Type: Factory Authorized Service Manual / Repair Manual Language Language: English Format Format: Digital (likely PDF), potentially printable 📖 Manual Coverage Systems Covered Systems Covered: Full coverage of mechanical, electrical, and body systems specific to the 1987 Mitsubishi Pajero/Montero. Procedures Included Procedures Included: Troubleshooting guides for electrical and mechanical issues, diagnostic charts, maintenance procedures, repair procedures, replacement of wear items, major component rebuilds. Technical Depth Technical Depth: In-depth diagnostic procedures, electrical schematics, component removal and installation instructions, torque specifications, specifications for engine, transmission, suspension, brakes, and electrical systems, overhaul instructions for major components. 📊 Manual Specifications File Format File Format: PDF (Searchable text, high-resolution images/diagrams recommended) Print Quality Print Quality: High-resolution scans of original factory documentation, ensuring clarity of diagrams and text for printing. Binding Type Binding Type: N/A (Digital Product) Paper Type Paper Type: N/A (Digital Product) ⚙️ Engine Specifications Primary Engine Primary Engine: 2.5L (2477cc) 4D56 I4 Turbocharged Diesel. Also available were naturally aspirated diesel and gasoline engines, notably the 2.6L (2555cc) 4G54 Sirius I4 gasoline engine. Specific engine options varied by market. Performance Performance: For the 2.5L 4D56 Turbo Diesel: Approximately 84-95 horsepower and 135-150 lb-ft of torque. The 2.6L gasoline engine produced around 105 horsepower and 144 lb-ft of torque. (Exact figures vary by specific tune and market). Fuel System Fuel System: Diesel: Indirect Injection, Turbocharged. Gasoline: Carbureted (early models) or Fuel Injection (later models). Engine Codes Engine Codes: Common engine codes include 4D56 (2.5L Turbo Diesel), 4G54 (2.6L Gasoline), and potentially others depending on market. Manual will specify detailed identification for each. Bore Stroke Bore Stroke: 4D56: Bore 3.58 in (91.1 mm), Stroke 3.74 in (95.0 mm). 4G54: Bore 3.50 in (89.0 mm), Stroke 3.11 in (79.0 mm). Compression Ratio Compression Ratio: 4D56: ~21.0:1. 4G54: ~8.5:1. Engine Family Engine Family: 4D50/4D55/4D56 series diesel, Sirius series gasoline. Engine Layout Engine Layout: Inline 4-cylinder 🔧 Transmission Standard Standard: 5-speed manual transmission with part-time 4WD system. Manual locking hubs were common on earlier models. Optional Optional: 4-speed automatic transmission with overdrive. Features Features: Transfer case with high and low range (2H, 4H, 4L). Some later models introduced the Super Select 4WD system offering full-time 4WD and automatic engagement, but this was less common on the 1987 model year, particularly in early production. Gear Ratios Gear Ratios: Manual transmission typically features ratios around: 1st: 3.50-4.00, 2nd: 2.00-2.50, 3rd: 1.30-1.50, 4th: 1.00, 5th: 0.80-0.90, Reverse: 3.50-4.00. Transfer Case: High range ~1.00, Low range ~2.00-2.50. (Exact ratios are model/market specific and will be detailed in the manual). Transfer Case Type Transfer Case Type: Part-time 4WD with manual hubs and high/low range. Some later models offered a more advanced system. 📐 Dimensions Exterior Exterior: Offered in Short Wheelbase (SWB) and Long Wheelbase (LWB) configurations. LWB models were typically around 175-180 inches in length, 66-67 inches wide, and 73-75 inches tall. Ground clearance was excellent for off-road use. Interior Interior: Seating for 5 to 7 occupants depending on configuration (SWB typically 5, LWB available with 3rd-row seating). Interior materials focused on durability and practicality. Cargo Cargo: Ample cargo space, especially in LWB models with rear seats folded. The tailgate design facilitated loading and unloading. Weights Weights: Curb weight typically ranged from 3,500 to 4,200 lbs (1588-1905 kg) depending on engine, transmission, and body style. Wheelbase Wheelbase: SWB: Approx. 90.0 inches (2286 mm). LWB: Approx. 105.5 inches (2680 mm). Track Width Track Width: Approx. 55-58 inches (1400-1470 mm) front and rear, varying slightly by model. Ground Clearance Ground Clearance: Approximately 8-9 inches (200-230 mm), varying with...
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Mitsubushi PAJERO MONTERO 1987 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Pajero / Montero
Year:
1987
Generation
Generation:
First Generation (L040 Series)
👋 Introduction
Market Position
Market Position:
Positioned as a capable and durable off-road vehicle with a comfortable and practical interior, making it suitable for both recreational use and daily driving.
Competitive Analysis
Competitive Analysis:
Competed with vehicles like the Toyota Land Cruiser, Nissan Patrol, Jeep Cherokee, and Ford Bronco. The Pajero/Montero distinguished itself with its sophisticated suspension, powerful engine options (for the era), and advanced features, often perceived as a more refined yet still highly capable off-road option.
Key Features
Key Features:
Durable chassis, robust 4WD system (Super Select 4WD on some later models, but early models had robust part-time 4WD), comfortable interior for its class, good cargo capacity, and a reputation for reliability and off-road prowess. The 1987 model year was part of a significant update for the first generation.
📋 Manual Details
Coverage Areas
Coverage Areas:
Front to back of the car, engine overhaul and rebuilding, troubleshooting, diagnostics, engine performance, front end alignment, suspension, transmission removal/installation, in-car transmission servicing, air conditioning, firing orders, timing belt service, brake servicing, U-joint and CV-joint service, repair procedures, wiring diagrams, vacuum diagrams.
Page Count
Page Count:
Estimated 1000+ pages (typical for a comprehensive factory service manual of this era)
Manual Type
Manual Type:
Factory Authorized Service Manual / Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF), potentially printable
📖 Manual Coverage
Systems Covered
Systems Covered:
Full coverage of mechanical, electrical, and body systems specific to the 1987 Mitsubishi Pajero/Montero.
Procedures Included
Procedures Included:
Troubleshooting guides for electrical and mechanical issues, diagnostic charts, maintenance procedures, repair procedures, replacement of wear items, major component rebuilds.
Technical Depth
Technical Depth:
In-depth diagnostic procedures, electrical schematics, component removal and installation instructions, torque specifications, specifications for engine, transmission, suspension, brakes, and electrical systems, overhaul instructions for major components.
📊 Manual Specifications
File Format
File Format:
PDF (Searchable text, high-resolution images/diagrams recommended)
Print Quality
Print Quality:
High-resolution scans of original factory documentation, ensuring clarity of diagrams and text for printing.
Binding Type
Binding Type:
N/A (Digital Product)
Paper Type
Paper Type:
N/A (Digital Product)
⚙️ Engine Specifications
Primary Engine
Primary Engine:
2.5L (2477cc) 4D56 I4 Turbocharged Diesel. Also available were naturally aspirated diesel and gasoline engines, notably the 2.6L (2555cc) 4G54 Sirius I4 gasoline engine. Specific engine options varied by market.
Performance
Performance:
For the 2.5L 4D56 Turbo Diesel: Approximately 84-95 horsepower and 135-150 lb-ft of torque. The 2.6L gasoline engine produced around 105 horsepower and 144 lb-ft of torque. (Exact figures vary by specific tune and market).
Fuel System
Fuel System:
Diesel: Indirect Injection, Turbocharged. Gasoline: Carbureted (early models) or Fuel Injection (later models).
Engine Codes
Engine Codes:
Common engine codes include 4D56 (2.5L Turbo Diesel), 4G54 (2.6L Gasoline), and potentially others depending on market. Manual will specify detailed identification for each.
Bore Stroke
Bore Stroke:
4D56: Bore 3.58 in (91.1 mm), Stroke 3.74 in (95.0 mm). 4G54: Bore 3.50 in (89.0 mm), Stroke 3.11 in (79.0 mm).
Compression Ratio
Compression Ratio:
4D56: ~21.0:1. 4G54: ~8.5:1.
Engine Family
Engine Family:
4D50/4D55/4D56 series diesel, Sirius series gasoline.
Engine Layout
Engine Layout:
Inline 4-cylinder
🔧 Transmission
Standard
Standard:
5-speed manual transmission with part-time 4WD system. Manual locking hubs were common on earlier models.
Optional
Optional:
4-speed automatic transmission with overdrive.
Features
Features:
Transfer case with high and low range (2H, 4H, 4L). Some later models introduced the Super Select 4WD system offering full-time 4WD and automatic engagement, but this was less common on the 1987 model year, particularly in early production.
Gear Ratios
Gear Ratios:
Manual transmission typically features ratios around: 1st: 3.50-4.00, 2nd: 2.00-2.50, 3rd: 1.30-1.50, 4th: 1.00, 5th: 0.80-0.90, Reverse: 3.50-4.00. Transfer Case: High range ~1.00, Low range ~2.00-2.50. (Exact ratios are model/market specific and will be detailed in the manual).
Transfer Case Type
Transfer Case Type:
Part-time 4WD with manual hubs and high/low range. Some later models offered a more advanced system.
📐 Dimensions
Exterior
Exterior:
Offered in Short Wheelbase (SWB) and Long Wheelbase (LWB) configurations. LWB models were typically around 175-180 inches in length, 66-67 inches wide, and 73-75 inches tall. Ground clearance was excellent for off-road use.
Interior
Interior:
Seating for 5 to 7 occupants depending on configuration (SWB typically 5, LWB available with 3rd-row seating). Interior materials focused on durability and practicality.
Cargo
Cargo:
Ample cargo space, especially in LWB models with rear seats folded. The tailgate design facilitated loading and unloading.
Weights
Weights:
Curb weight typically ranged from 3,500 to 4,200 lbs (1588-1905 kg) depending on engine, transmission, and body style.
Wheelbase
Wheelbase:
SWB: Approx. 90.0 inches (2286 mm). LWB: Approx. 105.5 inches (2680 mm).
Track Width
Track Width:
Approx. 55-58 inches (1400-1470 mm) front and rear, varying slightly by model.
Ground Clearance
Ground Clearance:
Approximately 8-9 inches (200-230 mm), varying with tire size and suspension setup.
🛡️ Safety Features
Ratings
Ratings:
Safety standards and ratings from 1987 were less stringent than today. Likely equipped with basic safety features like seatbelts. Specific crash test data for this model year may be limited or unavailable by modern standards.
Active Features
Active Features:
4WD system, Power-assisted brakes, Power steering.
Passive Features
Passive Features:
Lap and shoulder seat belts, reinforced passenger cage, energy-absorbing steering column. Limited airbag deployment in this era.
💡 Technology Features
Infotainment
Infotainment:
Factory-installed radio/cassette player, optional power accessories (windows, mirrors, door locks).
Driver Assistance
Driver Assistance:
Limited to the advanced 4WD system for off-road stability and traction. No electronic driver assistance systems (like traction control, stability control, lane departure warning) were available.
Connectivity
Connectivity:
N/A. No integrated Bluetooth, USB ports, or smartphone integration.
🔧 Maintenance
Service Intervals
Service Intervals:
Regular lubrication of suspension and driveline components, brake system inspection, cooling system checks, exhaust system inspection, battery terminal cleaning and testing.
Fluid Specifications
Fluid Specifications:
Engine Oil: API Service SF or SG, SAE 10W-30 or 10W-40 (check manual for exact viscosity based on temperature). Transmission Fluid: Manual - GL-4 SAE 75W-90 gear oil. Automatic - ATF Dexron II or equivalent. Brake Fluid: DOT 3. Coolant: Ethylene Glycol based, 50/50 mix with distilled water. Power Steering Fluid: ATF Dexron II or equivalent.
Known Issues
Known Issues:
Rust susceptibility (especially in certain climates), timing belt failure if not replaced on schedule (can cause catastrophic engine damage), cooling system leaks (radiator, hoses), potential turbocharger issues on diesel models if maintenance is neglected, aging electrical components, suspension wear (bushings, ball joints).
Filter Part Numbers
Filter Part Numbers:
Typical part numbers for oil filters (e.g., Mitsubishi MD069782, or aftermarket equivalents like Fram PH5119, Wix 51515). Air filter and fuel filter numbers vary significantly by engine. Manual will list OEM and recommended aftermarket part numbers.
Capacities
Capacities:
Engine Oil: ~5.5 - 7.0 quarts (5.2 - 6.6 L) with filter. Coolant: ~8.0 - 10.0 quarts (7.6 - 9.5 L). Manual transmission: ~2.5 - 3.0 quarts (2.4 - 2.8 L). Automatic transmission: ~6.0 - 8.0 quarts (5.7 - 7.6 L) for a drain and fill. Transfer case: ~1.5 - 2.0 quarts (1.4 - 1.9 L).
Tire Size
Tire Size:
Common sizes included 215/80R15, 235/75R15, and 30x9.50R15. Specific size depends on trim level and wheel option.
Wheel Bolt Pattern
Wheel Bolt Pattern:
5 x 139.7 mm (5 x 5.5 inches) with a hub bore of approximately 108 mm.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mitsubishi Motors has a long history of producing robust and capable vehicles, particularly in the off-road and utility segments. The Pajero lineage is a cornerstone of this heritage.
Model Evolution
Model Evolution:
The L040 generation marked a significant step for the Pajero, with improved styling, more powerful engines, and enhanced interior comfort, solidifying its reputation as a premium off-roader.
Production
Production:
First Generation (L040) production ran from 1983 to 1991. The 1987 model year falls within a period of refinement and expansion of engine and feature options.
Model Nickname
Model Nickname:
Pajero in most markets, Montero in North America (US & Canada), Shogun in the UK.
🏆 Awards & Recognition
Recognitions
Recognitions:
While specific awards for the 1987 model year are not widely publicized, the Pajero/Montero lineage consistently received recognition for its off-road capabilities and durability throughout its production runs, often winning endurance rallies and off-road competitions.
Ratings
Ratings:
Consumer and automotive publication ratings from the era would have focused on its utility, ruggedness, and off-road performance rather than modern metrics like infotainment or safety ratings.
Certifications
Certifications:
Met all Japanese safety and emissions standards for the model year. International markets had their own specific homologation requirements.
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