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Mitsubishi

Mitsubishi Montero 1982-1991 Workshop Service Repair Manual

Mitsubishi Montero 1982-1991 Workshop Service Repair Manual

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$16.99
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Vehicle data plateRef 391205
Brand
Mitsubishi
Vehicle
Cars
Models covered
Misc, Montero
Years
1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

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🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Montero
Generation Code:
First Generation (1982-1990/1991)
Codes
Chassis Code:
L040 Series
👋 Introduction
Market Position
Segment:
Compact SUV/Off-Road Utility Vehicle
Target Audience:
Enthusiasts, off-roaders, families seeking rugged and capable utility vehicles.
Competitive Analysis
Key Competitors:
Toyota 4Runner, Nissan Pathfinder, Jeep Cherokee (XJ), Ford Bronco II, Chevrolet S-10 Blazer.
Key Features
Off Road Capability:
Body-on-frame construction, available four-wheel drive (including low range), good ground clearance, robust suspension.
Versatility:
Suitable for daily commuting, family transport, and demanding off-road excursions.
Durability:
Known for its rugged build quality and ability to withstand demanding use.
📋 Manual Details
Coverage Areas
Countries Of Sale Covered:
Global (primarily North America, Europe, Australia, and Japan)
Page Count
Total Pages:
700+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete overhaul, timing belt/chain, valve adjustments, cylinder head, block, pistons, crankshaft, oil pump, cooling system, lubrication system
Engine Electrical:
Ignition system, starting system, charging system, fuel injection system (EFI), engine control unit (ECU) diagnostics, wiring diagrams
Transmission Manual:
Clutch, gearbox overhaul, gear ratios, shifting mechanisms, PTO (if applicable)
Transmission Automatic:
Torque converter, planetary gear sets, valve body, hydraulic control, shift solenoids, overhaul procedures, fluid type and capacity
Drivetrain:
Four-wheel drive system (Super Select 4WD if applicable), transfer case, front and rear differentials, drive shafts, CV joints, hubs
Suspension:
Front independent suspension (torsion bar or coil spring), rear leaf springs or coil springs, shock absorbers, control arms, bushings, steering knuckles
Steering:
Power steering system, steering gearbox/rack, tie rods, steering column, wheel alignment specifications
Brakes:
Front disc brakes, rear drum brakes (or disc brakes on some models), brake fluid type and capacity, master cylinder, calipers, wheel cylinders, parking brake system, ABS (if equipped)
Fuel System:
Fuel tank, fuel pump, fuel lines, fuel filter, carburetor (early models) or multi-point fuel injection (later models), fuel pressure specifications
Exhaust System:
Exhaust manifold, catalytic converter, muffler, pipes, hangers, emissions control systems
Cooling System:
Radiator, thermostat, water pump, coolant type and capacity, heater core, hoses, fan clutch/electric fan
Electrical Body:
Lighting system (headlights, taillights, interior), power windows, power locks, mirrors, wipers, horn, fuse box diagrams, relay locations
HVAC:
Air conditioning system (compressor, condenser, evaporator, refrigerant type), heater, blower motor, climate control system
Body And Chassis:
Frame, body panels, doors, hood, tailgate, bumpers, interior trim, glass replacement, corrosion prevention
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, drive belt inspection/replacement, tire rotation
Diagnostic Troubleshooting:
Step-by-step troubleshooting guides for common issues, diagnostic trouble codes (DTCs), symptom-based diagnostics
Repair And Rebuild:
Detailed instructions for component removal, installation, and complete overhaul for most major systems
Component Replacement:
Specific procedures for replacing wear items and major components like alternators, starters, radiators, pumps, etc.
Electrical Repair:
Wiring harness repair, component testing, circuit diagnostics using wiring diagrams
Wheel Alignment:
Specifications for camber, caster, toe-in, and steering axis inclination
Specifications And Tolerances:
Torque specifications for all fasteners, critical clearances, wear limits for engine and drivetrain components
Technical Depth
Depth:
Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics and electrical system troubleshooting.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable Text:
Yes
Printability:
Yes
Print Quality
Quality:
High-resolution scans of original factory manuals, ensuring clarity of diagrams and text.
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G54 (2.6L)
Displacement Cc:
2555
Configuration:
Inline-4, SOHC
Horsepower Hp Approx:
105-116
Torque Lb-Ft Approx:
138-140
Performance
Fuel Type:
Unleaded Gasoline
Fuel System
System:
Carburetor (early) or Electronic Fuel Injection (EFI) (later models)
Engine Options
Secondary Engine Code:
6G72 (3.0L V6)
Secondary Displacement Cc:
2972
Secondary Configuration:
V6, SOHC
Secondary Horsepower Hp Approx:
140-155
Secondary Torque Lb-Ft Approx:
160-180
🔧 Transmission
Standard
Type:
5-speed Manual Transmission
Optional
Type:
4-speed Automatic Transmission
Features
4Wd System:
Part-time 4WD (with manual front hub engagement) or available Full-time 4WD with low-range transfer case. Later models may feature 'Super Select' 4WD with electronically controlled modes.
📐 Dimensions
Exterior
Wheelbase Inches:
105.1
Overall Length Inches:
167.9 (short wheelbase), 178.5 (long wheelbase)
Overall Width Inches:
66.1
Overall Height Inches:
65.0 (short wheelbase), 66.5 (long wheelbase)
Interior
Seating Capacity:
4-7 (depending on configuration and wheelbase)
Weights
Curb Weight Lbs Approx:
3500-4200
🛡️ Safety Features
Ratings
NHTSA Rollover Rating:
N/A (Era before standardized ratings, generally considered stable for its class but prone to rollover in extreme conditions due to high center of gravity.)
Active Features
ABS:
Available on select later models, typically rear-wheel only.
Passive Features
Seatbelts:
Front three-point, rear lap belts. Shoulder belts may be available in later models.
Body Structure:
Body-on-frame construction provides a robust chassis.
💡 Technology Features
Infotainment
Audio System:
Basic AM/FM radio with cassette player. Upgrades often available from dealer or aftermarket.
Gauges And Displays:
Analog gauges for speedometer, tachometer (optional), fuel, temperature, oil pressure. Basic warning lights.
Driver Assistance
Features:
Primarily mechanical systems. ABS was an optional, later addition and not widely prevalent across the entire model run.
Connectivity
Features:
No factory connectivity features like Bluetooth or USB. Analog connections for external devices might be possible with aftermarket head units.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,000-5,000 miles or 3-6 months (depending on oil type and driving conditions).
Engine Oil Filter:
Replace with every oil change.
Air Filter:
Inspect every 15,000 miles, replace as needed or every 30,000 miles.
Spark Plugs:
Replace every 30,000 miles (typically for standard plugs).
Timing Belt 4G54:
Replace every 60,000 miles or 4-5 years (critical maintenance item).
Transmission Fluid Auto:
Change every 30,000-50,000 miles, inspect more frequently.
Transmission Fluid Manual:
Change every 50,000-60,000 miles.
Coolant Flush:
Every 2-3 years or 30,000-50,000 miles.
Fluid Specifications
Engine Oil:
API SG or higher, SAE 10W-30 or 10W-40 (depending on climate). Consult manual for specific viscosity.
Automatic Transmission Fluid:
Dexron II or equivalent.
Manual Transmission Fluid:
GL-4 or GL-5 gear oil, SAE 75W-90 or 80W-90.
Brake Fluid:
DOT 3.
Coolant:
Ethylene glycol based antifreeze mixed with distilled water (50/50 ratio).
Power Steering Fluid:
DEXRON II or equivalent power steering fluid.
Known Issues
Rust And Corrosion:
Common in areas with road salt due to body-on-frame construction and age. Frame rust can be a significant concern.
Engine Overheating:
Can occur due to aging cooling system components (radiator, hoses, water pump, thermostat).
Timing Belt Failure:
Critical to adhere to replacement intervals for the 4G54 engine to avoid catastrophic damage.
Drivetrain Wear:
U-joints, CV joints, and differential bearings can wear out with age and mileage, especially with off-road use.
Interior Electronics:
Power window motors, lock actuators, and gauge clusters can fail over time.
Fuel System Issues:
Carburetor issues on earlier models, fuel pump failures, and clogged injectors on EFI models.
📚 Vehicle History
Brand Heritage
Heritage:
Mitsubishi Motors Corporation, a Japanese automaker with a long history of producing durable and capable vehicles, including rugged 4x4s.
Model Evolution
Introduction Year:
1982
Evolution Points:
Initial models featured smaller, 4-cylinder engines and part-time 4WD. Later models saw the introduction of the more powerful V6 engine, automatic transmissions, improved interior features, and advanced 4WD systems (like Super Select).
Production
Manufacturing Locations:
Japan (primarily Mizushima Plant)
Production Period Covered By Manual:
1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991
🏆 Awards & Recognition
Recognitions
Off Road Magazine Awards:
Frequently praised by off-road publications for its capability and durability in its class during its production run.
Ratings
Consumer Reports Reliability:
Variable by year and specific components. Known to be mechanically robust if properly maintained, but older components can lead to issues.

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Check the model year and engine before you buy

Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.

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