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Mitsubishi

Mitsubishi Montero 1982-1991 Service Repair Workshop Manual

Mitsubishi Montero 1982-1991 Service Repair Workshop Manual

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Vehicle data plateRef 68616
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:
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
Infotainment Features:
Basic AM/FM radio with cassette player, optional premium sound systems, manual climate controls.
Driver Assistance
Driver Assistance Features:
Limited to ABS on some later/higher trim models. Primarily mechanical driver aids.
Connectivity
Connectivity Options:
N/A (No factory Bluetooth or USB connectivity)
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles or 6 months, depending on driving conditions (refer to manual for specific engine).
Air Filter Replacement Interval:
Every 15,000-30,000 miles or annually.
Spark Plug Replacement Interval:
Every 30,000-60,000 miles, depending on plug type.
Timing Belt Replacement Interval:
Critical for 4G63/4G64 engines; typically every 60,000-90,000 miles or 5-7 years. Refer to manual for exact interval.
Fluid Specifications
Engine Oil Type:
API SG/SH rated, SAE 10W-30 or 10W-40 recommended (check manual for ambient temperature suitability).
Engine Oil Capacity:
Approx. 4.5 - 5.5 quarts (4.3 - 5.2 liters) with filter, depending on engine.
Coolant Type:
Ethylene glycol based, typically a 50/50 mix of antifreeze and distilled water.
Transmission Fluid Manual:
GL-4 or GL-5 rated gear oil, SAE 75W-90 or 80W-90.
Transmission Fluid Automatic:
Dexron II or equivalent ATF.
Transfer Case Fluid:
GL-4 or GL-5 rated gear oil, SAE 75W-90 or 80W-90.
Differential Fluid:
GL-5 rated gear oil, SAE 80W-90.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Wear Items:
Suspension bushings, ball joints, tie rod ends, brake components, exhaust system, timing belts (critical replacement).
Engine Specific Concerns:
4G54 can be prone to oil leaks and head gasket issues if overheated. 4G63/4G64 timing belt failure can cause catastrophic engine damage.
Diesel Specific Concerns:
Glow plug system, injection pump maintenance, potential for turbocharger issues on later models.
Rust Prone Areas:
Wheel wells, rocker panels, frame rails, tailgate, rear quarter panels.
Electrical Issues
Common Electrical Faults:
Aging wiring harness connections, alternator/regulator issues, starter motor problems, sensor failures.
📚 Vehicle History
Brand Heritage
Brand Heritage Summary:
Mitsubishi Motors, established in 1970, with roots tracing back to the automotive division of Mitsubishi Heavy Industries. Known for developing robust, reliable vehicles.
Model Evolution
Model Introduction:
First generation (L040) introduced in 1982 in Japan as the Pajero. Rebadged and sold globally under various names, including Montero in North America from 1983.
Platform:
Body-on-frame construction, shared with other Mitsubishi SUVs and trucks of the era.
Production
Production Years First Gen:
1982-1991
Manufacturing Locations:
Primarily Japan
🏆 Awards & Recognition
Recognitions
Off Road Awards:
Recognized for its robust off-road capability and durability, often favored by off-road enthusiasts and overland travelers.
Ratings
Consumer Ratings:
Generally well-regarded for reliability and off-road prowess, though less refined than some contemporary competitors on-road. Value retention is often strong in the used market.

Delivery & file format

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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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