🏷️ Basic Information

Make:

Mitsubishi

Model:

Montero

Generation:

First Generation (L040 Series)

Chassis Code:

L040 Series

👋 Introduction

Vehicle Segment:

Compact/Mid-size SUV (Sport Utility Vehicle), rugged off-roader

Target Audience:

Off-road enthusiasts, utility-focused buyers, families seeking ruggedness and capability

Key Competitors:

Jeep Cherokee (XJ), Toyota 4Runner (first gen), Ford Bronco II, Nissan Pathfinder (first gen), Chevrolet S-10 Blazer/GMC S-15 Jimmy

Off Road Capability:

Renowned for its robust chassis, solid rear axle, available locking differentials, and excellent four-wheel-drive system.

Durability:

Built with a body-on-frame construction, contributing to its toughness and longevity.

Versatility:

Suitable for daily driving, family transport, and serious off-road excursions.

Design Philosophy:

Functional and rugged, prioritizing mechanical capability over luxury and advanced technology.

📋 Manual Details

Applicable Years:

1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991

Regions Covered:

Global (primarily North America, Australia, Europe, and Japan where the Montero and Pajero were sold)

Estimated Pages:

Thousands (comprehensive service manual)

Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine:

Complete engine overhaul, diagnostics, fuel system, ignition system, emission controls, cooling system, lubrication system, engine mechanicals (cylinder head, block, pistons, crankshaft, camshafts), turbocharging (where applicable)

Transmission:

Manual and Automatic transmission overhaul, diagnostics, clutch system, gear shifting mechanisms, transfer case operation and repair

Drivetrain:

Front and rear axle assembly, differentials, driveshafts, constant velocity (CV) joints, four-wheel drive (4WD) system operation and repair

Suspension:

Front and rear suspension components (leaf springs, coil springs, shock absorbers, control arms, sway bars), wheel alignment specifications

Steering:

Power steering system, steering gear box, tie rods, steering column, steering wheel replacement

Brakes:

Front and rear brake systems (disc and drum), brake fluid specifications, brake line routing, caliper and wheel cylinder overhaul, parking brake system

Electrical:

Wiring diagrams, lighting system, charging system (alternator, battery), starting system (starter motor), ignition system, dashboard instruments, fuses and relays, basic accessory circuits

Body And Chassis:

Body panel repair, door and window mechanisms, interior trim, seat removal and installation, chassis lubrication points, rust prevention measures

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system operation, component replacement (compressor, condenser, evaporator), refrigerant handling (basic)

Maintenance:

Regular maintenance checks, lubrication, fluid changes, filter replacements, belt adjustments

Troubleshooting:

Diagnostic procedures for common and uncommon problems, symptom-based troubleshooting guides, fault code interpretation (where applicable)

Repair:

Step-by-step repair instructions for all major components and systems, including complete disassembly and reassembly guidance

Diagnostics:

Detailed diagnostic charts, testing procedures for electrical components, mechanical adjustments

Specifications:

Torque specifications, clearance measurements, alignment angles, fluid capacities and types

Level Of Detail:

Comprehensive. Covers basic maintenance to complete engine and transmission rebuilds, including advanced troubleshooting and detailed schematics.

📊 Manual Specifications

File Type:

PDF

Searchability:

Text-searchable PDF for quick information retrieval

Printability:

Printable pages for workshop use

Image Resolution:

High-resolution images and diagrams for clarity

Binding:

N/A (Digital PDF)

Paper Quality:

N/A (Digital PDF)

Content Type:

Factory authorized repair and service information

⚙️ Engine Specifications

Engine Code Common:

4G54 (2.6L)

Engine Displacement Gas Std:

2.6 Liters (159 cubic inches)

Engine Configuration Gas Std:

Inline 4-cylinder, SOHC (Single Overhead Camshaft)

Bore X Stroke Gas Std:

91.1 mm x 100.0 mm

Compression Ratio Gas Std:

8.5:1 (typical)

Horsepower Gas Std:

105-116 hp @ 4500-5000 rpm (depending on year and market)

Torque Gas Std:

145-150 lb-ft @ 2500-3000 rpm (depending on year and market)

Engine Code Diesel:

4D55, 4D56 (2.3L/2.5L Diesel)

Engine Displacement Diesel:

2.3 Liters (4D55), 2.5 Liters (4D56)

Engine Configuration Diesel:

Inline 4-cylinder, Diesel (some turbocharged)

Top Speed Estimate:

Approx. 90-100 mph

Fuel Delivery Gas Std:

Carburetor (e.g., Mikuni/Aisan 2-barrel)

Fuel Type Gas:

Unleaded gasoline (87 octane recommended)

Fuel Type Diesel:

Diesel fuel

Oil Capacity With Filter:

Approx. 4.5-5.0 quarts (4.3-4.7 liters) for 2.6L engine

Coolant Capacity:

Approx. 7.0-8.0 quarts (6.6-7.6 liters)

Spark Plugs Recommendation:

NGK BP5FS or equivalent (check manual for specific plugs)

🔧 Transmission

Manual Transmission:

4-speed Manual (early models), 5-speed Manual (later models)

Automatic Transmission:

3-speed Automatic, 4-speed Automatic (with overdrive in later models)

Transfer Case:

Part-time 4WD system with manual or automatic front hub engagement (early models) or full-time 4WD (later models, depending on trim/market)

Manual Transmission Fluid:

GL-4 Gear Oil (e.g., SAE 75W-90)

Automatic Transmission Fluid:

Dexron II or equivalent

Capacity 5 Speed Manual:

Approx. 2.5 liters (2.6 quarts)

Capacity 4 Speed Automatic:

Approx. 6.0-7.0 liters (6.3-7.4 quarts) with torque converter

📐 Dimensions

Wheelbase Short:

Approx. 97.0 inches (2460 mm)

Wheelbase Long:

Approx. 112.4 inches (2855 mm)

Length Short:

Approx. 166.1 inches (4219 mm)

Length Long:

Approx. 181.7 inches (4615 mm)

Width:

Approx. 65.6 inches (1666 mm)

Height:

Approx. 71.7 inches (1821 mm)

Curb Weight Range:

Approx. 3500 - 4500 lbs (1588 - 2041 kg) depending on configuration

Towing Capacity:

Variable, consult specific model documentation or manual for exact figures (typically around 2000-3500 lbs)

Ground Clearance:

Approx. 8.1 inches (206 mm) or more, depending on tire size and suspension

Bolt Pattern:

5 x 114.3 mm (5 x 4.5 inches)

Standard Tire Size:

235/75R15 (common)

Wheel Size:

15 x 6 or 15 x 7 inches

🛡️ Safety Features

NHTSA Ratings Era:

Vehicle safety standards and testing methodologies were less stringent and comprehensive in this era compared to modern standards. Specific NHTSA ratings for these older models are often not readily available or comparable.

Four Wheel Drive:

Primary safety feature for off-road and adverse weather conditions.

Locking Differentials:

Available on some models for enhanced traction in extreme off-road situations.

Seat Belts:

Standard front seat belts; rear seat belts available on some models.

Body Construction:

Body-on-frame construction provides a robust structure.

Headrests:

Front and rear headrests (design and adjustability varies by year and trim).

💡 Technology Features

Audio System:

Basic AM/FM radio with cassette player. Speaker configurations varied by trim level.

Dashboard Instruments:

Analog gauges for speedometer, tachometer (on some models), fuel, coolant temperature, oil pressure, and voltage. Warning lights for various systems.

ABS:

Anti-lock Braking System (ABS) was not commonly available or was an optional feature on later models of this generation.

Cruise Control:

Optional on higher trim levels or later models.

Connectivity Features:

Minimal by modern standards. Primarily focused on mechanical function.

🔧 Maintenance

Oil Change Interval:

Every 3,000-5,000 miles (5,000-8,000 km) or 6 months, whichever comes first. Consult manual for specific engine and oil type.

Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on driving conditions.

Spark Plug Replacement:

Every 20,000-30,000 miles (32,000-48,000 km), depending on plug type.

Coolant Flush:

Every 24,000-36,000 miles (38,000-58,000 km) or 2-3 years.

Transmission Fluid Change:

Manual: Every 30,000-50,000 miles. Automatic: Every 24,000-30,000 miles or 2 years.

Timing Belt Replacement Note:

The 2.6L 4G54 engine uses a timing belt. Replacement interval is critical, typically around 60,000 miles (96,000 km). Refer to manual for precise interval and procedure.

Engine Oil Recommendation:

API Service SG or SH, SAE 10W-30 or 10W-40 recommended for most climates. Check manual for specific viscosity and ratings.

Brake Fluid Type:

DOT 3 or DOT 4

Power Steering Fluid:

Dexron II or equivalent power steering fluid

Differential Fluid:

API GL-5, SAE 80W-90 for both front and rear differentials.

Rust Corrosion:

Common in body panels, frame, fuel lines, and brake lines due to age and exposure, especially in areas with road salt. Thorough inspection is crucial.

Carburetor Issues:

The stock carburetor can be finicky and require periodic cleaning or adjustment to maintain smooth running.

Timing Belt Failure:

If the timing belt breaks, it can cause significant engine damage (interference engine). Strict adherence to replacement intervals is paramount.

Suspension Wear:

Leaf springs can sag over time, and bushings can wear out, leading to a less compliant ride and potential alignment issues.

Exhaust Manifold Cracks:

Exhaust manifolds can develop cracks due to heat cycles, leading to exhaust leaks and a noticeable ticking sound.

Transfer Case Issues:

Wear in the engagement collar or shift forks can cause issues with engaging 4WD.

📚 Vehicle History

Mitsubishi Motors:

Mitsubishi Motors, a Japanese multinational automotive manufacturer, has a history dating back to the early 20th century. They are known for robust engineering, particularly in their SUVs and 4x4 vehicles.

Pajero Origin:

The Mitsubishi Montero is the export name for the Mitsubishi Pajero, first introduced in Japan in 1982. It was designed to compete in the burgeoning SUV market.

First Generation Introduction:

The L040 series Pajero/Montero was launched in 1982. It offered a range of body styles including a two-door soft-top, a two-door hardtop, and a four-door wagon, available in short and long wheelbases.

Updates During Generation:

The first generation received several updates during its production run, including the introduction of more powerful engines (like the 2.5L turbodiesel and later 3.0L V6), improved transmissions, and revised styling and interior features. The most significant facelift often cited occurred around 1987-1988.

Manufacturing Locations:

Primarily manufactured in Japan (Pajero) and assembled in various global locations for export.

Production Years:

1982-1991 (for the first generation covered by this manual)

Market Success:

The Pajero/Montero achieved significant global sales success, establishing Mitsubishi as a major player in the SUV segment, particularly for its off-road prowess.

🏆 Awards & Recognition

Off Road Awards:

The Pajero/Montero has a strong reputation in off-road circles and has participated successfully in events like the Paris-Dakar Rally, though specific awards for the early models are more about market perception and capability than formal automotive awards.

Consumer Reputation:

Generally regarded as a very capable and durable off-road vehicle. Praised for its ruggedness and value for money in its segment.

Emissions Standards:

Compliant with prevailing emissions standards for the respective model years and regions. Manual will detail specific standards and testing procedures.