Market Position:
The Mitsubishi Montero/Pajero (first generation) was a pioneering rugged SUV, known for its off-road capability and durability. This manual caters to owners and technicians maintaining these classic vehicles, offering in-depth technical guidance crucial for preserving their performance and longevity in a niche market of off-road enthusiasts and classic car collectors.
Key Features:
This manual provides unparalleled access to factory-level repair and maintenance information, essential for DIY mechanics and professional workshops alike. It empowers users to perform complex repairs, diagnose issues accurately, and maintain the vehicle to original specifications, ensuring the continued reliability and capability of the Montero/Pajero.
Intended Users:
Owners, DIY mechanics, and professional automotive repair shops specializing in vintage or off-road vehicles.
Coverage Years:
1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991
Format:
Downloadable Digital Manual
Manual Type:
Workshop Service and Repair Manual
Geographical Coverage:
Covers models sold globally, including variations for North American (Montero) and other markets (Pajero), reflecting regional differences in specifications where applicable.
Systems Covered:
Engine Mechanical, Engine Fuel, Engine Cooling, Engine Lubrication, Ignition System, Starting System, Charging System, Emission Control System, Clutch, Manual Transmission, Automatic Transmission, Transfer Case, Driveshafts, Front Suspension, Rear Suspension, Steering System, Brake System, Electrical System, Body Electrical, HVAC System, Body Panels, Interior Trim, Exterior Trim, Wheels and Tires
Technical Depth:
Comprehensive; from basic maintenance and troubleshooting to complete engine and transmission overhauls, including detailed diagnostic procedures, specifications, and torque values.
Procedures Included:
Routine maintenance, component removal and installation, engine rebuilding, transmission repair, brake service, electrical diagnostics, suspension and steering alignment, bodywork, HVAC system repair, diagnostic trouble codes (DTC) interpretation.
Diagnostic Procedures:
Detailed troubleshooting guides for electrical, fuel, and mechanical issues, including symptom-based diagnostics and step-by-step repair instructions. Covers diagnostic trouble codes (DTCs) for applicable models.
Body And Chassis:
Detailed procedures for body panel alignment, door and tailgate adjustments, interior trim removal/installation, and chassis component inspection and repair.
Searchability:
Searchable text for quick information retrieval.
Accessibility:
Printable pages for hands-on workshop use.
Interactivity:
Hyperlinked table of contents and index for easy navigation within the digital document.
Print Quality:
Digital PDF quality optimized for clarity, ensuring all diagrams and text are easily readable.
Primary Engine Gasoline:
2.6L (2555cc) Sirius 4G54 SOHC 8-valve I4
Primary Engine Diesel:
2.3L (2346cc) 4D55/4D55T SOHC 8-valve I4 Diesel (Naturally Aspirated and Turbocharged)
Secondary Engine Gasoline:
3.0L (2972cc) Cyclone 6G72 SOHC 12-valve V6 (Introduced later in the generation)
Performance Gasoline 4G54
Horsepower 4G54:
Approx. 105-116 hp (varies by market and emissions)
Torque 4G54:
Approx. 133-142 lb-ft
Horsepower 4D55T:
Approx. 84 hp (Naturally Aspirated) / 95-100 hp (Turbocharged)
Torque 4D55T:
Approx. 128 lb-ft (NA) / 145-150 lb-ft (Turbocharged)
Fuel System 4G54:
Carburetor (e.g., Aisan) or Electronic Fuel Injection (EFI) depending on year/market
Fuel System 4D55:
Direct Injection with Rotary Pump
Engine Code System:
Manual includes detailed engine code identification and interpretation.
Engine Turbo Diesel 2 3L:
4D55/4D55T: 2.3L (2346cc) OHC Inline-4 Cylinder, Naturally Aspirated and Turbocharged Diesel. Known for torque and fuel efficiency.
Engine Gasoline Codes:
4G54, 6G72.
Engine Diesel Codes:
4D55, 4D55T.
Standard Transmission:
4-speed Manual Transmission
Optional Transmission:
3-speed or 4-speed Automatic Transmission (depending on market and engine)
Transfer Case Type:
2-speed (Hi/Lo range) Part-Time 4WD System with front freewheeling hubs or automatic front locking hubs.
Clutch Type:
Dry Single Plate Clutch (for manual transmissions)
Manual Gear Ratios:
Manual includes detailed gear ratios for both 4-speed manual transmissions, crucial for performance tuning and replacement.
Length Swb:
Approx. 3,950 mm (155.5 in)
Width Swb:
Approx. 1,690 mm (66.5 in)
Height Swb:
Approx. 1,745 mm (68.7 in)
Length Lwb:
Approx. 4,525 mm (178.1 in)
Width Lwb:
Approx. 1,690 mm (66.5 in)
Height Lwb:
Approx. 1,800 mm (70.9 in)
Curb Weight Range:
Approx. 1,600 - 1,900 kg (3,527 - 4,189 lbs), depending on configuration.
Wheelbase Swb:
Approx. 2,200 mm (86.6 in)
Wheelbase Lwb:
Approx. 2,650 mm (104.3 in)
Active Safety Features:
Primarily mechanical; features include robust braking system with heavy-duty components, and inherently stable 4WD chassis design for off-road stability.
Passive Safety Features:
Reinforced body structure, padded interior surfaces, seat belts, optional limited-slip differentials for enhanced traction control.
Crash Test Era:
Crash testing standards were less stringent during the early production years; official ratings from modern agencies are not directly applicable but the vehicle's construction was robust for its time.
Audio System:
Basic AM/FM radio with cassette player. Manual covers removal, installation, and wiring for basic audio systems.
Off Road Systems:
Key technology includes the robust 4WD system with selectable low range, providing exceptional off-road traction. Manual details the operation and maintenance of these systems.
HVAC System:
Covers maintenance and repair of the heating, ventilation, and air conditioning (HVAC) system, including component testing and refrigerant handling procedures.
Oil Change Interval:
Typically every 5,000 - 7,500 km (3,000 - 5,000 miles) or 6 months, whichever comes first, depending on driving conditions.
Air Filter Replacement:
Every 15,000 - 20,000 km (9,000 - 12,000 miles)
Spark Plug Replacement:
Every 30,000 - 40,000 km (18,000 - 24,000 miles) for gasoline engines.
Timing Belt Replacement:
Crucial for 4G54 and 6G72 engines. Recommended replacement every 80,000 - 100,000 km (50,000 - 60,000 miles) or 5 years. Failure can cause catastrophic engine damage.
Engine Oil Type:
API SG/SH or higher, SAE 10W-30 or 10W-40 (check specific engine and climate conditions; diesel engines may require specific diesel-rated oils).
Engine Oil Capacity:
Approx. 4.5 - 5.0 liters (4.8 - 5.3 US quarts) for 4-cylinder, higher for V6.
Coolant Type:
Ethylene Glycol based antifreeze (e.g., Prestone, Peak) mixed with distilled water at a 50/50 ratio.
Transmission Fluid Manual:
API GL-4 SAE 75W-90 or 80W-90 Gear Oil (Transfer case and differentials may use GL-5).
Transmission Fluid Automatic:
Dexron II or equivalent automatic transmission fluid (ATF).
Brake Fluid Type:
DOT 3 or DOT 4.
Rust And Corrosion:
Common in unibody construction, especially around wheel arches, rocker panels, and chassis points. Manual provides rust repair guidance.
Diesel Engine Glow Plugs:
Glow plug system can fail, leading to hard starting in cold weather. Manual details diagnostic and replacement procedures.
Carburetor Tuning:
Carbureted gasoline engines may require periodic tuning and cleaning for optimal performance and fuel economy. Manual provides carburetor overhaul and adjustment specs.
Transfer Case Bushings:
Wear in transfer case shifter bushings can lead to sloppy engagement or difficulty shifting between 2WD/4WD. Manual covers rebuilds.
Suspension Bushings:
Rubber bushings in suspension and steering components can degrade over time, affecting handling and ride quality. Manual provides replacement procedures and torque specs.
Cylinder Head Torque:
Precise torque sequence and values for cylinder head bolts are provided, critical for proper engine sealing.
Transfer Case Fluid Capacity:
Approx. 1.8 - 2.0 liters (1.9 - 2.1 US quarts) of GL-5 gear oil.
Differential Fluid Capacity:
Approx. 1.3 - 1.5 liters (1.4 - 1.6 US quarts) of GL-5 gear oil per axle.
Brand Focus:
Mitsubishi Motors has a long history of producing durable and capable vehicles, with a strong emphasis on off-road performance and reliability, established through decades of automotive engineering.
First Generation Launch:
The first generation Pajero (Montero in many export markets) was launched in Japan in 1982 and quickly gained a reputation for its off-road prowess, especially after success in the Paris-Dakar Rally.
Key Innovations 1St Gen:
Introduction of independent front suspension (on some models), turbocharged diesel engine, and advanced 4WD systems with low-range gearing.
Manufacturing Plants:
Primarily manufactured in Japan.
Predecessor:
N/A (First generation model).
Successor:
Second Generation Pajero (1991-2000).
