Mitsubishi Montero Complete Workshop Service Repair Manual 1984 1985 1986

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🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Generation: First Generation Body Style: SUV / Off-Road Vehicle Chassis Code Common: L040 Series 👋 Introduction Market Position Segment: Compact to Mid-size...

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Sku: 396865

Tags: 1984 1985 1986 Car Cars Misc Mitsubishi Montero

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Montero

Generation:

First Generation

Body Style:

SUV / Off-Road Vehicle

Chassis Code Common:

L040 Series

👋 Introduction

Market Position

Segment:

Compact to Mid-size SUV, known for off-road capability and ruggedness.

Target Audience:

Enthusiasts, off-roaders, DIY mechanics, and owners seeking to maintain their vehicles.

Competitive Analysis

Competitors:

Jeep Cherokee (XJ), Toyota 4Runner, Nissan Pathfinder, Ford Bronco II, Chevrolet S-10 Blazer.

Key Features Vehicle

Off Road Capability:

Body-on-frame construction, robust 4WD system (often with selectable low-range), good ground clearance.

Key Features Manual

Utility:

Essential for owners and technicians performing maintenance, repairs, and diagnostics on these robust vehicles.

📋 Manual Details

Coverage

Years Covered:

1984, 1985, 1986

Markets Covered:

Likely Global, with specific focus on North American and Japanese market variants as representative.

Format

Format Type:

Downloadable Digital Manual

File Format:

PDF (typically)

Language:

English

Manual Type:

Workshop Service Repair Manual

Pages

Estimated Page Count:

1000+ (Comprehensive workshop manuals are typically extensive)

📖 Manual Coverage

Systems

Engine Mechanical:

Engine disassembly, assembly, internal components, cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication, cooling.

Engine Fuel System:

Fuel injection systems (MPI/SPI depending on variant), carburetion (early models), fuel pump, injectors, lines, filters, evaporative emission controls.

Engine Ignition System:

Ignition timing, spark plugs, coils, distributor (if applicable), ignition control module.

Engine Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, pipes, emissions controls.

Transmission Manual:

Clutch, gearbox (5-speed likely), components, overhaul, fluid specifications.

Transmission Automatic:

Automatic transmission (if applicable), internal components, torque converter, hydraulic controls, overhaul, fluid specifications.

Drivetrain 4Wd:

Transfer case operation and repair, front and rear differentials, driveshafts, CV joints, hub mechanisms.

Suspension Front:

Independent front suspension (likely torsion bar or coil spring), control arms, ball joints, bushings, shock absorbers, steering knuckle.

Suspension Rear:

Multi-link or leaf spring rear suspension, shock absorbers, bushings.

Steering:

Power steering system, pump, rack and pinion or steering box, tie rods, steering column, wheel alignment specifications.

Brakes Front:

Disc brake system, calipers, pads, rotors, lines, master cylinder.

Brakes Rear:

Drum or disc brake system, shoes/pads, drums/rotors, parking brake mechanism.

Electrical System Charging:

Alternator, battery, voltage regulator, wiring diagrams.

Electrical System Starting:

Starter motor, starter solenoid, ignition switch.

Electrical System Lighting:

Headlights, taillights, brake lights, turn signals, interior lighting, wiring.

Electrical System Accessories:

Wipers, horn, power windows, power locks (if equipped), radio, HVAC controls.

Body Exterior:

Body panel removal and installation, doors, hood, tailgate, bumpers, glass, trim.

Body Interior:

Dashboard, seats, carpets, door panels, headliner, trim components.

HVAC System:

Heater core, A/C system components (compressor, condenser, evaporator), blower motor, controls, refrigerant handling.

Procedures

Routine Maintenance:

Oil changes, filter replacements, fluid checks and changes, tire rotation, tune-ups.

Diagnostic Troubleshooting:

Step-by-step procedures for diagnosing common and uncommon problems across all systems.

Engine Repair:

Complete engine rebuilds, cylinder head gasket replacement, timing belt/chain service, piston ring replacement, bearing replacement.

Transmission Repair:

Clutch replacement, manual gearbox overhaul, automatic transmission fluid service and potential rebuild procedures.

Brake System Repair:

Brake pad/shoe replacement, rotor/drum resurfacing or replacement, caliper/wheel cylinder overhaul, brake bleeding.

Suspension Steering Repair:

Component replacement (ball joints, tie rods, bushings), shock absorber/strut replacement, steering system repair.

Electrical Diagnostics:

Troubleshooting wiring issues, component testing, fuse/relay identification and testing.

Body Panel Repair:

Minor bodywork, dent removal, panel alignment, rust repair considerations.

HVAC Repair:

A/C system servicing, leak detection, component replacement, heater core replacement.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to full engine and transmission rebuilds, including electrical system diagnostics and component-level repair.

Specifications:

Includes detailed torque specifications, clearances, fluid capacities, electrical component resistance values, diagnostic trouble codes (DTCs), and alignment angles.

Wiring Diagrams:

Detailed electrical wiring diagrams for all major systems, crucial for troubleshooting electrical faults.

📊 Manual Specifications

File Format:

Searchability:

Typically text-searchable for quick information retrieval.

Printability:

Printable for use in a workshop environment.

Print Quality:

Depends on the source scan quality; generally aimed at clarity and legibility for technical information.

Binding

Binding Type:

N/A (Digital Download)

Paper

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine 1984-1986

Engine Code Common:

4G54 (2.6L)

Engine Type:

Inline 4-cylinder, SOHC (Single Overhead Cam)

Displacement Liters:

Displacement Cubic Inches:

Bore X Stroke Mm:

91.1 x 98.0

Compression Ratio:

8.5:1 (typical)

Horsepower Hp:

105-116 hp @ 4500-5000 rpm (variant dependent)

Torque Ft Lbs:

135-145 lb-ft @ 2500-3000 rpm (variant dependent)

Fuel System:

Electronic Fuel Injection (EFI) or Carburetor depending on market and specific model year.

Fuel Type:

Unleaded Gasoline (87 Octane recommended)

Engine Block Material:

Cast Iron

Cylinder Head Material:

Aluminum Alloy

Timing Drive:

Timing Chain (with tensioner)

🔧 Transmission

Standard Transmission

Type:

5-Speed Manual Transmission

Optional Transmission

Type:

4-Speed Automatic Transmission (likely)

Features

Clutch Type:

Dry, single plate (manual)

4Wd System:

Part-time 4WD system with selectable 2WD/4WD High/4WD Low engagement, often with manual locking hubs.

📐 Dimensions

Exterior

Wheelbase Inches:

104.5

Length Inches:

167.7 - 172.0 (variant dependent)

Width Inches:

Height Inches:

64.6 - 67.5 (variant dependent)

Weights

Curb Weight Lbs:

3500 - 3800 (approximate, variant dependent)

Towing

Towing Capacity Lbs:

2000 - 3500 (approximate, variant dependent)

🛡️ Safety Features

Ratings

Niosh Rating:

Not applicable for the era of vehicle; primary safety features are mechanical and passive.

Active Features

Braking System:

Front disc brakes, rear drum brakes (standard), Anti-lock Braking System (ABS) may be an option on later models in this generation, but unlikely for early '84-'86.

Passive Features

Seat Belts:

Front 3-point seat belts, rear lap belts (standard).

Body Construction:

Reinforced body structure, crumple zones (basic for the era).

Rollover Protection:

Basic structural integrity for rollovers; not specifically designed with advanced rollover protection systems.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio with cassette player, potentially optional CD player on later models. Speaker quality is basic.

Dashboard Controls:

Analog gauges for speed, RPM, fuel, temperature, oil pressure. Physical buttons and knobs for HVAC and radio.

Driver Assistance

Cruise Control:

Optional on higher trim levels.

Anti Lock Brakes:

Limited availability or non-existent on early models (1984-1986), became more common later in the generation.

Connectivity

Features:

No modern connectivity features such as Bluetooth, USB, or smartphone integration.

🔧 Maintenance

Service Intervals Oil

Oil Change Interval:

Every 3,000 - 5,000 miles or 3-6 months (owner's manual recommendation, consult manual for specific interval).

Service Intervals Filters

Oil Filter Replacement:

With every oil change.

Air Filter Replacement:

Every 15,000 - 30,000 miles or as needed based on driving conditions (consult manual).

Fuel Filter Replacement:

Every 30,000 - 60,000 miles (consult manual).

Fluid Specifications Engine Oil

Engine Oil Type:

API SF or SG service classification, SAE 10W-30 or 10W-40 (check manual for specific ambient temperature recommendations).

Engine Oil Capacity Quarts:

Approx. 5.3 quarts (with filter change).

Fluid Specifications Coolant

Coolant Type:

Ethylene Glycol based antifreeze, typically a 50/50 mix with distilled water.

Fluid Specifications Transmission Manual

Manual Transmission Fluid Type:

API GL-4, SAE 75W-90 or 80W-90 gear oil (consult manual for exact specification).

Fluid Specifications Transmission Automatic

Automatic Transmission Fluid Type:

Dexron II or equivalent (consult manual for specific type).

Fluid Specifications Differential Fluid

Front Rear Differential Fluid Type:

API GL-5, SAE 80W-90 gear oil (consult manual).

Fluid Specifications Transfer Case

Transfer Case Fluid Type:

API GL-4 or GL-5, SAE 75W-90 or 80W-90 gear oil (consult manual).

Fluid Specifications Brake Fluid

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Known Issues

Engine Performance:

Valve seat recession on early models if running leaded fuel, carburetor issues (if equipped), timing chain noise (tensioner wear).

Suspension:

Wear in ball joints, tie rod ends, and bushings due to off-road use; potential for torsion bar sag affecting ride height.

Electrical:

Corrosion in wiring connectors, starter motor wear, alternator issues, dashboard warning light malfunctions.

Rust:

Prone to rust in common areas such as rocker panels, wheel wells, and chassis frame, especially in areas with road salt.

4Wd System:

Transfer case linkages can seize, manual hubs can become difficult to operate if not serviced.

Cooling System:

Radiator leaks, thermostat failure, water pump seals can fail with age.

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

Japan

Specialty:

Mitsubishi Motors has a history of producing robust and capable off-road vehicles and reliable passenger cars.

Model Evolution

Debut Year:

1982 (globally as Pajero), 1983 (North America as Montero)

First Generation Years:

1983-1991 (North America)

Design Philosophy:

Designed as a versatile and rugged off-road utility vehicle, capable of both daily driving and serious off-roading.

Production

Assembly Locations:

Japan (primarily), potentially other global assembly plants for specific markets.

🏆 Awards & Recognition

Recognitions

Off Road Awards:

While specific 'awards' might be scarce for this exact period, the Montero (Pajero) consistently received acclaim for its off-road prowess in various global challenges and expeditions.

Ratings

Consumer Reports Historical Ratings:

Consumer Reports often rated vehicles of this era for reliability and performance, though specific ratings for the '84-'86 Montero would need historical data lookup.

Certifications

Emissions Certifications:

Meets US EPA emissions standards for the respective model years.