Mitsubishi Montero 1983 Repair Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Year: 1983 Codes Chassis Code: L040 Series Generation Generation Name: First Generation (1982–1991) Generation Introduction: The first generation Montero, also known as...

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标签: 1983 Car Cars Misc Mitsubishi Montero

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Montero

Year:

Codes

Chassis Code:

L040 Series

Generation

Generation Name:

First Generation (1982–1991)

Generation Introduction:

The first generation Montero, also known as the Pajero in many markets, debuted in 1982.

👋 Introduction

Market Position

Segment:

Compact SUV / Off-roader

Positioning:

The Montero was positioned as a rugged, capable off-road vehicle with comfortable on-road manners, competing with models like the Toyota Land Cruiser and Jeep Cherokee.

Competitive Analysis

Competitors 1983:

Toyota Land Cruiser (FJ60), Jeep Cherokee (XJ), Ford Bronco.

Key Features

Off Road Capability:

Body-on-frame construction, available 4WD with low-range gearing, robust suspension.

Body Styles:

Initially offered as a 2-door or 4-door wagon, with short and long wheelbase options.

Powertrain Options:

Reliable gasoline and diesel engines.

📋 Manual Details

Coverage Areas

Primary Coverage:

Mechanical systems, electrical systems, body and chassis.

Diagnostic Coverage:

Troubleshooting and diagnostic procedures for all major systems.

Page Count

Estimated Pages:

Over 1000

Manual Type

Type:

Factory Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Engine mechanical, lubrication, cooling, fuel, ignition, emission control systems.

Transmission:

Manual and automatic transmission overhaul, operation, and diagnosis.

Drivetrain:

4WD system, transfer case, differentials, axles, driveshafts.

Suspension:

Front and rear suspension, steering system, alignment specifications.

Brakes:

Brake system (disc and drum), hydraulic components, parking brake.

Electrical:

Complete wiring diagrams, charging system, starting system, lighting, instruments, accessories.

Body Chassis:

Body panels, interior trim, glass, frame, structural components.

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, tune-ups.

Repair:

Component removal, disassembly, inspection, assembly, and installation.

Troubleshooting:

Step-by-step diagnostic flowcharts and symptom-based troubleshooting.

Specifications:

Torque specifications, clearances, fluid capacities, electrical data.

Technical Depth

Depth:

Comprehensive, covering everything from basic fluid checks to complete engine and transmission overhauls.

Target Audience:

Professional technicians and experienced DIY enthusiasts.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content.

Print Quality

Quality:

High-resolution scans suitable for printing.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code Gas:

4G54 (2.6L)

Engine Type Gas:

Inline 4-cylinder, SOHC

Displacement Gas:

2.6 Liters (2555 cc)

Bore X Stroke Gas:

91.1 mm x 98.0 mm

Compression Ratio Gas:

8.5:1

Horsepower Gas:

105 hp @ 4,500 rpm

Torque Gas:

144 lb-ft @ 2,500 rpm

Fuel System

Fuel Delivery Gas:

Two-barrel downdraft carburetor (e.g., Aisan)

Fuel Delivery Diesel:

Injection Pump (e.g., Bosch VE)

Engine Code Diesel

Engine Code Diesel:

4D55T (2.3L Turbo Diesel)

Engine Type Diesel

Engine Type Diesel:

Inline 4-cylinder, OHC, Turbocharged Diesel

Displacement Diesel

Displacement Diesel:

2.3 Liters (2346 cc)

Horsepower Diesel

Horsepower Diesel:

84 hp @ 4,200 rpm

Torque Diesel

Torque Diesel:

125 lb-ft @ 2,000 rpm

Maintenance

Oil Type:

API SG or SF, SAE 10W-30 or 10W-40 (check manual for specific viscosity based on temperature)

Spark Plugs Gas:

NGK BP5ES or equivalent

Timing Belt Gas:

Not applicable (chain-driven camshaft)

🔧 Transmission

Standard

Transmission Type Std:

4-speed Manual Transmission

Optional

Transmission Type Opt:

3-speed Automatic Transmission

Features

Transfer Case:

2-speed manual transfer case with part-time 4WD engagement (2H, 4H, 4L)

Maintenance

Manual Transmission Fluid:

API GL-3 or GL-4, SAE 75W-90 or 80W-90

Automatic Transmission Fluid:

Dexron II or Dexron III

📐 Dimensions

Exterior

Wheelbase Short Wheelbase:

approx. 97.2 inches (2470 mm)

Wheelbase Long Wheelbase:

approx. 109.4 inches (2780 mm)

Length 4Door Swb:

approx. 165.4 inches (4200 mm)

Length 4Door Lwb:

approx. 179.1 inches (4550 mm)

Weights

Curb Weight Std:

approx. 3500-4000 lbs (1588-1814 kg) depending on configuration

Gross Vehicle Weight Rating:

approx. 5000-5500 lbs (2268-2495 kg)

Towing Capacity:

Typically rated around 2000-3500 lbs (907-1588 kg), check specific vehicle documentation.

Wheels Tires

Wheel Bolt Pattern:

5x139.7 mm (5x5.5 inches)

Typical Tire Size:

215/75R15 or 235/75R15

🛡️ Safety Features

Ratings

Crash Test Data:

Limited official crash test data available from this era, particularly for North American markets. Primarily designed with a robust chassis.

Active Features

Braking System:

Front disc brakes, rear drum brakes. Power assist standard.

Steering System:

Power steering standard on most models.

Passive Features

Seat Belts:

Front 3-point seat belts, lap belts for rear passengers.

Body Construction:

Body-on-frame construction for durability and off-road resilience.

💡 Technology Features

Infotainment

Audio System:

Basic AM/FM radio with optional cassette player. Speakers typically limited to front doors and dashboard.

Driver Assistance

Anti-lock Braking System (ABS) was not commonly available or standard on 1983 models.

Traction Control:

Traction control systems were not available.

Connectivity

Connectivity Features:

N/A (No connectivity features like Bluetooth or USB).

Comfort Features

Air Conditioning:

Optional, but commonly found on many trims.

Power Windows Locks:

Available on higher trim levels, but manual operation was common.

🔧 Maintenance

Service Intervals

Oil Change Interval Gas:

Every 3,000-5,000 miles (4,800-8,000 km) or 3-6 months, whichever comes first.

Air Filter Replacement:

Every 15,000 miles (24,000 km) or annually.

Fuel Filter Replacement:

Every 30,000 miles (48,000 km) or 2 years.

Spark Plug Replacement Gas:

Every 30,000 miles (48,000 km).

Coolant Flush:

Every 2 years or 30,000 miles (48,000 km).

Timing Belt Replacement:

Not applicable for the 4G54 (chain-driven). Diesel engines (4D55T) would have a timing belt with intervals around 60,000-90,000 miles (96,000-145,000 km) but check manual.

Fluid Specifications

Engine Oil Capacity Gas:

Approx. 5.2 US quarts (4.9 Liters) with filter change.

Cooling System Capacity:

Approx. 7.4 US quarts (7.0 Liters) for 2.6L engine.

Brake Fluid Type:

DOT 3 or DOT 4

Known Issues

Rust Corrosion:

Common in older vehicles, particularly in areas exposed to salt or moisture. Frame, wheel wells, and lower body panels are susceptible.

Carburetor Issues Gas:

The stock two-barrel carburetor can require periodic adjustment and can be prone to wear, affecting fuel economy and performance.

4Wd System Wear:

Transfer case, hubs, and CV joints can experience wear from heavy off-road use or lack of maintenance.

Electrical Gremlins:

Aging wiring harnesses and connections can lead to intermittent electrical issues.

Diesel Glow Plugs:

Glow plug system can be a source of hard starting issues in cold weather if not maintained.

📚 Vehicle History

Brand Heritage

Mitsubishi Motors Founding:

Mitsubishi Heavy Industries shipbuilding division began producing automobiles in 1917.

Mitsubishi Motors Establishment:

Mitsubishi Motors Corporation was established in 1970.

Model Evolution

Pajero Origins:

The Montero nameplate originated from the Mitsubishi Pajero, first introduced in Japan in 1982.

North American Launch:

The Montero was introduced to the North American market in 1983 as a rebadged Mitsubishi Pajero.

First Generation Design:

Characterized by its boxy styling, optional independent front suspension (IFS) for improved on-road comfort, and robust 4WD system.

Production

Manufacturing Location:

Japan (primarily by Mitsubishi Motors and sometimes other affiliated companies).

Production Span Gen1:

1982-1991

🏆 Awards & Recognition

Recognitions

Off Road Magazine Awards:

The Pajero/Montero platform gained a reputation for ruggedness and capability, earning praise in off-road publications of the era for its performance in challenging terrain.

Ratings

Reliability Reputation:

Generally considered reliable and durable, especially with proper maintenance, though typical wear-and-tear issues for vehicles of this age apply.

Certifications

Manufacturer Quality:

Built to Mitsubishi's quality standards of the time, focusing on durability and functionality for its intended use.