Mitsubishi Montero 1983 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Year: 1983 Codes Chassis Code: L040 series 👋 Introduction Market Position Segment: Compact SUV / Off-Road Vehicle Target Audience: Enthusiasts seeking robust...

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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

👋 Introduction

Market Position

Segment:

Compact SUV / Off-Road Vehicle

Target Audience:

Enthusiasts seeking robust off-road capability and reliability, families needing versatile transportation

Competitive Analysis

Key Competitors:

Jeep Cherokee (XJ), Toyota 4Runner, Nissan Pathfinder, Ford Bronco II

Key Features

Off Road Capability:

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

Versatility:

Available in short-wheelbase (2-door) and long-wheelbase (4-door) configurations, ample cargo space

Durability:

Renowned for robust construction and mechanical longevity when properly maintained

📋 Manual Details

Coverage Areas

Primary Regions Covered:

Global

Specific Markets:

North America, Europe, Australia, Asia

Page Count

Estimated Pages:

Approx. 800-1200 (typical for comprehensive workshop manuals of this era)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Internal combustion engine (gasoline and diesel variants), fuel delivery, ignition, cooling, lubrication, exhaust, engine management systems

Transmission:

Manual and automatic transmissions, transfer case, drivetrain components (driveshafts, axles, differentials)

Brakes:

Hydraulic brake system (front disc, rear drum), parking brake, ABS (if applicable to specific variants)

Suspension Steering:

Independent front suspension (torsion bar or coil spring), solid rear axle (leaf spring or coil spring), power steering system, steering linkage

Electrical:

Battery, charging system (alternator), starting system, lighting, wipers, horn, power windows, power locks, instrumentation, fuses, relays, wiring diagrams

Body Chassis:

Body panels, doors, glass, interior trim, chassis frame, mounts, body repair procedures

HVAC:

Heating, ventilation, and air conditioning (HVAC) system, components, and service

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, lubrication, inspections

Diagnostics:

Troubleshooting guides, diagnostic charts, symptom analysis, common fault identification

Repair:

Step-by-step repair instructions for all major components and systems, overhaul procedures

Disassembly Assembly:

Detailed procedures for component removal, disassembly, cleaning, inspection, repair, and reassembly

Specifications Tolerances:

Precise measurements, torque specifications, alignment procedures, diagnostic values

Technical Depth

Depth:

Comprehensive: Covers routine maintenance to major overhauls and advanced diagnostics, suitable for professional technicians and experienced DIYers

📊 Manual Specifications

File Format

File Type:

Portable Document Format (PDF)

Searchability:

Searchable text for quick information retrieval

Print Quality

Print Readability:

High-resolution scans ensuring clear text and diagrams for printing

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code Gasoline:

4G54 (2.6L SOHC I4)

Engine Code Diesel:

4D55 (2.3L SOHC I4 Turbo Diesel)

Performance Gasoline

Horsepower 4G54:

Approx. 105-116 hp @ 4500-4800 rpm (depending on variant and tuning)

Torque 4G54:

Approx. 135-145 lb-ft @ 2500-3000 rpm (depending on variant and tuning)

Performance Diesel

Horsepower 4D55:

Approx. 85-90 hp @ 4000 rpm

Torque 4D55:

Approx. 130-135 lb-ft @ 2500 rpm

Fuel System

Fuel Delivery Gasoline:

Carbureted (e.g., Mitsubishi Cyclone Twin-Barrel Carburetor)

Fuel Type Diesel:

Diesel fuel

Engine Management

Ignition System:

Electronic ignition (distributor-based)

Emission Controls:

Basic emission controls, catalytic converter (market dependent)

🔧 Transmission

Standard

Transmission Type Gasoline:

5-speed Manual Transmission

Optional

Transmission Type Automatic:

4-speed Automatic Transmission

Features

Transfer Case:

Part-time, 2-speed transfer case with manual front hub engagement (4H, 4L, 2H)

Fluid Specifications

Manual Transmission Fluid:

API GL-4, SAE 75W-90 or 80W-90 gear oil

Automatic Transmission Fluid:

Dexron III/Mercon or equivalent (check manual for exact spec)

Fluid Capacities

Transfer Case Capacity:

Approx. 1.5-2.0 liters

📐 Dimensions

Exterior Swb

Length Swb:

Approx. 4235 mm (166.7 in)

Width Swb:

Approx. 1695 mm (66.7 in)

Height Swb:

Approx. 1870 mm (73.6 in)

Exterior Lwb

Length Lwb:

Approx. 4680 mm (184.3 in)

Width Lwb:

Approx. 1695 mm (66.7 in)

Height Lwb:

Approx. 1880 mm (74.0 in)

Wheelbase

Wheelbase Swb:

Approx. 2450 mm (96.5 in)

Wheelbase Lwb:

Approx. 2715 mm (106.9 in)

Weights

Curb Weight:

Approx. 1750-1950 kg (3850-4300 lbs), varies by configuration

Gross Vehicle Weight Rating:

Approx. 2400-2600 kg (5290-5730 lbs)

Tires Wheels

Tire Size Standard:

215/80R15, 235/75R15 (common options)

Wheel Bolt Pattern:

6 x 139.7 mm (6 on 5.5 inch)

Wheel Offset:

ET 0 to +10 (typical)

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (No standardized crash test ratings like NHTSA/Euro NCAP for this era in many markets)

Active Features

Braking System:

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

Passive Features

Seat Belts:

Front and rear seat belts

Airbags:

No airbags

Rollover Protection:

Reinforced chassis and body structure

💡 Technology Features

Infotainment

Audio System:

AM/FM radio with cassette player (optional)

Display:

Analog gauges and warning lights

Driver Assistance

Cruise Control:

Optional on some higher trim levels

🔧 Maintenance

Service Intervals

Oil Change Interval:

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

Air Filter Replacement:

Every 15,000-20,000 miles (24,000-32,000 km) or 12 months

Spark Plug Replacement Gasoline:

Every 30,000-40,000 miles (48,000-64,000 km)

Fuel Filter Replacement:

Every 20,000-30,000 miles (32,000-48,000 km)

Fluid Specifications

Engine Oil Type Gasoline:

API SG or SH, SAE 10W-30 or 10W-40

Engine Oil Type Diesel:

API CD or CE, SAE 15W-40 Diesel Engine Oil

Coolant Type:

Ethylene Glycol based, 50/50 mix with distilled water

Brake Fluid Type:

DOT 3

Known Issues

Engine 4G54:

Carburetor issues (tuning, wear), oil leaks, timing belt wear

Diesel 4D55:

Glow plug issues, turbocharger wear (early models), fuel injection system maintenance

Chassis Corrosion:

Rust can be an issue in certain climates, particularly frame and body mounts

Suspension:

Wear in bushings, ball joints, and tie rod ends; potential for torsion bar fatigue (front suspension)

Electrical:

Age-related deterioration of wiring harnesses, alternator and starter issues

Torque Specs

Wheel Lug Nuts:

Approx. 80-100 ft-lbs (108-136 Nm)

📚 Vehicle History

Brand Heritage

Parent Company:

Mitsubishi Motors Corporation

Motorsport Connection:

Developed from Pajero lineage, successful in Paris-Dakar Rally

Model Evolution

First Generation Start:

1982 (Japan), known as Pajero

Name Introduction:

Introduced as Montero in export markets, including North America

Chassis Design:

Body-on-frame, based on the first-generation Pajero

Production

Production Start Year:

Manufacturing Locations:

Japan (Okazaki Plant)

🏆 Awards & Recognition

Recognitions

Off Road Awards:

Often cited for excellent off-road capability and value in its class.

Ratings

Reliability Reputation:

Generally considered reliable with proper maintenance, with a strong enthusiast following.