MITSUBISHI MONTERO 1989 1.G Workshop Manual

x
Service Manual
MONTCRO
GROUP INDEX NrJDAA-A
Introduction and
Master Troubleshooting ......*....*...*..
Lubrication and Maintenance . . . . . . . . .
m.
1989 : Volume 1
FOREWORD
This Service Manual has been prepared with the
latest service information available at the time of
publication. It is subdivided into various group
categories and each section contains diagnosis,
disassembly, repair, and installation procedures
along with complete specifications and tightening
references. Use of this manual will aid in properly
performing any servicing necessary to maintain or
restore the high levels of performance and reliability
designed into these outstanding vehicles.
4liP A
.
n
WESUPPORT
VOLUNTARY TECHNICIAN
CE,TT,flCA~ONMROUGH
MITSUBISHI MOlUR SALES OF AMERICR Inr
Mitsubishi Motors corporation reserves the right to make changes in
design or to make additions to or improvements in its products without
imposing any obligations upon itself to install them on its products
previously manufactured.
Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . y
Rear Axle *.......*.......*................a.....*..
m
Service
Srakes- Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &
Clutch ................................................
Hi
Cooling .............................................
w
Engine ............................................... m
Intake and Exhaust ,.......*..........*......
ml
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mE
Propeller Shaft and Universal
Joint . . . . . . . . m;
Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mt
Power Steering . . . . ..a*........................
m
Transmission - fity$tic . . . . . . . . . . . . . &!a
Wheels and Tires .............................
FP
Body .................................................. m
Heater and Air Conditioning ........... p!’
Emission Control Systems .............. &!!!!
NOTE
For Electrical refer to .._
Volume-2 “Electrical”
Q 198’8 Mitsubishi Motors Corporation Printed in Japan

~~~~ -~-L -.._i._--
--em._. -
2
~!
INTRODUCTION AND MASTER TROUBLESHOOTING - How To Use This Manual
E-m+
HOW TO USE THIS MANUAL
gg$I!
NWS&Wl g-
LIMIT g&i-
s : CONTENTS
Shows the standard for judging the quality of a part
or assembly on inspection and means the maxi- g ’
mum or minimum value within which the part or
ar-=
assembly must be-kept functionally or in strength. s
m.
It is a value established outside the range of
E-
standard value. z The preceding page contains the GROUP INDEX
which lists the group title and group number.
PAGE NUMBERS
All page numbers consist of two sets of digits
separated by a dash. The digits preceding the dash
identify the number of the group. The digits follow-
ing the dash represent the consecutive page
number within the group. The page numbers can
be found on the top left or right of each page.
TEXT
Unless otherwise specified, each service procedure
covers all models. Procedures covering specific
models are identified by the model codes, or similar
designation (engine type, transmission type, etc.).
A description of these designations is covered in
this unit under “VEHICLE IDENTIFICATION”.
TROUBLESHOOTING
Troubleshootings are classified into master trouble-
shooting and group troubleshooting and located as
follows:
The master troubleshooting is prepared when the
trouble symptom relates to two or more groups and
given in MASTER TROUBLESHOOTING.
The group troubleshooting guide is prepared for
causes of problems related to that individual group
only; a troubleshooting guide is prepared for each
appropriate group.
SERVICE PROCEDURES
The sewice steps are arranged in numerical order
and attentions to be paid in performing vehicle ser-
vice are described in detail in SERVICE POINTS.
DEFINITION OF TERMS
STANDARD VALUE
indicates the value used as the standard for judging
the quality of a part or assembly on inspection or the
value to which the part or assembly is corrected and
adjusted. It is given by tolerance.
incidental operation
rformed before re-
Removal steps : The numbers before part names b
correspond to numbers in the il-
lustration and indicate the order of
removal.
Disassemblv steos : The numbers before oat-t
I ---I-- names co&pond to num6&
in the illustration, and indicate
the order of’disassembly.
Installation steps : This is provided if installation
cannot be made in the reverse
order of “Removal steps”; omit-
ted if installation in the reverse
order of “Removal steps” is
possible.
Reassembly steps : This is provided if reassembly
cannot be made in the reverse
order of “Disassembly steps”:
omitted if reassembly in the
reverse order
The following abbreviations are used in this manual for classification of model types.
M/T : Indicates the manual transmission, or models equipped with the manual transmission.
A/T : Indicates the automatic transmission, or models equipped with the automatic transmission.
F.B.C. : Indicates the feed back carburetor, or engines equipped with the feed back carburetor.
M.P.I. : Indicates the multi-point injection, or engines equipped witkthe multi-point injection.
2.6 L Engine : Indicates the 2.6 liters (155.9 cuin.) engine, or a model equipped with such an engine.
3.0 L Engine : Indicates the 3.0 liters (181.4 cu.in.) engine, or a model equipped with such an engine.

INTRODUCTION AND MASTER TROUBLESHOOTING - How To Use This Manual
3
Page number
Group title Section title
7-io t COOLING - Thedostat
vrra-r I
THERML . -.
REMOVAL AND INSTALLATlON
I Indicates tightening
torque
Repair kit or set parts are
shown. fOnlv verv freouentlv
-
1. Connection of enginecoolant temperature
syitch connector (Vehicles with an air condition-
3. Water outlet fitting
4. Water outlet fitting gasket
+ee 5 Thermostat
I This number corresponds to
the number in “Removal
steps”, “Disassembly
steps”, “Installation steps”
or “Reassembly steps”.
L
SERVICE POINTS OF INSTALLATION-
S. INSTALIATION OF THERMOSTAT
Install the thermostat to the intake manifold as illustrated.
caution
The thermostat Range tits over
the manifold seat;
ensure that the thermostat is not installed at an angle.
An explanation of procedures, notes, etc.
regarding removal, installation. disassembly
and reassembly.

,, i
- ./a .*, ,., L
4 INTRODUCTION AND MASTER TROUBLESHOOTING -Vehicle Identification
VEHICLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER LOCATIONm..
The vehicle identification number (V.I.N.) is located on a plate
attached to the left top side of the instrument panel. --
VEHICLE IDENTIFICATION CODE CHART PLATE
All vehicle identification numbers contain 17 digits. The ve!h%
number is a code which tells country, make, vehicle type, etc.
I-
--
-
-.
6th
digit
Price
class
4-
High
5-
Pre-
mium
T
-
t
7th
digit 8th
digit 9th / 10th 11th 12th thru
digit digit digit 17th digit 3rd
digit
Vehicle
type
4
Multi-
purpose
vehicle
(MW
7-
Truck Body 1 Engine 1 zi$c” / Efe’ Plant Serial
number
J- 000001
I--
Nagoya to
-3 999999
3- cu.in.1 3
3-door S-
metal- 3.0liters
topor (181.4
van cuin.)
9 Ibs. and
with
hydraulic
brakes
G-
5001-
6000
Ibs. and
with
hydraulic
brakes
1
X
! 1 -
NOTE
““Check digit” means a single number or letter)( used to verify the accuracy of transcription of vehicle identification
number.
( TSB Revision

INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle Identification 5
VEHICLE \DENTlFlCATlON NUMBER LIST
FEDERAL
NWCG
L
VIN (except sequence number)
JA7FJ43E
q KJ Brand Engine displacement
2.555 liters (155.9 cu.in.) Model code
L042GTNJLF
JA7FJ43S 0 KJ
JA7FJ43S 0 KJ
JA7FJ53S Cl KJ
JA4GJ41 S 17 KJ
JA4GJ41 S 0 KJ
JA4GJSlSCiKJ MITSUBISHI
MONTERO
2.972 liters (181.4 cub.) L141GTNJLF
L141 GTRJLF
L141 GTRULF
Ll46GVMNJLF
L146GVMRJLF
L146GWMRULF
CALIFORNIA (Can also be sold in Federal states.]
VIN (except sequence number)
JA7FJ43E 0 KJ Brand
Engine displacement
2.555 liters (155.9 cu.in.) Model code
L042GTNJLH
I I I
.~
JA7FJ43S
q KJ
JA7FJ43S
q KJ
JA7FJ53S 0 KJ
JA4GJ41 S 0 KJ
JA4GJ41 S
q KJ
JA4GJ51 S Cl KJ MITSUBISHI
MONTERO
2.972 liters (181.4 win.) L141 GTNJLH
L141GTRJLH
L141 GTRULH
L146GVMNJLH
Ll46GVMRJLl-l
L146GWMRULH
A MllSUBlSHl
w-B-_1
mc .---I ^ I
I -----xv2 I
VEHICLE INFORMATION CODE PLATE NN!CO.-
Vehicle information code plate is riveted on the cowl top outer
panel (2.6L Engine) or front end upper bar (3.OL Engine) in the
engine compartment.
The plate shows model code, engine model, transmission
model, and body color code.
1. MODEL L146G VMNJLF
2. ENGINE 6672
L Engine model
3. TRANS V5MTl
AXLE
-L
Transmission model
4. COLOR, TRIM H84
OPT L Monotone exterior
HlXH84X85
color code
/-T___ Exterior code --: Two-tone color code
Two-tone exterior
is shown by the exterior
mevision code followed by the two color codes.

6 INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle Identification
~3.0 L Engine>
CHASSIS NUMBER
STAMPING LOCATION
NOOCE-
The chassis number is stamped on the side of the frame near ._
the right rear wheel.
CHASSIS NUMBER CODE CHART
L141 v KJOOOOOI
I I I I
VEHICLE SAFETY CERTIFICATION LABEL NWCF
The vehicle safety certification label is attached to face of left
door pillar.
This label indicates the month and year of manufacture, Gross
Vehicle Weight Rating (G.V.W.R.), front and rear Gross Axle
Weight Rating (G.A.W.R.), and Vehicle Identification Number
(V.I.N.).
ENGINE MODEL STAMPING
Nwce-
The engine model is stamped on the right front side on the
top edge of the cylinder block (for M-liter engines). For 3.0-
liter engines, it is stamped at the right rear of the top of the
cylinder block.
These engine model numbers are as shown in the following.
Engine model
Engine displacement 1
G54B 2.555 liters (155.9 cu.iiTI
6G72 2.972 liters (181.4 cu.in.)
The engine serial number is stamped near the engine model
number, and the serial number cycles, as shown below.
_ ~-
Engine serial number Number cycling
AA0201 to YY9999 AA0201 ----3 A.49989
/ Lo ABOOOl ---+ AY9999
I
1 LmBAOOOl ---+ YY9999
__.
-..:-:-- I 1-

INTRODUCTION AND MASTER TROUBLESHOOTING - Vehicle Identification 7
BODY COLOR CODE
Exterior code
Wonotone
C46
H84
R82
s55
T86
wo9
R48
x15
rwo-tone
Cl XC46X85
H 1 XH84X85
R2XR82X85
Sl XS55X85
T6HT86H84
W6XWO9X85
X2HX15H84
A) : Metallic paint Body color
Brown(M)
Silver(M)
Red
Beige(M)
Blue(M)
White
Red (M)
Black
Brown(M)/
Black
Silver(M)/
Black
Redl
Black
Beige (MM
Black
Blue(M)/
Silver(M)
White/
Black
Black/
Silver(M)
r
Tss Revision

A IV
~_-_ .L.
sYa-r*au.rd.. ._,a-- A _-
8 INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions Before Service
PRECAUTIONS BEFORE SERVICE
PROTECTING THE VEHICLE
WmoAAK
If there is a likelihood of damaging painted or interior parts
during service operations, protect them with suitable covers
(such as seat covers. fender covers, etc.).
REMOVAL AND DISASSEMBLY
When checking a malfunction. find the cause of the problem.
If it is determined that removal and/or disassembly is neces-
s&y, perform the work by following the procedures contained
in this Workshop Manual.
If punch marks or mating marks are made to avoid error in
assembly and facilitate the assembly work, be sure to make
them in locations which will have no detrimental effect on
performance and/or appearances.
If an area having many parts, similar parts, and/or parts which
are symmetrical right and left is disassembled, be sure to
arrange the parts so that they do not become mixed during the
assembly process.
I. Arrange the parts removed in the proper order.
2. Determine which parts are to be reused and which are to
be replaced.
3. If bolts, nuts, etc., are to be replaced, be sure to use only
the exact size specified.
SPECIAL TOOLS
If other tools are substituted for the special tools to do service
or repair work, there is the danger that vehicle parts might be
damaged, or the mechanic might be injured; therefore, be
sure to use the special tool whenever doing any work for
which the use of one is specified.
PARTS TO BE REPLACED
If any of the following parts are removed, they must be
replaced with new parts.
I. Oil seals
2. Gaskets (except rocker cover gasket)
3. Packings
4. O-rings
5. Lock washers
6. Cotter pins
7. Self-locking nuts

INTRODUCTION AND MASTER TROUBLESHOOTING - Precautions Before Service 9
nm (in.)
smo59
PARTS
When replacing parts, use MITSUBISHI genuine parts
VEHICLE WASHING
If high-pressure car-washing equipment or steam car-washing
equipment is used to wash the vehicle, be sure to maintain the
spray nozzle at a distance of at least 300 mm (11.8 in.) from
any plastic parts and all opening parts (doors, luggage
compartment, etc.).
SERVICING ELECTRICAL SYSTEM
1. Note the following before proceeding with work on the
electrical system.
Note that the following must never be done:
Unauthorized modifications of any electrical device or
wiring, because such modifications might lead to a vehicle
malfunction, over-capacity or short-circuit that could result
in a fire in the vehicle.
2. When servicing the electrical system, disconnect the
negative cable terminal from the battery.
Caution
1. Before connecting or disconnecting the negative
cable, be sure to turn off the ignition switch and the
fighting switch.
(If this is not done, there is the possibility of
semiconductor parts being damaged.)
2. After completion of the work steps [when the
battery’s negative (-) terminal is connected], warm
up the engine and allow it to idle for approximately
five minutes under the conditions described below,
in order to stabilize engine control conditions, and
then check to be sure that the idling is satisfactory.
For 3.OL Engine models: If the engine rpm is high,
switch OFF the ignition switch, and then, after
switching it ON again, let the engine idle for 2 or 3
minutes.
This will cause the engine rpm to decrease about
100 rpm, so repeat this procedure until the pre-
scribed idling speed is reached.
Engine coolant temperature : 85”-95°C (‘l85403”F)
Lights, accessories : OFF
Transmission : neutral position
(Automatic transmission models: “IV or “P”J
Steering wheel : neutral (center) position
1 TSB Revision

10 INTRODUCTION AND MASTER TROUBLESHOOTiNG - Precautions Before Service
F1617
WIRING HARNESSES
1. Secure the wiring harnesses by using clamps. However,
for any harness which passes to the engine or other
vibrating parts of the vehicle, allow some slack within a
range that does not allow the engine vibrations to cause
the harness to come into contact with any of the
surrounding parts.
Then secure the harness by using a clamp.
In addition, if a mounting indication mark (yellow tape) is
on a harness, secure the indication mark in the specified
location.
2. If any section of a wiring harness contacts the edge of a
part, or a corner, wrap the section of the harness with tape
or something similar in order to protect it from damage.
3. When disconnecting a connector, be sure to pull only the
connector, not the harness.
4. Disconnect connectors which have catches by pressing in
the direction
indicated by the arrows in the illustration.