fuel MITSUBISHI MONTERO 1989 1.G Workshop Manual

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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
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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

16 Treatment Before I INTRODUCTION AND MASTERTROUBLESHOOTING - AftertheFordingofaStream
INSPECTION AND SERVICE AFTER FORDING A
STREAM
After fording a stream, check the following points. If abnormal
condition is evident, clean, replace or lubricate.
= Check for water. mud. sand. etc. in the rear brake drum.
clutch housing, &tarte; mot&, brake pipe and fuel pipe:
Check for water in the fluid or oil inside the front
differential. rear differential, transmission and transfer
case.
Apply grease to the lubricating points of the front suspen-
sion, steering linkage and propeller shaft.
Check all boots and breather hoses for cracks and
damage.
rTSB Revi

INTRODUCTION AND MASTERTROUBLESHOOTING - GeneralDataandSpecmcations 21
L042G L141G
TNSL FM TNJL F/H
TRJL F/H TRUL F/H
Engine
Model No. G54B 6672 6672 6672
Type In-line OHC V-type, OHC V-type, OHC
V-type, OHC
Number of cylinders 4 6 6 6
Bore 91.1 mm(3.59in.j 91.1 mm(3.59in.j 91.1 mm(3.59in.) 91.1 mm(3.59in.
Stroke 98.0 mm (3.86 in.) 76.0 mm (2.99 in.) 76.0 mm (2.99 in.) 76.0 mm (2.99 in.
Piston displacement 2,555 cm3 2,972 cm3 2,972 cm3 2,972 cm3
(155.9 cuin.) (181.4cu.in.) (181.4cu.in.) (181.4 cuin.)
Compression ratio 8.7 8.9 8.9 8.9
Firing order 1-3-4-2 1-2-3-4-5-6 I -2-345-5 1-2-3-4.5-8
Basic ignition timing 7”BTDC 22” 5”BTDC 22” 5”BTDC i 2” 5”BTDC +-2”
Transmission &transfer case
Model No. KM145 V5MTl KM148 KM148
Type S-speed manual 5-speed manual &peed automatic &peed automatic
Gear ratio
Transmission 1st 3.967 3.918 2.826 2.826
2nd 2.136 2.261 1.493 1.493
3rd 1.360 1.395 1 .ooo 1.000
4th 1 .ooo 1.000 0.688 0.688
5th 0.856 0.829 -
Reverse 3.587 3.925 2.703 2.703
Transfer case High 1 .ooo 1 .ooo 1 .ooo 1 .ooo
Low 1.944 1.925 1.925 1.925
Final ring ratio gear 4.625 4.625 4.625 4.625
Clutch
Type Dry single disc & Dry single disc & -
diaphragm spring diaphragm spring
Chassis
Tire size
Front suspension
Type
Rear suspension
Type
Brakes
Type Front
Rear P225ff 5Rl5 P235ff5Rl5
independent Independent double-wishbone
double-wishbone
Rigid axle Rigid axle
Disc Disc
Drum Drum (Leading and trailing)
(Leading and trailing)
Power steering
Gear type
Gear ratio
Fuel tank capacity Integral type Integral type (Recirculating ball nut)
(Recirculating ball nut)
16.4 16.4
liters (gals.) 60 (15.9) 75 (19.8)
[ TSB Revision

INTRODUCTION AND MASTER TROUBLESHOOTING - General Dataand Swxifications 23
Transmission &transfer case
Model No.
Type
Gear ratio
Transmission 1 St
2nd
3rd
4th
5th
Reverse
Transfer case High
Low
Final ring gear ratio
Elutch
Type
Chassis
Tire size
Front suspension
Type
Rear suspension
Type
Brakes
Type Front
Rear
Power steering
Gear type
Gear ratio
Fuel tank capacity liter (gal.) VMNJL F/H VMRJL F/H WMRUL F/H
EMT1 KM148 KM148
5-speed manual 4-speed automatic 4-speed automatic
3.918
2261
1.395
1.000
0.829
3.925
1.000
1.925
4.625 2.826 2.826
1.493 1.493
1 .ooo 1 .ooo
0.688 0.688
2.703
1 .ooo
1.925
4.625 -
2.703
1 .ooo
-1.925
4.625
Dry single disc &
diaphragm spring
P235ff 5 R 15 L146G
7
Independent doublewishbone
Rigid axle
Disc
Drum (Leading and trailing)
Integral type (Recirculating ball nut)
16.4
92 (24.3)
1 TSB Revision

INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troubleshooting 25
ENGINE WILL NOT CRANK OR CRANKS SLOWLY
Symptom
Engine will not crank or cranks
slowly Probable cause
Starting system faulty Reference
page or remedy
8-134.135
ENGINE WILL NOT START OR BE HARD TO START (CRANKS OK)
Symptom
Engine will not start or be hard to
start(Cranks OK)
ROUGH IDLE OR ENGINE STALL
Probable cause
No fuel supply to carburetor or injection system
Carburetor or injection system problems
Ignition system problems
Vacuum leaks
- Purge control valve hose
- Vacuum hoses
l intake manifold
- Air intake plenum
l Carburetor or throttle body
l EGRvalve
Compression too low Reference
page or remedy
14-34,90
14-34,90
3-147 to 149
Repair as
necessary
3-11.65
Symptom Probable cause Reference
page or remedy
Rough idle or
engine stalls Vacuum leaks
l Purge control valve hose
l Vacuum hoses
l Intake manifold
l Air intake plenum
l Carburetor or throttle body
l EGRvalve
1 Ignition system problems Repair as
necessary
8-147 to 149
Idle speed set too low 1 O-10.14-62
1~ ~ . Idle mrxture too lean or too rich 14-11
Carburetor or fuel injection system problems
Exhaust gas recirculation (EGR) system problems m-34.90
25-17.32
Engine overheats 7-4
Compression too low 9-11, 65
1 TSB Revision

‘p ? f! .., .-, _-_ ,_- ____ ____ _L(
26 INTRODUCTION AND MASTER TROUBLESHOOTlNG - Master Troubleshooting
ENGINE HESITATES OR POOR ACCELERATION
Symptom Probable cause
Engine hesitates or
poor acceleration
-I
Ignition system problem
Vacuum leaks
l Purge control valve hose
l Vacuum hoses
- intake manifold
l Air intake plenum
* Carburetor or throttle body
l EGRvalve
ENGINE DIESELING
Reference
page or remedy
8-147 to 149
Repair as
necessary
Air cleaner clogged
Fuel line clogged 113.10
1442.99
Carburetor or fuel injection system problem
Auxiliary acceleration pump faulty (cold engine)
Emission control system problem
l EGR system always on
- High-altitude compensation (HAC) system problem
Engine overheats 14-34.90
14-23
25-77.22.32
7-4
Compression too low g-II.65
I Symptom Probable cause I
Reference
page or remedy
I I I I -..
Engine dieseling (runs after
ignition switch is turned off) Carburetor problems
Incorrect ignition timing 14-34
8-14710 149
EXCESSIVE OIL CONSUMPTION
Symptom Probable cause Reference
page or remedy
Excessive oil consumption Oil leak
Positive crankcaseventilation line clogged
Valve stem seal worn or damaged
Valve stem worn
Piston ring worn or damaged Repair as
necessary
o-13
Replace
Replace
9-43
1 TSB Revision

INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troubleshooting 27
POOR FUEL MILEAGE
Symptom Probable cause Reference
page or remedy
Poor fuel mileage Fuel leak Repair as
necessary
I
1 Air cleaner clogged
1 Ignition problems 1 11-3.10 1
1 8-147to 149 1
Carburetor or fuel injection system problems 1434.90
I
Compression too low
1 g-II.65 1
Tires improperly inflated 1 22-2
I
Clutch slips
16-4 I
Brakes drag 1 5-13 I
NOISE
Probable cause Reference
page or remedy
Noise Loose bolts and nuts Retighten as
necessary
I
1 Enaine noise
I 9-11 I
HARD STEERING
Symptom
Hard steering Probable cause
Loose power steering oil pump belt
Low fluid level
Air in power steering system
Low tire pressure
Excessive turning resistance of upper or lower ball joint
Excessivelytight linkage ball joint
Improperfrontwheel alignment
Excessive turning resistance of tie-rod ball joint
No lubricantion of tie-rod
Sticky flow control valve
No lubrication of idler arm Reference
page or remedy
19-10
19-11
19-11
22-2
2-27
1937
2-13
19-38 ’
Lubricate
19-33
19-39
) TSB Revision