steering 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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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

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
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14 Treatment Before I INTRODUCTION AND MASTER TROUBLESHOOTING - AftertheFotiingofastmsm
TREATMENT BEFORE/AFTER THE FORD-
ING OF A STREAM
INSPECTION AND SERVICE BEFORE FORDING
A STREAM NOW%-
Vehicles which are driven through water, or which may
possibly be driven through water, should be subjected to the
following inspections and maintenance procedures in ad-
vance.
e Seal the speedometer cable with a water-resistant grease ~_
or tape.
a Inspect the dust boots and breather hose for cracks or
damage, and replace them if cracks or damage are found.
,- . 1^. dometer cable 1
Steering joint assembly
/ 1 Drive shaft boot -\l(. ‘/ Torsion bar dust cover 1 Breath& hose==
OOW528
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Treatment Before / INTRODUCTION AND MASTER TROUBLESHOOTING - AftertheFordingofaStream I5
l Apply grease to the lubricating points of the front suspen-
sion, steering linkage and propeller shaft.
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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.
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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)
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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)
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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
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INTRODUCTION MASTER TROUBLESHOOTING - Master Troubleshootha
POOR RETURN OF STEERING WHEEL TO CENTER
Symptom Probable cause Reference
page or remedy
Poor return of steering
wheel to center improper front wheel alignment 2-13
Improper tire pressure 22-2
Damaged front wheel bearing 2-21
POOR RIDING
Probable cause Reference
page or remedy
Poor riding Impropertire pressure
lmbalanced wheels 22-2
22-4
1 Improper front or rear wheel alignment 1 2-13.17-3.6
1 Malfunctioning shock absorber 1 2-27,174.a
1 Broken or worn stabilizer
1 Broken or worn torsion bar spring j 2-36
I
Loose suspension securing bolt(s) Retighten
I
1 Worn lower arm bushing / 231
I
ABNORMAL TIRE WEAR
Symptom Probable cause Reference
page or remedy
Abnormal tire wear Improper front or rear wheel alignment 2-l 3,17-3.6
Improper tire pressure 22-2
lmbalanced wheels 22-4
Loose wheel bearings 2-19
Malfunctioning shock absorber 2-27. 174.8
ROAD WANDER
Symptom Probable cause Reference
page or remedy
Road wander z Improper front or rear wheel alignment 2-13. 17-3,6
Excessive play of steering wheel 19-6
Poor turning resistance of upper ball joint ~ 2-27
Improper tire pressure 22-2
/ Loose or worn lower arm or upper arm bushing 2-28.31
Loose or worn wheel bearinas
I
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I 2-19
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INTRODUCTION AND MASTER TROUBLESHOOTING - Master Troubleshootina 29
VEHICLE PULLS TO ONE SIDE
Symptom
Vehicle pulls to one side Probable cause
Improper front or rear wheel alignment
lmbalanced or worn tires
Uneven tire pressure
Excessive turning resistance of upper ball joint
Wheel bearing seizure
Broken or worn torsion bar spring
Bend front axle drive shaft
Deformed lowerarm Reference
page or remedy
2-l 3.17-3.6
/ 224
22-2
2-27
2-21
2-36
2-40
230
STEERING WHEEL SHIMMY
Symptom Probable cause Reference
page or remedy
Steering wheel shimmy Improper front or rear wheel alignment 1 2-13,17-3,6 1
Improper tire pressure 1 22-2
I
Imbalanced wheels Repair
I
1 Poorturning resistance of upper ball joint
Excessive play of steering wheel 1 2-27
I
19%
I
Broken or weak stabilizer 1 2-39
I
Worn lower arm or upper arm bushing I 2-28.31 1
Malfunctioning shock absorber I 2-27
I
/ Broken or weak torsion bar spring or, leaf spring or coil spring / 2-36,17-4,9
Wear, play, or seizure of wheel bearing 2-19
BOTTOMING
Symptom Probable cause Reference
page or remedy
Bottoming Overloaded vehicle Correct
Broken or weak torsion bar spring, leaf spring or coil spring 236.1749
1 Malfunctionina shock absorber 1 2-27,174 8 1
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