1984 MITSUBISHI MONTERO service

. . c-, :
Service Manual
MONTERO
1984
FOREWORD
This Sk-vice Manual has been prepared with the latest
service information available at the time of publi-
cation. It is subdivided into various group categories
-and each section contains diagnosis, disassembly,
repair, and installation procedures along with com-
plete 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.
WE SUPPORT l VOLUNTARY TECHNICIAN
CERTIFICATION
THROUGH
.&tsubishi Motors Corporation reserves the right to make changes in
Zesign or to make additions to or improvements in its products without
mposing any obligations upon itself to install them on its products
.reviously manufactured. Introduction . , . .,......,..........
0 Lubrication and Maintenance . . . . . . . . .
2
3
5
6 Front Suspension ..................
RearAxle:. ......................
Brakes - Service and Parking .........
Clutch ..........................
7
8 Cooling ...........................
Electrical System ..................
9
11 Engine ...........................
Exhaust System .....................
13 Body and Frame Alignment . . . . . . . . . .
14 Fuel System . , . . . . . . . . . . .,. . . . . . . . .
16 Propeller Shaft and Universal Joints . . .,.
17 Rear Suspension . . . . . . . . . . . . . . . . . . .
19 Steering - Power . . . . . . . . . . . . . . ., . . .
21 Manual
Transmission - Automatic .,........
22 Wheels and Tires. . . , . . . , , . . . . . . . . . .
23 Body and Sheet Metal , . . . . . . . . . . . . .
24 Heaters and Air-conditioning . . . . . . . . .
25 Emission Control Systems . . . . . . . . . . .
GROUP INDEX Alphabetical Index
0 1983 Mitsubishi Motors Corporation Printed in Japan

INTRODUCTION ..
i Section
title
I
: VICE-DRIVE SHAFT
i
This publication contains the
essential removal,
I
installation, adjustment and maintenance procedures
for servicing all Body Styles. This information is cur-
rent as of time of publication.
I
INDEX
i
The preceding page contains a table of contents
which lists the group number, group title /and symbol
of each group. The symbol is also located at the left
or right top of each page.
1
GROUP INDEX
I
The first page in each group has an index to the sub-
jects included in that group.
I.
PAGE NUMBERS
i
All page numbers consist of two sets of digits sepa-
rated by a dash. The digits preceding the dash identi-
fy the number of the group. The digits/following the
dash represent the consecutive page number :within
the group. The page numbers can be found on the
lower left or right of each page.
1
I
TEXT
i
1. This manual contains essential procedures for
removal, disassembly, inspection, reassembly and
installation. For reassembly a& installation,
L reverse the order of disassembli and removal
procedures respectively, paying attention to the
key points.
ILLUSTRATIONS 1
illustration is given in (
pertinent text for reference.
Symbol
I . 2-47 I
I G---J
Page
number
DEijINITION OF TERMS
Standard Dimensions or Values .
Design dimensions or values or finished dimensions
after adjustment of part.
Service Limit
The allowable limitation’of wear, bends, deformation
or other damage which restricts the use of parts due
to poor performance or insufficient strength.
I
Repair Limit
The limitation of wear, deterioration or functional
decline of parts at which correction or adjustment is I
required to maintain their performance in use.
1
SPECIAL TOOLS
Some of the special tools which appear in this
Manual I
are either not available in the United States, or have
,
been modified or replaced. If the tool pictured on 1
the “Special Tools” page at the beginning of each
section has an “*“, it has been modified or replaced.
i
Refer to the Mitsubishi Motors special tool catalog, i
MSSP-3ETC, check the numerical index and refer !
to the indicated page number for illustration, de- I
scription and application. If it is not listed in the
numerical ‘index,, :I
refer to the replacemen t/inter- ,
change list for an illustration and description of:
the new tool.
If the pictured tool has a “D”, it has been deleted, ;
and is not available in the U.S.-
i
, .’
i

PRECAUTIONS BEFORE SERVICE
m i
PROTECTING THE VEHICLE
If there is a likelihood of damaging painted or interior parts
during service operations, protect them with suitable covers
(such as seat 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-
sary, perform the work by following the procedures con-
tained in this Service 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.
1. 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 serv-
ice 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,
OOY 584
Q ? 0
0
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OOY 58:
YOO192 FOOO17

u ; I
PRECAl/TlONS BEFOFE SERVICE
PARTS TO BE REPLACED I I
If any of the following parts are removed, they must be re-i
placed with new parts.
1. Oil seals
2. Gaskets
3. Packings
4. O-rings
5. Lock washers
6. Cotter pins
7. Self-locking nuts
0
2
Q’
0
0
0
PARTS
.i genuin When replacing parts, use Mitsubish
VEHICLE WASHING
If high-pressure car-washing equipment or I
equipment is used to wash the vehicle, be
the spray nozzle at a distance of at least 3
from any plastic parts and all opfning par
compartment, sunroof, etc.).
SERVICING THE ELECTRICAL SYSTEM
When servicing the electrical system, discor
cab!e terminal from the battery.
Cautibn
Before connecting or disconnecting the I
sure to turn off the ignition’ switch and tl
(If this is not done, there is the possibility 1
parts being-damaged.) :
8
;te
: Is1
00
th jarts.
I
am &r-washing
Ire to maintain1
mm 1(11.8 in.>’
(doors, luggagk
ect the negativ
e:
:ativei cable, b
lighting switch
semi-conducta /
-3
D0051:
mm (in.)
SOOO5~

PRECAUTIONS BEFORE SERVICE
WIRING HARNESES
1. Secure the wiring harnesses by using clamps so that there
is no slack. 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 vibra-
tions 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 speci-
fied location. (C 1638 1)
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 using a circuit tester to perform continuity or volt-
age checks on connector terminals, insert the test probe
from the harness side.
If the connector is a sealed connector, insert the test
probe into the hole in the rubber cap for the electrical
wires, being careful not to damage the wire insulation.
Continue to insert the test probe until it makes contact
with the terminal.
4. When disconnecting a connector, be sure to pull only the
connector, not the harness.
F1617
Sealed connector
I 16YQ52 16YQ5
Correct
I Incorrect 1

n ;
I
PRECfiUTIONS BEFORE SERVICE
I
5. Disconnect connectors which have c
the direction indicated by the arrows
6. Connect connectors which have catcl
connectors until they snap. :hes by pressing in
the illustration.
les
ELECTRICAL COMPCiNENTS
1. When installing any of the vehicle part
pinch or damage any of the wiring han ; by inserting the
be careful no1
sses.
10
I
Cl6384
Y1634:
Cl6382

. . .
PRECAUTIONS BEFORE SERVICE
2. Sensors, relays, etc., are sensitive to strong impacts.
Handle them with care so that they are not dropped or,
mishandled.
3. The electronic parts used for relays, etc., are sensitive to
heat. If any service which causes a temperature of 80°C
(176’F) or more is performed, remove the part or parts
in question before carrying out the service,
FUSES AND FUSIBLE LINKS
1. If a blown-out fuse is to be replaced, be sure to use only
a fuse of the specified capacity. If a fuse of a capacity
larger than that specified is used, parts may be damaged
and the circuit may not be protected adequately.
2. If additional optional equipment is to be installed in the
vehicle, follow the procedure listed in the appropriate
instruction manual; however, be sure to pay careful
attention to the following points:
(1) In order to avoid overloading the wiring, take the
electrical current load of the optional equipment into
consideration, and determine the appropriate wire
size.
(2) Where possible, route the wiring through the existing
harnesses.
(3) If an ammeter or similar instrument is to be con-
nected to a live-wire circuit, use tape to protect the
wire, use. a clamp to secure the wire, and make sure
that there is no contact with any other parts.
(4) Be sure to provide a fuse for the load circuit of the
optional equipment.
OOY 58E
15A .
OOY 582
Nominal
size
0.3 mm2
0.5 mm2
0.85 mm2
1.25 mm2 2.0
mm2 3.0
mm2
5.0 mm2 SAE
gauge
No.
AWG 22
AWG 20
AWG 18
AWG 16
AWG 14
AWG 12
AWG 10
Permissible current
In engine
compartment
-
7A
9A
12A
16A
21A
31A Other areas
SA
13A
17A
22A
30A
40A
54A 11

I I
I PRECljUTlONS BEFORE SERVICE
1
I
TUBES AND OTHER RUBBER PARTS
Be careful to avoid spilling any gasoline, oil, etc., because if it
adheres to any tubes or other rubber parts, they might be ad-
versely affected.
LUBRICANTS
In accordance with the instructions in this Service Manual
apply the specified lubricants in the specified locations dur:
ing assembly and installation.
.
BRAKE FLUID
Be careful to avoid spilling any brake flui
.q, because if it ;
heres to the vehicle body, the paint coat n Ii{ $it be discolor-
DOING SERVICE WORK IN GROUPS C
MECHANICS
If the service work is to be done by two
working together, all the; mechanics inv
safety into consideration while they work. .TWO OR MO1
more mechan
ved should ta
12 ad
et
OOY 58f
F 00028