Service Manual
MONTERO
1987 : Volume 2
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.
WE SUPPORT
VOLUNTARY TECHNICIAN
CERTIFICATION THROUGH
MITSUBISHI MOTOR SALES OF AMERICA. Inc.
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.
I
GROUP/SECTION INDEX ‘kme-.
INTRODUCTION ..............................
Electrical ...........................................
Electrical System Parts
Location .........................................
Relays, Control Units, Sensors,
Fuses, Groundings
Inspection of Harness
Connector ......................................
Wiring Harness .............................
Charging System ..........................
Starting System ............................
Ignition System .............................
Meters and Gauges ......................
Lighting System .............................
Wiper and Washer System ..........
Horn ...............................................
Accessory ......................................
Audio System ................................
Back Door Window Defogger ......
Automatic Free-wheeling Hub
Indicator System ..........................
Heaters and Air-conditioning .........
Heaters ..........................................
Air-conditioning ............................
**, For Engine Chassis & Body refer to
0 1986 Mitsubishi Motors Corporation Printed in Japan
INTRODUCTION - Towing and Hoisting
TOWING AND HOISTING NOOGA-
This vehicle can only be towed from the front with convention-
al sling-type equipment and tow chain with grab hooks.
If a vehicle is towed from the rear, use a tow dolly.
A lumber spacer (4” x 4” x 55” wood beam) should be placed
forward of under guard and under towing hook/shipping tie
down hook.
Then, attach J-hook to the lower arm.
A safety chain system must be used. This system must be
completely independent of the primary lifting and towing
attachment. Care must be taken in the installation of safety
chains to insure they do not cause damage to bumper, painted
surfaces or lights.
LIFT!NG-GROUND CLEARANCE
Towed vehicle should be raised until wheels are a minimum of
10 cm (4 in.) from the ground. Be sure there is adequate
ground clearance at the opposite end of the vehicle, especially
when towing over rough terrain or when crossing sharp rises
such as curbs. If necessary, ground clearance can be in-
creased by removing the wheels from the lifted end of the
disabled vehicle and carrying the lifted end closer to the
ground. A 20 cm (8 in.) ground clearance must be maintained
between brake drums and ground.
FRONT TOWING PICKUP
The vehicle may be towed on its rear wheels for extended
distances, provided the parking brake is released.
Make cartain the transmission remains in “NEUTRAL”.
SAFETY PRECAUTIONS
The following precautions should be taken when towing the
vehicle.
1. Remove exhaust tips and any other optional equipment,
that interface with the towing sling. Padding (heavy shop
towel or carpeting) should be placed between the towing
sling cross bar and any painted surfaces, and bumper
surfaces.
2. A safety chain system completely independent of the
primary lifting and towing attachment must be used.
3. Any loose or protruding parts of damaged vehicle such as
hoods, doors, fenders, trim, etc., should be secured prior
to moving the vehicle.
4. Operator should refrain from going under a vehicle unless
the vehicle is adequately supported by safety stands.
5. Never allow passengers to ride in a towed vehicle.
6. State and local rules and regulations must be followed
when towing a vehicle.
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INTRODUCTION - Towing and Hoisting
HOISTING
POST TYPE
15
Special care should be taken when raising the vehicle on a
frame contact type hoist. The hoist must be equipped with the
proper adapters in order to support the vehicle at the proper
locations. (See next page)
Conventional hydraulic hoists may be used after determining
that the adapter plates will make firm contact with the side
frame.
FLOOR JACK
A regular floor jack may be used under the front crossmember
or rear axle housing.
Caution
1. A floor jack must never be used on any part of the
underbody.
2. Do not attempt to raise one entire side of the vehicle by
placing a jack midway between front and rear wheels.
This practice may result in permanent damage to the
body.
EMERGENCY JACKING
Jack receptacles are located at the No. 2 crossmember and
rear axle housing to accept the jack supplied with the vehicle
for emergency road service. Always block the opposite wheels
and jack only on a level surface.
.::
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.I
‘.
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INTRODUCTION - Geraeral Data and Specifications 17
GENERAL DATA AND SPECIFICATIONS
NOOHA-A
OOW556
Description L042G VNJ LFIH VRJLFIH
TNSLFIH TRSLF/H
Vehicle dimensions mm (in.)
Overall length
Without tire
spare 0 3,960 (155.9) 3,960 (155.9) 3,960 (155.9) 3,960 (155.9)
With tire spare 0 3,995 (157.3) 3,995 (157.3) 3,995 (157.3) 3,995 (157.3)
Overall width 0 1,680 (66.1) 1,680 (66.1) 1,680 (66.1) 1,680 (66.1)
Overall height 0 1,840 (72.4) 1,840 (72.4) 1,850 (72.8) 1,850 (72.8)
Wheelbase 0 2,350 (92.5) 2,350 (92.5) 2,350 (92.5) 2,350 (92.5)
Tread Front @ 1,400 (55.1) 1,400 (55.1) 1,400 (55.1) 1,400 (55.1)
Rear 0 1,375 (54.1) 1,375 (54.1) 1,375 (54.1) 1,375 (54.1)
Overhang Front @ 745 (29.3) 745 (29.3) 745 (29.3) 745 (29.3)
Rear @ 900 (35.4) 900 (35.4) 900 (35.4) 900 (35.4)
Height at curb weight
(wt.)
Front bumper to ground
@ 480 (18.9) 480 (18.9) 480(18.9) 480 (18.9)
Rear bumper to ground 440(17.3) 440(17.3) 440(17.3) 440(17.3)
Minimum running ground : 210 (8.3) 210 (8.3) 210 (8.3) 210 (8.3)
clearance
Angle of approach @ 38 38 38” 38
Angle of departure @ 28 28” 28 28
Ramp breakover angle
@ 21” 21” 21” 21”
Vehicle weights kg (Ibs.)
Curb weight 1,479 (3,260) 1,493 (3,290) 1,440 (3,175) 1,460 (3,219)
Gross vehicle weight rating 1,910 (4,210) I,91 0 (4,210) 1,910(4,210) I,91 0 (4.210)
Gross axle Front 1 ,I 00 (2,425) 1 ,I 00 (2,425) 1 ,I 00 (2,425) 1,100 (2,425)
weight ratin!g~:+y~ Rear 1,450 (3,197) 1,450 (3,197) 1,450 (3,197) 1,450 (3,197)
Seating,c&ac&~ 4 4 2 2
.’ .’ :I’ ;.,* ..,, VU.,
,: ‘,_. : ., ”
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18 INTRODUCTION - General Data and Specifications
Description L042G VNJLFIH VRJ L.F/H TNSLFIH TRSLFIH
1
Engine
Model No. G54B
G54B G54B G54B
Type i In-line OHC
In-line OHC In-line OHC In-line OHC
Number of cylinders ‘4 4
4 4
Bore 91 .I mm (3.59 in.) 91 .I mm (3.59 in.) 91 ,I mm (3.59 in.) 91 .I mm (3.59 in.)
Stroke 98.0 mm (3.86 in.) 98.0 mm (3.86 in.) 98.0 mm (3.86 in.) 98.0 mm (3.86 in.)
Piston displacement
2,555 cm” 2,555 cm” 2,555 cm3
2,555 cm3
(155.9 CID) (155.9 CID) (155.9 CID) (155.9 CID)
Compression ratio 8.7
8.7 8.7
8.7
Firing order
I-3-4-2 I-3-4-2 1-3-4-2
1-3-4-2
Basic ignitron trming
7” BTDC ? 2” 7” BTDC ? 2” 7” BTDC 2 2” ‘7” BTDC ? 2”
Transmission &transfer case
Model No.
KM145 KM148 KM145 KM148
Type 5-speed 4-speed 5-speed 4-speed
manual automatic manual automatic
Cear ratio
Transmjssion 1 st
3.967 2.826 3.967
2.826
2nd
2.136 1.493 2.136
1.493
3rd 1.360
1 .ooo 1.360
1.000
4th
1.000 0.688 1 .ooo
0.688
5th
0.856 - 0.856
-
Reverse 3.578
2.703 3.578
2.703
Transfer case High 1.000
1.000 1.000
1 ,040
Low 1.944
1.944 1.944
1.944
Final ring ratio
gear 4.625 4.625 4.625
4.625
Zlutch
Type Dry single
- Dry single
-
disc & disc &
diaphragm diaphragm
spring spring
Chassis
Tire size
Front suspension
P225/75R15
Type
Spring constant
(Wheel position)
Rear suspension
Type
Spring constant
At load of 1 ,OOO-2,500 N
(220-551 Ibs.)
At load of 4,670-8,870 N
(1,030-I ,955 tbs.) Wishbone compression type
22 N/mm (123 Ibs./in.)
Asymmetrical semi-elliptic leaf spring
22 N/mm (123 Ibs./in.)
50 N/mm (280 Ibs./in.)
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8-1
ELECTRICAL
CONTENTS
NOBAA-
ACCESSORY ......................................................
188
Cigarette Lighter ............................................
,190
Clock ...............................................................
,191
AUDIO SYSTEM ................................................
.192
AUTOMATIC FREE-WHEELING HUB
INDICATOR SYSTEM ........................................
208
Automatic Free-wheeling Hub
Indicator Control Unit
..................................... ,216
Pulse Generator ..............................................
215
BACK DOOR WINDOW DEFOGGER
................ .203
Defogger switch ............................................
,206
Printed Heater Lines
...................................... ,207
CHARGING SYSTEM .........................................
71
Alternator ........................................................
83
Service Adjustment Procedures
..................... 77
Battery Charging ........................................
82
Inspection of Battery ..................................
81
Output Current Test ...................................
78
Regulated Voltage Test ..............................
79
Voltage Drop Test of Alternator Output
Wire ............................................................
77
ELECTRICAL SYSTEM PARTS LOCATION
...... 2
Diode ...............................................................
5
Fusible Link and Fuse
..................................... 6
Grounding .......................................................
7
Relay and Control Unit ....................................
2
Sensor .............................................................
4
HORN ..................................................................
184
Horn Switch
.................................................... 187
IGNITION SYSTEM ............................................
105
Ignition Switch
................................................ 122
Ignition System ...............................................
1 14
Service Adjustment Procedures
.................... .l 1 1
Checking Ignition System
..........................
11 1
Checking Ignition Timing
...........................
11 1
Spark Plug Cable Test
................................
1 12
Spark Plug Test
.......................................... 1 12 INSPECTION OF HARNESS CONNECTOR ...... 9
Check for Improper Engagement of
Terminal .......................................................... 9
Continuity and Voltage Test for Connector .... 9
Engaging and Disengaging of Connector
Terminal ..........................................................
9
LIGHTING SYSTEM ........................................... 143
Column Switch
................................ .
.............. .I59
Dimmer Control Switch
................................. .I62
Hazard Warning Switch
................................. .I61
Headlight ........................................................ ,158
Service Adjustment Procedures
.................... .I57
Headlight Aiming .......................................
157
METERS AND GAUGES .................................... 123
Service Adjustment Procedures
.................... .I30
Fuel Gauge Simple Test ................................. .I31
Fuel Gauge Unit Inspection ........................... .I31
Oil Pressure Gauge Simple Test
.................... .I32
Oil Pressure Gauge Unit Simple Test
............ ,132
Speedometer Inspection
............................... .I30
Tachometer Inspection .................................. ,130
Voltage Meter Simple Test
............................ .I33
Water Temperature Gauge Simple Test
....... ..I3 1
Water Temperature Gauge Unit Inspection
. ..I3 2
STARTING SYSTEM .......................................... 91
Starter Motor ............ ....................................... 97
WIPER AND WASHER SYSTEM
....................... .163
WIRING HARNESS ............................................ 13
Centralized Junction ....................................... 69
Circuit Diagram ............................................... 34
Configuration Diagram .................................... 27
How to Read Wiring Diagrams ....................... 20
Troubleshooting .............................................. 13
8-2 ELECTRICAL SYSTEM PARTS LOCATION - Relay and Control Unit
ELECTRICAL SYSTEM IPARTS LOCATION NOIBAB-A
RELAY AND CONTROL UNIT
16W722
n 17
hub indicator control unit A A Automatic free-wheeling 2
Blower
assembiy& x v/i 16W152B Items Symbol
--
Air conditioner relay D
--
Auto choke relay G
--
Automatic free-wheeling hub indicator control
A
unit
Condenser blower motor relay H
Feed back carburetor control unit C
Hazard warning flasher unit F
Headlight washer relay F
Heater relay E
Intermittent wiper relay F
~___
Light control relay I
~___
Over drive relay F
Power window relay F
Seat belt warning timer B
Turn-signal flasher unit F
carburetor
control unit
Air conditioner relay
d--- I- Jr Evaporator E
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8-32 WIRING HARNESS - Instrument Panel
3 INSTRUMENT PANEL
Connector symbol
C
C-65 c-04
C-06
C-64
C-63
C-61
CL57 C-b6 C!55 d54 c!5
Remarks
For information concerning the ground points (example:
q ),
refer to P.8-7.
C-01 Back door lock switch
C-02 Defogger switch
C-03 Kev reminder and seat belt
warning buzzer
c-04
pi;’ Combination meter
C-08 Diode
C-09 Rear wiper and washer switch
r&~}Oil pressure gauge
C-12 f;hybination gauge illumination
C-l 3 Blower switch
C-14 Combination gauge wiring
harness and front wiring harness
combination
C-15 F;hybination gauge illumination
C,::F}Voltage meter C-l 8 Heater relay
C-l 9 Air conditioner wiring harness
and front wiring harness
combination
E:$)}Air conditioner relay C-31 Blower motor resistor
C-32 Dedicated fuse (Air conditioner
circuit)
C-33 Air conditioner switch
C-34 yl;Jer control lonob illumination
$:;;I Thermostat
$:;;I Feed back carburetor control unit
C-26 Front speaker (R.H.)
C-27 Front wiring harness and roof
wiring harness combination
C-28 Automatic free-wheeling hub
indicator control unit
C-29 Seat belt warning timer
C-30 Front wiring harness and door
wiring harness (R.H.)
combination c-35
C-36
c-37
C-38
c-39
c40
“3’ ‘. Blower switch
Clock
Heater control panel illumination
light
Ashtray illumination light
Air conditioner switch
illumination light
Front wiring harness and center
panel wiring harness
combination
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