1989 MITSUBISHI MONTERO manual transmission

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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
.
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

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2
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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 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