Mitsubishi Montero 1987 Manuel utilisateur

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.

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

- How To Use This Manual

HOW TO USE THIS MANUAL

NOOBAAK

CONTENTS

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”.

SERVICE PROCEDURES

The service 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.

LIMIT

Shows the standard for judging the quality of a part

or assembly on inspection and means the maximum

or minimum value within which the part or assembly

must be kept functionally or in strength. It is a value

established outside the range of standard value.

Installation steps

Indicates incidental operation

piiiKL=l-

Removal steps : The numbers before part names

correspond to numbers in the il-

lustration and indicate the order of

removal.

Disassembly steps : The numbers before part

names correspond to numbers

in the illustration, and indicate

the order of disassembly.

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 : Ihis IS provided It reassembly

cannot be made in the reverse

order of “Disassembly steps”;

omitted if reassembly in the

reverse order of “Disassembly

steps” is possible.

Classification of

SERVICE ROINTS

Oe : Removal

** : Installation

Oe : Disassembly

I)+ : Reassembly

INTRODUCTION -

How To Use This Manual

-L

Page number Group title Section title

THERMOSTAT

REMOVAL AND INSTALLATION I

I I

1 torque

Removal +

I s

0480031

Thermostat kit

Repair kit or set parts are

1. Connectw of water temperature switch

connector (Vehicles with an air condltlon-

eri

2 Connection of radiator upper hose

3 Water outlet fitting

4 Water outlet fitting gasket

B~C 5. Thermostat

This number corresponds to

the number in “Removal

steps”, ” Disassembly

steps”, “Installation steps”

or “Reassembly steps”.

NOTE

(1)

(3)

Nowreusable parts -r

Reverse the removal procedures to reinstall

12) l * : Refer to “Sewce Points of Installation”

SERVICE POINTS OF lNSTALLATlON--

45. INSTALLATION OF THERMOSTAT

Install the thermostat to the Intake manifold as illustrated.

Caution

The thermostat flange fits over the manifold seat;

ensure that the thermostat is not installed at an angle.

An explanation of procedures, notes, etc.

(and reassembly. ’ ’ -1

regarding removal installation disassembly

INTRODUCTION -

Vehicle

Identification

VEHlCLE IDENTIFICATION

“&LE IDENTIFICATION NUMBER LOCATIOyo(lcAmm

The vehicle identification number (V.I.N.) is located on a plate

attached to the left top side of the instrument panel.

VEHICLE lDENTlFlCATlON CODE CHART PLATEo,,.,

All vehicle identification numbers contain 17 digits. The vehicle

number is a code which tells country, make, vehicle type, etc.

Country Make

J- A-

Japan Mitsu-

bishi

Vehicle

type Line

4- F-

J-

Multi-

4001

Ibs. MON-

purpose or more TERO

vehicle with

(MPW hydraulic

brakes

7-Truck

6th

digit

Price

class

Low

High

7th 8th 9th 10th

digit digit digit digit

Body Engine Check Model

digit year

E- 0 H-

3-door 2.6 liters 1 1987

metal- (155.9 2 year

top or C.I.D.) 3

van

Plant 1ZZ-Zer 1

NOTE

*“Check digit” means a single number or letter X used to verify the accuracy of transcription of vehicle indentification

number.

1STB Revision

“’

INTRODUCTION - Vehicle Identification

VEHICLE IDENTIFICATION NUMBER LIST

FEDERAL

VIN (except sequence number) Brand Engine displacement

JA4FJ43EoHJ

JA4FJ43EoHJ MITSUBISHI 2.555 liters

JA7FJ23EoHJ MONTERO (155.9 C.I.D.)

JA7FJ23EoHJ

NOOCC-

Model code

L042GVNJLF

L042GVRJLF

L042GTNSLF

L042GTRSLF

CALIFORNIA (Can also be sold in Federal states.)

VIN (except sequence number)

JA4FJ43EoHJ

JA7FJ23EoHJ

JB7FJ23EoHJ

Brand

MITSUBISHI

MONTERO

Engine displacement

2.555 liters

(155.9 C.I.D.)

Model code

L042GVNJLH

L042GVRJLH

L042GTNSLH

1 L042GTNSLH

OOK520

VEHICLE INFORMATION CODE PLATE

NOOCO-A

Vehicle information code plate is riveted on the headlight sup-

port panel in the engine compartment.

The plate shows model code, engine model, transmission

model, and body color code.

1. MODEL L042G VNJLF

2. ENGINE G54B

I Engine model

3. TRANS

AXLE KM145

4. COLOR, TRIM

OPT 876

B2 1B76H43

Two-tone exterior is shown by the

Two-tone color code

Exterior code

Transaxle model

Montone exterior

color code

exterior code followed by the two

color codes.

) STB Revision

._:

INTRODUCTION

- Vehicle Identification

CHASSIS

NUMBER

STAMPING LOCATION

NOOCE-A

The chassis number is stamped on the side of the frame near

the right rear shock absorber.

CHASSIS NUMBER CODE CHART

LO4 2 V HJOOOOOl

A’ i’

VEHICLE SAFETY CERTIFICATION LABEL

NOOCF-

The vehicle safety certification label is attached to face of left

door pillar.

This label indicates the month and year of manufacture, Gross

Vehicle Weight Rating (G.V.W.R.), front and rear Gross Axle

Weight Rating (G.A.W.R.), and Vehicle Identification Number

(V.I.N.).

ENGINE MODEL STAMPING

NOOCG-

The engine model number is stamped at the right front side on

the top edge of the cylinder block as shown in the following:

1 Engine model 1 Engine displacement

1 2.555 liters (155.9 C.I.D.)

The engine serial number is stamped near the engine model

number, and the serial number cycles, as shown below

Engine serial number

AA020’toYY=

Number cycling

/ STB Revision --I f ,. ..-.

j ‘. .,

INTRODUCTION - Vehicle Identification

BODY COLOR CODE

Exterior code

Monotone

B76

Cl9

H43

R52

s70

x15

Two-tone

B21 B76H43

C38C19X13

H15H43X13

R06R52X13

S69S7OX13

X45X1 5H43

NOOCH-

Body color

Dark blue (Metallic)

Brown (Metallic)

Silver (Metallic)

Red

Beige

Black

Silver (Metallic)/

Dark blue (Metallic)

Black/

Brown (Metallic)

Black/

Silver (Metallic)

Black/Red

Black/Beige

Black/

Silver (Metallic)

1 STB Revision

INTRODUCTION - Precautions Before Service

oorn, FOOOl;

FOOOl8

PRECAUTIONS BEFORE SERVICE

PROTECTIN” THE VEHICLE

NOODAAC

If theIre is a likelihood of damaging painted or interior parts

during service operations, protect them with suitable covers

(such as seat covers. fender 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 contained

in this, Workshop 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 service

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.

PARTS TO IBE REPLACED

If any of the following parts are removed, they must be

replaced with new parts.

1. Oil seals

2. Gaskets (except rocker cover gasket)

3. Packings

4. O-rings

5. Lock washers

6. Cotter pins

7. Self-locking nuts

DO05111

STB Revision

,j .’

INTRODUCTION

- Precautions Before Service

nm (in.) so0059

PARTS

When replacing parts, use MITSUBISHI genuine parts.

VEHICLE WVASHING

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 (1 1.8 in.) from

any plastic parts and all opening parts (doors, luggage

compartment, etc.).

SERVICING THE ELECTRICAL SYSTEM

When servicing the electrical system, disconnect the negative

cable terminal from the battery.

Caution

Before connecting or disconnecting the negative cable, be

sure to turn off the ignition switch and the lighting switch.

(If this is not done, there is the possibility of semiconductor

parts being damaged.)

WIRING HARNESSES

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

vibrations 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 specified

location.

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.

F161711

* :, :, 1 STB Revision

INTRODUCTION

- Precautions Before Service

16Rl263

16R1264 Y16347

3. When disconnecting a connector, be sure to pull only the

connector, not the harness.

4. Disconnect connectors which have catches by pressing in

the direction indicated by the arrows in the illustration.

5. Connect connectors which have catches by inserting the

connectors until they snap.

( STB Revision

‘.

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