1. Introduction & Master Troubleshooting - Pajero 4x4 Off
Contents
1. 12th thru 17th digit 7th digit digit digit digit i Price j type Others Line class 4 bishi purposej5000 TERO 5 Serial number J 000001 Nagoya to 999999 M vehicle lbs and Pre MPV with mium M 7 hydraulic Truck brakes 5001 6000 lbs and with hydraulic brakes NOTE Check digit means a single number or letter X used to verify the accuracy of transcription of vehicle identification number TSB Revision _ vs gt X TEI Sy 72 e xL E v INTRODUCTION AND MASTER TROUBLESHOOTING Vehicle Identification 5 VEHICLE IDENTIFICATION NUMBER LIST FEDERAL NOOCC VIN except sequence number Engine displacement Model code JATFJASE OKJ 2 555 liters 155 9 cu in LO42GTNJLF JA7FJA3S OKJ L141GTNJLF JATEJSSS OK MONEO LIAIGTRULE MONTERO JAAGJA1S E KJ 2 972 liters 181 4 cuin L146GVMNJLF JAAGJATS OKJ L146GVMRJLF JA4GJ51S I KJ L146GWMRULF CALIFORNIA Can also be sold in Federal states VIN except sequence number Engine displacement Model code JA7FJ43E 0 2 555 liters 155 9 cu in LO42GTNJLH JA7FJ43S OKJ L141GTNJLH JA7EJ43S OKJ MITSUBISHI L141GTRJLH enced MONTERO 2 972 liters 181 4 cu in pm JA4GJATSCI KJ L146GVMRJLH JA4GJ5S1S O KJ L146GWMRULH VEHICLE INFORMATION CODE PLATE2. Transmission Heater and Air Conditioning Emission Control Systems NOTE For Electrical refer to Volume 2 Electrical EP 2 INTRODUCTION AND MASTER TROUBLESHOOTING How To Use This Manual HOW TO USE THIS MANUAL NOOBAAR 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 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 PROCEDURE
3. Treatment Before E INTRODUCTION AND MASTER TROUBLESHOOTING Atter the Fording of a Stream 15 e Apply grease to the lubricating points of the front suspen sion steering linkage and propeller shaft Lower arm ball joint Y Front propeller shaft Front propeller shaft grease fitting grease fitting S grease fitting 00W604 Rear propeller shaft Rear propeller shaft 7 o grease fitting grease fitting em TSB Revision AME Tn t IRL A dta nag mv Treatment Before 16 INTRODUCTION AND MASTER TROUBLESHOOTING After the Fording of a Stream 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 starter motor brake pipe and fuel pipe Check for water in the fluid or oil inside the front differential rear differential transmission and transfer case i Apply grease to the lubricating points of the front suspen sion Steering linkage and propeller shaft d Check all boots and breather hoses for cracks and damage u TSB Revision Lac n i ne E EC EC Fo 14 Term n pru io gd INTRODUCTION AND MASTER TROUBLESHOOTING Towing and Hoisting 17 TOWING AND HOISTING NDoGA This vehicle can only be to
4. Vehicle information code plate is riveted on the cowl top outer panel 2 6L Engine or front end upper bar 3 0L Engine in the engine compartment The plate shows model code engine model transmission model and body color code lt 2 6L Engine gt 1 MODEL L146G VMNJLF TE Model series ERES Vehicle model 2 ENGINE 6872 a cue p te Engine model 3 TRANS V5MT1 AXLE Transmission model 4 COLOR TRIM H84 OPT Monotone exterior H1XH84X85 color code LLL Two tone color code Exterior code i Two tone exterior is shown by the exterior code followed by the two color codes TSB Revision n 7 ML PUN T MER ETPP T 6 INTRODUCTION AND MASTER TROUBLESHOOTING Vehicle Identification CHASSIS NUMBER STAMPING LOCATION NOOCE The chassis number is stamped on the side of the frame near the right rear wheel CHASSIS NUMBER CODE CHART 1141 V KJ000001 L042 L141 V thru 17th digits or L146 metal top of V I N plate MONTERO VEHICLE SAFETY CERTIFICATION LABEL 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 VALN ENGINE MODEL STAMPING 00 6 The engine model is stamped on the right front side the top edge of the cylinder
5. Loose or worn wheel bearings TSB Revision a _ p id Imbalanced wheels 2H INTRODUCTION AND MASTER TROUBLESHOOTING Master Troubleshooting 29 VEHICLE PULLS TO ONE SIDE Reference 2 13 17 3 6 Vehicle pulls to one side Improper front or rear wheel alignment Imbafanced or worn tires 22 4 Excessive turning resistance of upper ball joint 2 27 STEERING WHEEL SHIMMY Reference Steering wheel shimmy Improper front or rear wheel alignment 2 13 17 3 6 Improper tire pressure 22 2 imbalanced wheels Repair Poor turning resistance of upper ball joint 2 27 Excessive play of steering wheel 19 8 Broken or weak stabilizer 2 39 Worn lower arm or upper arm bushing 2 28 31 Malfunctioning shock absorber 2 27 Broken or weak torsion bar spring or leaf spring or coil spring 2 36 17 4 9 2 19 Wear play or seizure of wheel bearing BOTTOMING Reference page or remedy Symptom Probable cause Overloaded vehicle Correct Bottoming Broken or weak torsion bar spring leaf spring or coil spring 2 36 17 4 9 Malfunctioning shock absorber 2 27 17 4 8 TSB Revision Y i ems See ui TA MN 30 INTRODUCTION AND MASTER TROUBLESHOOTING Master Troubleshooting WHEEL BEARING TROUBLESHOOTING Trouble Symptom Probable cause Pitting Pitting occurs because of
6. PEU ES Classification of SERVICE POINTS 44 Removal mA Installation ub Disassembly a Reassembly 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 M P 2 3 6 0 C Indicates the feed back carburetor or engines equipped with the feed back carburetor A Indicates the multi point injection or engines equipped with the multi point injection L Engine Indicates the 2 6 liters 155 9 cu in engine or a model equipped with such an engine L Engine Indicates the 3 0 liters 181 4 cu in engine or a model equipped with such an engine k P INTRODUCTION AND MASTER TROUBLESHOOTING How To Use This Manual Page number Group title Section title 7 10 COOLING Thermostat THERMOSTAT E E Indicates tightening REMOVAL AND INSTALLATION torque Pre removal Drainin GROU vice Post installation Operation of the Coolant Tee to LUBRICATION MAINTENANCE Maintenance Ser e Er vice Removal steps 1 Connection of engine coolant temperature or Reassemb ly step s switch connector Vehicles with an air condition er Thermostat at the qom Refer to 0 LUBRICATION AND MAINTENANCE
7. 91 1 mm 3 59 in 91 1 mm 3 59 in 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 cm 2 972 cm 2 972 cm 2 972 cm 155 9 cu in 181 4 cu in 181 4 cu in 181 4 cu in Compression ratio 8 7 8 9 8 9 8 9 Firing order 1 3 4 2 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 5 6 Basic ignition timing TBTDC 2 5 BTDC 2 5 BTDC 2 5 BTDC 2 Transmission 8 transfer case Model No KM145 V5MT1 KM148 KM148 Type 5 speed manual 5 manual 4 speed automatic 4 speed automatic Gear ratio Transmission ist 3 967 3 918 2 826 2 826 2nd 2 136 2 261 1 493 1 493 3rd 1 360 1 395 1 000 1 000 Ath 7 000 1 000 0 688 0 688 5th 0 856 0 829 heverse 3 587 3 925 2 703 2 703 Transfer case High 1 000 1 000 1 000 1 000 Low 1 944 1 925 1 925 1 925 Final ring gear ratio 4 625 4 625 4 625 4 625 Clutch Type Dry single disc amp Dry single disc amp diaphragm spring diaphragm spring Chassis Tire size P225 75R15 P235 75R15 Front suspension Type Independent Independent double wishbone double wishbone Rear suspension Type Rigid axle Rigid axle Brakes Type Disc Disc Drum Drum Leading and trailing Leading and trailing Power steering Gear type Integral type Integral type Recirculating ball nut Recirculating ball nut Gear ratio 16 4 16 4 Fuel tank capacity liters gals 60 15 9 75 19 8 TSB Revision Sen E 22 INTROD
8. Maintenance Ser Repair kit or set parts are shown Only very frequently used parts are shown Indicates non reusable part GAS KERT VAS WSS As QV NS 2 This number corresponds to the number in Removal steps Disassembly steps installation steps Connection of radiator upper hose Water outlet fitting 1 Reverse the rernoval procedures to reinstall Water outlet fitting gasket 2 44 Refer to Service Points of Installation 33 QM Non reusable parts SERVICE POINTS OF INSTALLATION 5 INSTALLATION OF THERMOSTAT Install the thermostat to the intake manifold as illustrated Intake manifold projection 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 regarding removal installation disassembly and reassembly 3 90759 Sete ooo amii 4 INTRODUCTION AND MASTER TROUBLESHOOTING Vehicle Identification VEHICLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER LOCATION The vehicle identification number V I N is located on a plate attached to the left top side of the instrument panel VEHICLE IDENTIFICATION CODE CHART PLATE NOOCB All vehicle identification numbers contain 17 digits The vehicle number is a code which tells country make vehicle type etc Ps ai
9. be sure that the idling is satisfactory For 3 0L 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 185 203 F Lights accessories OFF Transmission neutral position Automatic transmission models N or P Steering wheel neutral center position TSB Revision m RS itl i allatae oodi 10 INTRODUCTION AND MASTER TROUBLESHOOTING Precautions Before Service B E WIRING HARNESSES 1 Secure the wiring harnesses by using clamps 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 ll 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 F16171 3 When disconnecting a connector be sure to pull only the Correct connector not the harness in
10. li ULT INTRODUCTION AND MASTER TROUBLESHOOTING Precautions Before Service 13 DOING SERVICE WORK IN GROUPS OF TWO OR MORE TECHNICIANS If the service work is to be done by two or more technicians working together extra caution must be taken NOTE ON INSTALLATION OF RADIO EQUIPMENT The computers of the electronic control system has been designed so that external radio waves will not interfere with their operation However if antenna or cable of amateur transceiver etc is routed near the computers it may affect the operation of the computers even if the output of the transceiver is no more than 25W To protect each of the computers from interference by transmitter hum transceiver etc the following should be observed 1 install the antenna on the roof or rear bumper 2 Because radio waves are emitted from the coaxial cable of the antenna keep it 200 mm 8 in away from the computers and the wiring harness If the cable must cross Voltage the wiring harness route it so that it runs at right angles to Minimum voltage the wiring harness 3 The antenna and the cable should be well matched and cu the standing wave ratio should be kept low 4 A transmitter having a large output should not be installed High frequency Antenna in the vehicle power supply 5 After installation of transmitter run the engine at idle emit aa radio waves from the transmitter and make sure that the engine is
11. not affected STANDING WAVE RATIO if an antenna and a cable having different impedances are connected the input impedance Zi will vary in accordance with the length of the cable and the freguency of the transmitter and the voltage distribution will also vary in accordance with the location The ratio between this maximum voltage and minimum voltage is called the standing wave ratio It can also be represented by the ratio between the impedances of the antenna and the cable The amount of radio waves emitted from the cable increases as the standing wave ratio increases and this increases the possibility of the electronic components being adversely affected Voltage distribution Maximum voltage TSB Revision Treatment Before 14 INTRODUCTION AND MASTER TROUBLESHOOTING After the Fording of a Stream TREATMENT BEFORE AFTER THE FORD ING OF A STREAM INSPECTION AND SERVICE BEFORE FORDING A STREAM NOOFA 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 Seal the speedometer cable with a water resistant grease or tape Inspect the dust boots and breather hose for cracks or damage and replace them if cracks or damage are found Steering joint assembly lower boot oow604 Steering joint assembly upper boot 00W521 00W528 TSB Revision REN i ur
12. uneven rotation of race Excessive bearing preload and bearing surfaces Excessive load Flaking i The surface peels because of uneven rotation of End of bearing life the and bearing surfaces Improper bearing assembly Cracking Chipping or cracking of cage or roller edges Impact when bearing was installed such as being hit with a hammer Flat spotting When large load is applied race and roller contact Excessive bearing preload E surfaces compress forming indentations Excessive load Vibration when bearings are not used such as during shipment on freight cars transport trucks etc Nicks Instead of rolling along race surface Improper grease rollers slide thus damaging surface Excessive bearing preload Excessive load Faulty oil seal Smearing Damage or wear caused by minute particles Excessive variation of loads on adhering to surfaces results in rough movement bearings and such high temperatures that parts of surface Use of grease other than that melt specified Improper grease Rust corrosion Appears on various areas of the bearing Use of grease other than that specified Faulty oil seal Presence of water or moisture u n pn M Wear of surface areas caused by friction Improper grease Foreign matter Rust or corrosion due to moisture Use of grease other than that specified Faulty oil eal Discoloration Grease discoloration results from grease Use of grease other than deterioration wh
13. 6G72 V type OHC 6 91 1 mm 3 59 in 76 0 mm 2 99 in 2 972 cm 181 4 cu in 8 9 1 2 3 4 5 6 5BTDC 2 WMRUL F H 4 570 179 9 4 605 181 3 1 680 66 1 1 890 74 4 2 695 106 1 1 400 55 1 1 415 55 7 745 29 3 1 165 45 9 490 19 3 450 17 7 215 8 5 3g 28 18 1 805 3 979 2 400 5 291 1 100 2 425 1 600 3 527 5 6G72 V type OHC 6 91 1 mm 3 59 in 76 0 mm 2 99 in 2 972 cm 181 4 cu in 8 9 1 2 3 4 5 6 5 BTDC x2 INTRODUCTION AND MASTER TROUBLESHOOTING General Data and Specifications 23 L146G Description 2 Transmission amp transfer case Model No Type Gear ratio Transmission 1st 2nd 3rd 4th 5th Reverse Transfer case High Low Final ring gear ratio VMNJL F H 5 1 5 speed manual 3 918 2 261 1 395 1 000 0 829 3 925 1 000 1 925 4 625 Dry single disc amp diaphragm spring VMRJL F H KM148 4 speed automatic 2 826 1 493 1 000 0 688 2 703 1 000 1 925 4 625 WMRUL F H KM148 4 speed automatic 2 826 1 493 1 000 0 688 2 703 1 000 1 925 4 625 Chassis Tire size Front suspension Type Rear suspension Type Brakes Type Power steering Gear type Gear ratio Fuel tank capacity liter gal P235 75 R15 Independent double wishbone Rigid axle Disc Drum Leading and trailing Integral type Recirculating ball nut 16 4 92 24 3 TSB Rev
14. I i E INTRODUCTION AND MASTER TROUBLESHOOTING Master Troubleshooting 25 ENGINE WILL NOT CRANK OR CRANKS SLOWLY Reference Engine will not crank or cranks Starting system faulty 8 134 135 slowly ENGINE WILL NOT START OR BE HARD TO START CRANKS OK Reference Engine will not start or be hard to No fuel supply to carburetor or injection system 14 34 90 start Cranks OK Carburetor or injection system problems 14 34 90 Ignition system problems 8 147 to 149 Vacuum leaks Purge control valve hose es a Repair as ntake manifold Air intake plenum a ae Carburetor or throttle body EGR valve Compression too low ROUGH IDLE OR ENGINE STALL Reference Rough idle or Vacuum leaks engine stalls Purge control vaive hose Vacuum hoses Intake manifold Air intake plenum Carburetor or throttle body EGR valve Repair as necessary TSB Revision 7 aeaiia Aii uen 26 INTRODUCTION AND MASTER TROUBLESHOOTING Master Troubleshooting ENGINE HESITATES OR POOR ACCELERATION Symptom Engine hesitates or poor acceleration Probable cause M ignition system problem Vacuum leaks Purge control valve hose Vacuum hoses intake manifold Air intake plenum Carburetor or throttle body EGR valve Air cleaner clogged Fuel line clogged Carburetor or fuel injection system problem Auxiliary acceleration pump faulty cold
15. S 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 MODEL INDICATIONS LIMIT Shows the standard for judging the quality of a part or assembly on inspection and means the maxi mum 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 Indicates incidental operation to be performed before re moval or after installation 1 pum pesca compos 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 Installation steps This is provided if instailation 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 of Disassembly steps is possible
16. Service Manual MONTERO 1989 Volume 1 FOREWORD This Service Manual has been prepared with the latest service information available at the time of publication ft 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 SUPPORT WE VOLUNTARY TECHNICIAN CERTIFICATION THROUGH National Institute for AUTOMOTIVE SERVICE EXCELLENCE 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 preducts previously manufactured 1988 Mitsubishi Motors Corporation Printed in Japan GROU P INDEX NODAA A Introduction and Master Troubleshooting Lubrication and Maintenance Front Suspension Rear Service Brakes Parking Intake and Exhaust Fuel System pud LE KE Propeller Shaft and Universal Rear Suspension Power Steering M 79 Manual Automatic Wheels and Tires
17. UCTION AND MASTER TROUBLESHOOTING General Data and Specifications lt 4 door vehicles gt Description VMNJL L146G VMRJL F A Vehicle dimensions Overall length Without spare tire With spare tire Overall width Overall height Wheelbase Tread Front Rear Front Rear Height at curb weight Front bumper to ground Rear bumper to ground Minimum running ground clearance Angle of approach Angle of departure Ramp breakover angle kg Ibs Overhang Vehicle weights Curb weight Gross vehicle weight rating Front Rear Gross axle weight rating Seating capacity Engine Model No Type Number of cylinders Bore Stroke Piston displacement Compression ratio Firing order Basic ignition timing mm lin wt 4 570 179 9 4 605 181 3 1 680 66 1 1 890 74 4 2 695 106 1 1 400 55 1 1 415 55 7 745 29 3 1 165 45 9 490 19 3 450 17 7 215 8 5 38 28 18 1 780 3 924 2 400 5 291 1 100 2 425 1 600 3 527 5 6G72 V type OHC 6 91 1 mm 3 59 in 76 0 mm 2 99 in 2 972 cm 181 4 cu in 8 9 1 2 3 4 5 6 2 TSB Revision 2 4 570 179 9 4 605 181 3 1 680 66 1 1 890 74 4 2 695 106 1 1 400 55 1 1 415 55 7 745 29 3 1 165 45 9 490 19 3 450 17 7 215 8 5 38 i 28 18 1 795 3 957 2 400 5 291 1 100 2 425 1 600 3 527 5
18. block for 2 6 liter engines For 3 0 liter engines it is stamped at the right rear of the top of the cylinder block These engine model numbers are as shown in the following Engine model G54B 2 555 liters 1559cuin 0 6G72 2972 liters 181 4 cu in The engine serial number is stamped near the engine model number and the serial number cycles as shown below Engine serial number Number cycling AA0201 to YY9999 AA0201 gt AA9999 Engine displacement Lg rg ci BAO001 YY9999 UA IM uM I TSB Revision EE o pon P INTRODUCTION AND MASTER TROUBLESHOOTING Vehicle Identification 7 BODY COLOR CODE NOOCH Monotone C46 Brown M H84 Silver M R82 Red 55 Beige M T86 Blue M Wo9 White R48 Red M X15 Black Two tone C1XC46X85 Brown MY Black H1XH84X85 Silver M Black R2XR82X85 Red Black S1X555X85 Beige MY Black T6HT88H84 Blue MY Silver M W6XW09X85 White Black X2HX15H84 Black Silver M M Metallic paint TSB Revision l ta a ee 0 4 re 8 INTRODUCTION AND MASTER TROUBLESHOOTING Precautions Before Service PRECAUTIONS BEFORE SERVICE PROTECTING THE VEHICLE NOODAAK If there is a likelihood of damaging painted or interior parts during service operations protect them with suitable cov
19. correct 4 Disconnect connectors which have catches by pressing in the direction indicated by the arrows in the illustration A ip y C16384 16R1283 _ 16387 16R1284 Y16347 TSB Revision INTRODUCTION AND MASTER TROUBLESHOOTING Precautions Before Service 11 5 Connect connectors which have catches by inserting the gt connectors until they snap ELECTRICAL COMPONENTS 1 When installing any of the vehicle parts be careful not to pinch or damage any of the wiring harnesses 2 Sensors relays etc are sensitive to strong impacts Handle them with care so that they are not dropped or mishandled 001586 3 The electronic parts used for relays are sensitive to heat If any service which causes a temperature of 80 C ate 176 F or more is performed remove the part or parts in Se question before carrying out the service Rat 2 A FUSES AND FUSIBLE LINKS 1 If a blown out fuse is to be replaced be sure to use only a 00Y633 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 Caution 1 If a fuse is blown out be sure to eliminate the cause of the problem before installing a new fuse 2 Check the condition of fuse holders If rust or dirt is found clean metal parts with a fine grained sandpa per until proper metal to metal conta
20. ct is made Poor contact of any fuse holder will often lead to voltage drop or heating in the circuit and could 00Y589 result in improper circuit operation TSB Revision 2 If additional optional equipment is to be installed in the vehicle follow the procedure listed in the appropriate ee In engine instruction manual however be sure to pay careful compart attention to the following points 1 In order to avoid overloading the wiring take the 3mm electrical current load of the optional equipment into 5mm consideration and determine the appropriate wire size 2 Where possible route the wiring through the existing 0mm harnesses 0 mm mm 3 If an ammeter or similar instrument is to be connected 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 contactwith any other parts 4 Be sure to provide a fuse for the load circuit of the optional eguipment TUBES AND OTHER RUBBER PARTS Be careful to avoid spilling any gasoline oil etc or rubber parts they might be adversely affected LUBRICANTS In accordance with the instructions in this Service Manual apply the specified lubricants in the specified locations during assembly and installation F00028 BRAKE FLUID Be careful to avoid spilling any brake fluid on painted surfaces because the paint coat might be discolored or damaged TSB Revision E
21. ehicle weight rating Gross axle Front weight rating Rear Seating capacity mm in 3 900 153 5 3 935 154 9 1 680 66 1 1 840 72 4 2 350 92 5 1 400 55 1 1 375 54 1 685 27 0 900 35 4 480 18 9 440 17 3 210 8 3 38 28 21 1 455 3 207 1 910 4 210 1 100 2 425 1 450 3 197 2 TSB Revision 3 905 153 7 3 940 155 1 1 680 66 1 1 850 72 8 2 350 92 5 1 400 55 1 1 415 55 7 685 27 0 905 35 6 490 19 3 450 17 7 215 8 5 38 28 21 1 585 3 494 2 200 4 850 1 100 2 425 1 600 3 527 2 3 905 153 7 3 940 155 1 1 680 66 1 1 850 72 8 2 350 92 5 1 400 55 1 1 415 55 7 685 27 0 905 35 6 490 19 3 450 17 7 215 8 5 38 28 1 600 3 527 2 200 4 850 1 100 2 425 1 600 3 527 2 d de 00 606 3 905 153 7 3 940 155 1 1 680 66 1 1 850 72 8 2 350 92 5 1 400 55 1 1 415 55 7 685 27 0 905 35 6 490 19 3 450 17 7 215 8 5 38 28 21 1 605 3 538 2 200 4 850 1 100 2 425 1 600 3 527 2 mm Mn p Hn ug INTRODUCTION AND MASTER TROUBLESHOOTI NG General Data and Specifications 21 Models 10426 11416 Description TNSL F H TNJL F H TRJL F H TRUL F H Engine Model No G54B 6G72 6G72 6G72 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 59 in 91 1 mm 3 59 in
22. engine Emission control system problem EGR system always High altitude compensation HAC system problem Engine overheats Compression too low 8 147 to 149 Repair as necessary 11 3 10 1452 99 7 14 34 90 B 1423 25 17 22 32 911 65 0070 Reference page orremedy ENGINE DIESELING page orremedy Engine dieseling runs after Carburetor problems ignition switch is tumed off ee d ER Incorrect ignition timing 8 147 to 149 EXCESSIVE OIL CONSUMPTION Symptom Probable cause Excessive oil consumption Oil leak necessary Positive crankcase ventilation line clogged Valve stem seal worn or damaged Valve stem worn Piston ring worn or damaged ___ TSB Revision _ KMA Reference page orremedy m ali ie DE n e INTRODUCTION AND MASTER TROUBLESHOOTING Master Troubleshooting 27 POOR FUEL MILEAGE Reference Symptom Probable cause page or remedy Poor fuel mileage Fuel leak Repair as necessary Air cleaner clogged 11 3 10 Ignition problems 8 147 to 149 Carburetor or fuel injection system problems 14 34 90 Compression too low 9 11 65 Tires improperly inflated NOISE Symptom Probable cause page or remedy Loose bolts and nuts Retighten as necessary Engine noise 9 11 HARD STEERING Air in power steering system Low tire pressure Excessive turning resi
23. ers such as seat covers fender covers etc REMOVAL AND DISASSEMBLY When checking a maifunction find the cause of the problem If dt is determined that removal and or disassembly is neces s ty 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 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 bereplaced 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 BE REPLACED If any of the following parts are removed they must be replaced with new parts Cil seals Gaskets except rocker cover gasket Packings O rings Lock washers Cotter pins Self locking nuts DUPLO E E paco TSB Revision them in locations which will
24. have no detrimental effect on Era BEREE D INTRODUCTION AND MASTER TROUBLESHOOTING Precautions Before Service 9 PARTS When replacing parts use MITSUBISHI genuine parts 1 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 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 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 lighting switch If this is not done there is the possibility of semiconductor parts being damaged 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
25. he 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 adeguately supported by safety stands 5 Neverallow passengers to ride in a towed vehicle 6 State and local rules and regulations must be followed when towing a vehicle TSB Revision EN QM md cm 18 INTRODUCTION AND MASTER TROUBLESHOOTING Towing and Hoisting Sze NB FRAME CONTACT SUPPORT LOCATIONS 1 175 mm NOTE The locations of the support point shown as Sec HOISTING POST TYPE Special care should be taken when raising the vehicle on a frame contact type hoist The hoist must be eguipped with the proper adapters in order to support the vehicle at the proper locations Shown in the illustration 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 unde
26. ich causes particles of pigment that specified contained in grease to adhere to surfaces Faulty oil seal Heat discoloration will appear as a deep brown Excessive bearing preload purple Excessive load TSB Revision ___ at A
27. ision coiere eda meeer is E erae Tightening Torque 24 INTRODUCTION AND MASTER TROUBLESHOOTING master Troubleshooting TIGHTENING TORQUE Description 4 Head mark 7 ft Ibs Nm Thread for general purposes size x pitch mm 6x1 0 3 0 3 9 2 2 2 9 4 9 7 8 3 6 5 8 8x 1 25 7 9 12 5 8 8 7 13 19 9 4 14 10 1 25 16 23 12 17 27 39 20 29 12x 1 25 29 43 27 32 47 72 35 53 14 x 1 5 48 70 35 52 77 110 57 85 16x 1 5 67 100 51 77 130 160 90 120 18x 1 5 100 150 74 110 180 230 130 170 20x 1 5 150 190 110 140 160 320 190 240 22x1 5 200 260 150 190 340 430 250 320 24x1 5 260 320 190 240 420 550 310 410 mra Description Remarks Taper thread for pipes size ain PT 1 8 Internal thread Aluminum Internal thread Cast iron PT 1 4 Internal thread Aluminum internal thread Cast iron PT 3 8 Internal thread Aluminum Internal thread Cast iron Taper thread for dry sealed pipes size NPTF 1 16 Internal thread Aluminum Internal thread Cast iron NPTF 1 8 Internal thread Aluminum Internal thread Cast iron NPTF 1 4 internal thread Aluminum Internal thread Cast iron MASTER TROUBLESHOOTING NOOKAAG ENGINE OVERHEATS Symptom Probable cause Heference Y page or remedy Engine overheats Cooling system faulty Y E Incorrect ignition timing El matt Jakson 6 ki id nk HE Mens i IUE TSB Revision
28. rbody 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 463 n C e base Section 2 350 92 5 the same as those of the twin post hoist shown the next page 00W553 TSB Revision INTRODUCTION AND MASTER TROUBLESHOOTING Towing and Hoisting 19 LIFTING AND JACKING SUPPORT LOCATIONS lt 2 6L Engine gt M c 00W588 lt 3 0L Engine gt oow605 m Twin post hoist Floor jack e Emergency jacking jack supplied with the vehicle TSB Revision t F CU nm iss ele I t ES Menta re 20 INTRODUCTION AND MASTER TROUBLESHOOTING General Data and Specifications GENERAL DATA AND SPECIFICATIONS NDOHA Vehicle dimensions Overall length Without spare tire With spare tire Overall width Overall height Wheelbase Tread Overhang Height at curb weight Front bumper to ground Rear bumper to ground Minimum running ground clearance Angle of approach Angle of departure Ramp breakover angle Vehicle weights kg Ibs Curb weight Gross v
29. stance of upper or lower ball joint Excessively tight linkage ball joint improper front wheel alignment Excessive turning resistance of tie rod ball joint No lubricantion of tie rod Sticky flow control valve No lubrication of idler arm TSB Revision SS ain nan Poe ee jaa 28 INTRODUCTION MASTER TROUBLESHOOTING Master Troubleshooting POOR RETURN OF STEERING WHEEL TO CENTER Reference Poor return of steering Improper front wheel alignment 2 13 wheel to center Improper tire pressure Damaged front wheel bearing POOR RIDING Reference Probable cause page or remedy Poor riding Improper tire pressure kli 22 2 Imbalanced wheels za B Improper front or rear wheel alignment i 2 1 3 1 7 3 6 Malfunctioning shock absorber 2 27 1 7 4 8 Broken or worn stabilizer i Broken or worn torsion bar spring Loose suspension securing bolt s Retighten d Worn lower arm bushing 2 ABNORMAL TIRE WEAR Reference Abnormal tire wear Improper front or rear wheel alignment 2 13 17 3 6 Improper tire pressure ws Loose wheel bearings 2 27 174 8 Malfunctioning shock absorber ROAD WANDER Reference Road wander Improper front or rear wheel alignment 2 13 17 3 6 Poor turning resistance of upper joint Improper tire pressure Loose or worn lower arm or upper arm bushing
30. wed 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 LIFTING 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 eguipment that interface with t
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