1987 Mitsubishi Montero Service Manual

The 1987 Mitsubishi Montero is a rugged 4WD SUV featuring a 2.6L 4-cylinder engine, 5-speed manual transmission, part-time 4WD system with 2WD/4WD high/4WD low ranges, power-assisted brakes, and independent front suspension. This service manual covers maintenance procedures, specifications, troubleshooting, and repair guidelines for engine, transmission, drivetrain, suspension, brakes, electrical systems, and body components.

1. Vehicle Specifications 2. Maintenance Schedule 3. Engine Service 4. Transmission & Drivetrain 5. Suspension & Steering 6. Brake System 7. Electrical System 8. Body & Interior 9. Troubleshooting Guide 10. Technical Data 11. Wiring Diagrams

Vehicle Specifications

Key specifications for the 1987 Mitsubishi Montero 4WD SUV.

Component	Specification
Engine	2.6L 4-cylinder G54B, SOHC
Horsepower	106 hp @ 5000 rpm
Torque	139 lb-ft @ 2500 rpm
Transmission	5-speed manual, KM145
Transfer Case	Part-time 4WD, chain drive
Front Suspension	Independent with torsion bars
Rear Suspension	Leaf spring solid axle
Brakes	Front disc, rear drum
Fuel Capacity	19.8 gallons
Curb Weight	3,350 lbs

Maintenance Schedule

Recommended service intervals for optimal performance and longevity.

Oil Change: Every 3,000 miles or 3 months
Oil Filter: Replace with every oil change
Air Filter: Every 15,000 miles or 12 months
Spark Plugs: Every 30,000 miles
Timing Belt: Every 60,000 miles
Coolant Flush: Every 24 months
Brake Fluid: Every 24 months or 30,000 miles
Transfer Case Fluid: Every 30,000 miles

WARNING! Use only specified fluids and follow torque specifications precisely.

Engine Service

Procedures for engine maintenance and repair.

Valve Adjustment: Cold engine, intake 0.006 in, exhaust 0.010 in
Ignition Timing: 5° BTDC at 750 rpm
Compression: 142-171 psi, max variation 14 psi between cylinders
Fuel Pressure: 2.5-3.0 psi with vacuum, 3.5-4.0 psi without
Idle Speed: 750 rpm (manual), 800 rpm (auto)

CAUTION! Always disconnect battery before servicing electrical components.

Transmission & Drivetrain

Transmission Fluid: SAE 80W-90 GL-4, 3.2 quarts
Transfer Case Fluid: SAE 80W-90 GL-5, 2.4 quarts
Front Differential: SAE 80W-90 GL-5, 2.6 pints
Rear Differential: SAE 80W-90 GL-5, 3.7 pints
4WD Operation: Shift between 2WD and 4WD while moving under 50 mph
Clutch: Hydraulic system, pedal free play 0.4-0.8 in

Suspension & Steering

Front torsion bar adjustment and steering system maintenance.

Front Suspension: Torsion bars adjustable for ride height, ball joints non-serviceable (replace if worn). Steering: Recirculating ball type, power steering fluid Dexron II.

Wheel Alignment: Toe-in 0.08-0.20 in, Camber 0°30' ± 30', Caster 2°30' ± 30'. Steering Gear Play: Maximum 1.2 in at steering wheel rim.

Brake System

Hydraulic brake system service and specifications.

Brake Pad Replacement: Minimum thickness 0.08 in
Brake Drum: Maximum diameter 11.14 in
Brake Disc: Minimum thickness 0.87 in
Master Cylinder: Bench bleed before installation
Bleeding Sequence: RR, LR, RF, LF

Tip: Always replace brake fluid when servicing hydraulic components.

Electrical System

Battery, charging, and starting system specifications.

Battery: 12V, 55Ah, negative ground
Alternator: 60A output, regulator integral
Starter: 1.4 kW, draw current 180A max
Fuses: 10A to 30A, located in engine compartment
Bulb Types: Headlight 60/55W H4, brake 21W

WARNING! Disconnect battery before electrical work to prevent shorts.

Body & Interior

Body maintenance and interior component service.

Troubleshooting Guide

Common issues and diagnostic procedures.

Symptom	Possible Cause	Corrective Action
Hard starting	Fuel pump, ignition timing	Check fuel pressure, verify timing, inspect spark plugs
4WD not engaging	Vacuum system, shift mechanism	Check vacuum lines, inspect shift motor
Brake pull	Calipers, alignment	Inspect calipers for sticking, check alignment
Overheating	Thermostat, radiator	Test thermostat, flush cooling system
Transmission noise	Fluid level, bearings	Check fluid level and condition, inspect for wear

Technical Data

Torque specifications and fluid capacities.

Spark Plugs: 18-22 ft-lbs
Oil Drain Plug: 29-36 ft-lbs
Wheel Lug Nuts: 65-80 ft-lbs
Cylinder Head: 58-61 ft-lbs (final torque)
Engine Oil Capacity: 4.2 quarts with filter
Coolant Capacity: 9.5 quarts

Wiring Diagrams

Electrical schematics for complete vehicle systems.

Complete wiring diagrams included for: Starting/Charging System, Ignition System, Fuel Injection, Lighting, Instrument Cluster, 4WD Control System, and Body Electrical.

Service: Contact Mitsubishi Motors for technical support and genuine parts.