Mitsubishi Pickup Trucks 1983-1996, Montero 1983-1993 Repair Manual by Haynes

SKU: HY68040-996
Mitsubishi Pickup Trucks 1983-1996, Montero 1983-1993 Repair Manual
Mitsubishi Pickup Trucks 1983-1996, Montero 1983-1993 Repair Manual
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Item Description

This DIY repair workshop manual by Haynes, covers 1983-1996 Mitsubishi Pickup Trucks, and 1983-1993 Mitsubishi Montero.

Manual covers all 2WD and 4WD models with 2.0L, 2.4L, 2.6L 4-cylinder and 3.0L V6 engines.

Pickup models are available in standard or extended cab with short or long beds. Montero models are available in 2- or 4-door body styles.

Note: this manual DOES NOT include diesel engine information.

Book Excerpt:



This Part of Chapter 2 is devoted to in-vehicle repair procedures for the 3.0L V6 engine. All information concerning engine removal and installation and engine block and cylinder head overhaul can be found in Part D of this Chapter.

The following repair procedures are based on the assumption that the engine is installed in the vehicle. If the engine has been removed from the vehicle and mounted on a stand, many of the steps outlined in this Part of Chapter 2 will not apply.

The Specifications included in this Part of Chapter 2 apply only to the procedures contained in this Part. Part D of Chapter 2 contains the Specifications necessary for cylinder head and engine block rebuilding.

The 60-degree V6 has a cast iron block and aluminum heads with a camshaft in each head. The block has thin walled sections for light weight.

A "cradle frame" main bearing casting - the main bearing caps are cast as a unit, with a bridge, or truss, connecting them - supports the cast ductile iron crankshaft.

Both camshafts are driven off the crankshaft by a cog belt. A spring loaded tensioner, adjusted by an eccentric type locknut, maintains belt tension. Each camshaft actuates two valves per cylinder through hydraulic lash adjusters and shaft-mounted forged aluminum rocker arms.

Each cast aluminum three-ring piston has two compression rings and a three-piece oil control ring. The piston pins are pressed into forged steel connecting rods. The flat-topped pistons produce an 8.85:1 compression ratio.

The distributor (or crank angle sensor), which is mounted on the drivebelt end of the front cylinder head, is driven by a helical gear on the camshaft.

The water pump, which is bolted to the timing belt end of the block, is driven off the crankshaft by a drivebelt and pulley.

The gear type of pump is mounted in the oil pump case and attached to the timing belt cover. It is driven by the crankshaft.

From the oil pump, oil travels through the filter to the main oil gallery from which it is routed either directly to the main bearings, crankshaft, connecting rod bearings and pistons and cylinder walls or to the cylinder heads.

(Refer to illustrations 14.3a, 14.3b, 14.4, 14.5 14.6. 14.7 and 14.13)


  1. If any of the gauges or warning lights need servicing it will be necessary to remove the instrument cluster.
  2. Disconnect the negative battery cable from the battery.
  3. Remove the control knobs and the nuts on the studs from the radio, (see illustration), and then remove the radio trim plate (see illustration).
  4. Pull off the heater fan control knob and the heater control lever ends. Remove the nut from the fan control stud (see illustration).
  5. Remove the four screws from the cluster trim rim (see illustration) and lift it carefully out.
  6. Disconnect the wiring harness and the wire lead at the lower right corner of the rim (see illustration).
  7. Remove the four screws attaching the instrument cluster to the dash (see illustration).
  8. Remove the speedometer cable fitting and remove the cable from the back of the cluster (see illustration 19.4). Disconnect the electrical wire from the buzzer.
  9. Carefully pull out on the cluster until it is free of the dash, and then disconnect the two electrical connectors at the rear of the cluster.
  10. Installation is the reverse of removal.
  1. Disconnect the negative cable from the battery. Remove the hazard switch and hole cover.
  2. Remove the two lower screws, and then lift the instrument cluster hood off.
  3. Remove the four screws holding the instrument cluster in place (see illustration).
  4. Pull the instrument cluster out, disconnect the speedometer and electrical connectors, and then remove the cluster from the vehicle (see illustration 19.4).
  5. Installation is the reverse of removal.

Subject: 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996 Mitsubishi Pick-up Trucks, Montero service, maintenance, repair. ISBN-10: 1563921928 | ISBN-13: 9781563921926 | Haynes 68040

  • Publisher: Haynes Manuals
  • Pages: 376 - Hundreds of b&w photos and illustrations
  • Binding: Paperback - 8.5 x 11 inches
  • ISBN: 978-1-56392-192-6
  • Years: 1983 - 1996
Table of Contents
  • Introduction: Vehicle identification numbers; Buying parts; Maintenance techniques, and more.
  • Tune-up and routine maintenance
  • Engine and overhaul procedures
  • 2.6L four-cylinder engine
  • 2.0L and 2.4L four-cylinder engine
  • 3.0L V6 engine
  • Cooling, heating and air-conditioning systems
  • Fuel and exhaust systems
  • Engine electrical systems
  • Emissions control systems
  • Manual transmission
  • Automatic transmission
  • Transfer case
  • Brakes
  • Suspension and steering systems
  • Body
  • Chassis electrical system
  • Wiring diagrams
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Mitsubishi Pickup Trucks 1983-1996, Montero 1983-1993 Repair Manual by Haynes
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