1991 MITSUBISHI MONTERO change time
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Fig. 1: Fuel Pressure Testing Connection ID (Typical Fuel Inj. Eng.)
Courtesy of Mitsubishi Motor Sales of America.
5) Start engine and let idle. Measure fuel pressure with
vacuum hose connected to fuel pressure regulator. Record fuel pressure
reading. Disconnect and plug vacuum hose from fuel pressure regulator.
Record fuel pressure reading. See REGULATED FUEL PRESSURE table.
6) Check for fuel pressure in fuel return hose by gently
pinching hose while increasing engine speed. If fuel volume is low,
fuel pressure in return hose will not be felt. Increase engine speed
to 2500-3000 RPM, 2-3 times. Return engine to idle. Fuel pressure
should not drop when engine is returned to idle.
7) Turn engine off. Ensure fuel pressure reading does not
decrease within 2 minutes. If a decrease is noted, monitor speed of
decrease.
8) If fuel pressure is lower than specification, fuel
pressure drops at idle after increasing engine speed to 2500-3000 RPM,
or no fuel pressure in fuel return hose can be felt, check for clogged
fuel filter, faulty fuel pressure regulator, or fuel pump.
9) If fuel pressure is higher than specification, check for a
faulty fuel pressure regulator or plugged fuel return line. If fuel
pressure does not change when vacuum hose to regulator is connected or
disconnected, check for a leaking or clogged vacuum hose to fuel
pressure regulator or faulty fuel pressure regulator.
10) If fuel pressure decreases suddenly after engine is
stopped, check valve within fuel pump is not seated. Replace fuel
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brake pedal to center shoes, and check pedal travel. Rotate brake drum
to verify free movement.
STOPLIGHT SWITCH
Loosen lock nut, and adjust switch-to-pedal arm clearance to
.02-.04" (.5-1.0 mm). Tighten lock nut. DO NOT depress master cylinder
push rod during stoplight switch adjustment.
TESTING
POWER BRAKE UNIT
Check Valve Inspection
Remove vacuum hose from power brake unit. Remove check valve
from hose (if possible). Using a vacuum pump, ensure airflow is in
direction of intake manifold only.
System Check
1) Run engine for 2 minutes, and shut it off. Depress brake
pedal several times with normal pressure. If pedal height gradually
becomes higher with successive applications, power brake unit is okay.
If pedal height remains steady, power brake unit is faulty.
2) With engine stopped, depress brake pedal repeatedly until
it's height no longer falls. Hold brake pedal down, and start engine.
If pedal moves downward slightly, power brake unit is okay. If pedal
height does not change, power brake unit is faulty.
3) With engine running, press and hold brake pedal and shut
off engine. Hold brake pedal for 30 seconds. Brake pedal height should
not change. If pedal height falls, power brake unit is faulty.
LOAD-SENSING PROPORTIONING VALVE (LSPV) (PICKUP & RAM-50)
1) Before diagnosing Load-Sensing Proportioning Valve (LSPV)\
,
ensure all other brake components are operating properly. When all
other brake system components are determined to be okay, perform LSPV
test beginning with next step.
2) Ensure unladen vehicle is on level ground. Ensure lever is
not contacting stopper bolt. See Fig. 1.
3) When lever is pushed toward valve, distance from LSPV
lever hole and support hole must be 6.97-7.09 in. (177-180 mm). If
measured distance is not within specification, loosen support bolt.
Adjust support until measured distance is within specification.
4) After measured distance is within specification, connect
pressure gauges to input and output ports of LSPV. See Fig. 4. Bleed
brake system. See BLEEDING BRAKE SYSTEM .
Fig. 4: Connecting Pressure Gauges to LSPV (Pickup & Ram-50)
Courtesy of Mitsubishi Motor Sales of America.
Page 266 of 1333
1) Install drive pinion in differential carrier. Install
spacer, pinion front shim(s) and front pinion bearing. DO NOT install
oil seal at this time. Install pinion flange, washer and retaining
nut. Check pinion rotating torque without pinion oil seal.
2) Recheck rotating torque. Rotating torque must be within
specification. See PINION ROTATING TORQUE SPECIFICATIONS table. Adjust
rotating torque by replacing drive pinion front shims or spacer. Once
correct rotating torque is obtained, install oil seal. Coat seal lip
with grease.
3) Install pinion flange so alignment marks are correct.
Apply light coat of grease to flange washer contact area. Install new
retaining nut. Check pinion rotating torque with pinion oil seal
installed. Rotating torque must be within specification. See PINION
ROTATING TORQUE SPECIFICATIONS table.
SIDE BEARING
1) Using Bearing Installer (MB990802-01), install bearings o\
n
differential case. Select 2 side bearing adjusting shims thinner than
those removed. Shims must be equal thickness on both sides. Install
shims on each side of case assembly. Install case assembly in
differential carrier.
2) Push case assembly fully to one side of carrier. Using 2
feeler gauges, measure clearance between carrier and side bearing shim
at opposite sides of bearing. Remove shims from one side of
differential carrier.
3) Measure thickness of shims removed. Add removed shim
thickness and 1/2 of feeler gauge clearance measurement plus .002" (.
05 mm). This is thickness of shim that should be installed on each
side of case. Select proper shims. Install equal shims on each side of
case assembly.
NOTE: Ensure no clearance exists between gear carrier and
adjusting shim.
4) Install side bearing shims and differential case assembly
in differential carrier. Using brass drift, tap shims to fit them to
side bearing outer race. Install bearing caps. Check ring gear
backlash.
RING GEAR BACKLASH
1) Lock drive pinion in place. Using dial indicator, check
ring gear backlash at heel of ring gear tooth. Measure at 4 locations
of ring gear. Gear backlash must be within .004-.006" (.10-.15 mm).
2) If not within specification, change side bearing adjusting
shims and recheck backlash. If backlash is too small, install thinner
shim behind ring gear and thicker shim opposite ring gear.
3) If backlash is excessive, install thicker shim behind ring
gear and thinner shim opposite ring gear. Check gear tooth contact
using paint impression method.
CAUTION: When changing shims, total thickness of all shims must
remain constant.
RING GEAR RUNOUT
Using dial indicator, measure runout at back side of ring
gear. Runout must be within .002" (.05 mm). If runout is excessive,
change ring gear-to-differential case mounting position. Recheck
runout. Install cover and gasket.
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during manufacture, some new type valves cannot be reground.
Resurface valve on proper angle specification using valve
grinding machine. Follow manufacturer's instructions for valve
grinding machine. Specifications may indicate a different valve face
angle than seat angle.
Measure valve margin after grinding. Replace valve if not
within specification. Valve stem tip can be refinished using valve
grinding machine.
Valve Lapping
During valve lapping of recent designed valves, be sure to
follow manufacturers recommendations. Surface hardening and materials
used with some valves do not permit lapping. Lapping process will
remove excessive amounts of the hardened surface.
Valve lapping is done to ensure adequate sealing between
valve face and seat. Use either a hand drill or lapping stick with
suction cup attached.
Moisten and attach suction cup to valve. Lubricate valve stem
and guide. Apply a thin coat of fine valve grinding compound between
valve and seat. Rotate lapping tool between the palms or with hand
drill.
Lift valve upward off the seat and change position often.
This is done to prevent grooving of valve seat. Lap valve until a
smooth polished seat is obtained. Thoroughly clean grinding compound
from components. Valve to valve seat concentricity should be checked.
See VALVE SEAT CONCENTRICITY.
CAUTION: Valve guides must be in good condition and free of carbon
deposits prior to valve seat grinding. Some engines contain
an induction hardened valve seat. Excessive material removal
will damage valve seats.
Valve Seat Grinding
Select coarse stone of correct size and angle for seat to be
ground. Ensure stone is true and has a smooth surface. Select correct
size pilot for valve guide dimension. Install pilot in valve guide.
Lightly lubricate pilot shaft. Install stone on pilot. Move stone off
and on the seat approximately 2 times per second during grinding
operation.
Select a fine stone to finish grinding operation. Grinding
stones with 30 and 60 degree angles are used to center and narrow the
valve seat as required. See Fig. 10.
Fig. 10: Adjusting Valve Seat Width - Typical
This Graphic For General Information Only
Valve Seat Replacement
Replacement of valve seat inserts is done by cutting out
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interchangeable. Inspect all components for wear. Note amount of wear
in lifter body-to-camshaft contact area. Surface must have smooth and
convex contact face. If wear is apparent, carefully inspect cam lobe.
Inspect push rod contact area and lifter body for scoring
or signs of wear. If body is scored, inspect lifter bore for damage
and lack of lubrication. On roller type lifters, inspect roller for
flaking, pitting, loss of needle bearings and roughness during
rotation.
Measure lifter body O.D. in several areas. Measure lifter
bore I.D. of cylinder block. Some models offer oversized lifters.
Replace lifter if damaged.
If lifter check valve is not operating, obstructions may be
preventing it from closing or valve spring may be broken. Clean or
replace components as necessary.
Check plunger operation. Plunger should drop to bottom of the
body by its own weight when assembled dry. If plunger is not free,
soak lifter in solvent to dissolve deposits.
Lifter leak-down test can be performed on lifter. Lifter
must be filled with special test oil. New lifters contain special test
oil. Using lifter leak-down tester, perform leak-down test following
manufacturer's instructions. If leak-down time is not within
specifications, replace lifter assembly.
Lifters should be soaked in clean engine oil several hours
prior to installation. Coat lifter base, roller (if equipped) and
lifter body with ample amount of Molykote or camshaft lubricant. See
Fig. 13. Install lifter in original location. Install remaining
components. Valve lash adjustment is not required on most hydraulic
lifters. Preload of hydraulic lifter is automatic. Some models may
require adjustment.
Mechanical Lifters
Lifter assemblies must be installed in original locations.
Remove rocker arm assembly and push rod. Mark components for location.
Some applications require intake manifold or lifter cover removal.
Remove lifter retainer plate (if used). To remove lifters, use lifter
remover or magnet.
Inspect push rod contact area and lifter body for scoring or
signs of wear. If body is scored, inspect lifter bore for damage and
lack of lubrication. Note amount of wear in lifter body-to-camshaft
contact area. Surface must have smooth and convex contact face. If
wear is apparent, carefully inspect cam lobe.
Coat lifter base, roller (if equipped) and lifter body with
ample amount of Molykote or camshaft lubricant. Install lifter in
original location. Install remaining components. Tighten bolts to
specification. Adjust valves. See VALVE ADJUSTMENT in this article.
PISTONS, CONNECTING RODS & BEARINGS
* PLEASE READ THIS FIRST *
NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
RIDGE REMOVAL
Ridge in cylinder wall must be removed prior to piston
removal. Failure to remove ridge prior to removing pistons will cause
piston damage in piston ring locations.
With the piston at bottom dead center, place a rag in the
bore to trap metal chips. Install ridge reamer in cylinder bore.
Adjust ridge reamer using manufacturer's instructions. Remove ridge
Page 617 of 1333
HO W T O U SE S YSTE M W IR IN G D IA G RAM S
1991 M it s u bis h i M onte ro
GENERAL INFORMATION
Using Wiring Diagrams
All Models
INTRODUCTION
This CD obtains wiring diagrams and technical service
bulletins, containing wiring diagram changes from the domestic and
import manufacturers. These are checked for accuracy and are all
redrawn into a consistent format for easy use.
In the past, when cars were simpler, diagrams were simpler.
All components were connected by wires and diagrams seldom exceeded 4
pages in length. Today, some wiring diagrams require more than 16
pages. It would be impractical to expect a service technician to trace
a wire from page 1 across every page to page 16.
Removing some of the wiring maze reduces eyestrain and time
wasted searching across several pages. Today the majority of
these
diagrams follow a much improved format, which permits space for
internal switch details.
Wiring diagrams are drawn in a "top-down" format. The
diagrams are drawn with the power source at the top of the diagram and
the ground point at the bottom of the diagram. Components locations
are identified on the wiring diagrams. Any wires that don't connect
directly to a component are identified on the diagram to indicate
where they go.
COLOR ABBREVIATIONS
COLOR ABBREVIATIONS TABLE \
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Black ................ BLK .......................... BK
Blue ................. BLU .......................... BU
Brown ................ BRN .......................... BN
Clear ................ CLR .......................... CR
Dark Blue .......... DK BLU ...................... DK BU
Dark Green ......... DK GRN ...................... DK GN
Green ................ GRN .......................... GN
Gray ................. GRY .......................... GY
Light Blue ......... LT BLU ...................... LT BU
Light Green ........ LT GRN ...................... LT GN
Orange ............... ORG .......................... OG
Pink ................. PNK .......................... PK
Purple ............... PPL .......................... PL
Red .................. RED .......................... RD
Tan .................. TAN .......................... TN
Violet ............... VIO .......................... VI
White ................ WHT .......................... WT
Yellow ............... YEL .......................... YL
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IDENTIFYING WIRING DIAGRAM ABBREVIATIONS
NOTE: Abbreviations used on these diagrams are normally
self-explanatory. If necessary see ABBREVIATIONS
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![MITSUBISHI MONTERO 1991 Service Manual Replace A/T Fluid 30,000 Miles
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Replace A/T Fluid 30,000 Miles
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Case Fluid
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NORMAL MAINTENANCE SERVICE SCHEDULES
The following service schedules refer to vehicles driven
under normal operating conditions. For vehicles driven under severe
conditions, additional services may be necessary. See
SEVERE SERVICE REQUIREMENTS (PERFORM W/SERVICE SCHEDULES) above in
this article for additional service requirements.
7500 MILE (12,000 KM) SERVICE
7500 MILE (12,000 KM) SERVICE \
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Lubrication Specifications
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Application Specification
Engine Oil (
1)
Minimum Temperature
Greater Than 32
F (0
C) ...... SAE 20W-40 Or 20W-50 API SG/CD
Greater Than -10
F (-23
C) ..... SAE 10W-30, 10W-40 API SG/CD
Maximum Temperature
Less Than 60
F (16
C) .......... SAE 5W-30 Or 5W-40 API SG/CD
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1) - Since temperature ranges for different oil grades overlap,
brief fluctuations in outside temperatures are no cause for
concern.
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Fluid Capacities
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Application Quantity
Engine Oil
1987 ......................................... 5.2 Qts. (5.0L)
1988 ......................................... 5.0 Qts. (4.8L)
1989-92 ...................................... 5.5 Qts. (5.3L)
1993-95 ...................................... 5.2 Qts. (4.9L)
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15,000 MILE (24,000 KM) SERVICE
15,000 MILE (24,000 KM) SERVICE \
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50,000 MILE (80,000 KM) SERVICE (198")
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50,000 MILE (80,000 KM) SERVICE (1987-90)
50,000 MILE (80,000 KM) SERVICE (1987-90) \
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Replace
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Service Labor Times
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Application Hours
30,000 (60,000) 50,000
Application Mile Service Mile Service
2.6L 4-Cylinder
Automatic Transmission .... 7.9 (8.9) ................. 2.6
Manual Transmission ....... 6.9 (7.9) ................. 2.6
3.0L V6
Automatic Transmission .... 6.1 (10.6) ................ 2.6
Manual Transmission ....... 5.1 (9.6) ................. 2.6
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52,500 MILE (84,000 KM) SERVICE
52,500 MILE (84,000 KM) SERVICE \
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Application Specification
Engine Oil (
1)
Minimum Temperature
Greater Than 32
F (0
C) ...... SAE 20W-40 Or 20W-50 API SG/CD
Greater Than -10
F (-23
C) ..... SAE 10W-30, 10W-40 API SG/CD
Maximum Temperature
Less Than 60
F (16
C) .......... SAE 5W-30 Or 5W-40 API SG/CD
(
1) - Since temperature ranges for different oil grades overlap,
brief fluctuations in outside temperatures are no cause for