1991 MITSUBISHI MONTERO oil filter
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Fig. 24: Main Bearing Cap Bolt Tightening Sequence
Courtesy of Mitsubishi Motor Sales of America, Inc.
CONNECTING ROD BEARINGS
1) Mark bearing cap and connecting rod for location. Remove
connecting rod cap and bearing. Install replacement bearing.
2) Ensure reference marks on rod cap and connecting rod are
aligned. Check bearing clearance using Plastigage method. Ensure
connecting rod moves freely on crankshaft. Check connecting rod side
play. See CONNECTING RODS table under ENGINE SPECIFICATIONS at end of
article.
CRANKSHAFT END PLAY
If end play is not within specification, inspect thrust
bearings and crankshaft. Replace thrust bearing or crankshaft to
obtain correct end play. See CRANKSHAFT, MAIN & CONNECTING ROD
BEARINGS table under ENGINE SPECIFICATIONS at end of article.
ENGINE OILING
ENGINE LUBRICATION SYSTEM
Oil pressure is provided by a rotor-type pump driven by
crankshaft. Pressure relief valve is located in oil pump body.
CRANKCASE CAPACITY
Montero & Pick-up oil capacity is 5.0 qts. (4.7L). Add .5 qt.\
(.4L) with filter replacement. Add .5 qt. (.4L) with oil cooler.
3000GT oil capacity is 4.2 qts. (4.0L). Add .5 qt. (.4L) with filter\
replacement. Add .5 qt. (.4L) with oil cooler.
Page 33 of 1333
OIL PRESSURE
Oil pressure should be at least 11.4 psi (.8 kg/cm) at idle
and engine oil temperature of 167-194F (75-90C).
OIL PUMP
Removal
Remove timing belt and crankshaft sprocket. See TIMING BELT
under REMOVAL & INSTALLATION. Remove oil pan. See OIL PAN under
REMOVAL & INSTALLATION. Remove oil filter and mounting bracket. Remove
oil pump and gasket from cylinder block. Note bolt length and location
for installation.
Disassembly & Inspection
1) Disassemble pump, and check for scoring and cracks.
Install rotors in pump body. Check clearance between driven rotor and
pump body. See OIL PUMP SPECIFICATIONS table. Place straightedge
across pump body to check rotor side clearance.
2) Check clearance between straightedge and both rotors.
Replace rotor set or pump assembly if not within specification. Ensure
relief valve slides freely in pump body bore. Inspect relief valve
spring for damage.
OIL PUMP SPECIFICATIONS TABLE
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Application In. (mm)
Driven Rotor-To-Pump Body ........ .0039-.0071 (.099-.180)
Rotor Side Clearance ............. .0016-.0037 (.041-.094)
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Reassembly & Installation
1) Reassemble pump. Tighten pump rear cover bolts to
specification. See appropriate TORQUE SPECIFICATIONS table in this
article. Install oil pump and gasket. Ensure splined teeth of oil pump
align with crankshaft. Install bolts, and tighten to specification.
2) If oil seal was removed, coat new seal with grease. Using
Seal Installer (MD998717), install seal in oil pump until flush with
case. Install remaining components.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLE (MONTERO & PICKUP) \
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Application Ft. Lbs. (N.m)
Air Intake Plenum Stay Bolts ............... 11-14 (15-19)
Camshaft Bearing Cap Bolt .................. 14-15 (19-20)
Camshaft Sprocket Bolt ..................... 58-72 (79-98)
Connecting Rod Nut ......................... 37-38 (50-52)
Crankshaft Pulley Bolt
Montero .............................. 108-116 (146-157)
Pickup ............................... 130-137 (176-186)
Cylinder Head Bolt ( 1)
Cold Engine .............................. 65-72 (88-98)
Drive Plate Bolt ........................... 53-55 (72-75)
Exhaust Manifold Nut ....................... 11-16 (15-22)
Flywheel Bolt .............................. 53-55 (72-75)
Intake Manifold Bolts ...................... 11-15 (15-20)
Left Engine Support Bracket Bolt ........... 15-21 (20-30)
Page 34 of 1333
Main Bearing Cap Bolt ...................... 55-61 (75-83)
Oil Pick-Up Tube Bolt ...................... 11-15 (15-20)
Rear Engine Support
Bracket-To-Engine Bolt .................... 13-18 (18-25)
Relief Valve Plug .......................... 29-36 (39-49)
Right Engine Support Bracket Bolt
10x22 mm ................................. 25-36 (34-49)
12x22 mm & 12x32 mm ...................... 47-61 (64-83)
Rocker Shaft ............................... 14-15 (19-20)
Timing Belt Tensioner Bolt ................. 16-21 (22-29)
Water Pump Bolt ............................ 14-20 (19-27)
INCH Lbs. (N.m)
Delivery Pipe Bolt ......................... 84-108 (9-12)
Distributor Adapter Bolt .................. 108-132 (12-15)
Oil Filter Bracket Bolt .................. 108-120 (12-14)
Oil Pan Bolt ................................. 48-60 (5-7)
Oil Pump Cover Bolt ........................ 72-108 (8-12)
Oil Pump Mounting Bolt ................... 108-120 (12-14)
Rear Seal Case Bolt ........................ 84-108 (9-12)
Rocker Cover Bolt ............................ 72-84 (8-9)
Throttle Body Bolt ......................... 84-108 (9-12)
Timing Belt Cover Bolt ..................... 84-108 (9-12)
Transmission Mounting Plate Bolt ........... 84-108 (9-12)
( 1) - Tighten in 2 steps using proper sequence.
See Fig. 4.
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TORQUE SPECIFICATIONS TABLE (3000GT) \
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Application Ft. Lbs. (N.m)
Air Intake Plenum Stay Bolts ..................... 13 (18)
Automatic Tensioner Bolt ......................... 17 (23)
Camshaft Bearing Cap Bolt ........................ 15 (20)
Camshaft Sprocket Bolt ........................... 65 (88)
Connecting Rod Nut ............................... 38 (52)
Crankshaft Pulley Bolt
SOHC ................................. 108-116 (146-157)
DOHC ................................. 130-137 (176-186)
Cylinder Head Bolt ( 1)
SOHC ................................... 76-83 (103-113)
DOHC
Non-Turbo ............................. 76-83 (103-113)
Turbo ................................. 87-94 (118-127)
Distributor Adapter Bolt ......................... 11 (15)
Drive Plate Bolt ................................. 55 (75)
Engine Support Bracket Bolt
Except 10x40 mm ........................ 76-83 (103-113)
10x40 mm ................................. 47-54 (63-73)
Exhaust Manifold Nut ............................. 13 (18)
Flywheel Bolt .................................... 55 (75)
Intake Manifold Bolt
Lower Manifold
Non-Turbo ............................... 11-15 (15-20)
Turbo .................................... 9-11 (12-15)
Upper Manifold ................................. 13 (18)
Main Bearing Cap Bolt ............................ 58 (79)
Oil Filter Bracket Bolt .......................... 11 (15)
Oil Pick-Up Tube Bolt ............................ 14 (19)
Oil Pump Mounting Bolt ........................... 11 (15)
Page 95 of 1333
HEATER HOSES
HIGH PRESSURE RELIEF VALVES (HPRV)
IDLERS
IN-LINE FILTERS
METAL FITTINGS
METAL LINES
MIX AND AIR CONTROL DOORS (BLEND DOORS)
O-RINGS
ORIFICE TUBES
PILOT-OPERATED ABSOLUTES (POAS)
PLENUMS
PRESSURE CONTROL VALVES
PRESSURE SENSORS
PULLEYS
RADIATORS
RECEIVER-DRIERS
REFRIGERANT
REFRIGERANT OIL
RELAYS
SEALS
SERVICE PORTS
SPRING LOCK COUPLINGS
SUCTION THROTTLING VALVES (STVS)
SWITCHES (ELECTRICAL)
TENSIONERS
THERMISTORS AND PRESSURE SENSORS
THERMOSTATS AND HOUSINGS
VACUUM HOSES AND TUBES
VACUUM RESERVOIRS
VACUUM TUBES
VALVES IN RECEIVER (VIRS)
WATER PUMPS (ELECTRIC AUXILIARY)
WIRING HARNESSES AND CONNECTORS
MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt
(1) a Pledge of Assurance to their Customers and (2) the Motorist
Assurance Program Standards of Service. All participating service
providers have agreed to subscribe to this Pledge and to adhere to the
promulgated Standards of Service demonstrating to their customers that
they are serious about customer satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection communication standards
Page 105 of 1333
Connector missing ....... C ............ Require replacement.
Inoperative ............. A ........ (2) Require replacement.
Insulation overheated ... A ............ Require replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Inoperative includes intermittent operation or out of
OEM specification.
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BLOWER SWITCHES
See SWITCHES.
CABIN AIR FILTERS
CABIN AIR FILTER INSPECTION \
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Condition Code Procedure
Air flow obstruction .... A ............. Require cleaning or
replacement.
Maintenance intervals ... 3 ............ Suggest replacement.
Missing ................. C ............ Require replacement.
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CIRCUIT BREAKERS
See FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS .
COMPRESSOR CLUTCH ASSEMBLIES
COMPRESSOR CLUTCH ASSEMBLY INSPECTION \
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Condition Code Procedure
Air gap incorrect ....... B .. Require repair or replacement.
Bearing seized .......... A .. Require replacement of bearing
or assembly.
Bearing worn, affecting
performance ............ A .. Require replacement of bearing
or assembly.
Coil shows signs of
overheating ............ 1 .... Suggest replacement of coil.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted,
Page 214 of 1333
![MITSUBISHI MONTERO 1991 Service Manual Removal
1) Raise and support vehicle. Remove front wheel(s). Separat\
e
rubber flex hose from hydraulic line at brake hose mount, located on
strut housing. Secure end of hydraulic li](/manual-img/19/57332/w960_57332-213.png "MITSUBISHI MONTERO 1991 Service Manual Removal
1) Raise and support vehicle. Remove front wheel(s). Separat\
e
rubber flex hose from hydraulic line at brake hose mount, located on
strut housing. Secure end of hydraulic li")
Removal
1) Raise and support vehicle. Remove front wheel(s). Separat\
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rubber flex hose from hydraulic line at brake hose mount, located on
strut housing. Secure end of hydraulic line to prevent spillage of
brake fluid.
2) Remove hose clip from brake hose mount. Disconnect brake
hose from caliper. Remove upper and lower caliper-to-steering knuckle
bolts. Lift caliper body upward. Remove caliper.
Installation
To install, reverse removal procedure. Tighten bolts to
specification. See the TORQUE SPECIFICATIONS table. Bleed brake
system. See BLEEDING BRAKE SYSTEM .
FRONT BRAKE ROTOR
Removal (Montero, Pickup 4WD & Ram-50 4WD)
Raise and support vehicle. Remove and support brake calipers.
Place hub in free-wheeling position. Remove drive hub cover using an
oil filter wrench and protective cloth. Remove snap ring, shim and
free-wheeling hub from drive axle. See Fig. 7. Remove lock washer.
Remove lock nut using Lock Nut Wrench (MB990954). Remove front hub
assembly.
Fig. 7: Exploded View of Front Brake Assembly (4WD)
Courtesy of Mitsubishi Motor Sales of America.
Installation
1) Install front hub assembly. Install and tighten lock nut
to 94-145 ft. lbs. (127-197 N.m), and then loosen and retighten to 18
ft. lbs. (24 N.m). Loosen lock nut 30-40 degrees. Reverse removal
procedure for remaining components. After installation is complete,
check drive axle end play. Adjust end play if not .002" (.05 mm) or
less. Rotate drive axle forward and rearward until maximum end play is
obtained.
2) If adjusting axle shaft end play, use proper shim to
obtain desired end play. Shim is located behind snap ring on end of
drive axle. Install shim, and recheck axle end play.
Removal (Pickup 2WD & Ram-50 2WD)
Raise and support vehicle. Remove front caliper. Remove hub
(dust) cap, cotter pin and nut. Remove washer and outer wheel bearing.\
Remove front hub assembly. Remove bolts attaching rotor to front hub,
and separate assemblies.
Page 346 of 1333
Idle Speed Control Sensor On throttle body assembly.
Intake Air Temperature Sensor Inside airflow sensor
assembly.
Oil Pressure Sending Unit On right side of engine, near
oil filter.
Temp. Gauge Sending Unit On thermostat housing.
Page 350 of 1333
Inhibitor Switch (A/T) At base of shift lever.
Oil Pressure Switch On right side of engine, near
oil filter.
Power Steering Pressure Switch On power steering pump.
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MISCELLANEOUS \
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Component Component Location \
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A/C-Heater Blower Motor Resistor On blower motor housing.
Diagnostic/Test Connector: