1991 MITSUBISHI MONTERO engine
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![MITSUBISHI MONTERO 1991 Service Manual Torn .................... A ............ Require replacement. \
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Torn .................... A ............ Require replacement. \
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ENGINE MOUNTS
See MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION) .
EXCITER RINGS
See TOOTHED RINGS (TONE WHEELS) .
FILLER TUBES
See DIP STICK TUBES .
FILTERS AND SCREENS
FILTER AND SCREEN INSPECTION \
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Condition Code Procedure
At service interval ..... 3 ............ Suggest replacement.
Bent .................... A .. Require repair or replacement.
Exceeding service
interval ............... 3 ............ Suggest replacement.
Missing ................. C ............ Require replacement.
Near service interval ... 3 ............ Suggest replacement.
Restricted .............. A ........... ( 1) Require repair or
replacement.
Torn .................... A ............ Require replacement.
Worn, affecting
performance (metal or
nylon screen type) ..... A .. Require repair or replacement.
( 1) - Further inspection may be required to determine the
source of restriction or contamination.
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FLANGES
See COMPANION FLANGES .
FLEX PLATES
FLEX PLATE INSPECTION \
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Condition Code Procedure
Bent, affecting
performance ............ A ............ Require replacement.
Bent, not affecting
performance ............ .. ........ No service suggested or
required.
Bolt or stud holes
elongated .............. B ............ Require replacement.
Broken .................. A ............ Require replacement.
Cracked ................. A ............ Require replacement.
Ring gear worn close
to the end of its
useful life ............ 1 ............ Suggest replacement.
Ring gear worn to the
extent that it no longer
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Damaged, affecting
performance ............ A ............ Require replacement.
Missing ................. C ............ Require replacement.
Worn, affecting
performance ............ A ............ Require replacement.
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LUBRICANTS
See FLUIDS AND LUBRICANTS .
METAL-CLAD SEALS
See SEALS.
METALASTIC JOINTS
See RUBBER JOINTS (METALASTIC) .
MODULATOR PINS
MODULATOR PIN INSPECTION \
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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Missing ................. C ............ Require replacement.
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MODULATORS
MODULATOR INSPECTION \
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Condition Code Procedure
Bent, affecting
performance ............ A ............ Require replacement.
Contaminated (water, fuel,
etc.) .................. A ........ ( 1) Require replacement.
Housing cracked ......... A ............ Require replacement.
Inoperative ............. A ........ ( 2) Require replacement.
Leaking fluid
externally ............. A .. Require repair or replacement.
Leaking fluid
internally ............. A ............ Require replacement.
Leaking vacuum .......... A ............ Require replacement.
Nipple broken ........... A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Further inspection is required to determine the cause
of the contamination.
( 2) - Inoperative includes intermittent operation or out of OEM
specification.
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MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION)
MOUNT (ENGINE, TRANSAXLE AND TRANSMISSION) INSPECTION \
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Page 324 of 1333
incorrect .............. B ............ Require replacement.
Teeth broken ............ A ............ Require replacement.
Teeth damaged, affecting
performance ............ A ............ Require replacement.
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TORQUE CONVERTERS
TORQUE CONVERTER INSPECTION \
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Condition Code Procedure
Converter clutch lock-up
operation is faulty .... A ............ Require replacement.
Cover shell damaged,
affecting performance .. A ............ Require replacement.
Does not meet stall speed
specification .......... B ............ Require replacement.
End play exceeds
specifications ......... B ............ Require replacement.
Hub broken .............. A ............ Require replacement.
Hub cracked ............. A ............ Require replacement.
Internal component
failure ................ A ............ Require replacement.
Leaking ................. A .. Require repair or replacement.
Pilot broken ............ A ............ Require replacement.
Pilot worn, affecting
performance ............ A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Weights missing ......... C ............ Require replacement.
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TRANSAXLE MOUNTS
See MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION) .
TRANSDUCERS (TRANSMISSION)
See SENSORS.
TRANSMISSION COOLERS
TRANSMISSION COOLER INSPECTION \
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Condition Code Procedure
Air flow obstruction .... A ................. Require repair.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A .. Require repair or replacement
of hardware.
Connection leaking ...... A .. Require repair or replacement.
Contaminated ............ A .. Require repair or replacement.
Corroded ................ 1 .. Suggest repair or replacement.
Fins damaged, affecting
Page 325 of 1333
performance ............ A .. Require repair or replacement.
Fins damaged, not
affecting performance .. .. ........ No service suggested or
required.
Internal restrictions ... B .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A .. Require repair or replacement.
Tubes damaged, affecting
performance ............ A .. Require repair or replacement.
Tubes damaged, not
affecting performance .. .. ........ No service suggested or
required.
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TRANSMISSION MOUNTS
See MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION) .
TRANSMISSION PANS
TRANSMISSION PAN INSPECTION \
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Condition Code Procedure
Bent, interfering with
filter or other internal
components ............. A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
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TRANSMISSION RANGE INDICATORS (PRNDL)
TRANSMISSION RANGE INDICATOR (PRNDL) INSPECTION \
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Condition Code Procedure
Binding ................. A .. Require repair or replacement.
Broken .................. A .. Require repair or replacement.
Components missing ...... C .. Require replacement of missing
components.
Loose, affecting
performance ............ A .. Require repair or replacement.
Out of adjustment ....... A ................. Require repair.
Worn, affecting
performance ............ A .. Require repair or replacement.
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TUBES
See HOSES, LINES AND TUBES .
UNIVERSAL JOINTS (CARDON OR CROSS TYPE)
UNIVERSAL JOINT (CARDON OR CROSS TYPE) INSPECTION \
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Page 330 of 1333
\003P - E G R F U NCTIO N T E STIN G
1991 M it s u bis h i M onte ro
1989-95 ENGINE PERFORMANCE
Chrysler Motors/Mitsubishi Corp. EGR Function Testing
All Models
EGR FUNCTION TESTING
Colt Wagon 1.8L, Montero (A/T), Raider (A/T), Sigma,
Van/Wagon & All Other Federal Models (Ported EGR Valve)
1) Disconnect Green-striped hose from throttle body and
connect a vacuum pump to hose end. Plug nipple where hose was
connected to throttle body. With engine temperature 122
F (50 C) or
less, and engine idling, apply vacuum to hose. If idle does not change
and vacuum leaks down, system is functioning properly.
2) With engine temperature 176-205
F (80-95 C) and engine
idling, apply 2 in. Hg to hose. If idle does not change, and vacuum
holds, system is functioning properly.
3) Apply 7.7 in. Hg. If vacuum holds and idle becomes
unstable or engine stalls, EGR system is functioning properly.
Montero (M/T), Raider (M/T) & All Other California
Models (Ported EGR Valve)
1) Connect a vacuum tee into Green-striped hose from EGR
valve and connect a vacuum pump to vacuum tee. With engine temperature
68
F (20 C) or less and engine idling, snap throttle opened and
closed. If no change in vacuum reading on vacuum pump gauge is
detected, system is functioning properly.
2) With engine temperature 158
F (70 C) or higher and engine
idling, snap throttle open to race engine. If vacuum is now indicated
on vacuum pump gauge, system is functioning properly.
3) Using a vacuum pump, apply specified vacuum to open EGR
valve. See appropriate EGR VALVE SPECIFICATIONS table. If idle becomes
unstable or engine stalls, EGR system is functioning properly.
EGR VALVE SPECIFICATIONS TABLE (1989 Models)
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Application Closed Open
In. Hg In. Hg
Colt, Colt Wagon,
Mirage ....................... 1.8 ................ 7.7
Colt Vista .................... 2.1 ................ 6.8
Galant, Sigma ................. 1.7 ................ 7.5
Montero, Raider,
Van/Wagon .................... 1.9 ................ 6.7
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EGR VALVE SPECIFICATIONS TABLE (1990 Models)\
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Application Closed Open
In. Hg In. Hg
Colt, Colt 200, Mirage
& Colt Wagon ................. 1.8 ................ 7.7
Colt Vista .................... 2.1 ................ 6.8
Eclipse ....................... 1.8 ................ 8.5
Galant ........................ 1.7 ................ 7.5
Pickup, Ram-50 ................ 1.2 ................ 9.4
Precis ........................ 1.0 ................ 3.3
Sigma ......................... 1.6 ................ 8.7
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Alternator Relay On left front of engine
compartment, behind headlight.
Condenser Fan Motor Relay On left inner fender panel.
Control Relay Behind right kick panel.
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Hazard Flasher Relay Behind left side of dash,
above kick panel.
Headlight Control Relay On left front side of engine
compartment, behind headlight.
Page 340 of 1333
![MITSUBISHI MONTERO 1991 Service Manual \
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Component Compon](/manual-img/19/57332/w960_57332-339.png "MITSUBISHI MONTERO 1991 Service Manual \
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Component Compon")
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Component Component Location \
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A/C Dedicated Fuse Behind right side of dash, on
evaporator case.
Central Door Lock Dedicated Fuse Behind right side of dash,
left of blower assembly.
Defogger Sub-Fusible Link On wiring harness, near front
wiper motor.
Dual A/C Dedicated Fuse Behind right side of dash, on
blower case.
Headlight Dedicated Fuse On left front corner of engine
compartment.
Fuse Block On left end side of dash, near
door.
Fusible Links:
Main On right rear corner of engine
compartment, near battery.
Sub On right rear corner of engine
compartment, near battery.
Sun Roof Dedicated Fuse Behind right side of dash.
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CONTROL UNITS \
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Component Component Location \
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Auto. Free Wheeling Hub Cntrl. Unit Behind right side of dash,
left of blower unit.
Cruise Control Unit Behind right kick panel.
Door Lock Control Unit Under center console, beside
parking brake lever.