1991 MITSUBISHI MONTERO fuel

IN STR UM EN T P A N EL

1991 M it s u bis h i M onte ro
1991 ACCESSORIES & SAFETY EQUIPMENT
Chrysler Motors/Mitsubishi Switches & Instrument Panels
Dodge; Ram-50
Mitsubishi: Montero, Pickup
DESCRIPTION & OPERATION
Instrument cluster includes speedometer, fuel gauge and
temperature gauge. Fuel gauge has a built-in voltage limiter to keep
voltage supply to gauges at 7 volts. Some models may also have a
shunt-type ammeter, oil pressure gauge, tachometer, voltmeter and/or
turbo boost pressure gauge. Oil pressure gauge uses full battery
voltage. The tachometer operates by pulse feed.
TROUBLE SHOOTING
FUEL/TEMPERATURE GAUGE NOT WORKING
Check for blown fuse, faulty voltage limiter or faulty relay.
Ensure sending unit connections are clean and tight. Test sending unit
for correct operation. Tighten connections in instrument cluster.
SPEEDOMETER NOT WORKING
Ensure speedometer cable is properly connected and correctly
routed. If speedometer pointer and/or odometer still do not work,
replace speedometer as an assembly.
TACHOMETER NOT WORKING
Tachometer is serviced as an assembly. If wiring harness is
okay, replace tachometer assembly.
WARNING LIGHTS NOT WORKING
Test for defective sending unit, burned out bulb, or broken
printed circuit. Ensure all wire connections are clean and tight.
TESTING
FUEL TANK SENDING UNIT
Resistance Test
Remove fuel tank sending unit from fuel tank. Measure
resistance between appropriate terminals with fuel float in Full and
Empty positions. See Fig. 1. Compare resistance reading to
FUEL TANK SENDING UNIT RESISTANCE SPECIFICATIONS table. If resistance
is not to specifications, replace fuel tank sending unit.
FUEL TANK SENDING UNIT RESISTANCE SPECIFICATIONS TABLE









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Application Empty Full
All Models ........... 103-117 ................ 1-5









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FUEL GAUGE
Simple Test
Disconnect fuel sending unit connector wire in luggage
compartment, cargo space, or at tank unit. Connect a 12-volt, 3.4-watt
bulb to harness side of connector, between power terminal and ground
(Yellow and Black wires on Montero). On Pickup and Ram-50 see Fig. 1.
Turn ignition switch to ON position. Ensure test bulb flashes, or
stays on, and fuel gauge needle moves. If bulb or gauge needle does
not function as described, check and repair fuel gauge circuit.
CAUTION: Gauge coils can be damaged if wire is grounded too long.
Perform test as quickly as possible.
Fig. 1: Identifying Fuel Gauge Test Connection (Pickup & Ram-50)
Courtesy of Chrysler Motors.
NOTE: The following test must be completed with instrument panel
cluster removed. Use ohmmeter for all measurements. If
resistance is extremely low, there may be a short in the
coil. If resistance is extremely high, there may be a broken
wire or similar problem in the gauge.
Resistance Test
Remove instrument cluster. See INSTRUMENT CLUSTER under
REMOVAL & INSTALLATION. Measure resistance between appropriate
terminals of instrument cluster or combination gauges. See Fig. 2 or

Fig. 3. See FUEL GAUGE RESISTANCE SPECIFICATIONS table. If resistance
readings are not to specifications, replace fuel gauge.
FUEL GAUGE RESISTANCE SPECIFICATIONS TABLE









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Application Terminals Ohms
Montero .................... No. 1 & 2 ........................ 55
" .......................... No. 2 & 3 ....................... 165
" .......................... No. 1 & 3 ....................... 110
Pickup & Ram-50 .......... IGN & ground. ................... 62-78
" ........................... 7V & FU ...................... 49-61









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Fig. 2: Fuel Gauge Resistance Check Terminal ID (Montero)
Courtesy of Mitsubishi Motor Sales of America.
Fig. 3: Fuel Gauge Resistance Check Terminal ID (Pickup & Ram-50)
Courtesy of Mitsubishi Motor Sales of America.

1994-96 (3.0L DOHC & 3.5L) .................. 9.0 Qts. (8.5L)
Cooling System
1983-88 ..................................... 8.5 Qts. (8.0L)
1989-96
2.6L ....................................... 9.7 Qts. (9.2L)
3.0L ...................................... 10.0 Qts. (9.5L)
3.5L ...................................... 10.0 Qts. (9.5L)
Differential
1983-88 ..................................... 1.9 Qts. (1.8L)
1989-93
2.6L ....................................... 1.9 Qts. (1.8L)
3.0L ....................................... 2.7 Qts. (2.6L)
1994-96
3.0L & 3.5L ................................ 2.7 Qts. (2.6L)
Engine Oil
1983-86 ..................................... 6.0 Qts. (5.8L)
1987 ........................................ 5.2 Qts. (5.0L)
1988 ........................................ 5.0 Qts. (4.8L)
1989-91 ..................................... 5.5 Qts. (5.3L)
1992-96 ..................................... 5.2 Qts. (4.9L)
Power Steering ................................ 1.1 Qts. (1.0L)
Fuel Tank
1983-88 .................................... 15.9 Gals. (60L)
1989-90
2.6L 2-Door ............................... 15.9 Gals. (60L)
3.0L 2-Door ............................... 19.9 Gals. (75L)
2.6L & 3.0L 4-Door .......................... 24 Gals. (92L)
1991-96 ...................................... 24 Gals. (92L)
Manual Transmission
1983-91 ..................................... 2.3 Qts. (2.2L)
1992 ........................................ 2.4 Qts. (2.3L)
1993-96 ..................................... 2.6 Qts. (2.5L)
Transfer Case
1983-91 ..................................... 2.3 Qts. (2.2L)
1992-96 ..................................... 2.4 Qts. (2.3L)
(1) - Use of R12 in a R134a system will result in SEVERE DAMAGE.
( 2) - 1983 model equipped with manual transmission only.









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WHEEL & TIRE SPECIFICATIONS
Tire specifications are imprinted on the tire side wall. The
recommended cold tire inflation pressures are listed on a label
attached to the rear face of the driver's door. These pressures
provide the best combination of ride comfort, tire wear and stability
under normal conditions.
CAUTION: DO NOT mix tires of different design such as radial ply
with bias or bias-belted tires. Mixing tire types will
adversely affect road handling and may lead to loss of
vehicle control. When using snow tires, they must be used
in set of four for maneuverability and safety. DO NOT use
tire chains on front wheels.
TIRE & WHEEL SPECIFICATIONS TABLE









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Wheel Size Tire Size
1983-86
15 x 6JJ (Steel) .............................. 215 SR15
1987-88

CATALYTIC CONVERTER
Continued operation of vehicle with a severe malfunction
could cause converter to overheat, resulting in possible damage to
converter and vehicle.
COOLANT (PROPYLENE-GLYCOL FORMULATIONS)
CAUTION: To avoid possible damage to vehicle use only ethylene-glycol
based coolants with a mixture ratio from 44-68% anti-freeze.
DO NOT use 100% anti-freeze as it will cause the formation
of cooling system deposits. This results in coolant
temperatures of over 300
\b F (149\bC) which can melt plastics.
100% anti-freeze has a freeze point of only -8\b F (-22\bC).
CAUTION: Propylene-Glycol Mixtures has a smaller temperature range
than Ethylene-Glycol. The temperature range (freeze-boil)
of a 50/50 Anti-Freeze/Water Mix is as follows:
Propylene-Glycol -26
\b F (-32\bC) - 257\b F (125\bC)
Ethylene-Glycol -35\b F (-37\bC) - 263\b F (128\bC)
CAUTION: Propylene-Glycol/Ethylene-Glycol Mixtures can cause the
destabilization of various corrosion inhibitors. Also
Propylene-Glycol/Ethylene-Glycol has a different specific
gravity than Ethylene-Glycol coolant, which will result in
inaccurate freeze point calculations.
ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS
WARNING: Many solid state electrical components can be damaged by
static electricity (ESD). Some will display a warning label,
but many will not. Discharge personal static electricity by
touching a metal ground point on the vehicle prior to
servicing any ESD sensitive component.
ENGINE OIL
CAUTION: Never use non-detergent or straight mineral oil.
FUEL SYSTEM SERVICE
WARNING: Relieve fuel system pressure prior to servicing any fuel
system component (fuel injection models).
HALOGEN BULBS
WARNING: Halogen bulbs contain pressurized gas which may explode if
overheated. DO NOT touch glass portion of bulb with bare
hands. Eye protection should be worn when handling or working
around halogen bulbs.
RADIATOR CAP
CAUTION: Always disconnect the fan motor when working near the
radiator fan. The fan is temperature controlled and could
start at any time even when the ignition key is in the OFF
position. DO NOT loosen or remove radiator cap when cooling
system is hot.
RADIATOR FAN

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PR E-A LIG NM EN T C HEC KS

1991 M it s u bis h i M onte ro
Wheel Alignment
PRE-ALIGNMENT INSPECTION PROCEDURES
PRE-ALIGNMENT CHECKS
Before making wheel alignment adjustment, perform the
following checks:
1) Tires should be equal in size and runout must not be
excessive. Tires and wheels should be in balance, and inflated to
manufacturer's specifications.
2) Wheel bearings must be properly adjusted. Steering linkage
and suspension must not have excessive looseness. Check for wear in
tie rod ends and ball joints.
3) Steering gear box must not have excessive play. Check and
adjust to manufacturer's specifications.
4) Vehicle must be at curb height with full fuel load and
spare tire in vehicle. No extra load should be on vehicle.
5) Vehicle must be level with floor and with suspension
settled. Jounce front and rear of vehicle several times and allow it
to settle to normal curb height.
6) If steering wheel is not centered with front wheels in
straight-ahead position, correct by shortening one tie rod adjusting
sleeve and lengthening opposite sleeve equal amounts.
7) Ensure wheel lug nuts are tightened to torque
specifications.

Fig. 6: Exploded View of Distributor (Pickup & Ram-50 2.4L)
Courtesy of Mitsubishi Motor Sales of America.
Fig. 7: Exploded View of Distributor (Stealth 3.0L SOHC)
Courtesy of Mitsubishi Motor Sales of America.
FUEL SYSTEM

FUEL SYSTEM PRESSURE RELEASE
WARNING: ALWAYS relieve fuel pressure before disconnecting any fuel
injection-related component. DO NOT allow fuel to contact
engine or electrical components.
1) On Colt and Mirage, remove rear seat cushion. On all
models, disconnect fuel pump harness connector at fuel tank.
2) Start engine. Let engine run until it stops. Turn ignition
off. Disconnect negative battery terminal. Connect fuel pump harness
connector.
FUEL PUMP
Removal & Installation
1) Fuel pump assembly is located inside fuel tank. Release
fuel pressure from system. See FUEL SYSTEM PRESSURE RELEASE. Raise
vehicle on hoist. Drain fuel into suitable container. Disconnect
electrical connectors and fuel hoses at fuel tank.
2) Remove fuel filler hose from fuel tank. Remove nuts
securing fuel tank. Remove fuel tank from vehicle and remove fuel pump
assembly. To install, reverse removal procedure. Tighten nuts to
specification. See TORQUE SPECIFICATION table.
FUEL RAILS & INJECTORS (PFI)
Use a rag to cover fuel hose connection before disconnecting
high pressure fuel hose at fuel rail. Some residual fuel pressure may
still be in system.
Removal (Except Pickup & Ram-50 2.4L)
1) On all models, relieve fuel pressure. See
FUEL SYSTEM PRESSURE RELEASE . Disconnect negative battery cable. On
Montero, Pickup, Ram-50, Stealth and 3000GT 3.0L, disconnect air
intake plenum. On Eclipse, disconnect PCV valve hose.
2) On Colt Vista, disconnect coolant temperature sensor
connector, idle speed control servo connector and brake booster vacuum
hose. On all models, disconnect high pressure fuel hose at fuel rail.
3) Disconnect fuel return hose. Disconnect vacuum hoses. On
Eclipse, Colt and Colt 200, disconnect throttle cable clamp. Remove
center cover. On all models, disconnect injector electrical
connectors. Remove fuel rail bolts and lift fuel rail and injectors
from engine.
Installation
To install, reverse removal procedure. Tighten bolts to
specifications. See TORQUE SPECIFICATIONS table.
Removal (Pickup & Ram-50 2.4L)
1) Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELEASE.
Disconnect negative battery cable. Drain coolant. On all models,
disconnect air intake hose. Disconnect breather hose (if applicable)
and vacuum hoses.
2) Disconnect coolant lines as necessary for clearance.
Disconnect injector electrical connectors. Position all lines, hoses
and electrical connectors out of way. Disconnect throttle and/or
kickdown cables. Remove throttle body assembly and position it out of
the way.
3) Disconnect high pressure fuel hose at fuel rail.
Disconnect fuel return line and vacuum line connection at fuel rail.
Remove fuel rail bolts and lift fuel rail and injectors from engine.