1991 MITSUBISHI MONTERO engine oil
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TR AN SM IS SIO N S ER VIC IN G - A /T
1991 M it s u bis h i M onte ro
1991 TRANSMISSION SERVICING
Automatic Transmission
Mitsubishi: Eclipse, Galant, Mirage,
Montero, Pickup, Precis, 3000GT
IDENTIFICATION
MITSUBISHI AUTOMATIC TRANSMISSION APPLICATIONS \
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Model Transmission/Transaxle
Eclipse
1.8 & 2.0L ........................... Model F4A22 Transaxle
2.0L Turbo ........................... Model F4A33 Transaxle
All-Wheel Drive (AWD) ................ Model W4A33 Transaxle
Galant
AWD .................................. Model W4A32 Transaxle
DOHC ................................. Model F4A22 Transaxle
SOHC ........................ Model KM175 or F4A22 Transaxle
Mirage
1.5L ................................. Model F3A21 Transaxle
1.6L ................................. Model F4A21 Transaxle
Montero ............................ Model V4AW2 Transmission
Pickup ............................. Model R4AC1 Transmission
Precis ................................ Model KM176 Transaxle
3000GT ................................ Model F4A33 Transaxle
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LUBRICATION
TRANSAXLE/TRANSMISSION SERVICE INTERVALS
Check fluid level every 12 months or 15,000 miles. Change
fluid and filter every 30,000 miles. If vehicle is operated under
severe condition, change fluid more often. If severe darkening of
fluid and strong odor are noted, bands should also be adjusted (if
equipped).
TRANSFER CASE SERVICE INTERVALS
On 4WD and AWD models, change transfer case fluid every 30,
000 miles.
CHECKING FLUID LEVEL
TRANSAXLE/TRANSMISSION
1) Park vehicle on level area. Ensure oil is at normal
operating temperature, parking brake is engaged, and engine is at
idle. Move gear selector through each position, stopping briefly in
each position.
2) Place gear selector in Neutral, and clean area around
dipstick tube. Ensure fluid level is between lower and upper marks,
but never over upper mark, in HOT range. Add or drain fluid if
necessary.
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CAUTION: If severe darkening of fluid and strong odor are noted,
change fluid and filter, and adjust bands.
TRANSFER CASE (3000GT)
Lubricant level should be approximately .5" (13 mm) below
fill hole on side of transfer case.
TRANSFER CASE (ALL OTHERS)
Lubricant level should be to bottom of fill hole on side of
transfer case.
RECOMMENDED FLUID
TRANSAXLE/TRANSMISSION
Use Chrysler Plus/Mitsubishi Plus ATF, Dexron and Dexron-II
ATF.
TRANSFER CASES
Use SAE 75W-85 gear oil with API GL-4 rating or higher.
FLUID CAPACITY
TRANSAXLE/TRANSMISSION REFILL CAPACITIES \
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Refill Dry Fill
Application Qts. (L) Qts. (L\
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Mirage ..................... 4.8 (4.5) ............... 13.0 (12.2\
)
Eclipse
F4A22 .................... 4.2 (4.0) ................. 6.4 (6.1\
)
F4A33 & W4A33 ............ 6.4 (6.1) ................. 8.0 (7.6\
)
Galant
2WD ...................... 4.8 (4.5) ................. 6.4 (6.1\
)
AWD ...................... 4.8 (4.5) ................. 6.9 (6.5\
)
Montero .................... 5.8 (5.5) ................. 7.4 (7.0\
)
Pickup ................... 2.0 (1.9)( 1) ............... 10.2 (9.7)
Precis ..................... 4.8 (4.5) ................. 6.4 (6.1\
)
3000GT ..................... 4.8 (4.5) ................. 7.9 (7.5\
)
( 1) - Idle engine in Neutral, then add fluid to bring level between
notches at "H" mark.
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TRANSFER CASE REFILL CAPACITIES \
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Application Pts. (L)
Eclipse & Galant ............................ 1.3 (0.6)
Mirage ............................................ N/A
Montero & Pickup ............................ 4.6 (2.2)
3000GT ........................................ .6 (.3)
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DRAINING & REFILLING
NOTE: Although manufacturer recommends changing only fluid, the
oil filter/screen may also require replacement. If replacing
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oil filter/screen, note length and location of all bolts.
TRANSAXLE (EXCEPT MONTERO, PICKUP & RAM-50)
1) Remove drain plug(s), and drain fluid. See Fig. 1. Some
applications may contain a drain plug located in housing below drive
axle shaft, in oil pan. Remove oil pan. Remove oil filter/screen if
necessary.
2) If oil filter/screen is replaced, tighten bolts to
specification. See TORQUE SPECIFICATIONS table at end of article.
Clean oil pan, replace gasket, and install oil pan. Tighten oil pan
bolts and drain plug to specification. See TORQUE SPECIFICATIONS
table. Ensure dipstick hole area is clean, and pour approximately 4.2
qts. (4.0L) of Dexron-II fluid into dipstick hole.
3) Operate engine at idle for 2 minutes. Shift transaxle to
each position, ending in Neutral. Add sufficient fluid to reach lower
mark. After reaching normal operating temperature, fluid should be
between upper and lower marks of HOT range on dipstick.
Fig. 1: Locating Drain Plugs
Courtesy of Mitsubishi Motor Sales of America.
TRANSMISSION (MONTERO & PICKUP)
1) Remove drain plug (if equipped) from transmission pan, an\
d
allow fluid to drain. On models without drain plug, remove oil pan
must to drain fluid. Remove oil filter/screen if necessary.
2) If oil filter/screen is replaced, tighten bolts to
specification. See TORQUE SPECIFICATIONS table at end of article.
Clean oil pan, replace gasket, and install oil pan. Tighten oil pan
bolts and drain plug to specification. See TORQUE SPECIFICATIONS
table. Fill transmission, through filler tube, with 5.3 qts. (5.0L) of\
Dexron-II ATF on Montero, or 2.0 qts. (1.9L) on all others. Start
engine, and allow to idle for 2 minutes.
3) Shift transmission into each position, ending in Neutral.
Check fluid level with engine running at idle, and add sufficient
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fluid to bring level to lower mark of dipstick if necessary. Recheck
fluid level after transmission is at normal operating temperature.
TRANSFER CASE
Drain plug is located on bottom of transfer case. Change
drain plug gasket whenever fluid is changed. On 3000GT, lubricant
level should be approximately .5" (13 mm) below fill hole on side of
transfer case. On all others models, lubricant level should be to
bottom of fill hole on side of transfer case.
HYDRAULIC CONTROL PRESSURE ADJUSTMENTS
LINE PRESSURE CHECK (EXCEPT MONTERO & PICKUP)
1) Set parking brake. Place shift lever in Neutral position.
Attach engine tachometer. Remove line pressure port plug located above
front transaxle shaft, forward of governor pressure port plug. On
Precis, line pressure port is located below bell housing, at front of
transaxle oil pan. Using appropriate adapter, attach pressure gauge.
2) Start engine, and bring to operating temperature. With
gear selector in Drive position, bring engine speed to 2500 RPM. Pull
throttle control cable (if equipped) wide open at transaxle side.
3) Line pressure should be 98-100 psi (6.9-7.0 kg/cm
) on
Mirage, or 124-127 psi (8.7-8.9 kg/cm) on all others. If line
pressure is not to specification, proceed to LINE PRESSURE ADJUSTMENT.
LINE PRESSURE ADJUSTMENT (EXCEPT MONTERO & PICKUP)
1) Drain transaxle fluid. Remove oil pan. Disconnect throttle
control cable from throttle cam. Remove oil temperature sensor (if
equipped). Disconnect solenoid connector. On some models, it may be
necessary to push solenoid wire harness connector and grommet into
transaxle case.
2) Remove oil filter screen and plate. Noting location and
length of bolts, remove valve body. DO NOT drop internal parts. Adjust
line pressure by turning regulator valve adjusting screw.
3) Turn adjusting screw counterclockwise to increase pressure
or clockwise to decrease pressure. One complete turn of adjusting
screw changes line pressure as follows.
* 3.7 psi (.26 kg/cm
) on Mirage with F3A21 Transaxle
* 5.4 psi (.39 kg/cm) on Precis
* 54 psi (3.8 kg/cm) on all others
4) After adjustment, reverse removal procedure to install.
Refill transaxle.
LINE PRESSURE (MONTERO)
1) Remove plug from line pressure take-off port located
behind transmission shift control lever. Install Hydraulic Pressure
Meter (MD998330) with Adapter (MD998206).
2) Place vehicle on dynamometer. Apply parking brake and
start engine. With brake applied, place transmission in Drive. Note
pressure at idle. Pressure should be 74-85 psi (5.2-6.0 kg/cm
).
3) Raise engine RPM to stall speed (2100-2400 RPM). Note lin\
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pressure. Pressure should be 156-185 psi (11.0-13.0 kg/cm
).
4) Shift transmission into Reverse with brake applied. At
idle, pressure should be 112-130 psi (7.9-9.1 kg/cm
). Raise engine
RPM to stall speed (2100-2400 RPM). Note line pressure. Pressure
should be 227-285 psi (16.0-20.0 kg/cm
). If readings are not to
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widening the gap to 1/4-3/8".
Disconnect spark plug wire
and insert test plug. Ground
plug, crank engine, and
check for spark.
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GOOD SPARK NO SPARK
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* If plug sparks, driveability * Remove coil wire from the
problem is most likely NOT distributor and attach the
in the ignition system. modified spark plug. Ground
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the plug and crank engine
while checking for spark.
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GOOD SPARK NO SPARK
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* If plug has a good spark, * Proceed to the IGNITION
the problem is in the plug PRIMARY TROUBLE SHOOTING
wires, distributor cap, or CHECK CHART below in this
rotor. Replace components article.
as necessary.
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Ignition Primary Trouble Shooting Chart
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START: Visually inspect primary ignition wires for
broken, frayed, split, or cut wires. Also check
for loose, corroded, or disconnected connectors.
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OK NOT OK
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* Check that battery voltage * Repair or replace damaged
is at least 11.5 volts. components as necessary.
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NOT OK OK
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* Replace or recharge the * Check for battery voltage
battery. at the positive terminal of
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the coil.
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OK NOT OK
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* Check air Gap of the Pick-Up * Check resistance of ballast
coil in the distributor. resistor (if used) for the
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correct resistance value.
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![MITSUBISHI MONTERO 1991 Service Manual \
OK NOT OK
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OK NOT OK
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OK NOT OK
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* Check Pick-Up coil for * Adjust or replace as
correct resistance value. necessary.
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NOT OK OK
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* Replace Pick-Up coil if * Check control module for
not to specification. good ground connections.
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OK
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* If vehicle fails to run at this point, go to
the appropriate article in the ENGINE
PERFORMANCE section.
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OK NOT OK
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* Check wires from the battery/ * Replace ballast resistor
ignition switch to the coil. if the measured resistance
Also check the coil primary value is not within
and secondary resistance. specification.
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STARTER TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
BASIC STARTER TROUBLE SHOOTING CHART
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CONDITION POSSIBLE CAUSE CORRECTION \
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Starter Fails Dead battery or bad Check battery charge
to Operate connections between and all wires and
starter and battery connections to starter
Ignition switch faulty Adjust or replace
or misadjusted ignition switch
Open circuit between Check and repair wires
starter switch ignition and connections as
terminal on starter relay necessary
Starter relay or starter See Testing in STARTER
defective article
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Engine overheated See ENGINE COOLING
SYSTEM article
Engine oil too heavy Check that proper
viscosity oil
is used
Poor battery-to-starter Check that all
connections between
battery and starter are
clean and tight
Current draw too low or See Bench Tests in
too high STARTER article
Bent armature, loose pole See STARTER article
shoes screws or worn
bearings
Burned solenoid contacts Replace solenoid
Faulty starter Replace starter
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Starter Engages Engine timing too far See Ignition Timing in
Engine Only advanced TUNE-UP article
Momentarily
Overrunning clutch not Replace overrunning
engaging properly clutch. See STARTER
article
Broken starter clutch See STARTER article
Broken teeth on engine Replace flywheel and
flywheel check starter pinion
gear for damage
Weak drive assembly See STARTER article
thrust spring
Weak hold-in coil See Bench Tests in
STARTER article
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Starter Drive Defective point assembly See Testing in STARTER
Will Not Engage article
Poor point assembly ground See Testing in STARTER
article
Defective pull-in coil Replace starter
solenoid
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Starter Relay Dead battery Charge or replace
Does Not Close battery as necessary
Faulty wiring Check all wiring and
connections leading to
relay
Neutral safety switch Replace neutral safety
faulty switch
Starter relay faulty Replace starter relay
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![MITSUBISHI MONTERO 1991 Service Manual Fires With Key Flywheel runout contributes
released. Engine to the intermittent nature
Fires and Cranks
Normally
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released. Engine to the intermittent nature
Fires and Cranks
Normally
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Fires With Key Flywheel runout contributes
released. Engine to the intermittent nature
Fires and Cranks
Normally
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AIR CONDITIONING & HEAT
AIR CONDITIONING TROUBLE SHOOTING
WARNING: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
BASIC AIR CONDITIONING TROUBLE SHOOTING CHART
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CONDITION POSSIBLE CAUSE \
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Compressor Not Working
Compressor clutch circuit open.
Compressor clutch coil inoperative.
Poor clutch ground connection.
Fan belts loose.
Thermostatic switch inoperative.
Thermostatic switch not adjusted.
Ambient temperature switch open.
Superheat fuse blown. \
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Excessive Noise or Vibration
Missing or loose mounting bolts.
Bad idler pulley bearings.
Fan belts not tightened correctly.
Compressor clutch contacting body.
Excessive system pressure.
Compressor oil level low.
Damaged clutch bearings.
Damaged reed valves.
Damaged compressor. \
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Insufficient or No Cooling;
Compressor Working
Expansion valve inoperative.
Heater control valve stuck open.
Low system pressure.
Blocked condenser fins.
Blocked evaporator fins.
Vacuum system leak.
Vacuum motors inoperative.
Control cables improperly adjusted.
Restricted air inlet.
Mode doors binding.
Blower motor inoperative.
Temperature above system capacity. \
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HEATER SYSTEM TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to