1991 MITSUBISHI MONTERO Service Manual

turn signal bulb oil level technical specifications spark plugs tire type interior lights

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$MITSUBISHI MONTERO 1991 Service Manual \003 D - A D JU STM EN TS 1991 M it s u bis h i M onte ro 1991 ENGINE PERFORMANCE On-Vehicle Adjustments Chrysler Motors: Colt, Colt 200, Colt Vista, Ram-$

\003
D - A D JU STM EN TS

1991 M it s u bis h i M onte ro
1991 ENGINE PERFORMANCE
On-Vehicle Adjustments
Chrysler Motors: Colt, Colt 200, Colt Vista,
Ram-50, Stealth, Summit
Mitsubishi: Eclipse, Galant, Mirage, Montero,
Pickup, 3000GT
ENGINE MECHANICAL
Before performing any on-vehicle adjustments to fuel or
ignition system, ensure engine mechanical condition is okay.
VALVE CLEARANCE
NOTE: All engines except 1.5L use hydraulic valve lifters. Valve
adjustment is only required on 1.5L engines. To check
hydraulic valve lifter operation, see CHECKING HYDRAULIC
VALVE LIFTERS.
MECHANICAL VALVE LIFTERS
CAUTION: DO NOT rotate crankshaft in opposite direction of normal
engine rotation.
1.5L
1) Ensure engine is at normal operating temperature. Remove
all spark plugs and valve cover. Rotate crankshaft to position
cylinder No. 1 on TDC of compression stroke. Adjust intake valves on
cylinders No. 1 and No. 2, and exhaust valves on cylinders No. 1 and
No. 3. See VALVE CLEARANCE ADJUSTMENT table for specification.
2) Rotate crankshaft 360 degrees to position cylinder No. 4
on TDC of compression stroke. Adjust intake valves on cylinders No. 3
and No. 4, and exhaust valves on cylinders No. 2 and No. 4.
VALVE CLEARANCE ADJUSTMENT TABLE
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Cold Hot
Application In. (mm) In. (mm)
Intake ............ .003 (.07) ......... .006 (.15)
Exhaust ........... .007 (.17) ......... .010 (.25)
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CHECKING HYDRAULIC VALVE LIFTERS
Except 1.5L
1) Remove valve cover. Push downward on end of rocker arm
above lash adjuster. If lash adjuster is normal, it will feel hard. If
lash adjuster moves downward easily when pushed, replace adjuster.
2) If lash adjuster feels soft or spongy, oil with air has
probably entered lash adjuster. If this occurs, check engine oil
level. If engine oil level is okay, check oil screen and oil screen
gasket for damage.
3) After repairing cause of air leak, warm engine to
operating temperature. Drive vehicle at low speed for approximately 5
minutes. Turn engine off for a few minutes.
4) Restart engine and drive at low speed for approximately 5

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MITSUBISHI MONTERO 1991 Service Manual minutes. Repeat this step several times for about one hour. This helps
remove air from engine oil.
IGNITION TIMING
NOTE: Perform all adjustments with engine at normal operating
te

minutes. Repeat this step several times for about one hour. This helps
remove air from engine oil.
IGNITION TIMING
NOTE: Perform all adjustments with engine at normal operating
temperature, cooling fan and accessories off, transmission
in Park or Neutral, and front wheels in straight-ahead
position. Set curb idle speed to specification. See IDLE
SPEED SPECIFICATIONS table under IDLE SPEED & MIXTURE.
IGNITION TIMING
1) Locate ignition timing adjustment connector. See IGNITION
TIMING ADJUSTMENT CONNECTOR LOCATION table. Connect jumper wire
between ignition timing adjustment connector and ground. Check
ignition basic timing.
2) If ignition basic timing is not within specification,
loosen distributor (or crank angle sensor on engines with dual coil
assembly) and rotate to adjust timing if necessary. See IGNITION
TIMING SPECIFICATIONS table. Disconnect jumper wire from ignition
timing adjustment connector.
IGNITION TIMING SPECIFICATIONS TABLE (Degrees BTDC@RPM)
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Application (1) Basic (1) (2) Actual
1.5L
Colt, Colt 200
Mirage & Summit ....... 5@650-850 ........ 10@650-850
1.6L
Mirage ................. 5@650-850 ......... 8@650-850
1.8L
Eclipse ................ 5@600-800 ........ 10@600-800
2.0L
Colt Vista &
Galant (VIN V) ........ 5@600-800 ........ 10@600-800
Eclipse ................ 5@650-850 ......... 8@650-850
Galant
(VIN R) ............... 5@650-850 ......... 8@650-850
(VIN U) ............... 5@650-850 ........ 12@650-850
2.4L
Pickup & Ram-50 ........ 5@650-850 ......... 8@650-850
3.0L
Montero, Pickup, Ram-50
Stealth & 3000GT ...... 5@600-800 ........ 15@600-800
(1) - Transmission in Park or Neutral.
(2) - Actual timing may fluctuate.
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IGNITION TIMING ADJUSTMENT CONNECTOR LOCATION TABLE\
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Application (1)(2) Wire Color Locati\
on
Colt, Colt Vista, Colt 200,
Mirage & Summit
1.5L, 1.6L & 2.0L ................ Yellow/Red ............. (3)\
Eclipse
1.8L & 2.0L (Except Turbo) ........ Yellow/Red ............. (4\
)
2.0L Turbo ....................... Yellow/Black ............ (4)\
Galant

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$MITSUBISHI MONTERO 1991 Service Manual 2.0L .............................. Yellow/Red ............. (5)\ Montero 3.0L ............................. White/Yellow ............ (4)\ Pickup & Ram-50 2.4L ......................$

2.0L .............................. Yellow/Red ............. (5)\
Montero
3.0L ............................. White/Yellow ............ (4)\
Pickup & Ram-50
2.4L .............................. Black/Blue ............. (6)\
3.0L ............................. White/Yellow ............ (6)\
Stealth (SOHC)
3.0L ............................. White/Yellow ............ (4)\
Stealth & 3000GT (DOHC)
3.0L (Non-Turbo) ................. Black/Green ............. (4\
)
3.0L (Turbo) ..................... White/Yellow ............ (4\
)
(1) - Remove waterproof female connector (if equipped) for access to\
wire.
(2) - Ground connector at wire end for basic timing adjustment.
(3) - On main wiring harness, near center of firewall.
(4) - On main wiring harness, near wiper motor on firewall.
(5) - On main wiring harness, near master cylinder on firewall.
(6) - Between right shock tower and firewall.
(7) - Near front of right shock tower.
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IDLE SPEED & MIXTURE
NOTE: Perform adjustments with engine at normal operating
temperature, cooling fan and accessories off, transmission
in Park or Neutral, and front wheels in straight-ahead
position.
CURB (SLOW) IDLE SPEED
NOTE: Curb idle speed is controlled by Idle Speed Control (ISC)
motor. Adjustment is usually not necessary. For curb idle
speed specifications, see IDLE SPEED SPECIFICATIONS table
under BASIC IDLE SPEED.
1) Check ignition timing and adjust if necessary. Run engine
at 2000-3000 RPM for more than 5 seconds. Allow engine to idle for 2
minutes. Check curb idle speed.
2) If curb idle speed is not within specification, check ISC
system. If ISC system is okay, adjust basic idle speed. See BASIC IDLE
SPEED.
BASIC IDLE SPEED
NOTE: ALWAYS check TPS adjustment after adjusting basic idle
speed. See THROTTLE POSITION SENSOR (TPS).
BASIC IDLE SPEED TEST APPLICATION TABLE
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Application Test
1.5L
Colt, Colt 200,
Mirage & Summit ............. TEST NO. 1
1.6L
Mirage ....................... TEST NO. 2
1.8L
Eclipse ...................... TEST NO. 1
2.0L (VIN V)
Colt Vista & Galant .......... TEST NO. 1
2.0L (VIN R & U)

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$MITSUBISHI MONTERO 1991 Service Manual Eclipse & Galant ............. TEST NO. 2 2.4L Pickup & Ram-50 .............. TEST NO. 1 3.0L Montero, Pickup, Ram-50, Stealth & 3000GT ............ TEST NO. 2 ��\ ��$

Eclipse & Galant ............. TEST NO. 2
2.4L
Pickup & Ram-50 .............. TEST NO. 1
3.0L
Montero, Pickup, Ram-50,
Stealth & 3000GT ............ TEST NO. 2
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Test No. 1
1) Loosen throttle cable. Turn ignition on for more than 15
seconds. DO NOT start engine. Turn ignition off. This should fully
retract ISC motor plunger.
2) On 2.0L Galant (VIN V), connect jumper wire between
ignition timing adjustment connector and ground. See IGNITION TIMING
ADJUSTMENT CONNECTOR LOCATION table under IGNITION TIMING.
3) On all models, disconnect harness connector(s) from Idle
Speed Control (ISC) motor. Ensure ISC plunger is in fully retracted
position. Unscrew fixed Speed Adjusting Screw (SAS) until throttle
valve is fully closed. See Fig. 1.
CAUTION: When cleaning throttle body, plug air by-pass hole in
throttle body to prevent solvent from entering passage.
4) Start engine. Check basic idle speed. See IDLE SPEED
SPECIFICATIONS table. If basic idle speed is within specification, go
to step 7). If basic idle speed is not within specification, remove
air intake hose and clean throttle body. Reconnect air intake hose.
Recheck basic idle speed.
5) If basic idle speed is still not within specification
after cleaning throttle body, adjust basic idle speed by turning idle
speed adjusting screw. See Fig. 1. After adjusting basic idle speed,
turn fixed SAS screw clockwise until engine speed begins to increase.
6) Turn fixed SAS screw counterclockwise until engine speed
decreases. Turn fixed SAS screw counterclockwise an additional 1/2
turn from point at which engine speed no longer decreases. Turn off
engine.
7) Adjust throttle cable. Reconnect harness connector(s) at
ISC motor. Start engine. Operate engine for about 5 minutes. Ensure
engine idles within curb idle speed specification. See IDLE SPEED
SPECIFICATIONS table.
8) Turn ignition off. Disconnect negative battery cable for
at least 10 seconds to clear diagnostic trouble code. Reconnect
negative battery cable. Operate engine at idle for about 5 minutes to
ensure engine idles smoothly.
Test No. 2
1) Locate ignition timing adjustment connector. See IGNITION
TIMING ADJUSTMENT CONNECTOR LOCATION table under IGNITION TIMING.
Connect jumper wire between ignition timing adjustment connector and
ground.
2) Locate diagnostic connector under instrument panel.
Connect jumper wire between diagnostic connector terminal No. 10
(White wire) and ground. See Fig. 3. Start engine. Check basic idle
speed. See IDLE SPEED SPECIFICATIONS table. If basic idle speed is
within specification, go to step 9). If basic idle speed is not within
specification, go to step 3).
3) Remove air intake hose. Check throttle body. If throttle
body contains deposits, go to next step. If throttle body is clean,
disconnect jumper wires connected in steps 1) and 2). On all models
except Eclipse, Galant and Mirage, go to step 6). On Eclipse, Galant
and Mirage, go to step 5).
CAUTION: When cleaning throttle body, plug air by-pass hole in

Page 141 of 1333

MITSUBISHI MONTERO 1991 Service Manual throttle body to prevent solvent from entering passage.
4) Clean throttle body with solvent. Replace air intake hose.
Recheck basic idle speed. If basic idle speed is within specifi

throttle body to prevent solvent from entering passage.
4) Clean throttle body with solvent. Replace air intake hose.
Recheck basic idle speed. If basic idle speed is within specification
after cleaning throttle body, go to step 9). If basic idle speed is
still not within specification after cleaning throttle body,
disconnect jumper wires connected in steps 1) and 2). On all models
except Eclipse, Galant and Mirage, go to step 6). On Eclipse, Galant
and Mirage, go to step 5).
5) Adjust idle position switch and go to step 7). See IDLE
POSITION SWITCH under THROTTLE POSITION SENSOR (TPS).
6) Adjust fixed Speed Adjusting Screw (SAS) and go to next
step. See FIXED SPEED ADJUSTING SCREW under IDLE SPEED & MIXTURE.
7) Reconnect jumper wires as indicated in steps 1) and 2).
Check basic idle speed. If basic idle speed is within specification,
go to step 9). If basic idle speed is not within specification, adjust
by turning idle speed adjusting screw on throttle body. See Fig. 2. Go
to next step.
8) If basic idle speed is within specification after turning
idle speed adjusting screw, go to step 9). If basic idle speed cannot
be adjusted to specification by turning idle speed adjusting screw,
check for leaking fast idle air valve. Replace throttle body if fast
idle air valve leaks.
9) Turn ignition off. Disconnect jumper wires from ignition
timing adjustment connector and diagnostic connector. Operate engine
at idle for about 5 minutes. Ensure engine idles smoothly and within
curb idle specification. See IDLE SPEED SPECIFICATIONS table.
IDLE SPEED SPECIFICATIONS TABLE
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Application Curb Idle Basic Idle
1.5L
Colt, Colt 200,
Mirage & Summit .... 650-850 ...... 700-800
1.6L
Mirage .............. 650-850 ...... 700-800
1.8L
Eclipse ............. 600-800 ...... 650-750
2.0L (VIN V)
Colt Vista .......... 600-800 ...... 650-750
Galant .............. 650-850 ...... 700-800
2.0L (VIN R & U)
Eclipse ............. 650-850 ...... 650-750
Galant .............. 650-850 ...... 700-800
2.4L
Pickup & Ram-50 ..... 650-850 ...... 700-800
3.0L
Montero, Pickup, Ram-50,
Stealth & 3000GT . 600-800 ...... 650-750
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Fig. 1: Idle & Fixed Speed Adj. Screws (1.5L, 1.8L, 2.0L (VIN V)
& 2.4L)

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MITSUBISHI MONTERO 1991 Service Manual Courtesy of Mitsubishi Motor Sales of America.
Fig. 2: Idle Speed Adj. Screw (1.6L, 2.0L (VIN R & U) & 3.0L)
Courtesy of Mitsubishi Motor Sales of America.
Fig. 3: Identifying Diagnostic Connector T

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MITSUBISHI MONTERO 1991 Service Manual NOTE: Fixed Speed Adjusting Screw (SAS) is preset by manufacturer
and usually does not require adjustment. Only adjust fixed
SAS if other adjustment procedures require it, or if

Page 144 of 1333

MITSUBISHI MONTERO 1991 Service Manual NOTE: Idle mixture is computer controlled on fuel injected engines
and is nonadjustable. CO level specifications are not
available from manufacturer.
THROTTLE POSITION SE

NOTE: Idle mixture is computer controlled on fuel injected engines
and is nonadjustable. CO level specifications are not
available from manufacturer.
THROTTLE POSITION SENSOR (TPS)
TPS ADJUSTMENT
NOTE: Ensure basic idle speed is set to specification before
adjusting TPS. See BASIC IDLE SPEED under IDLE SPEED &
MIXTURE. Perform all adjustments with engine at normal
operating temperature, front wheels in straight-ahead
position, cooling fan and all accessories off, and
transmission in Park or Neutral.
TPS TEST APPLICATION
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Application Test
1.5L
Colt, Colt 200,
Mirage & Summit ............. TEST NO. 1
1.6L
Mirage ....................... TEST NO. 2
1.8L
Eclipse ...................... TEST NO. 3
2.0L (VIN V)
Colt Vista & Galant .......... TEST NO. 1
2.0L (VIN R & U)
Galant ....................... TEST NO. 1
Eclipse ...................... TEST NO. 3
2.4L
Pickup & Ram-50 .............. TEST NO. 1
3.0L
Montero, Pickup & Ram-50 ..... TEST NO. 4
Stealth & 3000GT ............. TEST NO. 5
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Test No. 1
1) Turn ignition on for more than 15 seconds. DO NOT start
engine. Turn ignition off. ISC plunger should be retracted fully.
2) Ensure ISC plunger is in fully retracted position.
Disconnect harness connector(s) from ISC motor. Turn ignition on. DO
NOT start engine.
3) Using digital voltmeter, backprobe terminal No. 19
(Green/White wire) and terminal No. 24 (Black or Green/Black wire) a\
t
Engine Control Unit (ECU) wiring harness connector. Note TPS output
voltage.
4) If output voltage is .48-.52 volt, go to step 6). If
output voltage is not .48-.52 volt, loosen TPS mounting screw(s) and
rotate TPS clockwise, or counterclockwise, until output voltage is
within specification. Tighten TPS mounting screws.
5) Turn ignition off. Reconnect harness connector(s) at ISC
motor. Start engine. Ensure engine idles within curb idle speed
specification.
6) Turn ignition off. Disconnect negative battery cable for
at least 15 seconds to clear diagnostic trouble code. Reconnect
negative battery cable. Operate engine at idle for about 5 minutes to
ensure engine idles smoothly.
Test No. 2
1) Turn ignition on. DO NOT start engine. Loosen throttle

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