1991 MITSUBISHI MONTERO length
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CYLINDER HEAD
Check cylinder head height and warpage at gasket and manifold
surfaces. Resurface head if warpage exceeds specification. See
appropriate CYLINDER HEAD table under ENGINE SPECIFICATIONS at end of
article. Replace cylinder head if it is not within specification after
resurfacing.
VALVE SPRINGS
Measure free length of valve springs. Check spring pressure
at specified height. Replace springs if not within specification. See
appropriate VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS
at end of article. Check valve spring for squareness. Replace spring
if out-of-square exceeds 4 degrees.
NOTE: Install valve springs with enamel-coated side toward valve
spring retainer.
VALVE STEM OIL SEALS
With valves removed, remove oil seals from cylinder head.
Coat new seals with oil. Using Valve Stem Oil Seal Installer (MD998377
for Montero, MD998729 for Pick-up or MD998763 for DOHC), install valve
stem oil seal.
VALVE GUIDES
1) Measure valve stem-to-guide clearance. Replace valve guide
if not within specification. See appropriate VALVES & VALVE SPRINGS
table under ENGINE SPECIFICATIONS at end of article.
2) Using rod of Valve Guide Remover/Installer (MD998115) for\
SOHC, drive out valve guide toward combustion chamber side of cylinder
head. Note length of valve guides. On DOHC, use press and
appropriately-sized rod to press valve guide toward combustion chamber
side of head.
3) On all models, cylinder head must be bored to install
oversized valve guide once guide is removed. DO NOT install valve
guide of same dimension as old guide. Bore cylinder head to
specification for oversize valve guide. See appropriate OVERSIZE VALVE
GUIDE SPECIFICATIONS table.
4) On SOHC, install proper length valve guide. Intake guide
is 1.73" (43.9 mm) long and exhaust guide is 1.89" (48.0 mm) long. O\
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all models, position cylinder head with combustion chamber downward.
5) Using valve guide remover/installer, install valve guide.
Remover/installer sets valve guide height on SOHC. On DOHC, install
valve guide to .689" (17.5 mm), measured from cylinder head spring
seating area to top of valve guide. On all models, ensure valve slides
smoothly in valve guide. Recondition valve seat.
OVERSIZE VALVE GUIDE SPECIFICATIONS TABLE (SOHC)
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Oversize In. (mm) Size Mark Bore Size In. (mm)
.002 (.05) ............ 5 ... .5138-.5145 (13.050-13.068)
.010 (.25) ............ 25 .. .5217-.5224 (13.251-13.269)
.020 (.51) ............ 50 .. .5315-.5322 (13.500-13.518)
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OVERSIZE VALVE GUIDE SPECIFICATIONS TABLE (DOHC) \
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Page 29 of 1333
.012" (.3 mm) Oversize ............ .311-.319 (7.9-8.1)
.024" (.6 mm) Oversize ............ .323-.331 (8.2-8.4)
Bore Diameter
.012" (.3 mm) Oversize .. 1.3110-1.3120 (33.300-33.325)
.024" (.6 mm) Oversize .. 1.3228-1.3238 (33.600-33.625)
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VALVES
Disassemble cylinder head. Measure valve stem diameter, valve
margin and overall length. Replace valves if not within specification.
See appropriate VALVES & VALVE SPRINGS table under ENGINE
SPECIFICATIONS at end of article. Check valve for worn valve tip.
Measure valve margin after grinding valves.
LASH ADJUSTERS
Before installation, submerge lash adjuster in diesel fuel.
Using a small wire, hold down internal check valve. Pump plunger up
and down 4 or 5 times to bleed air from lash adjuster.
CYLINDER BLOCK ASSEMBLY OVERHAUL
CYLINDER BLOCK
1) Inspect cylinder block for cracks, warpage, cylinder bore
taper and out-of-round. Replace or repair cylinder block if it is not
within specification. See CYLINDER BLOCK table under ENGINE
SPECIFICATIONS at end of article.
2) Measure cylinder bore and piston skirt diameter. Piston
skirt diameter should be measured at 90-degree angle to piston pin.
Clearance between piston and cylinder bore must be within
specification. See appropriate PISTONS, PINS & RINGS table under
ENGINE SPECIFICATIONS at end of article.
PISTON & ROD ASSEMBLY
1) Remove cylinder heads, and remove oil pan. See CYLINDER
HEADS and OIL PAN under REMOVAL & INSTALLATION. Ensure cylinder ridge
is removed. Mark connecting rod and cap for cylinder identification.
2) Note front mark on piston and connecting rod. See Fig. 23.
Mark is positioned toward timing belt side of engine. Remove rod cap
and piston assembly.
3) Ensure piston ring end gap and side clearance are within
specification. See appropriate PISTONS, PINS & RINGS table under
ENGINE SPECIFICATIONS at end of article. Install rings on piston with
ring code identification marks toward top of piston. On DOHC, top ring
is marked "T" and No. 2 ring is marked "T2". On SOHC, top ring is
marked "T1" and No. 2 ring is marked "2R". Lubricate piston, rings and
cylinder bore with engine oil.
4) Properly space ring end gaps on piston. See Fig. 23.
Install piston and rod into cylinder bore. Ensure piston is installed
with front mark toward timing belt side of engine.
NOTE: Front mark "R" on piston indicates installation in
cylinders No. 1, 3 or 5 while front mark "L" indicates
installation in cylinders No. 2, 4 or 6. Ensure front mark
on piston and connecting rod are toward timing belt side of
engine. See Fig. 23.
5) Check bearing clearance using Plastigage method. Tighten
rod cap nuts to specification. See appropriate TORQUE SPECIFICATIONS
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 36 of 1333
![MITSUBISHI MONTERO 1991 Service Manual CRANKSHAFT, MAIN & CONNECTING
ROD BEARINGS SPECIFICATIONS
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS TABLE
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ROD BEARINGS SPECIFICATIONS
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS TABLE
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CRANKSHAFT, MAIN & CONNECTING
ROD BEARINGS SPECIFICATIONS
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS TABLE
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Application In. (mm)
Crankshaft
End Play
Standard ...................... .0020-.0098 (.050-.250)
Limit ...................................... .012 (.30)
Main Bearings
Journal Diameter ........................... 2.36 (59.9)
Journal Out-Of-Round
SOHC ..................................... .0002 (.005)
DOHC .................................... .00012 (.003)
Journal Taper ............................. .0002 (.005)
Oil Clearance
Standard
SOHC ........................ .0008-.0019 (.020-.048)
DOHC ........................ .0007-.0017 (.018-.043)
Limit ...................................... .004 (.10)
Connecting Rod Bearings
Journal Diameter ......................... 1.965 (49.91)
Journal Out-Of-Round
SOHC ..................................... .0002 (.005)
DOHC .................................... .00012 (.003)
Journal Taper ............................. .0002 (.005)
Oil Clearance
Standard ...................... .0006-.0018 (.015-.046)
Limit ...................................... .004 (.10)
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CONNECTING RODS SPECIFICATIONS
CONNECTING RODS TABLE \
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Application In. (mm)
Maximum Bend .................................. .002 (.05)
Maximum Twist (Total Rod Length) .............. .004 (.10)
Side Play
Standard ....................... .0039-.0099 (.099-.251)
Limit ....................................... .016 (.41)
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PISTONS, PINS & RINGS SPECIFICATIONS (SOHC)
PISTONS, PINS & RINGS TABLE (SOHC) \
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Application In. (mm)
Pistons
Clearance ...................... .0008-.0016 (.020-.040)
Diameter ................................. 3.587 (91.11)
Pins
Piston Fit ......................................... ( 1)
Rod Fit ............................................ ( 2)
Rings
No. 1
End Gap
Standard .................... .0118-.0177 (.300-.450)
Limit .................................... .031 (.79)
Page 38 of 1333
![MITSUBISHI MONTERO 1991 Service Manual \
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VALVES & VALVE SPRINGS SPECIFICATIONS (SOHC)
VALVES & VAL](/manual-img/19/57332/w960_57332-37.png "MITSUBISHI MONTERO 1991 Service Manual \
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VALVES & VALVE SPRINGS SPECIFICATIONS (SOHC)
VALVES & VAL")
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VALVES & VALVE SPRINGS SPECIFICATIONS (SOHC)
VALVES & VALVE SPRINGS TABLE (SOHC) \
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Application Specification
Intake Valves
Face Angle ..................................... 45-45.5
Minimum Margin ........................... .028" (.71 mm)
Standard Length ...................... 4.055" (103.00 mm)
Stem Diameter ............. .3134-.3140" (7.960-7.976 mm)
Exhaust Valves
Face Angle ..................................... 45-45.5
Minimum Margin .......................... .059" (1.50 mm)
Standard Length ...................... 4.043" (102.70 mm)
Stem Diameter ............. .3122-.3130" (7.930-7.950 mm)
Valve Springs
Free Length
Standard ............................. 1.988" (50.50 mm)
Limit ................................ 1.949" (49.50 mm)
Installed Height ...................... 1.591" (40.41 mm)
Out-Of-Square
Standard ............................................ 2
Limit ............................................... 4
Lbs. @ In. (kg @ mm)
Pressure
Valve Closed ..................... [email protected] ([email protected])
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VALVES & VALVE SPRINGS SPECIFICATIONS (DOHC)
VALVES & VALVE SPRINGS TABLE (DOHC) \
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Application Specification
Intake Valves
Face Angle ..................................... 45-45.5
Minimum Margin ........................... .019" (.48 mm)
Standard Length ...................... 4.185" (106.30 mm)
Stem Diameter ........................... .260" (6.60 mm)
Exhaust Valves
Face Angle ..................................... 45-45.5
Minimum Margin ........................... .039" (.99 mm)
Standard Length ...................... 4.150" (105.41 mm)
Stem Diameter ........................... .260" (6.60 mm)
Valve Springs
Free Length
Standard ............................. 1.846" (46.89 mm)
Limit ................................ 1.807" (45.90 mm)
Installed Height ...................... 1.492" (37.90 mm)
Out-Of-Square
Standard ............................................ 2
Limit ............................................... 4
Lbs. @ In. (kg @ mm)
Pressure
Valve Closed ..................... [email protected] ([email protected])
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![MITSUBISHI MONTERO 1991 Service Manual CYLINDER HEAD SPECIFICATIONS (SOHC)
CYLINDER HEAD TABLE (SOHC) \
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CYLINDER HEAD TABLE (SOHC) \
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CYLINDER HEAD SPECIFICATIONS (SOHC)
CYLINDER HEAD TABLE (SOHC) \
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Application Specification
Cylinder Head Height ................... 3.307" (84.00 mm)
Maximum Warpage ........................... .008" (.20 mm)
Valve Seats (Intake & Exhaust)
Seat Angle ......................................... 45
Seat Width .................... .035-.051" (.90-1.30 mm)
Seat Bore Diameter ....... 1.732-1.742" (44.00-44.25 mm)
Valve Guides
Intake Valve
Valve Guide Cylinder Head
Bore I.D. ............. .5118-.5189" (13.00-13.18 mm)
Valve Guide Length ..................... 1.732" (44 mm)
Stem-To-Guide Clearance
Standard ................ .0012-.0024" (.030-.060 mm)
Limit ................................ .004" (.10 mm)
Exhaust Valve
Valve Guide Cylinder Head
Bore I.D. ............. .5118-.5189" (13.00-13.18 mm)
Valve Guide Length ..................... 1.890" (48 mm)
Stem-To-Guide Clearance
Standard ................ .0020-.0035" (.050-.090 mm)
Limit ................................ .006" (.15 mm)
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CYLINDER HEAD SPECIFICATIONS (DOHC)
CYLINDER HEAD TABLE (DOHC) \
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Application Specification
Cylinder Head Height .................... 5.20" (132.1 mm)
Maximum Warpage ........................... .008" (.20 mm)
Valve Seats (Intake & Exhaust)
Seat Angle ......................................... 45
Seat Width .................... .035-.051" (.90-1.30 mm)
Seat Bore Diameter ....... 1.417-1.427" (35.99-36.25 mm)
Valve Guides
Intake Valve
Valve Guide Cylinder Head
Bore I.D. ............. .5118-.5189" (13.00-13.18 mm)
Valve Guide
Installed Height ................... .689" (17.50 mm)
Stem-To-Guide Clearance
Standard ................ .0008-.0020" (.020-.051 mm)
Limit .............................. .0039" (.099 mm)
Exhaust Valve
Valve Guide Cylinder Head
Bore I.D. ............. .5118-.5189" (13.00-13.18 mm)
Valve Guide
Installed Height ................... .689" (17.50 mm)
Valve Stem-To-Guide
Clearance
Standard ............... .0020-.0035" (.051-.089 mm)
Limit ............................. .0047" (.119 mm)
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CAMSHAFT SPECIFICATIONS (SOHC)
Page 209 of 1333
length. If spring length is not 6.97-7.09 in. (177-180 mm), adjust
cable or support until correct length is obtained. See Fig. 1.
Fig. 1: Testing LSPV Spring Length (Pickup & Ram-50)
Courtesy of Mitsubishi Motor Sales of America.
MASTER CYLINDER PUSH ROD
Check and adjust clearance between back of master cylinder
piston and power brake push rod. See PUSH ROD CLEARANCE SPECIFICATIONS
table. See Fig. 2. After adjusting push rod clearance, adjust pedal
height, and bleed brake system.
Fig. 2: Adjusting Push Rod Clearance
Courtesy of Mitsubishi Motor Sales of America.
PUSH ROD CLEARANCE SPECIFICATIONS TABLE
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Page 212 of 1333
5) Remove the LSPV load-sensing spring. Slowly depress the
brake pedal. Check the readings on the pressure gauges. Refer to the
LSPV PRESSURE SPECIFICATIONS table.
6) Install LSPV load-sensing spring. Load weight into rear of
vehicle until measured spring length distance is 7.0" (178 mm) with
lever slightly pressed in. See Fig. 1.
7) Slowly depress brake pedal. Check readings on pressure
gauges. See LSPV PRESSURE SPECIFICATIONS table. If fluid pressure is
not within specification, ensure all other brake system components are
okay. If other components are okay, replace LSPV assembly.
LSPV PRESSURE SPECIFICATIONS (PICKUP & RAM-50)
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Application Inlet Pressure Outlet Pressure
psi (kg/cm) psi (kg/cm)
Load-Sensing Spring
Removed ........... 853 (60) ......... 242-327 (17-23)
Installed ........ 1991 (140) .... ( 1) 299-583 (21-40)
( 1) - On vehicles with 2WD and heavy-duty suspension,
outlet pressure is 526-697 psi (37-49 kg/cm
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PROPORTIONING VALVE (NON-LOAD-SENSING) (MONTERO)
Pressure Test
1) Connect pressure gauges to input and output ports of the
proportioning valve. See Fig. 5. Bleed brake hydraulic system. Refer
to BLEEDING BRAKE SYSTEM .
2) Slowly depress brake pedal. Check readings on pressure
gauges. See the PROPORTIONING VALVE PRESSURE SPECIFICATIONS table. If
fluid pressures are not within specification, replace proportioning
valve.
Fig. 5: Connecting Pressure Gauges to Proportioning Valve (Typical)
Courtesy of Mitsubishi Motor Sales of America.
PROPORTIONING VALVE PRESSURE SPECIFICATIONS (MONTERO)
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