1991 MITSUBISHI MONTERO stop start

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.

 








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 Replace  Transfer  30,000 Miles 

  Case Fluid  










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Severe Dust  Replace  Engine Oil  3,000 Miles or 3 Months 

Conditions 









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 Inspect  Cooling  6,000 Miles or 6 Months 

  System  











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 Replace  Engine Oil  6,000 Miles or 6 Months 

  Filter  











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 Inspect  Throttle  ONLY ONCE AT FIRST: 

  Position  15,000 Miles 











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 Inspect  Drive Belt START AT: 15,000 Miles; 

  Tension REPEAT EVERY SUBSEQUENT: 

   30,000 Miles 











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 Replace  A/T Fluid  30,000 Miles 











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 Replace  M/T Fluid  30,000 Miles 











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 Replace  Transfer  30,000 Miles 

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Hot Weather,  Replace  Engine Oil  3,000 Miles or 3 Months 

Stop-And-Go 









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Driving  Inspect  Cooling  6,000 Miles or 6 Months 

  System  











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 Replace  Engine Oil  6,000 Miles or 6 Months 

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 Inspect  Throttle  ONLY ONCE AT FIRST: 

  Position  15,000 Miles 











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 Inspect  Drive Belt START AT: 15,000 Miles; 

  Tension REPEAT EVERY SUBSEQUENT: 

   30,000 Miles 











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 Replace  A/T Fluid  30,000 Miles 











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 Replace  M/T Fluid  30,000 Miles 











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 Replace  Transfer  30,000 Miles 

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Extensive Idling  Replace  Engine Oil  3,000 Miles or 3 Months 











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 Inspect  Cooling  6,000 Miles or 6 Months 

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 Replace  Engine Oil  6,000 Miles or 6 Months 

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 Inspect  Throttle  ONLY ONCE AT FIRST: 

  Position  15,000 Miles 











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 Inspect  Drive Belt START AT: 15,000 Miles; 

  Tension REPEAT EVERY SUBSEQUENT: 

   30,000 Miles 











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Light comes on with the ignition switch in the "ON" position
as a bulb check, but should go out shortly after engine is started. If
light remains on or comes on while driving, it indicates low oil
pressure and possible system malfunction. Have the system checked and
serviced immediately. Do not operate vehicle until cause is located
and corrected.
ALTERNATOR WARNING LIGHT
Light comes on with the ignition switch in the "ON" position
as a bulb check and goes out after engine is started. If light remains
on or comes on while driving, it indicates possible fault in the
electrical charging system. The alternator belt may be loose or
broken. Have the system checked and serviced promptly. Do not drive
vehicle if alternator belt is loose or broken.
"BRAKE" WARNING LIGHT
Light comes on with the ignition switch in the "ON" position
as a bulb check and goes out after engine is started. Light will also
come on with the parking brake fully or partially engaged. If light
remains on or comes on at any other time, it indicates low brake fluid
level in the master cylinder reservoir or the parking brake switch may
be damaged. Have the system checked and serviced immediately if brake
fluid level is low. Do not continue driving if further trouble is
experienced.
"CHECK ENGINE" WARNING LIGHT (IF EQUIPPED)
Light is designed to come on briefly with the ignition switch
in the "ON" position as a bulb check. If light remains on or comes on
while driving, it indicates fault in an exhaust gas related component
and the system is not functioning properly. Have the system checked
and serviced as soon as possible.
"MAINTENANCE REQUIRED" WARNING LIGHT (IF EQUIPPED)
Light comes on at 50,000 miles, 80,000 miles, 100,000 miles
and 120,000 miles (150,000 miles on 1990-91 models) as a service
reminder that it is time for the periodic maintenance of the emission
control system. Have the system inspected and serviced as necessary
when light comes on. Continued operation of vehicle without having
system serviced after warning light comes on may adversely affect
proper performance of the emission control system. Reset warning
light, after the system has been checked, by pushing the reset switch
in front of the combination meter. Remove the warning light bulb after
the last maintenance service at 120,000 miles (150,000 miles on 1990-
91 models).
"A/T TEMPERATURE" WARNING LIGHT (IF EQUIPPED)
Light comes on when the automatic transmission fluid
temperature becomes abnormally high. If light comes on, reduce engine
speed, stop car and put it in "P" (Park) position. Leave engine
running until light goes out. Normal vehicle operation may be resumed
after light has gone out. If light does not go out, have the system
checked and serviced as necessary.
WHEEL LOCK INDICATOR LIGHT (IF EQUIPPED)
Light comes on when automatic free-wheeling hubs are locked.
If ignition is turned off, indicator light will not come on when

CAUTION: Perform tests in less than 10 seconds to prevent coil
damage.
1) Disconnect field coil wire from terminal "M" at starter
solenoid. See Fig. 2. Connect jumper wire between positive battery
terminal of 12-volt battery and terminal "S" of starter solenoid.
2) Connect a second jumper wire from negative battery
terminal and touch starter case. If solenoid plunger is pulled-in,
hold-in coil is good. If not, replace solenoid.
RETURN TEST
CAUTION: Perform tests in less than 10 seconds to prevent coil
damage.
1) Disconnect field coil wire from terminal "M" at starter
solenoid. See Fig. 2. Connect jumper wire between positive battery
terminal of 12-volt battery and terminal "M" of starter solenoid.
2) Connect a second jumper wire from negative battery
terminal and touch starter case. Pull pinion outward and release it.
Replace solenoid if pinion remains outward.
PINION GAP CHECK
1) Disconnect field coil wire from terminal "M" at starter
solenoid. See Fig. 2. Connect jumper wire between positive battery
terminal of 12-volt battery and terminal "S" of starter solenoid.
2) Connect a second jumper wire from negative battery
terminal and touch terminal "M" of starter solenoid. See Fig. 2.
Measure clearance between pinion and stopper. See Fig. 3.
3) Clearance should be within specification. See STARTER
SPECIFICATIONS table. Adjust clearance by adding or removing gaskets
between solenoid and front housing.
Fig. 3: Measuring Pinion Gap
Courtesy of Mitsubishi Motor Sales of America.
REMOVAL & INSTALLATION

Remove negative battery cable. If necessary, raise vehicle on
hoist. Remove starter mounting bolts and starter. To install, reverse
removal procedure.
NOTE: On Raider models with A/T, it may be necessary to disconnect
transmission oil cooler line for starter removal.
OVERHAUL
Check commutator for out-of-round and proper amount of
undercut. Replace or repair armature if not within specification. See
STARTER SPECIFICATIONS table. Ensure brushes are not worn beyond wear
line (outer line closest to commutator contact surface). Check pinion
gap. See PINION GAP CHECK in this article.
DISASSEMBLY
NOTE: Procedures may vary slightly between conventional and
reduction gear starters.
1) Loosen nut securing connecting plate-to-magnetic switch
"M" terminal. Remove screws securing magnetic switch and remove switch
(solenoid) assembly. Remove through bolts and brush cover assembly.
Tap yoke assembly loose with wooden mallet. Remove yoke, armature
assembly and pinion shift lever.
2) Remove pinion stop ring from end of armature shaft by
pushing stop ring to clutch side. Remove snap ring and overrunning
clutch assembly from armature shaft.
Fig. 4: Disassembled View of Typical Mitsubishi Starter
CLEANING & INSPECTION
Clean all parts. Do not use grease dissolving solvent on

overrunning clutch, armature assembly, solenoid assembly or field
coils due to possible damage. Inspect all parts for damage or wear and
replace as required.
BENCH TESTS
Brushes & Springs
Check brush spring tension using a spring scale. Check brush
contact surface condition and brush length. Check lead clip and wire
connections and condition of brush holders. Replace as required. See
Brush Spring Tension and Minimum Brush Length Charts.
BRUSH & SPRING SPECIFICATIONS
BRUSH SPRING TENSION








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Application Ozs. (g)
Chrysler Corp. Imports ............ 46-59 (1302-1670)









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MINIMUM BRUSH LENGTH ( 1)








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Application In. (mm)
Chrysler Corp. Imports ................... .45 (11.5)
(1) - Minimum brush length should coincide with the
brush wear mark.









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Armature
Check external condition of armature for scoring or other
damage. Measure shaft distortion with dial indicator. Replace armature
if shaft distortion exceeds .004" (.10 mm).
Commutator
1) Inspect commutator for roughness, grooves, burns or
pitting. Sand lightly with 500 grit sandpaper if necessary. Check
commutator for out-of-round and mica insulators undercut to a depth of
.020-.031" (.5-.8 mm).
2) If necessary, commutator may be turned less than .04" (1
mm) from original size and mica undercut. Replace if excessively worn.
Field Coil
1) Check field coil continuity by connecting test probe of
circuit tester or an ohmmeter to the field coil positive terminal and
brush holder. If circuit is open, replace field coil.
2) Check for grounding of field coils by placing one probe of
circuit tester on starter housing and other probe to field coil
positive terminal. If little or no resistance, field coil is grounded
and must be replaced.
Overrunning Clutch Assembly
1) Inspect pinion assembly and sleeve. Sleeve should slide
freely on armature shaft and spline. If damage or resistance is noted,
replace assembly.
2) Check pinion and flywheel teeth for excessive rubbing or
damaged teeth. Replace as required.
Pinion Gear Clearance
The clearance between the pinion gear and pinion stopper

collar should be .02-.08" (.51-2.03 mm) on Mitsubishi starters, when
solenoid is engaged. Adjust as necessary by changing shims between
solenoid and starter yoke.
Fig. 5: Measuring Pinion Gear-to-Pinion Stopper Clearance
Pinion Case Bearing
Inspect bearing for wear and check side play. If clearance
exceeds .008" (.2 mm), replace bearing. New bearing clearance should
be .002-.004" (.05-.10 mm) for Mitsubishi starters.
NOTE: Ensure that bearing is installed so that end of bearing is
flush with gear case end.
REASSEMBLY
To reassemble, reverse disassembly procedure. Fill gear case
on reduction gear models with grease. Lightly oil pinion and all
bearing surfaces.

UPPER CONTROL ARM R & I
REMOVAL
1) Remove shock absorber. Support lower control arm with jack
stand. Remove wheel assembly. Loosen anchor bolt lock nut. See Fig. 1.
2) Mark anchor bolt for reassembly reference. Loosen anchor
bolt to release torsion bar tension. Disconnect and plug brake hose at
frame mount bracket. Remove cotter pin from ball joint stud. Loosen
but DO NOT remove ball joint stud knuckle nut.
3) Using ball joint fork, loosen ball joint from steering
knuckle. Remove ball joint stud nut. Remove rebound stopper and brake
hose support from control arm. Remove upper control arm mounting
bolts. Note direction of bolt installation and location of camber
adjustment shims. Remove control arm.
4) If clearance is inadequate for control arm removal, move
control arm toward rear of vehicle and pull out front part of arm.
Rotate control arm pivot shaft and remove arm. If arm still cannot be
removed, loosen 10 front body mounting nuts. Raise body and remove
arm.
NOTE: On Montero, rotating control arm shaft will alter caster
setting.
INSPECTION
1) Inspect control arm for cracks or deformation. On Montero,
mount control arm in soft-jawed vise using control arm shaft. Attach
spring scale to upper end of control arm, near ball joint.
2) Using spring scale, measure starting torque required to
rotate control arm on the shaft. Replace control arm if starting
torque exceeds 1.4 lbs. (6.5 N).
3) On all models, check ball joints. See BALL JOINT CHECKING
under ADJUSTMENTS & INSPECTION. Inspect ball joint dust cover for
damage and replace as necessary.
INSTALLATION
1) To install, reverse removal procedure. On Montero, ensure
control arm shaft is correctly positioned before installing. Rotate
control arm shaft to obtain correct measurement. See Fig. 6.
Fig. 6: Positioning Upper Control Arm Shaft (Montero)
Courtesy of Mitsubishi Motor Sales of America.
2) On Ram-50 & Pickup, install control arm-to-crossmember
bolts from the inside of crossmember, with nuts against control arm