1991 MITSUBISHI MONTERO torque

revolutions clockwise. DO NOT rotate counterclockwise. Realign all
timing marks. Tighten belt tensioner bolts to specification. Using
belt tension gauge, measure belt tension halfway between crankshaft
sprocket and camshaft sprocket on side opposite belt tensioner.
7) Belt tension should be 57.3-83.8 lbs. (26-38 kg). To
install remaining components, reverse removal procedure. Install
proper length bolts in timing belt covers. See Fig. 9. Tighten bolts
to specification. See TORQUE SPECIFICATIONS (MONTERO & PICKUP) table.
Fig. 9: Identifying Timing Belt Cover Bolt Lengths (MONTERO & PICKUP)\
Courtesy of Mitsubishi Motor Sales of America, Inc.

Inspect belt tensioner for smooth rotation. Replace if defective.
Installation
1) Install rear timing belt cover. Tighten bolts to
specification. See TORQUE SPECIFICATIONS (3000GT) table at end of
article. Install camshaft sprockets (if removed). Using holder, hold
camshaft and tighten camshaft sprocket bolt to specification.
2) Install belt tensioner and spring. Ensure spring is
secured on pin of water pump and engaged in hole of belt tensioner
with hook of spring pointing from cylinder block.
3) Rotate belt tensioner counterclockwise as much as
possible, and temporarily tighten bolt. Align all timing marks with
No. 1 cylinder at TDC of compression stroke. See Fig. 8.
4) Install timing belt on crankshaft sprocket, rear cylinder
bank camshaft sprocket, water pump pulley, front cylinder bank
camshaft sprocket and timing belt tensioner. Ensure belt is installed
in original direction of rotation and all timing marks are aligned.
Install flange on crankshaft. Loosen belt tensioner bolts slightly,
and allow tensioner to apply belt tension.
5) Using Crankshaft Socket (MD998716), rotate crankshaft 2
revolutions clockwise. DO NOT rotate counterclockwise. Realign all
timing marks. Tighten belt tensioner bolts to specification. See
TORQUE SPECIFICATIONS (3000GT) table. Using belt tension gauge,
measure belt tension halfway between crankshaft sprocket and camshaft
sprocket on side opposite belt tensioner.
6) Belt tension should be 46.3-63.3 lbs. (21-29 kg). To
install remaining components, reverse removal procedure. Install
proper length bolts in timing belt covers and engine support bracket.
See Figs. 9 and 10. Tighten bolts to specification. See TORQUE
SPECIFICATIONS (3000GT) table.
NOTE: Engine support bracket reamer bolt must be tightened slowly
while spraying lubricant on bolt.
Fig. 11: Identifying Timing Belt Cover Bolt Length (SOHC)
Courtesy of Mitsubishi Motor Sales of America, Inc.
Removal (DOHC)
1) Remove lower splash shields. Remove cruise control

bracket. Remove timing belt upper lower cover, noting length and
location of cover bolts.
4) If reusing timing belt, place arrow on belt to indicate
direction of belt rotation. Remove timing belt and belt tensioner.
Rotate crankshaft and align all timing marks. See Fig. 13. Loosen
center tensioner bolt, and remove timing belt.
5) If camshaft sprocket requires removal, install wrench on
hexagonal portion of camshaft. Hold camshaft while loosening camshaft
sprocket bolt. Remove camshaft sprocket bolt and camshaft sprocket.
Fig. 13: Aligning Timing Marks Initial Alignment (DOHC)
Courtesy of Mitsubishi Motor Sales of America, Inc.
Inspection (DOHC)
Inspect timing belt for wear on edges of drive teeth. Inspect
belt for oil and coolant contamination. Replace belt if damaged or
contaminated. Inspect belt tensioner for smooth rotation. Replace if
defective.
Installation (DOHC)
1) Install camshaft sprockets (if removed). Using wrench,
hold camshaft at hexagonal section and tighten camshaft sprocket bolt
to specification. See TORQUE SPECIFICATIONS (3000GT) table at end of

tensioner center bolt. Using Tensioner Pulley Socket (MD998767) and
torque wrench, apply 84 INCH lbs. (9.5 N.m). See Fig. 17. Retighten
center bolt to specification. See TORQUE SPECIFICATIONS (3000GT) table\
at end of article. Ensure tensioner pulley does not rotate while
tightening center bolt.
10) Ensure wire installed in automatic tensioner can be
easily removed and installed. Rotate crankshaft 2 revolutions
clockwise. Wait 5 minutes. Ensure wire can still be removed and
installed easily or automatic tensioner rod projects from tensioner
body .150-.177" (3.8-4.5 mm).
11) If rod projection is not to specification, repeat steps
9) and 10). To complete installation, reverse removal procedure.
Install proper length bolts in timing belt covers. Install bolts into
engine support bracket in reverse order of removal sequence. See
Fig. 10 . Tighten bolts to specification. See TORQUE SPECIFICATIONS
(3000GT) table.
NOTE: Engine support bracket reamer bolt must be tightened slowly
while spraying lubricant on bolt.
CAMSHAFT & ROCKER ARMS
Removal (SOHC)
1) Remove PCV valve and breather hoses. Remove timing belt,
camshaft sprocket and rear timing belt cover. See TIMING BELT under
REMOVAL & INSTALLATION. Remove rocker covers and gaskets. Remove
circular packing from rear of camshafts.
2) Remove camshaft oil seal from front of cylinder head or
distributor adapter. Remove distributor adapter and "O" ring. Install
Valve Lash Adjuster Holder (MD998443) on rocker arm. See Fig. 18. Note
arrow marks on bearing caps and cylinder head. See Fig. 19.
3) Bearing cap location number is stamped on front side of
bearing cap. Remove bearing cap bolts. Keep components in order for
reassembly reference. Remove rocker arm assembly. Remove camshaft from
cylinder head.
Fig. 18: Installing Valve Lash Adjuster Holder (SOHC)
Courtesy of Mitsubishi Motor Sales of America, Inc.

Install valve lash adjusters and valve lash adjuster holders (if
removed). See Fig. 18.
2) Apply 3M Sealant (4171) to designated areas of cylinder
head. See Fig. 19. Use care so sealant does not get on camshaft or
camshaft bearing journals. Install rocker arm assembly. Ensure arrow
on bearing cap faces same direction as arrow on cylinder head. See
Fig. 19 . Tighten bearing cap bolts to specification. See appropriate
TORQUE SPECIFICATIONS table at end of article. Remove valve lash
adjuster holders.
3) Coat camshaft oil seal area with oil. Using Seal Installer
(MD998713), install camshaft oil seal. Using Circular Packing
Installer (MD998306), install circular packing to press-in depth of .
02" (.5 mm).
4) Apply Three Bond (1212D) sealant to rocker cover sealing
surfaces before installation. See Fig. 6. Coat new "O" ring with oil,
and install on distributor adapter (if removed).
5) Coat camshaft area with oil before installing distributor
adapter. To complete installation, reverse removal procedure. Tighten
bolts to specification. See appropriate TORQUE SPECIFICATIONS table.
Removal (DOHC)
1) Remove UPPER INTAKE MANIFOLD and LOWER INTAKE MANIFOLD as
necessary. See UPPER INTAKE MANIFOLD and LOWER INTAKE MANIFOLD under
REMOVAL & INSTALLATION. Remove timing belt, camshaft sprockets and
rear timing belt covers. See TIMING BELT under REMOVAL & INSTALLATION.
2) Remove center cover and spark plug wires. Remove PCV and
breather hoses. Remove rocker covers and gaskets. Remove crank angle
sensor adapter. Remove front and rear camshaft bearing caps along with
seals and circular packings.
3) Remove remaining camshaft bearing caps in sequence: No. 2,
No. 4 and No. 3. Remove camshaft, rocker arms and lash adjusters. Mark
component location for reassembly reference.
Inspection (DOHC)
Inspect rocker arm for damaged roller and flaking. Inspect
camshaft for damage. Measure camshaft end play, journal diameter and
lobe height. Replace camshaft if it is not within specification. See
CAMSHAFT (DOHC) table in ENGINE SPECIFICATIONS at end of article.
Installation (DOHC)
1) Coat components with oil. Install lash adjusters and
rocker arms. Bring No. 1 cylinder to TDC. Ensure intake and exhaust
camshafts are installed correctly. Intake camshaft is marked with a
"V" and exhaust camshaft is marked with a "C" on hexagon section.
Position camshaft dowels as shown. See Fig. 21.
NOTE: If cylinder head is off vehicle, support cylinder head at
least .39" (10 mm) above work surface to prevent valve
damage while installing camshaft bearing caps.
Fig. 21: Installing Camshafts & Bearing Caps (DOHC)
Courtesy of Mitsubishi Motor Sales of America, Inc.
2) Install camshaft bearing caps in sequence: No. 3, No. 4

and No. 2. Install bearing caps with front mark arrow facing the same
direction as similar mark on cylinder head beside bearing journal.
Note bearing cap number and identification mark ("I" for intake
camshaft and "E" for exhaust). See Fig. 22.
3) Install front and rear bearing caps. Tighten bearing cap
bolts to specification. See TORQUE SPECIFICATIONS (3000GT) table at
end of article. Coat camshaft oil seal area with oil. Using Seal
Installer (MD998761), install camshaft oil seal. Using Circular
Packing Installer (MD998761), install circular packing.
4) Install crankshaft angle sensor adapter. To complete
installation, reverse removal procedure. Tighten bolts to
specification. See TORQUE SPECIFICATIONS table.
REAR CRANKSHAFT OIL SEAL
Removal
Remove transaxle/transmission. See appropriate article in
TRANSMISSION SERVICING or CLUTCHES. Remove flywheel or drive plate.
Remove rear oil seal case. Pry seal from seal case.
Installation
To install, coat seal lip with oil. Using Seal Installer
(MD998718), install seal in seal case. Apply sealant to sealing
surface of seal case. Install seal case. Install flywheel or drive
plate. Tighten bolts to specification. See appropriate TORQUE
SPECIFICATIONS table at end of article. To complete installation,
reverse removal procedure.
WATER PUMP
Removal
Drain cooling system. Remove timing belt and crankshaft
sprocket. See TIMING BELT under REMOVAL & INSTALLATION. Remove coolant
pipes to water pump (if required). Remove water pump bolts, noting
length and location for reassembly reference. Remove water pump.
Installation
To install, reverse removal procedure using new gasket and
"O" rings. Coat all "O" rings with water before installation. Install
water pump and gasket. Tighten bolts to specification. See appropriate
TORQUE SPECIFICATIONS table at end of article.
OIL PAN
Removal (Montero)
1) Remove hood. Remove skid plate and lower covers. Raise and
support vehicle. Disconnect and remove exhaust pipe from exhaust
manifolds. Drain engine oil. Remove starter cover and starter. Remove
oil pressure sending unit connector. Remove front suspension
crossmember.
2) Remove transmission stays. Remove ground cable and motor
mount heat shields. Attach engine hoist. Remove motor mount bolts.
Raise engine, and insert a 1" wood spacer between front insulator and
mounts. Lower engine onto wood blocks.
3) Raise vehicle using a hoist. Remove oil pan bolts. Using
Seal Cutter (MD998727), separate oil pan from cylinder block. Remove
pan from vehicle.
Removal (Pickup)
1) Remove skid plate and lower covers. Raise and support
vehicle. Drain engine oil. Using Steering Linkage Puller (C-3894-A or
MB990635), disconnect relay rod from idler arm and steering box.
2) Remove oil pan bolts. Using Seal Cutter (MD998727),

separate oil pan from cylinder block. Remove pan from vehicle.
Removal (3000GT)
1) Raise and support vehicle. Remove engine undercovers.
Drain engine oil. Disconnect O2 sensor connector. Remove front exhaust
pipe from manifolds. On All-Wheel Drive (AWD) models, drain transfer
assembly. Remove front air dam. Remove AWD drive shaft and transfer
assembly.
2) On turbocharged models, remove oil return lines from oil
pan. On all models, remove starter. Remove crossmember and transaxle
stays. Remove bellhousing cover. Remove oil pan bolts. Using Seal
Cutter (MD998727), separate oil pan from cylinder block. Remove pan
from vehicle.
Inspection (All Models)
Clean sealant from oil pan mating surface on engine block and
oil pan. Check oil pan for cracks and damage. Check sealing surface
for damage and deformation. Inspect oil pick-up screen for damage.
Installation (All Models)
1) To install, reverse removal procedure. Apply sealant to
oil pan flange in a continuous .16" (4 mm) diameter bead. See Fig. 22.
Install oil pan within 15 minutes of applying sealant.
2) Tighten bolts to specification in proper sequence. See
appropriate TORQUE SPECIFICATIONS table at end of article. Wait at
least 30 minutes before adding oil and starting engine. On AWD models,
refill transfer assembly with GL-4 hypoid gear oil. On all models,
complete installation by reversing removal procedure.
Fig. 22: Sealant Application & Oil Pan Bolt Tightening Sequence
Courtesy of Mitsubishi Motor Sales of America, Inc.
OVERHAUL

.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