1991 MITSUBISHI MONTERO Service Manual

oil seal using seal driver. Apply grease to outside circumference of
bearing outer race. Apply grease to lip of oil seal and to roller
surfaces of bearing inner race.
2) Press bearing onto axle shaft. Install rear brake assembly
and bearing case. Pack bearing case and axle threads with grease.
Install lock washer (tab aligned with axle slot) and lock nut (chamfe\
r
toward lock washer). Tighten lock nut to 130-159 ft. lbs. (176-216 N.
m).
3) Bend tabs on lock washer into slots of lock nut. Apply
grease to oil seal area of rear axle housing. Adjust clearance between
bearing case and rear axle by inserting .04" (1.0 mm) shim and "O"
ring into left rear axle housing.
4) Apply semi-drying sealant to mating surface of bearing
case. Install left axle shaft into rear housing. Tighten nuts
diagonally to 36-43 ft. lbs. (49-58 N.m).
5) Install right axle shaft without shims and "O" ring.
Temporarily tighten to about 53 INCH lbs. (6 N.m). Using a feeler
gauge, measure clearance between bearing case and rear axle housing.
6) Remove right axle shaft. Install shims to equal bearing
case-to-axle housing clearance plus .002-.008" (.05-.20 mm). Install
"O" ring to right rear axle housing. Apply sealant to mating surfaces
of bearing case and shim. See Fig. 10.
7) Install axle into housing, tightening nuts diagonally to
36-43 ft. lbs. (50-58 N.m). Check axle shaft for .002-.008" (.05-.20
mm) end play using dial indicator.
Fig. 10: Applying Sealant (Montero, Pickup & Ram-50)
Courtesy of Mitsubishi Motor Sales of America.
Removal (Pickup & Ram-50)
1) With drum removed, disconnect brake line from wheel

cylinder. Disconnect parking brake cable end, and remove cable
attaching bolts. Remove brake backing plate, bearing case and axle
shaft as an assembly. If axle shaft binds, use slide hammer with
puller to remove.
2) Remove shims, "O" ring and snap ring. Retain shims for
reassembly. Secure axle shaft assembly in a vise, and remove one
retainer bolt from backing plate. Push bearing case completely to side
of dust cover. Place adhesive tape around edge of bearing case at
retainer bolt hole to prevent damage.
3) Secure axle shaft, and grind retainer ring until retainer
ring wall thickness is .04-.06" (1.0-1.5 mm) on axle shaft side and
retainer ring wall thickness is .08" (2.0 mm) on bearing side. See
Fig. 11.
CAUTION: DO NOT damage bearing case or axle shaft when grinding or
chiseling retainer ring.
4) Change angle of grind, and remove remaining .08" (2.0 mm)\
of retainer ring wall on bearing side. See Fig. 11. Using a chisel,
cut retainer ring, and remove. DO NOT damage axle shaft.
Fig. 11: Grinding Bearing Retainer Ring (Pickup & Ram-50)
Courtesy of Mitsubishi Motor Sales of America.
5) Install Puller (MB990787-01) to remove bearing case from
axle shaft. Rotate nuts with equal force to remove wheel bearing.

Remove bearing outer race using a hammer and drift. Remove oil seal
from axle housing using a slide hammer and hook.
Installation
1) Apply Multipurpose Grease (SAE J310) to oil seal. Install\
oil seal using seal driver. Apply grease to outside circumference of
oil seal lip. Install backing plate and bearing case. Apply grease to
oil seal.
2) Press new oil seal into bearing case until it is flush
with face of bearing case. Apply grease to lip of oil seal and to
external surfaces of bearing outer race. Press bearing outer race into
bearing case.
3) Apply grease to roller surfaces of bearing inner race.
Install rear brake assembly and bearing case. Pack bearing case and
axle threads with grease. Install new retainer ring.
4) Adjust clearance between bearing case and rear axle by
inserting .04" (1.0 mm) shim and "O" ring into left rear axle housing.\
Apply semi-drying sealant to mating surface of bearing case. Install
left axle shaft into rear housing. Tighten nuts diagonally to 36-43
ft. lbs. (50-58 N.m).
5) Install right axle shaft without shims and "O" ring.
Temporarily tighten to about 53 INCH lbs. (6 N.m). Using a feeler
gauge, measure clearance between bearing case and rear axle housing.
6) Remove right axle shaft. Install shims to equal bearing
case-to-axle housing clearance plus .002-.008" (.05-.20 mm). Install
"O" ring to right rear axle housing. Apply sealant to mating surface
of bearing case. See Fig. 10.
7) Install axle into housing, tightening nuts diagonally to
36-43 ft. lbs. (49-58 N.m). Check axle shaft for .002-.008" (.05-.20
mm) end play using dial indicator.
OVERHAUL
NOTE: For exploded views of front disc brake caliper, see Fig. 12.
For exploded view of master cylinder, see Fig. 13.
Fig. 12: Exploded View of Front Disc Brake Caliper (Typical)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 13: Exploded View of Master Cylinder (Typical)
Courtesy of Mitsubishi Motor Sales of America.
DISC BRAKE SPECIFICATIONS
DISC BRAKE SPECIFICATIONS TABLE








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Application In. (mm)
Disc Diameter
Montero
2.6L ...................................... 10.2 (259)
3.0L ...................................... 10.9 (277)
Pickup & Ram-50
2WD ....................................... 10.2 (259)
4WD ....................................... 10.9 (277)
Lateral Runout ................................ .006 (.15)
Parallelism .......................................... ( 1)
Original Thickness .............................. .87 (22)
Master Cylinder Diameter .................... .938 (23.83)
Minimum Refinish Thickness .................... .80 (20.4)
Discard Thickness ............................. .78 (19.8)
( 1) - Information is not available.









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DRUM BRAKE SPECIFICATIONS
DRUM BRAKE SPECIFICATIONS TABLE








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Application In. (mm)
Drum Diameter ................................. 10.0 (254)
Drum Width ........................................... ( 1)
Master Cylinder Diameter .................... .938 (23.83)

Maximum Refinish Diameter ..................... 10.1 (257)
Wheel Cylinder Diameter
Montero ................................... .875 (22.22)
Pickup & Ram-50
2WD ..................................... .937 (23.80)
4WD ..................................... .875 (22.22)
Discard Diameter ........................... 10.12 (257.0)
(1) - Information is not available.









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TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLE








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Application Ft. Lbs. (N.m)
Caliper Guide or Lock Pin Bolt
Guide Pin Bolt ........................... 29-36 (40-49)
Lock Pin Bolt ............................ 23-30 (31-41)
Caliper Mounting Bolts ..................... 58-72 (79-98)
Front Wheel Bearing Nut .............................. ( 1)
Rotor-To-Hub Bolts Or Nuts
Pickup (2WD) ............................ 34-38 (46-52)
All Others ............................... 36-43 (49-58)
INCH Lbs. (N.m)
Master Cylinder-To-Power Brake Unit Nut .... 72-108 (8-12)
( 1) - See FRONT BRAKE ROTOR under REMOVAL & INSTALLATION.









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CO M PU TE R R ELE A R N P R O CED URES

1991 M it s u bis h i M onte ro
GENERAL INFORMATION
Computer Relearn Procedures
All Models
* PLEASE READ THIS FIRST *
The following general procedures are to be used if
driveability problems are encountered after power loss or battery has
been disconnected. These procedures may provide an aid in eliminating
these problems.
To reduce the possibility of complaints, after any service
which requires battery power to be disconnected, vehicle should be
road tested.
COMPUTER RELEARN PROCEDURES
Vehicles equipped with engine or transmission computers may
require a relearn procedure after vehicle battery is disconnected.
Many vehicle computers memorize and store vehicle operation patterns
for optimum driveability and performance. When vehicle battery is
disconnected, this memory is lost. The computer will use default data
until new data from each key start is stored. As computer memorizes
vehicle operation for each new key start, driveability is restored.
Vehicle computers may memorize vehicles operation patterns for 40 of
more key starts.
Customers often complain of driveability problems during
relearn stage because vehicle acts differently then before being
serviced. Depending on type and make of vehicle and how it is
equipped, the following complaints (driveability problems) may exist:
* Harsh Or Poor Shift Quality
* Rough Or Unstable Idle
* Hesitation Or Stumble
* Rich Or Lean Running
* Poor Fuel Mileage
These symptoms and complaints should disappear after a number
of drive cycles have been memorized. To reduce the possibility of
complaints, after any service which requires battery power to be
disconnected, vehicle should be road tested. If a specific relearn
procedure is not available, the following procedure may be used:
Automatic Transmission
* Set parking brake, start engine in "P" or "N" position.
Warm-up vehicle to normal operating temperature or until
cooling fan cycles.
* Allow vehicle to idle for one minute in "N" position. Select
"D" and allow engine to idle for one minute.
* Accelerate at normal throttle position (20-50%) until vehicle
shifts into top gear.
* Cruise at light to medium throttle.
* Decelerate to a stop, allowing vehicle to downshift, and use
brakes normally.
* Process may be repeated as necessary.
Manual Transmission

* Place transmission in Neutral position.
* Ensure emergency brake has been set and all accessories
are turned off.
* Start engine and bring to normal operating temperature.
* Allow vehicle to idle in Neutral for one minute.
* Initial relearn is complete: process will be completed during
normal driving.
Some manufacturers identify a specific relearn procedure
which will help establish suitable driveability during relearn stage.
These procedures are especially important if vehicle is equipped with
and electronically controlled automatic transmission or transaxle.
Always complete procedure before returning vehicle to customer.

CO OLIN G S YSTE M S PEC IF IC ATIO NS

1991 M it s u bis h i M onte ro
1991 ENGINE COOLING
Mitsubishi Cooling System Specifications
Mitsubishi: Eclipse, Galant, Mirage,
Montero, Pickup, Precis, 3000GT
COOLING SYSTEM SPECIFICATIONS
COOLING SYSTEM SPECIFICATIONS TABLE








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Application Specification
Coolant Replacement Interval ............. 30,000 Miles or 24 Months
Coolant Capacity
(Includes Heater & Reserve Tank)
Eclipse
1.8L .......................................... 6.6 qts. (6.2L)\
2.0L .......................................... 7.6 qts. (7.2L)\
Galant .......................................... 7.6 qts. (7.2L)\
Montero ........................................ 10.0 qts. (9.5L)\
Pickup
2WD
Automatic Transmission ....................... 6.4 qts. (6.1L)\
Manual Transmission .......................... 6.3 qts. (6.0L)\
4WD ........................................... 8.9 qts. (8.4L)\
Precis .......................................... 5.6 qts. (5.3L)\
3000GT .......................................... 8.8 qts. (8.3L)\
Pressure Cap ............................................. 11-15 psi
Thermostat Opens
Except 3000GT
Starts ............................................. 190
F (88C)
Fully Open ........................................ 212F (100C)
3000GT
Starts ............................................. 170
F (77C)
Fully Open ......................................... 190F (88C)








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