1991 MITSUBISHI MONTERO engine

1994-96 (3.0L DOHC & 3.5L) .................. 9.0 Qts. (8.5L)
Cooling System
1983-88 ..................................... 8.5 Qts. (8.0L)
1989-96
2.6L ....................................... 9.7 Qts. (9.2L)
3.0L ...................................... 10.0 Qts. (9.5L)
3.5L ...................................... 10.0 Qts. (9.5L)
Differential
1983-88 ..................................... 1.9 Qts. (1.8L)
1989-93
2.6L ....................................... 1.9 Qts. (1.8L)
3.0L ....................................... 2.7 Qts. (2.6L)
1994-96
3.0L & 3.5L ................................ 2.7 Qts. (2.6L)
Engine Oil
1983-86 ..................................... 6.0 Qts. (5.8L)
1987 ........................................ 5.2 Qts. (5.0L)
1988 ........................................ 5.0 Qts. (4.8L)
1989-91 ..................................... 5.5 Qts. (5.3L)
1992-96 ..................................... 5.2 Qts. (4.9L)
Power Steering ................................ 1.1 Qts. (1.0L)
Fuel Tank
1983-88 .................................... 15.9 Gals. (60L)
1989-90
2.6L 2-Door ............................... 15.9 Gals. (60L)
3.0L 2-Door ............................... 19.9 Gals. (75L)
2.6L & 3.0L 4-Door .......................... 24 Gals. (92L)
1991-96 ...................................... 24 Gals. (92L)
Manual Transmission
1983-91 ..................................... 2.3 Qts. (2.2L)
1992 ........................................ 2.4 Qts. (2.3L)
1993-96 ..................................... 2.6 Qts. (2.5L)
Transfer Case
1983-91 ..................................... 2.3 Qts. (2.2L)
1992-96 ..................................... 2.4 Qts. (2.3L)
(1) - Use of R12 in a R134a system will result in SEVERE DAMAGE.
( 2) - 1983 model equipped with manual transmission only.









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WHEEL & TIRE SPECIFICATIONS
Tire specifications are imprinted on the tire side wall. The
recommended cold tire inflation pressures are listed on a label
attached to the rear face of the driver's door. These pressures
provide the best combination of ride comfort, tire wear and stability
under normal conditions.
CAUTION: DO NOT mix tires of different design such as radial ply
with bias or bias-belted tires. Mixing tire types will
adversely affect road handling and may lead to loss of
vehicle control. When using snow tires, they must be used
in set of four for maneuverability and safety. DO NOT use
tire chains on front wheels.
TIRE & WHEEL SPECIFICATIONS TABLE









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Wheel Size Tire Size
1983-86
15 x 6JJ (Steel) .............................. 215 SR15
1987-88

2.6L Engine ........................................... 45
2.6L Optional ......................................... 45
3.0L V6 ........................................... (1) 24
3.5L V6 ........................................... ( 1) 24
( 1) - Check hood clearance on 1986 and newer models.









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CAUTIONS & WARNINGS
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG SYSTEM
NOTE: See the AIR BAG RESTRAINT SYSTEM article in the
ACCESSORIES/SAFETY EQUIPMENT Section.
The SRS has no user-servicable parts. Always have servicing
done by an authorized dealer.
When performing maintenance on air bag equipped vehicles
always observe proper safety precautions.
WARNING: To avoid injury from accidental air bag deployment, read and
carefully follow all warnings and service precautions. See
appropriate AIR BAG RESTRAINT SYSTEM article in the
ACCESSORIES/SAFETY EQUIPMENT section.
CAUTION: Disconnect negative battery cable before servicing any air
bag system, steering column or passenger side dash
component. After any repair, turn ignition key to the ON
position from passenger's side of vehicle in case of
accidental air bag inflation
ANTI-LOCK BRAKE SYSTEM (ABS)
CAUTION: Never mix different diameter tires. On loose or uneven
surfaces, the ABS system may require longer stopping
distances than conventional brake systems. Exercise caution
when removing mud or snow from the wheels so as not to
damage the ABS wiring or speed sensors.
BATTERY WARNING
WARNING: When battery is disconnected, vehicles equipped with
computers may lose memory data. When battery power is
restored, driveability problems may exist on some vehicles.
These vehicles may require a relearn procedure. See
appropriate COMPUTER RELEARN PROCEDURES article in the
GENERAL INFORMATION section below.
REPLACING BLOWN FUSES
Before replacing a blown fuse, remove ignition key, turn off
all lights and accessories to avoid damaging the electrical system. Be
sure to use fuse with the correct indicated amperage rating. The use
of an incorrect amperage rating fuse may result in a dangerous
electrical system overload.
BRAKE PAD WEAR INDICATOR
Indicator will cause a squealing or scraping noise, warning
that brake pads need replacement.

CATALYTIC CONVERTER
Continued operation of vehicle with a severe malfunction
could cause converter to overheat, resulting in possible damage to
converter and vehicle.
COOLANT (PROPYLENE-GLYCOL FORMULATIONS)
CAUTION: To avoid possible damage to vehicle use only ethylene-glycol
based coolants with a mixture ratio from 44-68% anti-freeze.
DO NOT use 100% anti-freeze as it will cause the formation
of cooling system deposits. This results in coolant
temperatures of over 300
\b F (149\bC) which can melt plastics.
100% anti-freeze has a freeze point of only -8\b F (-22\bC).
CAUTION: Propylene-Glycol Mixtures has a smaller temperature range
than Ethylene-Glycol. The temperature range (freeze-boil)
of a 50/50 Anti-Freeze/Water Mix is as follows:
Propylene-Glycol -26
\b F (-32\bC) - 257\b F (125\bC)
Ethylene-Glycol -35\b F (-37\bC) - 263\b F (128\bC)
CAUTION: Propylene-Glycol/Ethylene-Glycol Mixtures can cause the
destabilization of various corrosion inhibitors. Also
Propylene-Glycol/Ethylene-Glycol has a different specific
gravity than Ethylene-Glycol coolant, which will result in
inaccurate freeze point calculations.
ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS
WARNING: Many solid state electrical components can be damaged by
static electricity (ESD). Some will display a warning label,
but many will not. Discharge personal static electricity by
touching a metal ground point on the vehicle prior to
servicing any ESD sensitive component.
ENGINE OIL
CAUTION: Never use non-detergent or straight mineral oil.
FUEL SYSTEM SERVICE
WARNING: Relieve fuel system pressure prior to servicing any fuel
system component (fuel injection models).
HALOGEN BULBS
WARNING: Halogen bulbs contain pressurized gas which may explode if
overheated. DO NOT touch glass portion of bulb with bare
hands. Eye protection should be worn when handling or working
around halogen bulbs.
RADIATOR CAP
CAUTION: Always disconnect the fan motor when working near the
radiator fan. The fan is temperature controlled and could
start at any time even when the ignition key is in the OFF
position. DO NOT loosen or remove radiator cap when cooling
system is hot.
RADIATOR FAN

WARNING: Keep hands away from radiator fan. Fan is controlled by a
thermostatic switch which may come on or run for up to
15 minutes even after engine is turned off.
WARRANTY INFORMATION
CAUTION: Always refer to customer's copy of warranty information for
specific model application and/or coverage limitations.
NEW VEHICLE LIMITED WARRANTY
Covers all manufacturer-installed parts and components for
any repairs, replacements or adjustments needed to correct defects in
materials or workmanship under normal use and maintenance for 36
months or 36,000 miles, whichever comes first, from date of delivery
to the first retail buyer or first date of use.
POWERTRAIN LIMITED WARRANTY
Upon expiration of New Vehicle Limited Warranty, this
warranty covers powertrain against defects in materials or workmanship
up to a maximum of 36 months or 50,000 miles, whichever occurs first.
On 1991-96 models, warranty period is extended to 5 years or 60,000
miles, whichever occurs first. See copy of warranty for specific
components covered.
BATTERY WARRANTY
Covers replacement of original battery for 12 months or 12,
000 miles, whichever occurs first.
AIR CONDITIONER WARRANTY
Covers manufacturer's air conditioners for 36 months or 36,
000 miles, whichever occurs first. Air conditioner refrigerant charge
is covered for the first 12 months or 12,000 miles, whichever occurs
first. On 1992-96 models, refrigerant is covered only as part of a
warranty repair.
ANTI-CORROSION PERFORATION LIMITED WARRANTY
Covers any body sheet metal panel found to have developed
perforation (rust-through) due to corrosion for 5 years regardless of
mileage. Outer panel coverage extends to 7 years or 100,000 miles,
whichever occurs first, on 1992-96 models.
EMISSION SYSTEM DEFECT WARRANTY (EXCEPT CALIFORNIA)
Warrants that the vehicle was designed, built and equipped to
conform at the time of sale with all applicable U.S. emission
standards. Covers any repairs needed to correct defects in materials
or workmanship which would cause the vehicle not to meet these
standards for 5 years or 50,000 miles, whichever occurs first.
EMISSION SYSTEM PERFORMANCE WARRANTY (EXCEPT CALIFORNIA)
Covers all repairs, adjustments, or replacements if vehicle
has been maintained in accordance with the prescribed scheduled
maintenance instructions and fails to conform to applicable emission
standards and such failure results or will result in the vehicle owner
having to bear any penalty or other sanctions under local, state or

1 - 20 Amp
Not Used
2 - Not Used
10 Amp (1994-96)
ELC-4 A/T Control Module, Cruise Control Unit
3 - 10 Amp
Blower Motor Relay, Headlight Washer Relay, Defogger Relay,
Car Telephone (1992-93)
4 - 10 Amp
Radio Clock, Accessory Socket Relay,
Cruise Control Unit (1994-96), Data Link Connector (1994-96)\
5 - 15 Amp
Remote Controlled Mirror, Cigarette Lighter
Accessory Socket Relay (1992-93)
6 - 15 Amp
Door Lock Relay, Door Lock Control Unit (1994-96)
7 - 10 Amp
Overdrive Relay, Variable Shock Absorber Control Unit,
4WD Indicator Control Unit, ABS Power Relay (1992-93),
ABS Control Unit (1994-96), Combination Meter (1994-96)
8 - 10 Amp
Power Window Relay
9 - 15 Amp
Wiper, Washer, Sunroof
10 - 10 Amp
Horn, Cruise Control Unit (1992-93)
11 - 10 Amp
Combination Meter, Multi-meter, Motor Antenna Control Unit,
Buzzer Assembly
12 - 15 Amp
Turn Signal Light, Hazard Light, SRS Diagnosis Unit
13 - 10 Amp
Not Used
14 - 15 Amp
Accessory Socket
15 - Not Used
16 - 25 Amp
Blower Motor
17 - 15 Amp
Stoplight
18 - 10 Amp
Back-up Light, Rear Differential Lock Control Unit
19 - 10 Amp
Engine Control Module, Dome Light, Reading Light,
Cargo Light, Combination Meter, Clock, Door Lock Relay,
Cruise Control Unit, Car Telephone (1992-93)
ELC-4 A/T Control Module (1994-96), Ignition Key Illumination\
Light Timer (1994-96)

\003
N - R EM OVE/IN STA LL/O VER HAU L
1991 Mitsubishi Montero
1991 ENGINE PERFORMANCE
Removal, Overhaul & Installation
Dodge; Colt, Colt 200, Colt Vista, Ram-50, Stealth
Eagle; Summit
Mitsubishi; Eclipse, Galant, Mirage, Montero, Pickup, 3000GT
Plymouth; Colt, Colt 200, Colt Vista
INTRODUCTION
Removal, overhaul and installation procedures (when given by
manufacturer) are covered in this article. If component removal and
installation is primarily an unbolt and bolt-on procedure, only a
torque specification may be furnished.
IGNITION SYSTEM
DISTRIBUTOR
Fig. 1: Exploded View of Distributor (Colt Vista)
Courtesy of Mitsubishi Motor Sales of America.

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.

Installation
1) To install, reverse removal procedure. Injectors may be
removed after fuel rail is removed from intake manifold. Use new
insulators and "O" rings when installing injectors.
2) Use spindle oil or gasoline on "O" ring. Install injectors
into fuel rail with a twisting motion. Adjust throttle and kickdown
cable (if applicable). Do not drop injectors while removing or
installing fuel rail.
OXYGEN (O2) SENSOR
Removal & Installation
1) O2 Sensor is mounted in exhaust pipe below exhaust header.
It is equipped with a permanent pigtail which must be protected from
damage when sensor is removed. Ensure sensor is free of contaminants,
avoid using cleaning solvents of any type. Sensor may be difficult to
remove when engine temperature is less than 120
F (48 C).
2) Always use anti-seize compound on threads before
installation. On non-turbo models, remove sensor using Remover
(MD998703). On turbo models, use Remover (MD998748) on Eclipse and
Galant, or Remover (MD998770) on Stealth and 3000GT. Tighten oxygen
sensor to specification. See TORQUE SPECIFICATIONS table.
THROTTLE BODY
Removal
Disconnect air intake hose. Remove accelerator and automatic
speed control cables (if equipped). Disconnect fuel vapor hose,
electrical harness connector, vacuum hose and coolant hoses. Remove
throttle body retaining bolts.
Disassembly
Remove throttle position sensor. Remove idle speed control
motor. Remove throttle bracket and connector bracket (if equipped).
Remove idle position switch and adjusting nut.
NOTE: DO NOT remove throttle valve. DO NOT use cleaning solvents
on throttle position sensor, idle speed control motor or
idle position switch.
Cleaning
Clean all parts except those noted in solvent. Check vacuum
port and passage for clogging. Clean vacuum, vapor and fuel passages
with compressed air.
Reassembly
To reassemble, reverse disassembly procedure.
Installation
To install, reverse removal procedure.
THROTTLE POSITION SENSOR/SWITCH
Removal & Installation
Throttle position sensor/switch is located on throttle body.
Disconnect TPS electrical connector. Remove bolts holding TPS and
remove TPS. To install, reverse removal procedure. Tighten throttle
position sensor/switch to specification. See TORQUE SPECIFICATIONS
table. For adjustment procedure, see ON-VEHICLE ADJUSTMENTS article.
TURBOCHARGERS