1991 MITSUBISHI MONTERO Service Manual

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

article.
2) Place automatic tensioner assembly in a soft-faced vise.
Squeeze rod back into automatic tensioner in small increments until
both rod and housing holes are aligned. Install a .055" (1.39 mm)
diameter wire through both holes.
3) Remove automatic tensioner from vise, and install assembly
with wire installed. Install crankshaft sprocket (if removed). Align
timing marks on crankshaft and camshaft sprockets. See Fig. 13.
CAUTION: Turning camshaft sprockets while No. 1 cylinder is at TDC
may damage valve and piston. Use care when aligning timing
marks.
4) To lower No. 1 piston from TDC and prevent valve and
piston contact, turn crankshaft back 3 sprocket teeth (measured at
timing mark). Starting with front bank of cylinders, ensure intake and
exhaust camshaft timing marks are not within shaded area of figure.
See Fig. 14 .
When camshaft sprocket timing marks are in indicated area,
camshaft is under valve spring pressure and may rotate suddenly,
pinching hand between sprockets. Use care when aligning timing marks.
Fig. 14: Adjusting Timing Marks to Prevent Valve & Piston Damage
(DOHC)
Courtesy of Mitsubishi Motor Sales of America, Inc.
5) If camshaft sprocket timing mark is within indicated area,
carefully rotate camshaft sprocket until timing mark is located in
nearest safe area. See Fig. 14.
6) Rotate either camshaft sprocket clockwise to align timing
marks as shown in Fig. 15. If camshaft sprocket is turned past timing
mark, turn it counterclockwise to realign it. Repeat procedure for

other front bank camshaft sprocket.
Fig. 15: Aligning Timing Marks Final Alignment (DOHC)
Courtesy of Mitsubishi Motor Sales of America, Inc.
7) Repeat steps 4)-6) for rear cylinder bank camshafts. Alig\
n
crankshaft timing mark. Install timing belt on sprockets in sequence.
See Fig. 16 . Use spring-type paper clips to secure belt on sprockets.
Use offset box-end wrenches on camshaft sprocket bolts to keep
camshafts from turning during belt installation.
NOTE: If necessary, crankshaft sprocket may be turned one tooth
counterclockwise to aid belt installation.

Fig. 16: Installing Timing Belt (DOHC)
Courtesy of Mitsubishi Motor Sales of America, Inc.
8) Rotate timing belt tensioner pulley until pin holes are
located above center bolt. See Fig. 17. Push tensioner pulley against
belt, and temporarily tighten center bolt. Ensure all timing marks are
still aligned, and remove clips.
Fig. 17: Adjusting Timing Belt Tensioner (DOHC)
Courtesy of Mitsubishi Motor Sales of America, Inc.
9) Rotate crankshaft 1/4 revolution counterclockwise. Rotate
crankshaft clockwise until timing marks are realigned. Loosen

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.

Fig. 19: Identifying Bearing Cap & Sealant Locations (SOHC)
Courtesy of Mitsubishi Motor Sales of America, Inc.
Inspection (SOHC)
1) Remove bearing caps, rocker arms and springs from shafts.
Mark component location for reassembly reference. Inspect rocker arm
and shaft for damaged roller and flaking. Measure rocker arm I.D. and
rocker arm shaft O.D. Determine oil clearance. Check spring free
length. Replace components if not within specification. See ROCKER ARM
& SHAFT SPECIFICATIONS (SOHC) table.

2) Inspect camshaft and distributor gear for damage. Measure
camshaft end play, journal diameter and lobe height. Replace camshaft
if it is not within specification. See CAMSHAFT (SOHC) table under
ENGINE SPECIFICATIONS at end of article.
3) Coat components with oil. Reassemble rocker arms, springs
and bearing caps. Install bearing caps with identification number
toward camshaft sprocket. Ensure oil holes and notch of shafts are
properly positioned. See Fig. 19.
ROCKER ARM & SHAFT SPECIFICATIONS TABLE (SOHC)









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Application In. (mm)
Oil Clearance ................. ( 1).0004-.0016 (.010-.041)
Rocker Arm I.D. ............................ .7444 (18.91)
Rocker Arm Shaft O.D. ...................... .7440 (18.90)
Spring Free Length ......................... 2.173 (55.19)
( 1) - Maximum clearance is .0039" (.099 mm).









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Fig. 20: Installing Rocker Arm Shafts (SOHC)
Courtesy of Mitsubishi Motor Sales of America, Inc.
Installation
1) Coat camshaft with oil, and install in cylinder head.

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