1991 MITSUBISHI MONTERO height

adjusting shims between drive pinion gear and rear pinion bearing.
Using bearing installer, install rear pinion bearing.
Fig. 11: Setting Pinion Height
Courtesy of Chrysler Motors.
DRIVE PINION PRELOAD

spring tester, test valve spring pressure at installed and compressed
heights. See Fig. 5.
Usually compressed height is installed height minus valve
lift. Replace valve spring if not within specification. It is
recommended to replace all valve springs when overhauling cylinder
head.
Fig. 5: Checking Valve Spring Pressure - Typical
This Graphic For General Information Only
VALVE GUIDE
Measuring Valve Guide Clearance
Check valve stem-to-guide clearance. Ensure valve stem
diameter is within specifications. Install valve in valve guide.
Install dial indicator assembly on cylinder head with tip resting
against valve stem just above valve guide. See Fig. 6.

the old insert and machining an oversize insert bore. Replacement
oversize insert is usually chilled and the cylinder head is sometimes
warmed. Valve seat is pressed into the head. This operation requires
specialized machine shop equipment.
Valve Seat Concentricity
Using dial gauge, install gauge pilot in valve guide.
Position gauge arm on the valve seat. Adjust dial indicator to zero.
Rotate arm 360 degrees and note reading. Runout should not exceed
specification.
To check valve-to-valve seat concentricity, coat valve face
lightly with Prussian Blue dye. Install valve and rotate it on valve
seat. If pattern is even and entire seat is coated at valve contact
point, valve is concentric with the seat.
REASSEMBLY
Valve Stem Installed Height
Valve stem installed height must be checked when new valves
are installed or when valves or valve seats have been ground. Install
valve in valve guide. Measure distance from tip of valve stem to
spring seat. See Fig. 11. Distance must be within specifications.
Fig. 11: Measuring Valve Stem Installed Height - Typical
This Graphic For General Information Only
Remove valve and grind valve stem tip if height exceeds
specification. Valve tips are surface hardened. DO NOT remove more

than .010" (.25 mm) from tip. Chamfer sharp edge of reground valve
tip. Recheck valve stem installed height.
VALVE STEM OIL SEALS
Valve stem oil seals must be installed on valve stem. See
Fig. 2 . Seals are needed due to pressure differential at the ends of
valve guides. Atmospheric pressure above intake guide, combined with
manifold vacuum below guide, causes oil to be drawn into the cylinder.
Exhaust guides also have pressure differential created by
exhaust gas flowing past the guide, creating a low pressure area. This
low pressure area draws oil into the exhaust system.
Replacement (On Vehicle)
Mark rocker arm or overhead cam components for location.
Remove rocker arm components or overhead cam components. Components
must be installed in original location. Remove spark plugs. Valve stem
oil seals may be replaced by holding valves against seats using air
pressure.
Air pressure must be installed in cylinder using an adapter
for spark plug hole. An adapter can be constructed by welding air hose
connection to spark plug body with porcelain removed.
Install adapter in spark plug hole. Apply a minimum of 140
psi (9.8 kg/cm
) to adapter. Air pressure should hold valve closed. If
air pressure does not hold valve closed, check for damaged or bent
valve. Cylinder head must be removed for service.
Using valve spring compressor, compress valve springs. Remove
valve locks. Carefully release spring compressor. Remove retainer or
rotator and valve spring. Remove valve stem oil seal.
If oversized valves have been installed, oversized oil seals
must be used. Coat valve stem with engine oil. Install protective
sleeve over end of valve stem. Install new oil seal over valve stem
and seat on valve guide. Remove protective sleeve. Install spring
seat, valve spring and retainer or rotator. Compress spring and
install valve locks. Remove spring compressor. Ensure valve locks
are fully seated.
Install rocker arms or overhead cam components. Tighten all
bolts to specification. Adjust valves if required. Remove adapter.
Install spark plugs, valve cover and gasket.
VALVE SPRING INSTALLED HEIGHT
Valve spring installed height should be checked during
reassembly. Measure height from lower edge of valve spring to the
upper edge. DO NOT include valve spring seat or retainer. Distance
must be within specifications. If valves and/or seats have been
ground, a valve spring shim may be required to correct spring height.
See Fig. 12 .
Fig. 12: Measuring Valve Spring Installed Height - Typical
This Graphic For General Information Only

length of cylinder block at several points.
If warpage exceeds specifications, deck must be resurfaced.
If warpage exceeds manufacturer's maximum tolerance for material
removal, replace block.
DECK HEIGHT
Distance from the crankshaft centerline to the block
deck is termed the deck height. Measure and record front and rear main
journals of crankshaft. To compute this distance, install crankshaft
and retain with center main bearing and cap only. Measure distance
from the crankshaft journal to the block deck, parallel to the
cylinder centerline.
Add one half of the main bearing journal diameter to distance
from crankshaft journal to block deck. This dimension should be
checked at front and rear of cylinder block. Both readings should be
the same.
If difference exceeds specifications, cylinder block must be
repaired or replaced. Deck height and warpage should be corrected at
the same time.
MAIN BEARING BORE & ALIGNMENT
For checking main bearing bore, remove all bearings from
cylinder block and main bearing caps. Install main bearing caps in
original location. Tighten bolts to specification. Using inside
micrometer, measure main bearing bore in 2 areas 90 degrees apart.
Determine bore size and out-of-round. If diameter is not within
specification, block must be align-bored.
For checking alignment, place a straightedge along centerline
of main bearing saddles. Check for clearance between straightedge and
main bearing saddles. Block must be align-bored if clearance is
present.
EXPANSION PLUG REMOVAL & INSTALLATION
Removal
Drill a hole in the center of expansion plug. Remove with
screwdriver or punch. Use care not to damage sealing surface.
Installation
Ensure sealing surface is free of burrs. Coat expansion plug
with sealer. Use a wooden dowel or pipe of slightly smaller diameter,
install expansion plug. Ensure expansion plug is evenly located.
OIL GALLERY PLUG REMOVAL & INSTALLATION
Removal
Remove threaded oil gallery plugs using the appropriate
wrench. Soft, press-in plugs are removed by drilling into plug and
installing a sheet metal screw. Remove plug with slide hammer or
pliers.
Installation
Ensure threads or sealing surface is clean. Coat threaded oil
gallery plugs with sealer and install. Replacement soft press-in plugs
are driven in place with a hammer and drift.
CAMSHAFT
* PLEASE READ THIS FIRST *

Brake On/Off (BOO) Switch ................... Cruise Control Systems\
Engine Performance
Shift Interlock Systems
Buzzer Module ...................................... Warning Systems
Camshaft Position (CMP) Sensor .................. Engine Performance\
Central Control Module ........................... Anti-Theft System
Clockspring ............................... Air Bag Restraint System
Cruise Control Systems
Steering Column Switches
Clutch Pedal Position Switch .............................. Starters
Clutch Start Switch ....................................... Starters
Combination Meter ......................... Analog Instrument Panels
Constant Control Relay Module (CCRM) ............ Engine Performance\
Electric Cooling Fans
Convenience Center .............................. Power Distribution
Illumination/Interior Lights
Convertible Top Motor ........................ Power Convertible Top
Convertible Top Switch ....................... Power Convertible Top
Crankshaft Position (CKP) Sensor ................ Engine Performance\
Cruise Control Module ....................... Cruise Control Systems
Cruise Control Switch ....................... Cruise Control Systems
Condenser Fan Relay(s) ....................... Electric Cooling Fans\
Data Link Connector (DLC) ....................... Engine Performance\
Daytime Running Lights Module ............... Daytime Running Lights
Exterior Lights
Defogger Relay ................................ Rear Window Defogger
Diagnostic Energy Reserve Module (DERM) ... Air Bag Restraint System\
Discriminating Sensor (Air Bag) ........... Air Bag Restraint System\
Distributor ..................................... Engine Performance
Door Lock Actuators ............................... Power Door Locks
Remote Keyless Entry
Door Lock Relay(s) ................................ Power Door Locks\
Electrochromic Mirror ................................ Power Mirrors
Electronic Level Control (ELC)
Height Sensor .............................. Electronic Suspension
Electronic Level Control (ELC) Module ........ Electronic Suspension\
Engine Coolant Temperature (ECT)
Sending Unit ............................ Analog Instrument Panels
Engine Coolant Temperature (ECT) Sensor ......... Engine Performance\
Engine Control Module ........................... Engine Performance
Generators & Regulators
Starters
ETACS ECU .......................................... Warning Systems
Power Windows
Remote Keyless Entry
Evaporative (EVAP) Emissions Canister ........... Engine Performance\
EVAP Canister Purge Solenoid .................... Engine Performance
EVAP Canister Vent Solenoid ..................... Engine Performance
Exhaust Gas Recirculation (EGR) Valve ........... Engine Performance\
Fuel Tank Vacuum Sensor ......................... Engine Performance
Fog Lights ....................................... Headlight Systems
Daytime Running Lights
Fog Light Relay .................................. Headlight Systems
Daytime Running Lights
Fuel Door Release Solenoid ................. Power Fuel Door Release
Fuel Gauge Sending Unit ................... Analog Instrument Panels
Fuel Injectors .................................. Engine Performance
Fuel Pump ....................................... Engine Performance
Fuel Pump Relay ................................. Engine Performance
Power Distribution
Fuse/Relay Block ................................ Power Distribution
Fusible Links ................................... Power Distribution
Generators & Regulators

Starters
Generator .................................. Generators & Regulators
Engine Performance
Power Distribution
Generic Electronic Module (GEM) ............... Body Control Modules\
Electronic Suspension
Glow Plug Relay ................................. Engine Performance
Glow Plugs ...................................... Engine Performance
Grounds ........................................ Ground Distribution
Headlight Door Module .............................. Headlight Doors
Headlight Relay .................................. Headlight Systems
Daytime Running Lights
Headlights ....................................... Headlight Systems
Daytime Running Lights
Heated Oxygen Sensor(s) (HO2S) .................. Engine Performan\
ce
Heated Windshield Control Module ................ Heated Windshields
Height Sensor ................................ Electronic Suspension
Horns ..................................... Steering Column Switches
Horn Relay ................................ Steering Column Switches
Idle Air Control (IAC) Motor/Valve .............. Engine Performance\
Ignition Coil(s) ................................ Engine Performance\
Ignition Key Lock Cylinder ....................... Anti-Theft System
Ignition Module ................................. Engine Performance
Ignition Switch ................................. Power Distribution
Engine Performance
Generators & Regulators
Starters
Illuminated Entry Module .............. Illumination/Interior Lights
Illumination Lights ................... Illumination/Interior Lights
Impact Sensor ............................. Air Bag Restraint System
Inertia Fuel Shutoff Switch ..................... Engine Performance
Inhibit Relay ............................................. Starters
Instrument Cluster ........................ Analog Instrument Panels
Intake Air Temperature (IAT) Sensor ............. Engine Performance\
Interior Lights ....................... Illumination/Interior Lights
Interlock Switch .......................................... Starters
Junction Block .................................. Power Distribution
Keyless Entry Receiver ........................ Remote Keyless Entry
Key Reminder Switch ....................................... Starters
Knock Sensor .................................... Engine Performance
Lamp Control Module ................................ Exterior Lights
License Plate Lamp ................................. Exterior Lights
Lighting Control Module ................... Lighting Control Modules
Anti-Theft System
Daytime Running Lights
Headlight Systems
Lower Relay .................................. Power Convertible Top
Malfunction Indicator Light (MIL) ............... Engine Performance\
Instrument Panels
Manifold Absolute Pressure (MAP) Sensor ......... Engine Performance\
Mass Airflow (MAF) Sensor ....................... Engine Performance\
Mega Fuse .................................. Generators & Regulators
Memory Seat/Mirror Module ........................... Memory Systems
Mirror Defogger ............................... Rear Window Defogger
Moon Roof Motor .................................... Power Moon Roof
Moon Roof Relay .................................... Power Moon Roof
Multi-Function Control Module ...................... Warning Systems
Neutral Safety Switch ..................................... Starters
Oil Level Switch ................................ Engine Performance
Oil Pressure Switch/Sending Unit .......... Analog Instrument Panels
Engine Performance
Overhead Console .................................. Overhead Console
Oxygen Sensor(s) (O2S) .......................... Engine Performan\
ce

\003
PR E-A LIG NM EN T C HEC KS

1991 M it s u bis h i M onte ro
Wheel Alignment
PRE-ALIGNMENT INSPECTION PROCEDURES
PRE-ALIGNMENT CHECKS
Before making wheel alignment adjustment, perform the
following checks:
1) Tires should be equal in size and runout must not be
excessive. Tires and wheels should be in balance, and inflated to
manufacturer's specifications.
2) Wheel bearings must be properly adjusted. Steering linkage
and suspension must not have excessive looseness. Check for wear in
tie rod ends and ball joints.
3) Steering gear box must not have excessive play. Check and
adjust to manufacturer's specifications.
4) Vehicle must be at curb height with full fuel load and
spare tire in vehicle. No extra load should be on vehicle.
5) Vehicle must be level with floor and with suspension
settled. Jounce front and rear of vehicle several times and allow it
to settle to normal curb height.
6) If steering wheel is not centered with front wheels in
straight-ahead position, correct by shortening one tie rod adjusting
sleeve and lengthening opposite sleeve equal amounts.
7) Ensure wheel lug nuts are tightened to torque
specifications.