1991 MITSUBISHI MONTERO oil pressure

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A/C S YSTE M P R EC AU TIO NS

1991 M it s u bis h i M onte ro
AIR CONDITIONING & HEAT
A/C System Precautions
* PLEASE READ THIS FIRST *
CAUTION: When discharging air conditioning system, use only approved
refrigerant recovery/recycling equipment. Make every attempt
to avoid discharging refrigerant into the atmosphere.
BEFORE OPENING THE SYSTEM
Before disconnecting any lines or fittings, the system must
be completely discharged using approved refrigerant recovery/recycling
equipment.
DISCHARGING A/C SYSTEM
NOTE: Recent findings by the EPA indicate that R-11, R-12 and R-113
are harmful to the Earths' protective Ozone layer. Make every
attempt possible, to avoid discharging R-11, R-12 or R-113
into the atmosphere.
1) Remove service valve caps and install gauges. For high
side gauge hose, Adapter (D81L-19703-A) must be used to connect to
high side service valve.
2) Place open end of center hose in garage exhaust outlet or
in a well ventilated area. Slightly open low side gauge valve and let
refrigerant escape slowly without loosing refrigerant oil.
3) When system is nearly discharged, using approved
refrigerant recovery/recycling equipment, open high side gauge valve
to release any pressure trapped in compressor. Close valves
immediately after discharging to prevent entry of moisture.
DISCONNECTING LINES & FITTINGS
1) After system is discharged, using approved refrigerant
recovery/recycling equipment, carefully clean entire area around
coupling nut to prevent dirt entering system. Always use two wrenches
to avoid twisting or distorting lines and fittings (hold fitting with
one wrench while loosening coupling nut with second wrench).
2) Cap or plug all LINES and FITTINGS immediately to prevent
entry of air and moisture into system. Do not remove these caps until
connections are being made.
COMPONENT REPLACEMENT
When components are replaced, system oil level must be
adjusted. Add refrigeration oil to replacement component. See
Compressor oil Check article, as well as, Component Oil Replacement
Quantities" chart under "A/C SYSTEM SPECS" article in this section.
USING R-12 REFRIGERANT - SAFETY PRECAUTIONS
1) Always work in a well-ventilated, clean area. Refrigerant
(R-12) is heavier than oxygen, and will displace oxygen in a confined

system is in operation. This high pressure could rupture can
or fitting at safety can valve, resulting in damage and
personal injury.
CONNECTING LINES & FITTINGS
A new "O" ring should be used in all instances when
connecting lines and fittings (dip "O" ring in clean refrigeration oil
and make certain it is not twisted during installation). Always use
two wrenches to avoid twisting or distorting lines and fittings,
tighten coupling nuts securely.
PLACING SYSTEM IN OPERATION
After component replacement and/or system servicing has been
completed and all connections have been made, proceed as follows:
1) Evacuate the system using a vacuum pump.
2) Charge the system with new R-12 (refrigerant) according t\
o
each individual vehicle as outlined in the
GENERAL COOLING SYSTEM SERVICING article. Also see Refrigerant
Capacity in this Section.
3) Leak test the system, with particular attention to all new
connections and components.
4) Make a performance test of the system. Never assume that a
recharging has automatically corrected a problem.
COMPRESSOR REMOVAL INFORMATION - ISOLATION METHOD
On systems which have compressors equipped with stem-type
service valves (Tecumseh), it is possible to isolate the compressor
for removal.
Isolating
Turn both high and low pressure manual valves to extreme
clockwise (front seat) position. Loosen cap on high pressure manual
valve connection to compressor and allow gas to escape until
compressor is relieved of pressure.
COMPRESSOR REMOVAL INFORMATION - DISCHARGE METHOD
This procedure is to be used on vehicles which have
compressor equipped with Schrader service valves. In these cases, the
compressor cannot be isolated and the system must be discharged, using
approved refrigerant recovery/recycling equipment, prior to compressor
removal.

pump. If fuel pressure drops slowly, fuel injector is leaking or fuel
pressure regulator valve seat is leaking. Check for faulty fuel
injector or fuel pressure regulator. Repair as required.
11) When fuel pressure test is complete, repeat fuel pressure
release procedure in steps 1) and 2) before disconnecting fuel
pressure gauge. Install new "O" ring at end of high pressure hose.
Check for fuel leaks.
FUEL PUMP TEST TERMINAL LOCATION TABLE









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Application Wire Color Location
Colt, Colt 200 ......... BLK/WHT .............. Center Of Firewall
Colt Vista ............. BLK/WHT ........ Right Center Of Firewall
Eclipse ................ BLK/WHT .......... Rear Of Battery Compt.
Galant ................. YEL/GRN ........... Left Rear Eng. Compt.
Mirage 1.5L ............ BLK/WHT .............. Center Of Firewall
Mirage 1.6L ............ BLK/BLU .............. Center Of Firewall
Montero .................. WHT .......... Right Center Of Firewall
Pickup ................. BLK/BLU ....... Right Side Of Eng. Compt.
Precis ................... YEL ............. Left Rear Eng. Compt.
Summit ................. BLK/WHT .............. Center Of Firewall
Ram-50 ................. BLK/BLU ....... Right Side Of Eng. Compt.
Stealth, 3000GT ........ BLK/BLU .......... Rear Of Battery Compt.









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REGULATED FUEL PRESSURE TABLE








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At Idle At Idle
w/Vacuum w/o Vacuum
Application psi (kg/cm
) psi (kg/cm)
Non-Turbo .................. 38 (2.7) ....... 47-50 (3.3-3.5)
Turbo
Except Eclipse A/T ....... 27 (1.9) ....... 36-38 (2.5-2.7)
Eclipse A/T .............. 33 (2.3) ....... 36-38 (2.9-3.2)









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Control Relay
Multipurpose relay switches power to vehicle sensors and
actuators including airflow sensor, crank angle sensor, idle speed
control, injectors and fuel pump. When ignition switch is turned to ON
position, ECU energizes coils controlling injectors, airflow sensor
and idle speed control. When ignition switch is turned to START
position, ECU energizes coils (through inhibitor switch on A/T models)\
to supply power to fuel pump. Relay failure will cause a no-start
condition. For testing procedure, see SYSTEM & COMPONENT TESTING
article.
IGNITION CHECKS
SPARK
Check for spark at coil wire (if applicable) and at each
spark plug wire using a high output spark tester. Check spark plug
wire resistance on suspect wires. For wire resistance specification,
see C - SPECIFICATIONS article in the ENGINE PERFORMANCE Section.
CRANK ANGLE SENSOR
For crank angle sensor testing procedure on all models except
Ram-50, Stealth, Eclipse, Laser, Pickup and 3000GT, see TEST NS-5:

thickness into left side axle housing. Install left axle shaft
assembly into axle housing and tighten nuts to specification. See
TORQUE SPECIFICATIONS table at the end of this article.
2) Install right axle shaft assembly into axle housing
WITHOUT a shim or "O" ring. Temporarily tighten nuts in diagonal
sequence to 51.6 INCH lbs. (5.8 N.m) in 2 stages. Measure clearance
between bearing case and rear axle housing end with a feeler gauge.
3) Select shims equal to the sum of the thickness of the
measured clearance plus .0020-.0079" (.05-.20 mm). Remove right axle
shaft and install the selected shim(s) and "O" ring into right axle
housing end. Install right axle shaft assembly into rear axle housing.
Tighten nuts in diagonal sequence to specification. See TORQUE
SPECIFICATIONS table.
4) Using dial indicator, check end play of axle shaft. End
play must be .0020-.0079" (.05-.20 mm). If end play is not within
specification, change shim(s) to obtain correct end play. Reverse
removal procedure to install remaining components. Adjust parking
brake and bleed brake system.
DIFFERENTIAL CARRIER
Removal
Raise and support vehicle. Drain gear oil. Mark drive shaft
flange-to-pinion flange position. Remove drive shaft. Remove axle
shafts. See AXLE SHAFTS under REMOVAL & INSTALLATION. Support
differential carrier with jack. Remove differential carrier retaining
nuts. Remove differential carrier.
Inspection
Inspect for leakage at vent plug, differential carrier
companion flange and where carrier joins axle housing.
Installation
Apply sealant to axle housing surface. To install, reverse
removal procedure. Align marks on drive shaft and pinion flange.
DRIVE SHAFT
Removal
Make match marks on drive shaft yoke flange and pinion
flange. Remove bolts. Remove drive shaft from vehicle.
Installation
To install, reverse removal procedure. Ensure match marks are
aligned. Tighten bolts to specification. See TORQUE SPECIFICATIONS
table at end of article.
OVERHAUL
AXLE SHAFTS
Disassembly
1) Mount backing plate and axle shaft assembly in soft-jawed
vise. Bend over axle shaft bearing lock washer. Using Spanner Wrench
(MD990785), remove lock nut from axle shaft. Remove washers. Reinstall\
lock nut on axle shaft approximately 3 turns.
2) Attach Bearing Puller (MB990787-01) to rear of backing
plate to remove bearing case from axle shaft. See Fig. 2. Using equal
pressure to avoid binding, tighten puller nuts diagonally to remove
bearing case. Using hammer and drift, remove bearing outer race from
bearing case. Remove oil seal from end of axle housing with Slide
Hammer and Adapter (MB990211).

Fig. 4: Exploded View of Typical Limited Slip Differential
Courtesy of Chrysler Motors.
Drive Pinion
1) Remove pinion flange retaining nut. Scribe alignment marks
on drive pinion and pinion flange for reassembly. Using soft-faced
hammer, drive out pinion. Remove front adjusting shim and spacer from
pinion.
2) Using bearing puller, remove rear bearing from pinion.
Remove rear adjusting shim from pinion. Remove oil seal and bearing
races from differential carrier.
Inspection
1) Inspect all gears for cracked or flaking teeth. Inspect
pinion shaft for wear. Inspect pinion flange and drive pinion for
damaged splines.
2) Inspect bearings and races for roughness or flaking.
Replace worn components. On limited slip axles, inspect clutch
components and contact areas for wear or overheating. Inspect friction
plates, friction discs, spring plates and pressure rings for signs of
seizure, excessive heat, severe friction or nicks.
NOTE: Outer areas of friction surfaces will wear heavier due to
clutch plate and preload spring.
3) Using dial indicator, check friction plate and friction
disc for warpage. Replace components if beyond specification. See
FRICTION PLATE & DISC SPECIFICATIONS table.
4) Measure friction plates and disc thickness at projection
areas not within wear area. Measure plate and disc thickness in
friction surface. Difference between thickness of projections and
friction surface indicates amount of wear. Replace components if not

Thrust washer must be changed to obtain correct specification. Correct
clearance is .002-.008" (.05-.20 mm).
10) Select thrust washers to obtain correct clearance from
pressure ring face and end of thrust washer surface. Thrust washers
are available in 3 sizes.
11) Apply gear oil and friction modifier to all components.
Install components in differential case. Ensure assembly order and
direction of clutch components are correct. See Fig. 9.
Fig. 9: Limited Slip Differential Assembly
Courtesy of Chrysler Motors.
12) Install differential case cover with reference marks
aligned. Tighten screws to specification in several steps. See TORQUE
SPECIFICATIONS table at end of article. Ensure cases contact each
other completely when fully assembled. Check for incorrect clutch
assembly if gap exists.
13) Using Clutch Plate Preload Tool (MB990988), Shaft
(MB990989) and torque wrench, measure starting torque. Slightly rotate\
unit before measuring starting torque. See Fig. 10.

FLANGES
FLEX PLATES
FLUID LEVEL INDICATORS
FLUIDS AND LUBRICANTS
FLYWHEELS
FORCE MOTORS
GUIDES
HALF SHAFTS
HOSES, LINES AND TUBES
HOUSINGS (BELL, CASE, TAIL (EXTENSION) AND AUXILIARY)
INTERMEDIATE SHAFT SUPPORT BEARINGS
KEY INTERLOCK SYSTEMS
LIMITED SLIPS
LINES
LINKAGES (EXTERNAL)
LOCKING HUB ASSEMBLIES
LOCKING HUB CONTROL KNOBS
LUBRICANTS
METAL-CLAD SEALS
METALASTIC JOINTS
MODULATOR PINS
MODULATORS
MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION)
ODOMETER DRIVES (MECHANICAL)
ODOMETER HEADS (MECHANICAL)
OIL PANS
PANS
PILOT HOLES
PRESSURE PLATES
PRESSURE SWITCHES
RACES
RUBBER JOINTS (METALASTIC)
SCREENS
SEALS
SEALS (METAL-CLAD)
SELECTOR INTERLOCK SYSTEMS
SERVOS
SHIFT INTERLOCK SYSTEMS (SELECTOR AND KEY INTERLOCK SYSTEMS)
SENSORS
SIDE COVERS
SLIP YOKES
SOLENOIDS
SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)
SPEEDOMETER-DRIVEN GEAR HOUSINGS
SPEEDOMETER/ODOMETER DRIVES (MECHANICAL)
SPEEDOMETER/ODOMETER HEADS (MECHANICAL)
SPEEDOMETERS AND ODOMETERS (ELECTRONIC)
SWITCHES
TONE WHEELS
TOOTHED RINGS (TONE WHEELS)
TORQUE CONVERTERS
TRANSAXLE MOUNTS
TRANSDUCERS (TRANSMISSION)
TRANSMISSION COOLERS
TRANSMISSION MOUNTS
TRANSMISSION PANS
TRANSMISSION RANGE INDICATORS (PRNDL)
TUBES
UNIVERSAL JOINTS (CARDON OR CROSS TYPE)
VACUUM CONTROLS
VACUUM HOSES
VACUUM MOTORS
VACUUM-OPERATED SWITCHES

CLUTCH DISCS (MANUAL TRANSMISSION)
CLUTCH DISC (MANUAL TRANSMISSION) INSPECTION








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Condition Code Procedure
Backing plate cracked ... A ............ Require replacement.
Broken .................. A ............ Require replacement.
Contaminated with oil ... A ............ Require replacement.
Damper cushion broken ... A ............ Require replacement.
Damper cushion
collapsed .............. A ............ Require replacement.
Damper spring collapsed . A ............ Require replacement.
Damper spring missing .. C ........ ( 1) Require replacement.
Friction material cracked
through ................ B ............ Require replacement.
Friction material flaking
or chunking ............ B ............ Require replacement.
Friction material surface
cracking ............... B ......... No service suggested or
required.
Grooved ................. B ......... No service suggested or
required unless the pressure
plate or flywheel is being
resurfaced or replaced. In this
case, replacement of clutch
disc is required.
Ridged .................. B ......... No service suggested or
required unless the pressure
plate or flywheel is being
resurfaced or replaced. In this
case, replacement of clutch
disc is required.
Splines worn, affecting
performance ............ A ............ Require replacement.
Warped .................. A ............ Require replacement.
Wear exceeds
specifications (where
applicable) ............ B ............ Require replacement.
Worn close to the end of
its useful life ........ 1 ............ Suggest replacement.
Worn, affecting
performance ............ A ............ Require replacement.
( 1) - Not all clutch discs have springs in all spring
chambers on the disc.









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CLUTCH FORKS
CLUTCH FORK INSPECTION








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Condition Code Procedure
Bent .................... B ............ Require replacement.
Broken .................. A .. Require repair or replacement.
Cracked ................. B .. Require repair or replacement.
Worn close to the end of
its useful life ........ 1 ............ Suggest replacement.
Worn, affecting
performance ............ A ............ Require replacement.









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