1991 MITSUBISHI MONTERO length

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 *

Fig. 31: Measuring Rotor Clearance - Typical
This Graphic For General Information Only
Install rotors in pump body. Position straightedge across
pump body. Using feeler gauge, measure clearance between rotors and
straightedge. Pump cover wear is measured using a straightedge and
feeler gauge. Replace pump if clearance exceeds specification.
GEAR TYPE
Oil pump gears must be marked for location prior to removal.
See Fig. 32 . Remove gears from pump body. Inspect gears for pitting
or damage. Inspect cover for grooving or wear.
Fig. 32: Typical Gear Type Oil Pump
This Graphic For General Information Only
Measure gear diameter and length. Measure gear housing cavity
depth and diameter. See Fig. 33. Replace components if worn or

HO W T O U SE S YSTE M W IR IN G D IA G RAM S
1991 M it s u bis h i M onte ro
GENERAL INFORMATION
Using Wiring Diagrams
All Models
INTRODUCTION
This CD obtains wiring diagrams and technical service
bulletins, containing wiring diagram changes from the domestic and
import manufacturers. These are checked for accuracy and are all
redrawn into a consistent format for easy use.
In the past, when cars were simpler, diagrams were simpler.
All components were connected by wires and diagrams seldom exceeded 4
pages in length. Today, some wiring diagrams require more than 16
pages. It would be impractical to expect a service technician to trace
a wire from page 1 across every page to page 16.
Removing some of the wiring maze reduces eyestrain and time
wasted searching across several pages. Today the majority of
these

diagrams follow a much improved format, which permits space for
internal switch details.
Wiring diagrams are drawn in a "top-down" format. The
diagrams are drawn with the power source at the top of the diagram and
the ground point at the bottom of the diagram. Components locations
are identified on the wiring diagrams. Any wires that don't connect
directly to a component are identified on the diagram to indicate
where they go.
COLOR ABBREVIATIONS
COLOR ABBREVIATIONS TABLE








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Color Normal Optional
Black ................ BLK .......................... BK
Blue ................. BLU .......................... BU
Brown ................ BRN .......................... BN
Clear ................ CLR .......................... CR
Dark Blue .......... DK BLU ...................... DK BU
Dark Green ......... DK GRN ...................... DK GN
Green ................ GRN .......................... GN
Gray ................. GRY .......................... GY
Light Blue ......... LT BLU ...................... LT BU
Light Green ........ LT GRN ...................... LT GN
Orange ............... ORG .......................... OG
Pink ................. PNK .......................... PK
Purple ............... PPL .......................... PL
Red .................. RED .......................... RD
Tan .................. TAN .......................... TN
Violet ............... VIO .......................... VI
White ................ WHT .......................... WT
Yellow ............... YEL .......................... YL









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IDENTIFYING WIRING DIAGRAM ABBREVIATIONS
NOTE: Abbreviations used on these diagrams are normally
self-explanatory. If necessary see ABBREVIATIONS

NOTE: When routing speedometer cable, DO NOT bend cable sharply.
Minimum bending radius is 6" (150 mm). Speedometer cable
length varies with transmission type.
Removal
Disconnect speedometer cable from transmission or transaxle.
Remove instrument cluster from instrument panel. See
INSTRUMENT CLUSTER under REMOVAL & INSTALLATION. Disconnect
speedometer cable from instrument cluster and/or adapter (if
equipped). Remove speedometer cable from firewall grommet.
Installation
Install new cable. Insert cable until stopper seats properly
in groove on rear of speedometer housing. Pull speedometer cable
through firewall grommet until cable marking is visible from engine
compartment. Install adapter onto speedometer cable (if equipped).
Install instrument cluster. See INSTRUMENT CLUSTER under REMOVAL &
INSTALLATION. Install cable onto transmission or transaxle. Check for
proper operation.
NOTE: An improperly installed cable can cause fluctuating meter,
noise or damaged harness inside instrument panel.
WIRING DIAGRAMS
See appropriate chassis wiring diagram in the WIRING DIAGRAMS
Section.

1) Check drive gear and slide gear splines for damage. Check
cam portion of retainer "A" for wear or damage. Check cam for wear and
damage. Check slide gear and housing tooth surfaces for damage. Check
retainer "B" and housing contact surfaces for wear and damage.
2) Check brake assembly thickness. See Fig. 2. Assemble brake
"A" and brake "B". Using slide calipers, measure thickness of
assembled brake at both brake "A" lugs.
3) Standard thickness is .413" (10.49 mm). Minimum thickness\
is .378" (9.60 mm). If measured thickness is less than minimum
thickness, replace brake "A" and brake "B".
4) Check length of return spring. Measure length "A" of
spring. Ensure length "A" is 1.38" (35.1 mm). See Fig. 3. If length
"A" is NOT as specified, replace return spring.
5) Check length of shift spring. Measure length "B" of
spring. Ensure length "B" is 1.18" (30.0 mm). See Fig. 3. If length
"B" is NOT as specified, replace shift spring.
Reassembly Pack grooves of retainer "B" with multipurpose
grease and apply grease to attaching surfaces of all components. To
complete assembly, reverse disassembly procedure.
Fig. 2: Measuring Brake Assembly Thickness
Courtesy of Chrysler Motors.

Fig. 3: Measuring Lengths of Return Spring & Shift Spring
Courtesy of Chrysler Motors.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)
Hub Cover ........................... 13-25 (18-34)
Locking Hub Bolts ................... 36-43 (49-58)









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METR IC C O NVER SIO NS

1991 M it s u bis h i M onte ro
GENERAL INFORMATION
METRIC CONVERSIONS
METRIC CONVERSIONS
Metric conversions are making life more difficult for the
mechanic. In addition to doubling the number of tools required,
metric-dimensioned nuts and bolts are used alongside English
components in many new vehicles. The mechanic has to decide which tool
to use, slowing down the job. The tool problem can be solved by trial
and error, but some metric conversions aren't so simple. Converting
temperature, lengths or volumes requires a calculator and conversion
charts, or else a very nimble mind. Conversion charts are only part of
the answer though, because they don't help you "think" metric, or
"visualize" what you are converting. The following examples are
intended to help you "see" metric sizes:
LENGTH
Meters are the standard unit of length in the metric system.
The smaller units are 10ths (decimeter), 100ths (centimeter), and
1000ths (millimeter) of a meter. These common examples might help you
to visualize the metric units:
* A meter is slightly longer than a yard (about 40 inches).
* An aspirin tablet is about one centimeter across (.4 inches).
* A millimeter is about the thickness of a dime.
VOLUME
Cubic meters and centimeters are used to measure volume, just
as we normally think of cubic feet and inches. Liquid volume
measurements include the liter and milliliter, like the English quarts
or ounces.
* One teaspoon is about 4 cubic centimeters.
* A liter is about one quart.
* A liter is about 61 cubic inches.
WEIGHT
The metric weight system is based on the gram, with the most
common unit being the kilogram (1000 grams). Our comparable units are
ounces and pounds:
* A kilogram is about 2.2 pounds.
* An ounce is about 28 grams.
TORQUE
Torque is somewhat complicated. The term describes the amount
of effort exerted to turn something. A chosen unit of weight or force
is applied to a lever of standard length. The resulting leverage is
called torque. In our standard system, we use the weight of one pound
applied to a lever a foot long, resulting in the unit called a foot-
pound. A smaller unit is the inch-pound (the lever is one inch long).
Metric units include the meter kilogram (lever one meter long
with a kilogram of weight applied) and the Newton-meter (lever one

meter long with force of one Newton applied). Some conversions are:
* A meter kilogram is about 7.2 foot pounds.
* A foot pound is about 1.4 Newton-meters.
* A centimeter kilogram (cmkg) is equal to .9 inch pounds.
PRESSURE
Pressure is another complicated measurement. Pressure is
described as a force or weight applied to a given area. Our common
unit is pounds per square inch. Metric units can be expressed in
several ways. One is the kilogram per square centimeter (kg/cm
).
Another unit of pressure is the Pascal (force of one Newton on an area
of one square meter), which equals about 4 ounces on a square yard.
Since this is a very small amount of pressure, we usually see the
kiloPascal, or kPa (1000 Pascals). Another common automotive term for
pressure is the bar (used by German manufacturers), which equals 10
Pascals. Thoroughly confused? Try the examples below:
* Atmospheric pressure at sea level is about 14.7 psi.
* Atmospheric pressure at sea level is about 1 bar.
* Atmospheric pressure at sea level is about 1 kg/cm
.
* One pound per square inch is about 7 kPa.
CONVERSION FACTORS
CONVERSION FACTORS
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LENGTH
  

Millimeters (mm) Inches  .03937 

Inches Millimeters  25.4 

Meters (M) Feet  3.28084 

Feet Meters  .3048 

Kilometers(Km) Miles  .62137 
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AREA
  

Square Centimeters (cm) Square Inches  .155 

Square Inches Square Centimeters  6.45159 
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VOLUME
  

Cubic Centimeters Cubic Inches  .06103 

Cubic Inches Cubic Centimeters  16.38703 

Liters Cubic Inches  61.025 

Cubic Inches Liters  .01639 

Liters Quarts  1.05672 

Quarts Liters  .94633 

Liters Pints  2.11344 

Pints Liters  .47317 

Liters Ounces  33.81497 

Ounces Liters  .02957 
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WEIGHT
  

Grams Ounces  .03527 

Ounces Grams  28.34953 

Kilograms Pounds  2.20462 

Pounds Kilograms  .45359 
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WORK
  

Centimeter Kilograms Inch Pounds  .8676 

Pounds/Sq. Inch Kilograms/Sq.Centimeter .07031 

Bar Pounds/Sq. Inch  14.504