1991 MITSUBISHI MONTERO oil type

OIL PRESSURE SENDING UNIT INSPECTION








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Condition Code Procedure
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... (1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Inoperative ............. A ........... ( 2) Require repair or
replacement.
Leaking ................. A ............ Require replacement.
Output signal incorrect . B .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Inoperative includes intermittent operation or out of
OEM specification.









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OIL PUMP PICK-UP SCREENS
OIL PUMP PICK-UP SCREEN INSPECTION








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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Bypass stuck ............ A .. Require repair or replacement.
Cracked ................. A .. Require repair or replacement.
Loose ................... A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Positioned incorrectly .. A .. Require repair or replacement.
Restricted .............. A .. Require repair or replacement.
Screen torn ............. A ............ Require replacement.









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OIL PUMPS

OIL PUMP INSPECTION








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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A .. Require repair or replacement
of hardware.
Broken .................. A .. Require repair or replacement.
Housing cracked ......... A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Pressure relief valve
stuck .................. A .. Require repair or replacement.
Seized .................. A .. Require repair or replacement.
Worn beyond
specifications ......... B .. Require repair or replacement.









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PARK NEUTRAL POSITION SWITCHES
PARK NEUTRAL POSITION SWITCH INSPECTION








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Condition Code Procedure
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of hardware.
Attaching hardware
threads stripped
(threads missing) ...... A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... ( 1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Contaminated ............ A ........... ( 2) Require repair or
replacement.
Inoperative ............. B ........... ( 3) Require repair or
replacement. Further
inspection required.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Resistance out of
specification .......... B .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.

Missing ................. C ............ Require replacement.
Restricted .............. A .. Require repair or replacement.









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PCV VALVES
PCV VALVE INSPECTION








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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Grommet broken .......... A ... Require repair or replacement
of grommet.
Grommet missing ......... C . Require replacement of grommet.
Grommet not
functioning ............ A ... Require repair or replacement
of grommet.
Inoperative ............. A ........ ( 1) Require replacement.
Leaking ................. A ............ Require replacement.
Maintenance interval .... 3 ... Suggest replacement to comply
with vehicle's OEM recommended
service intervals.
Missing ................. C ............ Require replacement.
Restricted .............. A ............ Require replacement.
( 1) - Inoperative includes intermittent operation or out of
OEM specification.









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PICK-UP ASSEMBLIES (INCLUDES MAGNETIC, HALL EFFECT AND
OPTICAL)
PICK-UP ASSEMBLY (MAGNETIC, HALL EFFECT AND OPTICAL) INSPECTION









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Condition Code Procedure
Adjustment incorrect .... B ................. Require repair.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... ( 1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Inoperative ............. B ........ ( 2) Require replacement.
Oil-soaked .............. A ............ Require replacement.

IN STR UM EN T P A N EL

1991 M it s u bis h i M onte ro
1991 ACCESSORIES & SAFETY EQUIPMENT
Chrysler Motors/Mitsubishi Switches & Instrument Panels
Dodge; Ram-50
Mitsubishi: Montero, Pickup
DESCRIPTION & OPERATION
Instrument cluster includes speedometer, fuel gauge and
temperature gauge. Fuel gauge has a built-in voltage limiter to keep
voltage supply to gauges at 7 volts. Some models may also have a
shunt-type ammeter, oil pressure gauge, tachometer, voltmeter and/or
turbo boost pressure gauge. Oil pressure gauge uses full battery
voltage. The tachometer operates by pulse feed.
TROUBLE SHOOTING
FUEL/TEMPERATURE GAUGE NOT WORKING
Check for blown fuse, faulty voltage limiter or faulty relay.
Ensure sending unit connections are clean and tight. Test sending unit
for correct operation. Tighten connections in instrument cluster.
SPEEDOMETER NOT WORKING
Ensure speedometer cable is properly connected and correctly
routed. If speedometer pointer and/or odometer still do not work,
replace speedometer as an assembly.
TACHOMETER NOT WORKING
Tachometer is serviced as an assembly. If wiring harness is
okay, replace tachometer assembly.
WARNING LIGHTS NOT WORKING
Test for defective sending unit, burned out bulb, or broken
printed circuit. Ensure all wire connections are clean and tight.
TESTING
FUEL TANK SENDING UNIT
Resistance Test
Remove fuel tank sending unit from fuel tank. Measure
resistance between appropriate terminals with fuel float in Full and
Empty positions. See Fig. 1. Compare resistance reading to
FUEL TANK SENDING UNIT RESISTANCE SPECIFICATIONS table. If resistance
is not to specifications, replace fuel tank sending unit.
FUEL TANK SENDING UNIT RESISTANCE SPECIFICATIONS TABLE









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Application Empty Full
All Models ........... 103-117 ................ 1-5









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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

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

No. 3 Wire ....................... 12,000
No. 4 Wire ....................... 14,000
3.0L (VIN B & C)
Coil Wire ...................... Not Used
No. 1 Wire ......................... 8600
No. 2 Wire ....................... 13,900
No. 3 Wire ......................... 6400
No. 4 Wire ....................... 11,500
No. 5 Wire ......................... 4500
3.0L (VIN S)
Coil Wire .......................... 3000
No. 1 Wire ......................... 9000
No. 2 Wire ......................... 8500
No. 3 Wire ....................... 10,000
No. 4 Wire ......................... 9000
No. 5 Wire ....................... 12,000
No. 6 Wire ....................... 10,000
No. 6 Wire ....................... 11,700
(1) - See A - ENGINE/VIN ID article in the
ENGINE PERFORMANCE Section for VIN
information.
( 2) - Information not available from mfg.









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SPARK PLUGS
SPARK PLUG TYPE








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Application Nippondenso No.
1.5L (VIN A) .................... W20EPR-11
1.6L (VIN Y) .................... W20EPR-11
1.8L (VIN T) .................... W20EPR-11
2.0L (VIN R) ....................... W20EPR
2.0L (VIN U & V) ................ W20EPR-11
2.4L (VIN W) .................... W20EPR-11
3.0L (VIN B & C) ............... PK20PR-P11
3.0L (VIN S) .................... W16EPR-11









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SPARK PLUG SPECIFICATIONS








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Gap Torque
Application In. (mm) Ft. Lbs. (N.m\
)
2.0L (VIN R & U) ....... .028-.031 (.7-.8) ......... 15-21 (20-\
30)
All Others ............ .039-.043 (1.0-1.1) ........ 15-21 (20-30\
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FIRING ORDER & TIMING MARKS
WARNING: On the 3.0L V6, the firing order and the spark plug
connection order on the top of the distributor do not match.
Circuits internal to the distributor cap differ from the
external spark plug wire connections. This is intentional and
is done to avoid spark plug wires crossover. See Fig. 3.

STA R TE R

1991 M it s u bis h i M onte ro
ELECTRICAL
Starters
Diamante, Eclipse, Expo/Expo LRV, Galant, Mirage, Montero,
Pickup, Precis, 3000GT
DESCRIPTION
Starter is a conventional 12-volt, 4-pole brush-type motor,
with direct or gear reduction drive. The starter-mounted solenoid
shifts overrunning clutch and pinion into flywheel when starter is
energized.
TROUBLE SHOOTING
NOTE: See the TROUBLE SHOOTING - BASIC PROCEDURES article
in the GENERAL TROUBLE SHOOTING section.
NO LOAD TEST
CAUTION: Perform tests in less than 10 seconds to prevent coil
damage.
1) Install starter in soft-jawed vise. Connect starter in
series with a fully charged 12-volt battery. Connect a 100-amp ammeter
and carbon pile rheostat in series with positive battery post and
starter motor terminal. See Fig. 1.
2) Install voltmeter across starter motor. Adjust carbon pile
rheostat to full resistance. Connect cable from starter motor body to
negative battery terminal. Adjust carbon pile rheostat to proper test
voltage. See STARTER NO LOAD SPECIFICATIONS table.
3) Note that maximum amperage is within specification and
starter rotates smoothly. See STARTER NO LOAD SPECIFICATIONS table.
Fig. 1: Starter No Load Test Connections
Courtesy of Chrysler Motors.
STARTER NO LOAD SPECIFICATIONS