1991 MITSUBISHI MONTERO oil level
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oil filter/screen, note length and location of all bolts.
TRANSAXLE (EXCEPT MONTERO, PICKUP & RAM-50)
1) Remove drain plug(s), and drain fluid. See Fig. 1. Some
applications may contain a drain plug located in housing below drive
axle shaft, in oil pan. Remove oil pan. Remove oil filter/screen if
necessary.
2) If oil filter/screen is replaced, tighten bolts to
specification. See TORQUE SPECIFICATIONS table at end of article.
Clean oil pan, replace gasket, and install oil pan. Tighten oil pan
bolts and drain plug to specification. See TORQUE SPECIFICATIONS
table. Ensure dipstick hole area is clean, and pour approximately 4.2
qts. (4.0L) of Dexron-II fluid into dipstick hole.
3) Operate engine at idle for 2 minutes. Shift transaxle to
each position, ending in Neutral. Add sufficient fluid to reach lower
mark. After reaching normal operating temperature, fluid should be
between upper and lower marks of HOT range on dipstick.
Fig. 1: Locating Drain Plugs
Courtesy of Mitsubishi Motor Sales of America.
TRANSMISSION (MONTERO & PICKUP)
1) Remove drain plug (if equipped) from transmission pan, an\
d
allow fluid to drain. On models without drain plug, remove oil pan
must to drain fluid. Remove oil filter/screen if necessary.
2) If oil filter/screen is replaced, tighten bolts to
specification. See TORQUE SPECIFICATIONS table at end of article.
Clean oil pan, replace gasket, and install oil pan. Tighten oil pan
bolts and drain plug to specification. See TORQUE SPECIFICATIONS
table. Fill transmission, through filler tube, with 5.3 qts. (5.0L) of\
Dexron-II ATF on Montero, or 2.0 qts. (1.9L) on all others. Start
engine, and allow to idle for 2 minutes.
3) Shift transmission into each position, ending in Neutral.
Check fluid level with engine running at idle, and add sufficient
Page 1176 of 1333
fluid to bring level to lower mark of dipstick if necessary. Recheck
fluid level after transmission is at normal operating temperature.
TRANSFER CASE
Drain plug is located on bottom of transfer case. Change
drain plug gasket whenever fluid is changed. On 3000GT, lubricant
level should be approximately .5" (13 mm) below fill hole on side of
transfer case. On all others models, lubricant level should be to
bottom of fill hole on side of transfer case.
HYDRAULIC CONTROL PRESSURE ADJUSTMENTS
LINE PRESSURE CHECK (EXCEPT MONTERO & PICKUP)
1) Set parking brake. Place shift lever in Neutral position.
Attach engine tachometer. Remove line pressure port plug located above
front transaxle shaft, forward of governor pressure port plug. On
Precis, line pressure port is located below bell housing, at front of
transaxle oil pan. Using appropriate adapter, attach pressure gauge.
2) Start engine, and bring to operating temperature. With
gear selector in Drive position, bring engine speed to 2500 RPM. Pull
throttle control cable (if equipped) wide open at transaxle side.
3) Line pressure should be 98-100 psi (6.9-7.0 kg/cm
) on
Mirage, or 124-127 psi (8.7-8.9 kg/cm) on all others. If line
pressure is not to specification, proceed to LINE PRESSURE ADJUSTMENT.
LINE PRESSURE ADJUSTMENT (EXCEPT MONTERO & PICKUP)
1) Drain transaxle fluid. Remove oil pan. Disconnect throttle
control cable from throttle cam. Remove oil temperature sensor (if
equipped). Disconnect solenoid connector. On some models, it may be
necessary to push solenoid wire harness connector and grommet into
transaxle case.
2) Remove oil filter screen and plate. Noting location and
length of bolts, remove valve body. DO NOT drop internal parts. Adjust
line pressure by turning regulator valve adjusting screw.
3) Turn adjusting screw counterclockwise to increase pressure
or clockwise to decrease pressure. One complete turn of adjusting
screw changes line pressure as follows.
* 3.7 psi (.26 kg/cm
) on Mirage with F3A21 Transaxle
* 5.4 psi (.39 kg/cm) on Precis
* 54 psi (3.8 kg/cm) on all others
4) After adjustment, reverse removal procedure to install.
Refill transaxle.
LINE PRESSURE (MONTERO)
1) Remove plug from line pressure take-off port located
behind transmission shift control lever. Install Hydraulic Pressure
Meter (MD998330) with Adapter (MD998206).
2) Place vehicle on dynamometer. Apply parking brake and
start engine. With brake applied, place transmission in Drive. Note
pressure at idle. Pressure should be 74-85 psi (5.2-6.0 kg/cm
).
3) Raise engine RPM to stall speed (2100-2400 RPM). Note lin\
e
pressure. Pressure should be 156-185 psi (11.0-13.0 kg/cm
).
4) Shift transmission into Reverse with brake applied. At
idle, pressure should be 112-130 psi (7.9-9.1 kg/cm
). Raise engine
RPM to stall speed (2100-2400 RPM). Note line pressure. Pressure
should be 227-285 psi (16.0-20.0 kg/cm
). If readings are not to
Page 1186 of 1333
Check transaxle/transmission and transfer case fluid level
every 30,000 miles. Change fluid at 30,000 miles if operated under
severe service conditions.
CHECKING FLUID LEVEL
TRANSAXLE/TRANSMISSION
Lubricant level is checked at fill hole on side of transaxle
or transmission. Lubricant must be at bottom of fill hole.
TRANSFER CASE
Transfer case contains separate drain and fill plugs.
Lubricant must reach to bottom of fill hole.
On 3000GT models, transfer case contains separate drain and
fill plugs. Lubricant should be .5" (13 mm) from bottom of fill hole.
RECOMMENDED FLUID
Use API GL-4 or GL-5 SAE 75W-85 gear oil.
FLUID CAPACITY SPECS TABLE
TRANSMISSION REFILL CAPACITIES TABLE \
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Application Pts. (L)
Eclipse
F5M22 .............................. 3.8 (1.8)
F5M33 .............................. 4.7 (2.2)
Galant ............................... 3.8 (1.8)
Mirage
KM201 .............................. 3.8 (1.8)
KM210 .............................. 4.4 (2.0)
Montero
2.6L ............................... 4.7 (2.2)
3.0L ............................... 5.3 (2.6)
Pickup
2WD ................................ 4.9 (2.4)
4WD ................................ 4.7 (2.2)
Precis ............................... 4.4 (2.0)
Sigma ................................ 5.2 (2.5)
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1991 TRANSMISSION REFILL CAPACITIES \
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Application Pts. (L)
Mirage (1.5L)
F4M21 ................................... 3.6 (1.7)
F5M21 ................................... 3.8 (1.8)
Eclipse, Galant (2WD) & Mirage (1.6L) ..... 3.8 (1.8)
Eclipse (Turbo) & 3000GT (2WD) ............ 4.9 (2.3)
Galant (AWD) .............................. 4.9 (2.3)
Montero & Pickup .......................... 5.2 (2.5)
Pickup .................................... 4.9 (2.3)
Pickup .................................... 4.6 (2.2)
Precis
Page 1198 of 1333
![MITSUBISHI MONTERO 1991 Service Manual Fires With Key Flywheel runout contributes
released. Engine to the intermittent nature
Fires and Cranks
Normally
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\](/manual-img/19/57332/w960_57332-1197.png "MITSUBISHI MONTERO 1991 Service Manual Fires With Key Flywheel runout contributes
released. Engine to the intermittent nature
Fires and Cranks
Normally
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Fires With Key Flywheel runout contributes
released. Engine to the intermittent nature
Fires and Cranks
Normally
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AIR CONDITIONING & HEAT
AIR CONDITIONING TROUBLE SHOOTING
WARNING: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
BASIC AIR CONDITIONING TROUBLE SHOOTING CHART
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CONDITION POSSIBLE CAUSE \
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Compressor Not Working
Compressor clutch circuit open.
Compressor clutch coil inoperative.
Poor clutch ground connection.
Fan belts loose.
Thermostatic switch inoperative.
Thermostatic switch not adjusted.
Ambient temperature switch open.
Superheat fuse blown. \
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Excessive Noise or Vibration
Missing or loose mounting bolts.
Bad idler pulley bearings.
Fan belts not tightened correctly.
Compressor clutch contacting body.
Excessive system pressure.
Compressor oil level low.
Damaged clutch bearings.
Damaged reed valves.
Damaged compressor. \
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Insufficient or No Cooling;
Compressor Working
Expansion valve inoperative.
Heater control valve stuck open.
Low system pressure.
Blocked condenser fins.
Blocked evaporator fins.
Vacuum system leak.
Vacuum motors inoperative.
Control cables improperly adjusted.
Restricted air inlet.
Mode doors binding.
Blower motor inoperative.
Temperature above system capacity. \
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HEATER SYSTEM TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
Page 1199 of 1333
problem symptoms. For model-specific Trouble Shooting,
refer to DIAGNOSTIC, or TESTING articles available in the
section(s) you are accessing.
BASIC HEATER SYSTEM TROUBLE SHOOTING CHART
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CONDITION POSSIBLE CAUSE \
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Insufficient, Erratic,
or No Heat
Low Coolant Level
Incorrect thermostat.
Restricted coolant flow through
heater core.
Heater hoses plugged.
Misadjusted control cable.
Sticking heater control valve.
Vacuum hose leaking.
Vacuum hose blocked.
Vacuum motors inoperative.
Blocked air inlet.
Inoperative heater blower motor.
Oil residue on heater core fins.
Dirt on heater core fins. \
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Too Much Heat
Improperly adjusted cables.
Sticking heater control valve.
No vacuum to heater control valve.
Temperature door stuck open. \
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Air Flow Changes During
Acceleration
Vacuum system leak.
Bad check valve or reservoir. \
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Air From Defroster At All
Times
Vacuum system leak.
Improperly adjusted control cables.
Inoperative vacuum motor. \
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Blower Does Not Operate
Correctly
Blown fuse.
Blower motor windings open.
Resistors burned out.
Motor ground connection loose.
Wiring harness connections loose.
Blower motor switch inoperative.
Blower relay inoperative.
Fan binding or foreign object
in housing.
Fan blades broken or bent. \
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BRAKES
BRAKE SYSTEM TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
Page 1206 of 1333
Excessive Oil Worn valve stems or guides Replace stems or
Consumption guides, See ENGINES
Valve "O" ring seals Replace "O" ring seals,
damaged See ENGINES
Plugged oil drain back holes Remove restrictions
Improper PCV valve Replace PCV valve
operation
Engine oil level too high Remove excess oil
Engine oil too thin Replace thicker oil
Valve stem oil deflectors Replace oil deflectors
damaged
Incorrect piston rings Replace piston rings,
See ENGINES
Piston ring gaps not Reinstall piston rings,
staggered See ENGINES
Insufficient piston ring Replace rings, See
tension ENGINES
Piston ring grooves or oil Replace piston rings,
return slots clogged See ENGINES
Piston rings sticking in Replace piston rings,
grooves See ENGINES
Piston ring grooves Replace piston and
excessively worn rings, See ENGINES
Compression rings installed Replace compression
upside down rings correctly, See
ENGINES
Worn or scored cylinder Rebore cylinders or
walls replace block
Mismatched oil ring Replace oil ring
expander and rail expander and rail, See
ENGINES
Intake gasket dowels too Replace intake gasket
long dowels
Excessive main or connecting Replace main or
rod bearing clearance connecting rod
bearings, See ENGINES
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No Oil Pressure Low oil level Add oil to proper level
Oil pressure sender or Replace sender or gauge
gauge broken
Oil pump malfunction Remove and overhaul oil
pump, See ENGINES
Oil pressure relief valve Remove and reinstall
sticking valve
Oil pump passages blocked Overhaul oil pump, See
ENGINES
Oil pickup screen or tube remove restriction
blocked
Loose oil inlet tube Tighten oil inlet tube
Loose camshaft bearings Replace camshaft
bearings, See ENGINES
Internal leakage at oil Replace block or
passages cylinder head
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Low Oil Pressure Low engine oil level Add oil to proper level
Engine oil too thin Remove and replace with
thicker oil
Excessive oil pump Reduce oil pump
clearance clearance, See ENGINES
Oil pickup tube or screen Remove restrictions
blocked
Main, rod or cam bearing Replace bearing to
clearance excessive reduce clearance, See
Page 1231 of 1333
Excessive Noise Loose pump-to-drive Tighten screws
assembly screws
Loose tube on pump assembly Tighten tube
Valves not functioning Replace valves
properly
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Oil Leakage Loose end plug Tighten end plug
Bad seal crimp Remove and re-crimp
seal
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MANUAL TRANSMISSION
MANUAL TRANSMISSION TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
MANUAL TRANSMISSION/TRANSAXLE TROUBLE SHOOTING
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Condition Possible Cause \
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Noisy In Forward Gears .Low gear oil level,
.Loose bell housing bolts,
.Worn bearings or gears
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Clunk On Deceleration
(FWD Only) .Loose engine mounts,
.Worn inboard CV joints,
.Worn differential pinion shaft,
.Side gear hub counterbore
in case worn oversize
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Gear Clash When Shifting
Forward Gears .Clutch Out Of Adjustment,
.Shift linkage damaged or
out of adjustment,
.Gears or synchronizers damaged,
.Low gear oil level
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Transmission Noisy When
Moving (RWD Only) Quiet In
Neutral With Clutch Engaged .Worn rear outputshaft bearing
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Gear Rattle .Worn bearings,
.Wrong gear oil,
.Low gear oil,
.Worn gears
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Steady Ticking At Idle
(Increases With RPM) .Broken tooth on gear
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Gear Clash When Shifting
Forward Gears .Worn or broken synchronizers
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Loud Whine In Reverse .Normal condition ( 1) \
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Page 1244 of 1333
Reaction ring sticking See POWER STEERING GEAR
in housing head article
Steering pump internal See POWER STEERING PUMP
leakage article
Steering gear-to-column See STEERING COLUMN
misalignment article
Lack of lubrication in Service front suspension
linkage
Lack of lubrication in Service front suspension
ball joints
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Increased Effort High internal pump leakage See POWER STEERING PUMP
When Turning article
Wheel Fast Power steering pump belt Adjust or replace if
Foaming, Milky slipping necessary
Power Steering
Fluid, Low Fluid Low fluid level Check and fill to
Level or Low proper level
Pressure
Engine idle speed to low Adjust to correct
setting
Air in pump fluid system See POWER STEERING PUMP
article
Pump output low See POWER STEERING PUMP
article
Steering gear See POWER STEERING GEAR
malfunctioning article
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Wheel Surges Low fluid level Check and fill to proper
or Jerks level
Loose fan belt Adjust or replace if
necessary
Insufficient pump See POWER STEERING PUMP
pressure article
Sticky flow control valve See POWER STEERING PUMP
article
Linkage hitting oil pan Replace bent components
at full turn
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Kick Back or Air in pump fluid system See POWER STEERING PUMP
Free Play article
Worn poppet valve in See POWER STEERING PUMP
steering gear article
Excessive over center See POWER STEERING GEAR
lash article
Thrust bearing out of See POWER STEERING GEAR
adjustment article