1991 MITSUBISHI MONTERO air condition

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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

area. Always wear eye protection when working around air conditioning
systems and R-12. The system's high pressure can cause severe injury
to eyes and skin if a hose were to burst. R-12 evaporates quickly
when exposed to atmosphere, freezing anything it contacts.
2) Use care when handling refrigerant containers. DO NOT drop
or strike containers or expose refrigerant containers to excessive
heat. Containers must never be heated more than 125
F (52C). Never
expose R-12 directly to open flame.
CAUTION: When R-12 is exposed to an open flame, drawn into a running
engine, or detected with a Halide (propane) leak tester,
poisonous phosgene gas is formed. Keep work areas ventilated
and avoid running engines near work area.
USING INDIVIDUAL R-12 CANS
Disposable refrigerant cans (referred to as one pound cans)
have a flat type seal or a screw type seal, and proper can tap must be
used for each type. Be sure sealing gasket on can tap is in good
condition. A proper safety can tap will prevent refrigerant from
flowing back into open can, as tap has a one-way flow control.
NOTE: Recent findings by the EPA indicate that refrigerant is
harmful to the Earth's protective Ozone layer. When
discharging refrigerant avoid allowing refrigerant to enter
the atmosphere. Refrigerant recovery system should be used
when discharging the system.
MULTI-CAN DISPENSING VALVES
A multi-can dispensing valve allows attachment of several
cans of refrigerant, and is a good substitute when a bulk container is
not available. Cans are installed onto each leg of multi-can
dispensing valve in the same manner as the individual cans, and each
leg has its own can tap.
CAN TAP INSTALLATION FLAT TYPE SEAL CANS
On cam-lock or one-piece can taps, first turn the handle
outward to the fully open position. Securely engage locking lugs over
the can flange, and lock them in place by turning cam lock or locking
nut. Screw tap assembly into adapter so sealing gasket is fully seated
against the can top. Turn tap inward to pierce the can and close the
tap. DO NOT open tap until ready to purge the service hose or dispense
refrigerant into the system.
On 2-piece can taps, be certain tap handle is turned fully
inward to the closed position. Check that locking base is turned to
its outer limit. Securely engage locking lugs over the can flange.
Turn entire tap assembly (without disturbing the closed setting)
downward into the locking base to pierce the can. DO NOT open tap
until ready to dispense into system.
SCREW TYPE SEAL CANS
Ensure can tap is fully closed. Screw refrigerant can into
can tap fitting until tight. This will pierce the can. Connect tap to
center hose on manifold gauge set. DO NOT open tap until ready to
dispense R-12 into system.
WARNING: DO NOT open high side hand valve while air conditioning

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D - A D JU STM EN TS

1991 M it s u bis h i M onte ro
1991 ENGINE PERFORMANCE
On-Vehicle Adjustments
Chrysler Motors: Colt, Colt 200, Colt Vista,
Ram-50, Stealth, Summit
Mitsubishi: Eclipse, Galant, Mirage, Montero,
Pickup, 3000GT
ENGINE MECHANICAL
Before performing any on-vehicle adjustments to fuel or
ignition system, ensure engine mechanical condition is okay.
VALVE CLEARANCE
NOTE: All engines except 1.5L use hydraulic valve lifters. Valve
adjustment is only required on 1.5L engines. To check
hydraulic valve lifter operation, see CHECKING HYDRAULIC
VALVE LIFTERS.
MECHANICAL VALVE LIFTERS
CAUTION: DO NOT rotate crankshaft in opposite direction of normal
engine rotation.
1.5L
1) Ensure engine is at normal operating temperature. Remove
all spark plugs and valve cover. Rotate crankshaft to position
cylinder No. 1 on TDC of compression stroke. Adjust intake valves on
cylinders No. 1 and No. 2, and exhaust valves on cylinders No. 1 and
No. 3. See VALVE CLEARANCE ADJUSTMENT table for specification.
2) Rotate crankshaft 360 degrees to position cylinder No. 4
on TDC of compression stroke. Adjust intake valves on cylinders No. 3
and No. 4, and exhaust valves on cylinders No. 2 and No. 4.
VALVE CLEARANCE ADJUSTMENT TABLE









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Cold Hot
Application In. (mm) In. (mm)
Intake ............ .003 (.07) ......... .006 (.15)
Exhaust ........... .007 (.17) ......... .010 (.25)









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CHECKING HYDRAULIC VALVE LIFTERS
Except 1.5L
1) Remove valve cover. Push downward on end of rocker arm
above lash adjuster. If lash adjuster is normal, it will feel hard. If
lash adjuster moves downward easily when pushed, replace adjuster.
2) If lash adjuster feels soft or spongy, oil with air has
probably entered lash adjuster. If this occurs, check engine oil
level. If engine oil level is okay, check oil screen and oil screen
gasket for damage.
3) After repairing cause of air leak, warm engine to
operating temperature. Drive vehicle at low speed for approximately 5
minutes. Turn engine off for a few minutes.
4) Restart engine and drive at low speed for approximately 5

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F - B ASIC T E STIN G

1991 M it s u bis h i M onte ro
1991 ENGINE PERFORMANCE
Basic Diagnostic Procedures
Chrysler; Colt, Colt 200, Colt Vista, Ram-50, Stealth,
Summit
Mitsubishi; Eclipse, Galant, Mirage, Montero, Pickup, 3000GT
INTRODUCTION
The following diagnostic steps will help prevent overlooking
a simple problem. This is also where to begin diagnosis for a no start
condition. First step in diagnosing any driveability problem is
verifying customer's complaint with a test drive under conditions
problem reportedly occurred.
Before entering self-diagnostics, perform a careful and
complete visual inspection. Most engine control problems result from
mechanical breakdowns, poor electrical connections or
damaged/misrouted vacuum hoses. Before condemning computerized system,
perform each test listed in article.
NOTE: Perform all voltage tests with a Digital Volt-Ohmmeter (DVOM)\
with a minimum 10-megohm input impedance, unless stated
otherwise in test procedure.
PRELIMINARY INSPECTION & ADJUSTMENTS
VISUAL INSPECTION
Visually inspect all electrical wiring, looking for chafed,
stretched, cut or pinched wiring. Ensure electrical connectors fit
tightly and are not corroded. Ensure distributor cap and rotor are
free of cracks, carbon trails or contamination. Ensure vacuum hoses
are properly routed and not pinched or cut. See M - VACUUM DIAGRAMS
article in the ENGINE PERFORMANCE Section to verify routing and
connections (if necessary). Inspect air induction system for possible
vacuum leaks.
MECHANICAL INSPECTION
Compression
Check engine mechanical condition with a compression gauge,
vacuum gauge, or an engine analyzer. See engine analyzer manual for
specific instructions.
WARNING: DO NOT use ignition switch during compression tests. Use a
remote starter to crank engine. Fuel injectors on many models
are triggered by ignition switch during cranking mode, which
can create a fire hazard or contaminate engine's oiling
system.
COMPRESSION SPECIFICATIONS TABLE (1)









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Application Specification
psi (kg/cm)
1.5L (VIN X) .............................. 137 (9.6)
1.6L (VIN Y) ............................. 171 (12.0)
1.8L (VIN T) .............................. 131 (9.2)

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:

satisfied with a repair transaction, the Motorist Assurance Program
offers mediation and arbitration through MAP/BBB-CARE and other non-
profit organizations. MAP conducted pilot programs in twelve states
before announcing the program nationally in October, 1998. During the
pilots, participating repair shops demonstrated their adherence to the
Pledge and Standards and agreed to follow the UICS in communicating
the results of their inspection to their customers. To put some
"teeth" in the program, an accreditation requirement for shops was
initiated. The requirements are stringent, and a self-policing method
has been incorporated which includes the "mystery shopping" of
outlets.
We welcome you to join us as we continue our outreach with
your support, both the automotive repair industry and your customers
will reap the benefits. Please visit MAP at our Internet site www.
motorist.org or contact us at:
1444 I Street, NW Suite 700
Washington, DC 20005
Phone (202) 712-9042 Fax (202) 216-9646
January 1999
MAP UNIFORM INSPECTION GENERAL GUIDELINES
OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS
It is MAP policy that all exhaust, brake, steering,
suspension, wheel alignment, drive-line, engine performance and
maintenance, and heating, ventilation and air conditioning, and
electrical services be offered and performed under the standards and
procedures specified in these sections.
Before any service is performed on a vehicle, an inspection
of the appropriate system must be performed. The results of this
inspection must be explained to the customer and documented on an
inspection form. The condition of the vehicle and its components will
indicate what services/part replacements may be "Required" or
"Suggested". In addition, suggestions may be made to satisfy the
requests expressed by the customer.
When a component is suggested or required to be repaired or
replaced, the decision to repair or replace must be made in the
customer's best interest, and at his or her choice given the options
available.
This section lists the various parts and conditions that
indicate a required or suggested service or part replacement.
Although this list is extensive, it is not fully inclusive. In
addition to this list, a technician may make a suggestion. However,
any suggestions must be based on substantial and informed experience,
or the vehicle manufacturer's recommended service interval and must be
documented.
Some conditions indicate that service or part replacement is
required because the part in question is no longer providing the
function for which it is intended, does not meet a vehicle
manufacturer's design specification or is missing.
Example:
An exhaust pipe has corroded severely and has a hole in it
through which exhaust gases are leaking. Replacement of the
exhaust pipe in this case is required due to functional
failure.
Example:
A brake rotor has been worn to the point where it measures
less than the vehicle manufacturer's discard specifications.

Replacement of the rotor is required because it does not meet
design specifications.
Some conditions indicate that a service or part replacement
is suggested because the part is close to the end of its useful life
or addresses a customer's need, convenience or request. If a
customer's vehicle has one of these conditions, the procedure may be
only to suggest service.
Example:
An exhaust pipe is rusted, corroded or weak, but no leaks are
present. In this case, the exhaust pipe has not failed.
However, there is evidence that the pipe may need replacement
in the near future. Replacement of the pipe may be suggested
for the customer's convenience in avoiding a future problem.
Example:
The customer desires improved ride and/or handling, but the
vehicle's shocks or struts have not failed. In this case,
replacement may be suggested to satisfy the customer's
wishes. In this case, replacement of the shocks or struts may
not be sold as a requirement.
A customer, of course, has the choice of whether or not a
shop will service his or her vehicle. He or she may decide not to
follow some of your suggestions. When a repair is required, a MAP
shop must refuse partial service on that system if, in the judgment of
the service provider, proceeding with the work could create or
continue an unsafe condition. When a procedure states that required
or suggested repair or replacement is recommended, the customer must
be informed of the generally acceptable repair/replacement options
whether or not performed by the shop.
When presenting suggested repairs to the customer, you must
present the facts, allowing the customer to draw their own conclusions
and make an informed decision about how to proceed.
The following reasons may be used for required and suggested
services. These codes are shown in the "Code" column of the MAP
Uniform Inspection & Communications Standards that follow:
Reasons to Require Repair or Replacement
A - Part no longer performs intended purpose
B - Part does not meet a design specification (regardless of
performance)
C - Part is missing
NOTE: When a repair is required, the shop must refuse partial
service to the system in question, if the repair creates
or continues an unsafe condition.
Reasons to Suggest Repair or Replacement
1 - Part is close to the end of its useful life (just above
discard specifications, or weak; failure likely to occur
soon, etc.)
2 - To address a customer need, convenience, or request (to
stiffen ride, enhance performance, eliminate noise, etc.)
3 - To comply with maintenance recommended by the vehicle's
Original Equipment Manufacturer (OEM)
4 - Technician's recommendation based on substantial and
informed experience
NOTE: Suggested services are always optional. When presenting
suggested repairs to the customer, you must present the
facts, allowing the customer to draw their own conclusions

and make an informed decision about how to proceed.
BRAKES
SERVICE PROCEDURES REQUIRED & SUGGESTED FOR PROPER
VEHICLE OPERATION
Some states may have specifications that differ from OEM.
Check your local/state regulations. Where state or local laws are
stricter, they take precedence over these guidelines.
ACCELEROMETERS (G SENSOR OR LATERAL)
ACCELEROMETER INSPECTION








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Condition Code Procedure
Broken .................. A ............ Require replacement.
Connector loose ......... A .. Require repair or replacement.
Loose ................... B .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Out of position ......... B ....... Require re-positioning to
vehicle manufacturer's
specifications.
Output signal incorrect . B ............ Require replacement.









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ACCUMULATORS
ACCUMULATOR INSPECTION








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Condition Code Procedure
Leaking ................. B ............ Require replacement.
Missing ................. C ............ Require replacement.
Pre-charge incorrect .... B ............ Require replacement.









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ANCHOR PINS
See BACKING PLATES .
ANTI-LOCK BRAKE SYSTEMS
NOTE: Anti-lock brakes are an integral part of the brake system. It
is essential that the anti-lock brakes function properly when
brake service is performed.
Anti-lock brake systems are commonly referred to as "ABS" and
will be referred to as "ABS" throughout these guidelines. Some ABS
components also function as part of a traction control system (TCS).
WARNING: When diagnosing and servicing high pressure components,
observe safety procedures and equipment requirements
established by the vehicle manufacturer to reduce the
possibility of serious personal injury.
NOTE: Intermittent electrical conditions are often caused by a loss
of ground, poor connection, or water intrusion into the
wiring harness.