1991 MITSUBISHI MONTERO battery

SC HED ULE D S ER VIC ES
1991 Mitsubishi Montero
1987-95 MAINTENANCE
Mitsubishi Maintenance & Service Intervals
Montero
* PLEASE READ THIS FIRST *
NOTE: All SERVICE SCHEDULES are listed for normal service
vehicles. If vehicle is operated under severe service
conditions, see
SEVERE SERVICE REQUIREMENTS (PERFORM W/SERVICE SCHEDULES)
for items requiring additional maintenance.
NOTE: This article contains scheduled maintenance service
information. Fluid types and capacities listed with each
service in this article are only those necessary to perform
that scheduled service. For specifications pertaining to
fluid capacities for the entire vehicle, fuse and circuit
breaker identification, wheel and tire size, battery type,
warranty information, or model identification refer to the
MAINTENANCE INFORMATION article in this section.
CAUTIONS & WARNINGS
SUPPLEMENTAL RESTRAINT SYSTEM (AIR BAG)
NOTE: See the AIR BAG RESTRAINT SYSTEM article in the
ACCESSORIES/SAFETY EQUIPMENT Section.
Modifications or improper maintenance, including incorrect
removal and installation of the Supplemental Restraint System (SRS),
can adversely affect system performance. DO NOT cover, obstruct or
change the steering wheel horn pad in any way, as such action could
cause improper function of the system. Use only plain water when
cleaning the horn pad. Solvents or cleaners could adversely affect the
air bag cover and cause improper deployment of the system.
WARNING: To avoid injury from accidental air bag deployment, read and
carefully follow all warnings and service precautions. See
appropriate AIR BAG RESTRAINT SYSTEM article in the
ACCESSORIES/SAFETY EQUIPMENT section.
CAUTION: Disconnect negative battery cable before servicing any air
bag system, steering column or passenger side dash
component. After any repair, turn ignition key to the ON
position from passenger's side of vehicle in case of
accidental air bag inflation
AIR CONDITIONING SERVICING
WARNING: R-134a service equipment or vehicle A/C systems SHOULD NOT
be pressure tested or leak tested with compressed air. Some
mixtures of air/R134a have shown to be combustible at
elevated pressures. These mixtures are dangerous and may
cause fire and/or explosions. See the appropriate
A/C SYSTEM GENERAL SERVICING article in the AIR CONDITIONING
& HEAT section.

WARNING: Avoid breathing R-134a refrigerant and PAG lubricant vapors,
exposure may irritate eyes, nose and throat. To remove
R-134a from system use R-134a recycling equipment that meets
SAE J2210 specifications. If accidental system discharge
occurs, ventilate work area before resuming service.
ANTI-LOCK BRAKE SYSTEM
The anti-lock brake system contains electronic equipment that
can be susceptible to interference caused by improperly installed or
high output radio transmitting equipment. Since this interference
could cause the possible loss of the anti-lock braking capability,
such equipment should be installed by qualified professionals.
On models equipped with anti-lock brake systems, ALWAYS
observe the following cautions:
* DO NOT attempt to bleed hydraulic system without first
referring to the appropriate ANTI-LOCK BRAKE SYSTEM article
in the BRAKES Section.
* DO NOT mix tire sizes. As long as tires remain close to the
original diameter, increasing the width is acceptable.
Rolling diameter must be identical for all 4 tires. Some
manufacturers recommend tires of the same brand, style and
type. Failure to follow this precaution may cause inaccurate
wheel speed readings.
* Use ONLY recommended brake fluids. DO NOT use silicone brake
fluids in an ABS-equipped vehicle.
REPLACING BLOWN FUSES
Before replacing a blown fuse, remove ignition key, turn off
all lights and accessories to avoid damaging the electrical system. Be
sure to use fuse with the correct indicated amperage rating. The use
of an incorrect amperage rating fuse may result in a dangerous
electrical system overload.
BATTERY WARNING
WARNING: When battery is disconnected, vehicles equipped with
computers may lose memory data. When battery power is
restored, driveability problems may exist on some vehicles.
These vehicles may require a relearn procedure. See
appropriate COMPUTER RELEARN PROCEDURES article in the
GENERAL INFORMATION section below.
BRAKE FLUID
For vehicles equipped with a traction control system, idle
engine while pouring brake fluid into reservoir.
CATALYTIC CONVERTER
Continued operation of vehicle with a severe malfunction
could cause converter to overheat, resulting in possible damage to
converter and vehicle.
ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS
WARNING: Many solid state electrical components can be damaged by
static electricity (ESD). Some will display a warning label,
but many will not. Discharge personal static electricity by

\003
C - S PEC IF IC ATIO NS

1991 M it s u bis h i M onte ro
1991 ENGINE PERFORMANCE
Service & Adjustment Specifications
Chrysler Motors: Colt, Colt 200, Colt Vista,
Ram-50, Stealth, Summit
Mitsubishi: Eclipse, Galant, Mirage, Montero,
Pickup, 3000GT
INTRODUCTION
Use this article to quickly find specifications related to
servicing and on-vehicle adjustments. This is a quick reference
article for when you are familiar with an adjustment procedure and
only need a specification.
CAPACITIES
BATTERY SPECIFICATIONS








\









\









\









\









Application Amp. Hr. Rating
Colt, Mirage & Summit
Type 1 ............................... 48
Type 2 ............................... 36
Colt Vista ............................. 36
Colt 200 ............................... 52
Eclipse ................................ 50
Galant ................................. 40
Montero ................................ 52
Pickup
2.4L ................................. 36
3.0L ................................. 52
Ram-50
2.4L ................................. 36
3.0L
Standard ........................... 52
Optional ........................... 55
Stealth & 3000GT ....................... 52









\









\









\









\









FLUID CAPACITIES








\









\









\









\









\









\









\







Application Quantity
Automatic Transaxle (Dexron-II)
Colt, Colt 200, Colt Vista, Galant & Mirage ...... 6.4 Qts. (6.1L)\
Galant (AWD) ..................................... 6.8 Qts. (6.5L\
)
Eclipse
Except Turbo ................................... 6.4 Qts. (6.1L)\
Turbo .......................................... 7.4 Qts. (7.0L)\
Stealth & 3000GT ................................. 7.9 Qts. (7.5L)\
Summit ........................................... 6.1 Qts. (5.8L)\
Automatic Transmission (Dexron-II)
Montero .......................................... 7.6 Qts. (7.2L)\
Pickup & Ram-50 .................................. 7.4 Qts. (7.0L)\
Cooling System (Includes Heater & Reserve Tank)
Colt, Colt 200, Mirage & Summit .................. 5.3 Qts. (5.0L)\
Colt Vista ....................................... 7.4 Qts. (7.0L)\
Eclipse

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

STARTER NO LOAD SPECIFICATIONS








\









\









\









\









\









\









\


Starter Test Maximum Amps @
Application Type (1) Voltage Minimum RPM
Diamante ............ GR .......... 11 .......... 90 @ 3000
Expo/Expo LRV
1.8L ............. DD ......... 11.5 ......... 53 @ 6000
1.8L ............. GR .......... 11 .......... 90 @ 3000
2.4L ............. DD ......... 11.5 ......... 60 @ 6600
2.4L ............. GR .......... 11 .......... 90 @ 3000
Eclipse
1.8L .............. DD ......... 11.5 ......... 60 @ 6600
2.0L .............. GR .......... 11 .......... 90 @ 3000
Galant
A/T & M/T DOHC .... GR .......... 11 .......... 90 @ 3000
M/T SOHC .......... DD ......... 11.5 ......... 60 @ 6600
Mirage
1.5L
A/T ............. DD ......... 11.5 ......... 60 @ 6600
M/T ............. DD ......... 11.5 ......... 60 @ 6500
1.6L .............. GR .......... 11 .......... 90 @ 3000
Montero ............. GR .......... 11 .......... 90 @ 3000
Pickup
2.4L A/T & 3.0L ... GR .......... 11 .......... 90 @ 3000
2.4L M/T .......... DD ......... 11.5 ......... 60 @ 6600
Precis
A/T ............... DD ......... 11.5 ......... 60 @ 6600
M/T ............... DD ......... 11.5 ......... 60 @ 6500
3000GT .............. GR .......... 11 .......... 90 @ 3000
( 1) - The letters DD indicates direct drive and GR indicates gear
reduction.









\









\









\









\









\









\









\


PULL-IN COIL TEST
CAUTION: Perform tests in less than 10 seconds to prevent coil
damage.
1) Disconnect field coil wire from terminal "M" at starter
solenoid. See Fig. 2. Connect jumper wire between positive battery
terminal of 12-volt battery and terminal "S" of solenoid.
2) Connect a second jumper wire from negative battery
terminal and touch terminal "M" of starter solenoid. See Fig. 2. If
solenoid plunger moves inward, solenoid is good. If not, replace
solenoid.
Fig. 2: Starter Solenoid Terminal Identification
Courtesy of Chrysler Motors.
HOLD-IN COIL TEST

CAUTION: Perform tests in less than 10 seconds to prevent coil
damage.
1) Disconnect field coil wire from terminal "M" at starter
solenoid. See Fig. 2. Connect jumper wire between positive battery
terminal of 12-volt battery and terminal "S" of starter solenoid.
2) Connect a second jumper wire from negative battery
terminal and touch starter case. If solenoid plunger is pulled-in,
hold-in coil is good. If not, replace solenoid.
RETURN TEST
CAUTION: Perform tests in less than 10 seconds to prevent coil
damage.
1) Disconnect field coil wire from terminal "M" at starter
solenoid. See Fig. 2. Connect jumper wire between positive battery
terminal of 12-volt battery and terminal "M" of starter solenoid.
2) Connect a second jumper wire from negative battery
terminal and touch starter case. Pull pinion outward and release it.
Replace solenoid if pinion remains outward.
PINION GAP CHECK
1) Disconnect field coil wire from terminal "M" at starter
solenoid. See Fig. 2. Connect jumper wire between positive battery
terminal of 12-volt battery and terminal "S" of starter solenoid.
2) Connect a second jumper wire from negative battery
terminal and touch terminal "M" of starter solenoid. See Fig. 2.
Measure clearance between pinion and stopper. See Fig. 3.
3) Clearance should be within specification. See STARTER
SPECIFICATIONS table. Adjust clearance by adding or removing gaskets
between solenoid and front housing.
Fig. 3: Measuring Pinion Gap
Courtesy of Mitsubishi Motor Sales of America.
REMOVAL & INSTALLATION

Remove negative battery cable. If necessary, raise vehicle on
hoist. Remove starter mounting bolts and starter. To install, reverse
removal procedure.
NOTE: On Raider models with A/T, it may be necessary to disconnect
transmission oil cooler line for starter removal.
OVERHAUL
Check commutator for out-of-round and proper amount of
undercut. Replace or repair armature if not within specification. See
STARTER SPECIFICATIONS table. Ensure brushes are not worn beyond wear
line (outer line closest to commutator contact surface). Check pinion
gap. See PINION GAP CHECK in this article.
DISASSEMBLY
NOTE: Procedures may vary slightly between conventional and
reduction gear starters.
1) Loosen nut securing connecting plate-to-magnetic switch
"M" terminal. Remove screws securing magnetic switch and remove switch
(solenoid) assembly. Remove through bolts and brush cover assembly.
Tap yoke assembly loose with wooden mallet. Remove yoke, armature
assembly and pinion shift lever.
2) Remove pinion stop ring from end of armature shaft by
pushing stop ring to clutch side. Remove snap ring and overrunning
clutch assembly from armature shaft.
Fig. 4: Disassembled View of Typical Mitsubishi Starter
CLEANING & INSPECTION
Clean all parts. Do not use grease dissolving solvent on

Remove horn pad and steering wheel. See Figs. 1-6. See
STEERING COLUMN TESTING/REMOVAL & INSTALLATION table for figure
directory on specific model. Remove knee protector and upper and lower
column covers (if necessary). On Eclipse, remove hood lock release
handle and air ducts. On all models, remove any necessary cable bands,
and remove steering column switch. To install, reverse removal
procedure.
Removal (Stealth & 3000GT)
1) Disconnect negative battery cable. Wait 30 seconds, and
then remove air bag module mounting nut from back side of module. To
remove clockspring connector from air bag module, force lock outward
and pry it using a flat screwdriver. Ensure no undue force is exerted
on connector when it is removed. Remove air bag module, and store it
face up. See Fig. 7.
CAUTION: Wait at least 30 seconds after disconnecting battery cable
before continuing servicing.
2) Remove steering wheel and knee protector. Remove upper and
lower column covers. Remove air ducts. Remove right and left steering
column switches.
WARNING: DO NOT hammer on steering wheel. Collapsible steering column
mechanism may be damaged.
Installation
1) To install, reverse removal procedure. Before installing
steering wheel, center clockspring by lining up NEUTRAL mark of
clockspring with mark on steering column. To complete installation,
reverse removal procedure. DO NOT reconnect negative battery cable
until air bag module is installed.
2) After installation is complete, turn ignition on from
passenger side of vehicle. Supplemental Restraint System (SRS) light
on dash should come on for approximately 7 seconds. If SRS light does
not come on, stays on or flashes, repair air bag system.