1991 MITSUBISHI MONTERO Service Manual

suspension fuse box diagram steering wheel boot diagram coolant level

Page 697 of 1333

MITSUBISHI MONTERO 1991 Service Manual 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 m

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

Page 698 of 1333

MITSUBISHI MONTERO 1991 Service Manual touching a metal ground point on the vehicle prior to
servicing any ESD sensitive component.
ENGINE OIL
CAUTION: Never use non-detergent or straight mineral oil.
F

Page 699 of 1333

MITSUBISHI MONTERO 1991 Service Manual Fig. 2: Service Point Locations (1987-91 3.0L V6 Engine)
Courtesy of Mitsubishi Motor Sales of America.
Fig. 3: Service Point Locations (1992-95 3.0L V6 Engine)
Courtesy of Mitsubishi Motor Sales of

Page 700 of 1333

MITSUBISHI MONTERO 1991 Service Manual Fig. 4: Service Point Locations (1994-95 3.0L V6 Engine - 24 Valve)
Courtesy of Mitsubishi Motor Sales of America.
Fig. 5: Service Point Locations (1994-95 3.5L V6 Engine)
Courtesy of Mitsubishi Mot

Page 701 of 1333

MITSUBISHI MONTERO 1991 Service Manual CAMSHAFT TIMING BELT REPLACEMENT INFORMATION
CAUTION: Failure to replace a faulty camshaft timing belt may result
in serious engine damage.
The condition of camshaft drive

CAMSHAFT TIMING BELT REPLACEMENT INFORMATION
CAUTION: Failure to replace a faulty camshaft timing belt may result
in serious engine damage.
The condition of camshaft drive belts should always be
checked on vehicles which have more than 50,000 miles. Although some
manufacturers do not recommend belt replacement at a specified
mileage, others require it at 60,000-100,000 miles. A camshaft drive
belt failure may cause extensive damage to internal engine components
on most engines, although some designs do not allow piston-to-valve
contact. These designs are often called "Free Wheeling".
Many manufacturers changed their maintenance and warranty
schedules in the mid-1980's to reflect timing belt inspection and/or
replacement at 50,000-60,000 miles. Most service interval schedules in
this manual reflect these changes.
Belts or components should be inspected and replaced if any
of the following conditions exist:
* Cracks Or Tears In Belt Surface
* Missing, Damaged, Cracked Or Rounded Teeth
* Oil Contamination
* Damaged Or Faulty Tensioners
* Incorrect Tension Adjustment
Replace camshaft timing belt at 60,000 mile intervals.
SEVERE & NORMAL SERVICE DEFINITIONS
NOTE: Use the Severe Service schedule if the vehicle to be serviced
is operated under ANY (one or more) of these conditions:
Service is recommended at mileage intervals based on vehicle
operation. Service schedules are based on the following primary
operating conditions.
Normal Service
* Driven More Than 10 Miles Daily
* No Operating Conditions From Severe Service Schedule
Severe Service (Unique Driving Conditions)
* Short Trips In Freezing Temperatures
* Towing Or Commercial Use
* Driving Off-Road Or In Salty Or Sandy Areas
* Severe Dust Conditions
* Hot Weather, Stop-And-Go Driving
* Extensive Idling
SEVERE SERVICE REQUIREMENTS (PERFORM W/SERVICE SCHEDULES)
NOTE: The following services are to be performed on vehicles
subjected to severe service. See SEVERE & NORMAL SERVICE
DEFINITIONS. This service is to be performed in addition
to the normal services listed in the NORMAL MAINTENANCE
SERVICE SCHEDULES.
SEVERE SERVICE CONDITIONS/ACTIONS TABLE
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Condition Action Item Perform Every (1)

Page 702 of 1333

$MITSUBISHI MONTERO 1991 Service Manual \ \ \b\ \b\ \b\ \ \ Short Trips In Replace Engine Oil$

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Short Trips In Replace Engine Oil 3,000 Miles or 3 Months

Freezing
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Temperatures Inspect Cooling 6,000 Miles or 6 Months

System

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Replace Engine Oil 6,000 Miles or 6 Months

Filter

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Inspect Throttle ONLY ONCE AT FIRST:

Position 15,000 Miles

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Inspect Drive Belt START AT: 15,000 Miles;

Tension REPEAT EVERY SUBSEQUENT:

30,000 Miles

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Replace A/T Fluid 30,000 Miles

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Replace M/T Fluid 30,000 Miles

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Replace Transfer 30,000 Miles

Case Fluid

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Towing Or Replace Engine Oil 3,000 Miles or 3 Months

Commercial Use
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Inspect Cooling 6,000 Miles or 6 Months

System

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Replace Engine Oil 6,000 Miles or 6 Months

Filter

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Inspect Throttle ONLY ONCE AT FIRST:

Position 15,000 Miles

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Inspect Drive Belt START AT: 15,000 Miles;

Tension REPEAT EVERY SUBSEQUENT:

30,000 Miles

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Replace A/T Fluid 30,000 Miles

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Replace M/T Fluid 30,000 Miles

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Replace Transfer 30,000 Miles

Case Fluid

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Driving Off-Road Replace Engine Oil 3,000 Miles or 3 Months

Or In Salty Or
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Sandy Areas Inspect Cooling 6,000 Miles or 6 Months

System

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Replace Engine Oil 6,000 Miles or 6 Months

Filter

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Inspect Throttle ONLY ONCE AT FIRST:

Position 15,000 Miles

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Inspect Drive Belt START AT: 15,000 Miles;

Tension REPEAT EVERY SUBSEQUENT:

30,000 Miles

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Replace A/T Fluid 30,000 Miles

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Replace M/T Fluid 30,000 Miles

Page 703 of 1333

$MITSUBISHI MONTERO 1991 Service Manual \ \b\ \b\ \ \ Replace Transfer 30,000 Miles$

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Replace Transfer 30,000 Miles

Case Fluid

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Severe Dust Replace Engine Oil 3,000 Miles or 3 Months

Conditions
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Inspect Cooling 6,000 Miles or 6 Months

System

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Replace Engine Oil 6,000 Miles or 6 Months

Filter

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Inspect Throttle ONLY ONCE AT FIRST:

Position 15,000 Miles

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Inspect Drive Belt START AT: 15,000 Miles;

Tension REPEAT EVERY SUBSEQUENT:

30,000 Miles

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Replace A/T Fluid 30,000 Miles

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Replace M/T Fluid 30,000 Miles

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Replace Transfer 30,000 Miles

Case Fluid

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Hot Weather, Replace Engine Oil 3,000 Miles or 3 Months

Stop-And-Go
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Driving Inspect Cooling 6,000 Miles or 6 Months

System

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Replace Engine Oil 6,000 Miles or 6 Months

Filter

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Inspect Throttle ONLY ONCE AT FIRST:

Position 15,000 Miles

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Inspect Drive Belt START AT: 15,000 Miles;

Tension REPEAT EVERY SUBSEQUENT:

30,000 Miles

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Replace A/T Fluid 30,000 Miles

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Replace M/T Fluid 30,000 Miles

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Replace Transfer 30,000 Miles

Case Fluid

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Extensive Idling Replace Engine Oil 3,000 Miles or 3 Months

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Inspect Cooling 6,000 Miles or 6 Months

System

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Replace Engine Oil 6,000 Miles or 6 Months

Filter

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Inspect Throttle ONLY ONCE AT FIRST:

Position 15,000 Miles

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Inspect Drive Belt START AT: 15,000 Miles;

Tension REPEAT EVERY SUBSEQUENT:

30,000 Miles

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Page 704 of 1333

$MITSUBISHI MONTERO 1991 Service Manual Replace A/T Fluid 30,000 Miles \ \b\ \b\ \ \$

Replace A/T Fluid 30,000 Miles

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Replace M/T Fluid 30,000 Miles

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Replace Transfer 30,000 Miles

Case Fluid

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1) - Perform these services at the mileage or number of months

(since the last time), whichever comes first.

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NORMAL MAINTENANCE SERVICE SCHEDULES
The following service schedules refer to vehicles driven
under normal operating conditions. For vehicles driven under severe
conditions, additional services may be necessary. See
SEVERE SERVICE REQUIREMENTS (PERFORM W/SERVICE SCHEDULES) above in
this article for additional service requirements.
7500 MILE (12,000 KM) SERVICE
7500 MILE (12,000 KM) SERVICE\
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Service Or Inspect

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Change Engine Oil

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Lubrication Specifications

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Application Specification

Engine Oil (
1)

Minimum Temperature

Greater Than 32
F (0
C) ...... SAE 20W-40 Or 20W-50 API SG/CD

Greater Than -10
F (-23
C) ..... SAE 10W-30, 10W-40 API SG/CD

Maximum Temperature

Less Than 60
F (16
C) .......... SAE 5W-30 Or 5W-40 API SG/CD

(
1) - Since temperature ranges for different oil grades overlap,

brief fluctuations in outside temperatures are no cause for

concern.

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Fluid Capacities

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Application Quantity

Engine Oil

1987 ......................................... 5.2 Qts. (5.0L)

1988 ......................................... 5.0 Qts. (4.8L)

1989-92 ...................................... 5.5 Qts. (5.3L)

1993-95 ...................................... 5.2 Qts. (4.9L)

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15,000 MILE (24,000 KM) SERVICE
15,000 MILE (24,000 KM) SERVICE\
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Service Or Inspect

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Verify Last Major Service Was Performed

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