1991 MITSUBISHI MONTERO alternator belt

install, reverse removal procedure using new gaskets and "O" rings.
Coat "O" ring with fuel before installation.
2) Install lower intake manifold gasket with adhesive side
toward intake manifold and gasket protrusions facing outboard of
engine. Tighten bolts and nuts to specification. See appropriate
TORQUE SPECIFICATIONS table at end of article. Check for fuel leaks.
TURBOCHARGER
Removal (Front)
1) Drain coolant, and remove radiator. Disconnect exhaust
pipe from turbo. Remove all air intake pipes. Note match marks and
installation depth on air pipes and hoses for reinstallation. Remove
serpentine drive belt. Remove alternator. Remove A/C compressor and
bracket, and support aside.
2) Remove O2 sensor. Remove dipstick assembly and turbo heat
shield. Disconnect turbo coolant feed and return lines. Disconnect
turbo oil feed and return lines. Remove turbocharger assembly.
Removal (Rear)
1) Drain coolant. Remove battery. Disconnect accelerator
cable at bracket and throttle body. Disconnect exhaust pipe from
turbo. Remove all air intake pipes and heat shields. Disconnect
accelerator cable at pedal.
2) Remove clutch booster vacuum hose. Remove O2 sensor.
Remove EGR pipe and turbo heat shield. Disconnect turbo coolant feed
and return lines. Disconnect turbo oil feed and return lines. Remove
turbocharger assembly.
CAUTION: DO NOT allow foreign material into turbocharger air intakes
or coolant and oil passages.
Inspection (Front & Rear)
1) Inspect turbocharger for oil leakage. Check turbine and
compressor wheels for cracks and other damage. Both wheels should turn
easily by hand.
2) Apply 6.8 psi (61 kPa) vacuum to wastegate diaphragm.
Ensure wastegate operates and diaphragm holds vacuum pressure. Use
care when cleaning gasket surfaces so no foreign material enters
turbocharger oil, coolant and air passages.
Installation (Front & Rear)
Refill turbocharger with clean engine oil through oil pipe
installation hole. To complete installation, reverse removal
procedure. Align match marks, and install air pipes and hoses to
proper depth.
EXHAUST MANIFOLDS
Removal (Montero & Pickup)
1) Remove splash shields. Remove O2 sensor. Remove exhaust
pipe-to-manifold nuts. Lower exhaust pipe, and remove gasket. Remove
heat protector. To remove right exhaust manifold, remove air duct,
engine lift bracket and alternator bracket.
2) To remove left exhaust manifold, remove EGR pipe and
gasket. Remove front intake manifold plenum bracket. Remove exhaust
manifolds and gaskets.
Inspection (Montero & Pickup)
Clean all gasket mating surfaces. Inspect for damage and
cracks on all mounting surfaces. Check mounting surfaces of manifold
and cylinder head for warpage. Repair or replace components if warpage
exceeds .012" (.30 mm).

Installation (Montero & Pickup)
To install, reverse removal procedure using new gaskets.
Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS
(MONTERO & PICKUP) table at end of article.
Removal (3000GT)
1) Remove turbocharger(s) (if equipped). See TURBOCHARGER
under REMOVAL & INSTALLATION. On front manifold, remove serpentine
drive belt and alternator. Remove oil dipstick. On rear manifold,
remove EGR pipe (if equipped).
NOTE: Note locations and direction of installation of exhaust
manifold plain and spring washers for reinstallation
reference. DO NOT mix these fasteners.
2) On all manifolds, remove exhaust pipe-to-manifold nuts.
Lower exhaust pipe, and remove gasket. Remove heat protector. Remove
exhaust manifold nuts and washers. Note locations and direction of
installation of plain and spring washers for reinstallation reference.
DO NOT mix these fasteners. Remove exhaust manifold and gasket.
Inspection (3000GT)
Clean all gasket mating surfaces. Inspect for damage and
cracks on all mounting surfaces. Check mounting surfaces of manifold
and cylinder head for warpage. Repair or replace components if warpage
exceeds .012" (.30 mm).
Installation (3000GT)
To install, reverse removal procedure using new gaskets.
Install new "O" ring on dipstick guide. Coat "O" ring with oil before
installation. Install manifold nuts and washers in original locations.
Tighten nuts to specification in sequence. See Fig. 4. See TORQUE
SPECIFICATIONS (3000GT) table at end of article.
Fig. 4: Exhaust Manifold Tightening Sequence (3000GT)
Courtesy of Mitsubishi Motor Sales of America, Inc.
CYLINDER HEADS

actuator (if equipped). Remove all drive belts. Remove alternator.
Remove drive belt tensioner assembly.
2) Using Holder (MB990767) and Adapter Bolts (MD998754),
remove crankshaft pulley. See Fig. 12. Disconnect brake fluid level
sensor. Remove upper timing belt covers. Support engine. Remove front
engine mount through bolt and front engine mount.
NOTE: Apply spray lubricant on reamer bolt during removal as bolt
is sometimes seized in engine support bracket.
Fig. 12: Exploded View of Timing Belt Components (DOHC)
Courtesy of Mitsubishi Motor Sales of America, Inc.
3) Remove drive belt idler pulley. Remove engine support
bracket bolts in proper sequence. See Fig. 10. Remove engine support

BELT ADJUSTMENT TABLE








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Application ( 1) New Belt Deflection: In. (mm)
Colt, Colt 200 & Summit ..................... .28-.35 (7.1-8.9)
Mirage
1.5L ...................................... .28-.35 (7.1-8.9)
1.6L ..................................... .35-.45 (8.9-11.4)
Colt Vista .................................. .28-.34 (7.1-8.6)
Eclipse & Galant
1.8L ..................................... .32-.43 (8.1-10.9)
2.0L ..................................... .35-.45 (8.9-11.4)
Montero ..................................... .22-.32 (5.6-8.1)
Pickup & Ram-50
2.4L ...................................... .28-.39 (7.1-9.9)
3.0L ...................................... .32-.39 (8.1-9.9)
Precis ...................................... .28-.32 (7.1-8.1)
Stealth & 3000GT
DOHC ...................................... .16-.22 (4.1-5.6)
SOHC ...................................... .24-.35 (6.1-8.9)
( 1) - Deflection measured with 22 lbs. (10 kg) pressure applied midway
on belt run.









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TROUBLE SHOOTING
NOTE: See TROUBLE SHOOTING - BASIC PROCEDURES article in the
GENERAL INFORMATION section.
TESTING (ON-VEHICLE)
ALTERNATOR TO BATTERY CONTINUITY TEST
NOTE: Check alternator wire harness connections and drive belt
tension and ensure battery is fully charged before
performing test.
1) Turn ignition switch to OFF position. Disconnect negative
battery cable. Remove output lead from alternator terminal "B". See
Fig. 10 . Install a 100-amp ammeter in series to terminal "B" and
disconnected output lead. Install positive lead of ammeter to terminal
"B" and negative lead to disconnected output wire.
Fig. 10: Identifying Alternator Terminals
Courtesy of Chrysler Motors.
2) Install a digital voltmeter between alternator terminal
"B" and positive battery terminal. Install positive voltmeter lead to

terminal "B" and negative lead to positive battery terminal. Reconnect
negative battery cable.
3) Start engine. Turn accessories on and adjust engine speed
until ammeter indicates 20 amps, and note voltmeter reading. If
voltmeter indicates .2 volt or less, system is okay.
4) If voltage is greater than .2 volt, wiring is defective
between alternator terminal "B", fusible link and battery positive
terminal. Disconnect negative battery cable, and remove test
equipment.
ALTERNATOR OUTPUT TEST
NOTE: During alternator output test, a slightly discharged battery
should be used as a fully charged battery may not allow full
alternator output.
1) Turn ignition switch to OFF position. Disconnect negative
battery cable. Disconnect alternator output wire from terminal "B".
Install positive lead of 100-amp ammeter to terminal "B" and negative
lead to disconnected output lead.
CAUTION: Tighten each connection securely as heavy current flow will
exist. DO NOT use clips on ammeter.
2) Connect positive voltmeter lead (0-20 volts) to alternato\
r
terminal "B" and negative lead to ground. Install tachometer, and
reconnect negative battery cable.
3) Ensure voltmeter indicates battery voltage. If no voltage
exists, an open circuit is present in wire between alternator terminal
"B" and battery negative terminal. Check grounds and fusible link.
4) Turn headlights on, and start engine. Set headlights at
high beam and heater switch on HIGH. Quickly accelerate engine speed
to 2500 RPM and note alternator output current registered on the
ammeter. Minimum output should be within specification. Refer to the
ALTERNATOR MINIMUM OUTPUT SPECIFICATIONS table.
NOTE: Output voltage changes with electrical load and temperature.
Ensure proper electrical load is applied while checking
output. Nominal output may not be obtained if alternator or
ambient temperature is excessive. Allow to cool, and recheck
output. Alternator output is stamped on metal plate attached
to alternator case.
5) If minimum output is not obtained and alternator wiring is
okay, repair alternator. Disconnect negative battery cable, and remove
test equipment.
REGULATED VOLTAGE TEST
NOTE: Ensure battery is fully charged and proper drive belt
tension exists.
1) Turn ignition switch to OFF position. Disconnect negative
battery cable. Install a digital voltmeter between alternator terminal
"S" and ground. See Fig. 10. Connect positive voltmeter lead to
terminal "S" of alternator. Connect negative voltmeter lead to ground.
2) Disconnect alternator output wire from terminal "B".
Install a 100-amp ammeter in series to terminal "B" and disconnected
output lead. Install positive lead of ammeter to terminal "B" and
negative lead to disconnected output wire. Install a tachometer, and
reconnect negative battery cable.
3) Turn ignition switch to ON position and ensure voltmeter
indicates battery voltage. If no voltage exists, an open circuit

DRIV E B ELT R O UTIN G

1991 M it s u bis h i M onte ro
1991 ENGINE COOLING
Mitsubishi Drive Belt Routing
Mitsubishi; Eclipse, Galant, Mirage,
Montero, Pickup, Precis, 3000GT
BELT ADJUSTMENT SPECIFICATIONS
BELT ADJUSTMENT TABLE








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Deflection
Application ( 1) In. (mm)
Eclipse
1.8L .......................................... .32-.43 (8.1-10.9)\
2.0L .......................................... .35-.45 (8.9-11.4)\
Galant ( 2)
Alternator Belt ............................... .35-.45 (8.9-11.4)\
A/C Belt ............................................... .32 (8.1)\
Power Steering Belt ............................ .24-.35 (6.1-8.9)\
Montero ( 3) ...................................... .20-.24 (5.1-6.1)
Pickup
2.4L ........................................... .27-.39 (6.8-9.9)\
3.0L ( 3) ....................................... .32-.39 (8.1-9.9)
Precis
A/C Belt ...................................... .32-.40 (8.1-10.2)\
Alternator Belt ................................ .28-.32 (7.1-8.1)\
3000GT ( 4)
DOHC
Alternator Belt ............................... .16-.22 (4.1-5.6)\
Power Steering Belt .......................... .35-.43 (8.9-10.9)\
SOHC
Alternator & Power Steering Belt .............. .24-.35 (6.1-8.9)\
A/C Belt ...................................... .28-.37 (7.1-9.5)\
( 1) - With 22 lbs. (10 kg) pressure applied midway on belt run.
( 2) - For belt routing, see Fig. 1.
( 3) - For belt routing, see Fig. 2.
( 4) - For belt routing, see Figs. 3, 3 or 4.









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* E LE C TR IC AL S YSTE M U NIF O RM IN SPEC TIO N G UID ELIN ES *

1 991 M it s u bis h i M onte ro
GENERAL INFORMATION
Electrical System Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
ACTUATOR MOTORS (SOLENOIDS) (ELECTRIC)
ACTUATOR MOTORS (VACUUM)
AIR BAGS
ALTERNATORS AND GENERATORS
AMPLIFIERS
ANTENNAS
BATTERIES
BATTERY CABLES
BATTERY CABLES
BATTERY HOLD DOWN HARDWARE
BATTERY TRAYS AND HOLD DOWN HARDWARE
BATTERY WIRES
BELTS
BULB SOCKETS
BULBS, SEALED BEAMS AND LEDS
CD PLAYERS
CIGARETTE LIGHTER ASSEMBLIES
CIRCUIT BREAKERS
CLUTCH SWITCHES
CONNECTORS
CONTROL MODULES
CRUISE CONTROL BRAKE SWITCHES
CRUISE CONTROL CABLES
CRUISE CONTROL CLUTCH SWITCHES
CRUISE CONTROL LINKAGES AND CABLES
CRUISE CONTROL RESERVOIRS
CRUISE CONTROL TUBES
CRUISE CONTROL VACUUM DUMP RELEASE VALVES
CRUISE CONTROL VACUUM HOSES, TUBES AND RESERVOIRS
CRUISE CONTROL VEHICLE SPEED SENSORS
DEFOGGERS
DEFROSTERS
DELAYS
DIMMERS
ELECTRIC HEATERS
EQUALIZERS
FUSE BLOCKS
FUSE BOXES AND BLOCKS
FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS
FUSIBLE LINKS
GAUGES
GENERATORS
GROUND CABLES AND STRAPS
GROUND STRAPS
HEADLIGHT ADJUSTERS
HEATING ELEMENTS (DEFROSTERS, DEFOGGERS, ELECTRIC HEATERS AND SEATS)
HORNS AND SIRENS

Courtesy of Mitsubishi Motor Sales of America.
2) Disconnect air intake hose and vacuum hoses. Remove air
hose and air outlet housing. Remove heat protectors. Disconnect
exhaust pipe. Remove power steering oil pump and bracket. Remove
engine hanger bracket. Disconnect oil inlet pipe.
3) Disconnect coolant hose and tubes. Remove nuts and bolts
securing exhaust manifold. Remove exhaust manifold and gaskets.
Disconnect oil return pipe. Remove turbocharger assembly.
Removal (Stealth & 3000GT Front)
1) Disconnect negative battery cable. Drain engine oil and
coolant. Remove radiator. Disconnect exhaust pipe. Remove air intake
hose, air hoses and air pipe. Remove alternator and belt. Remove oil
dipstick guide.
2) Remove heat protector. Disconnect oxygen sensor electrical
connector. Remove oil return pipe. Remove turbocharger support bracket
and remove turbocharger from exhaust manifold. See Fig. 10.
Fig. 10: Removing Front Turbocharger (Stealth & 3000GT)
Courtesy of Mitsubishi Motor Sales of America.
Removal (Stealth & 3000GT Rear)
1) Disconnect battery cables and remove battery. Drain engine
oil and coolant. Remove accelerator cable. Remove air hose, air pipe
and heat protectors. Disconnect clutch booster vacuum hose. Remove air