1991 MITSUBISHI MONTERO cruise control

* Wrap shop towels around fuel return and high pressure hoses
to prevent fuel splashing on engine. Disconnect fuel return
hose and high pressure fuel hose to drain any residual fuel.
ENGINE
Removal (Montero & Pickup)
1) Remove hood. Drain cooling system, and remove radiator.
Remove skid plate and splash shields. Release fuel system pressure.
See FUEL PRESSURE RELEASE under REMOVAL & INSTALLATION. Disconnect
negative battery cable.
2) Remove air cleaner ducts. Remove accessory drive belts.
Remove and support A/C compressor and power steering pump. DO NOT
disconnect hoses from compressor or pump. Disconnect oil cooler hoses.
Cover fuel hose using shop towel, and disconnect high pressure fuel
hose and "O" ring. Remove fuel return hose.
3) Label and disconnect all vacuum hoses. Disconnect cooling
system hoses. Label and disconnect all electrical connections from
engine. Remove heat shield from motor mounts. Remove motor mount
bolts. Ensure all hoses and wires are disconnected and set aside.
4) Disconnect exhaust pipe from exhaust manifolds. Remove
starter. Attach engine hoist to engine. Support transmission.
Disconnect engine from transmission. See appropriate article in
CLUTCHES or TRANSMISSION SERVICING. Remove engine.
Installation (Montero & Pickup)
To install, reverse removal procedure. Install new "O" ring
on fuel line. Install new exhaust gaskets and nuts. See TORQUE
SPECIFICATIONS (MONTERO & PICKUP) table at end of article. Adjust
fluid levels.
Removal (3000GT)
1) Release fuel pressure. See FUEL PRESSURE RELEASE under
REMOVAL & INSTALLATION. Remove hood. Remove cruise control vacuum pump
and linkage. On turbo models, remove necessary turbo air intake hoses
and pipes. On all other models, remove air cleaner hoses.
2) On all models, drain cooling system. Drain engine oil and
transaxle oil. Remove heater hoses and radiator hoses. Remove
transaxle assembly. See appropriate article in CLUTCHES or
TRANSMISSION SERVICING.
3) Remove radiator. Label and disconnect all vacuum hoses.
Label and disconnect all electrical connections and harnesses from
engine. Remove accessory drive belts.
4) Remove and support A/C compressor and power steering pump.
DO NOT disconnect hoses from compressor or pump. Cover fuel hose using
shop towel, and disconnect high pressure fuel hose and "O" ring.
Remove fuel return hose.
5) On turbo models, disconnect oil cooler and vacuum hoses.
On all models, remove motor mount bolts and brackets. Ensure all hoses
and wires are disconnected and set aside. Attach engine hoist to
engine. Remove engine.
Installation
To install, reverse removal procedure. Install new "O" ring
on fuel line. Install new exhaust gaskets and nuts. See TORQUE
SPECIFICATIONS (3000GT) table at end of article. Adjust fluid levels.
UPPER INTAKE MANIFOLD
Removal (Montero & Pickup)
1) Remove air intake hose. See Fig. 1. Remove accelerator
cable adjusting bolts. On models equipped with automatic transmission,
remove throttle control cable. On all models, remove accelerator

Fig. 10: Engine Support Bracket Bolt Removal Sequence (3000GT)
Courtesy of Mitsubishi Motor Sales of America, Inc.
NOTE: Apply spray lubricant on reamer bolt during removal as bolt
is sometimes seized in engine support bracket.
Removal (3000GT)
1) Remove lower splash shields. Remove cruise control
actuator (if equipped). Remove all drive belts. Disconnect electrical
connector at power steering pump. Remove A/C tensioner pulley and
mounting bracket.
2) Remove power steering pump with hoses connected, and wire
aside. Support engine. Remove front engine mount through bolt and
front engine mount. Remove timing belt No. 1 upper outer cover and
gaskets. See Fig. 7.
3) Remove engine support bracket bolts in proper sequence.
See Fig. 10 . Remove engine support bracket. Remove cover cap and
timing belt No. 2 upper outer cover and gaskets. Using Holder
(MB990767) and Adapter Bolts (MD998719), remove crankshaft pulley.
4) Remove lower outer cover, gaskets and flange. See Fig. 7.
Rotate crankshaft and align all timing marks. See Fig. 8. Loosen belt
tensioner bolt, and rotate belt tensioner counterclockwise to release
belt tension.
5) If reusing timing belt, place arrow on belt to indicate
direction of belt rotation. Remove timing belt and belt tensioner.
6) If camshaft sprocket requires removal, install Holder
(MB990767) with Adapter Bolts (MD998719) on camshaft sprocket. Remov\
e
camshaft sprocket bolt and camshaft sprocket. Remove rear timing belt
cover (if required).
Inspection (3000GT)
Inspect timing belt for wear on edges of drive teeth. Inspect
belt for oil contamination. Replace belt if damaged or contaminated.

Inspect belt tensioner for smooth rotation. Replace if defective.
Installation
1) Install rear timing belt cover. Tighten bolts to
specification. See TORQUE SPECIFICATIONS (3000GT) table at end of
article. Install camshaft sprockets (if removed). Using holder, hold
camshaft and tighten camshaft sprocket bolt to specification.
2) Install belt tensioner and spring. Ensure spring is
secured on pin of water pump and engaged in hole of belt tensioner
with hook of spring pointing from cylinder block.
3) Rotate belt tensioner counterclockwise as much as
possible, and temporarily tighten bolt. Align all timing marks with
No. 1 cylinder at TDC of compression stroke. See Fig. 8.
4) Install timing belt on crankshaft sprocket, rear cylinder
bank camshaft sprocket, water pump pulley, front cylinder bank
camshaft sprocket and timing belt tensioner. Ensure belt is installed
in original direction of rotation and all timing marks are aligned.
Install flange on crankshaft. Loosen belt tensioner bolts slightly,
and allow tensioner to apply belt tension.
5) Using Crankshaft Socket (MD998716), rotate crankshaft 2
revolutions clockwise. DO NOT rotate counterclockwise. Realign all
timing marks. Tighten belt tensioner bolts to specification. See
TORQUE SPECIFICATIONS (3000GT) table. Using belt tension gauge,
measure belt tension halfway between crankshaft sprocket and camshaft
sprocket on side opposite belt tensioner.
6) Belt tension should be 46.3-63.3 lbs. (21-29 kg). To
install remaining components, reverse removal procedure. Install
proper length bolts in timing belt covers and engine support bracket.
See Figs. 9 and 10. Tighten bolts to specification. See TORQUE
SPECIFICATIONS (3000GT) table.
NOTE: Engine support bracket reamer bolt must be tightened slowly
while spraying lubricant on bolt.
Fig. 11: Identifying Timing Belt Cover Bolt Length (SOHC)
Courtesy of Mitsubishi Motor Sales of America, Inc.
Removal (DOHC)
1) Remove lower splash shields. Remove cruise control

CRUIS E C O NTR O L S YSTE M

1991 M it s u bis h i M onte ro
1991-92 SAFETY EQUIPMENT
Mitsubishi Cruise Control Systems
Montero
DESCRIPTION & OPERATION
The cruise control system is electronically and vacuum
controlled. System components include a control unit, actuator, vacuum
pump, cruise control switch, clutch pedal switch, cruise indicator
light, diode, inhibitor switch (A/T), stoplight switch, vehicle speed
sensor and A/T control unit.
The system has self-diagnostic capability. When
self-diagnostic mode is activated, each switch and sensor is checked
for defects. When cruise control system has been cancelled without
using a normal cancel method, a code will be set and stored in control
unit. Codes can be retrieved to help determine which circuit is
malfunctioning.
PRELIMINARY INSPECTION
Before performing TROUBLE SHOOTING steps, inspect linkage
assembly, actuator, cables and vacuum hoses. Ensure linkage and cables
move smoothly. Ensure cables do not have excessive slack or tension.
TROUBLE SHOOTING
NOTE: For further trouble shooting information, see CHECK RESULTS
& SYMPTOM CHARTS. See Figs. 11-16.
SYSTEM CANCELS OR WILL NOT RESET AFTER CANCELLATION
1) Check trouble codes, see SELF-DIAGNOSTICS under DIAGNOSIS
& TESTING. If no trouble codes are stored, ensure cruise control can
be set.
2) If cruise control can be set, system may have cancelled
because of driving on steep hills or loose wiring connection. If
cruise control still cannot be set, perform SYSTEM INPUT TESTS under
DIAGNOSIS & TESTING.
3) On 1991 models, if SYSTEM INPUT TESTS check okay, check
actuator circuit. See TEST NO. 5 under CIRCUIT TESTS (1991). On 1992
models, if SYSTEM INPUT TESTS check okay, check vacuum pump circuit.
See TEST NO. 6 under CIRCUIT TESTS (1992). On all models, if SYSTEM
INPUT TESTS do not check okay, see INPUT CODE CHART. See Fig. 9 or 10.
ADJUSTMENTS
CRUISE CONTROL CABLE
1991
1) Ensure cruise control and accelerator cables are free of
bends and folds. Remove actuator cover. Loosen lock nuts and adjusting
nuts to free cables. Adjust accelerator cable "A" to correct
dimension. See Fig. 1 or 2.
2) Tighten lock nuts. Loosen adjustment bolts on intake air
plenum. Adjust plate so that inner cable free play is .04-.08" (1-2

mm). Tighten adjustment plate bolts.
3) Ensure throttle link is touching fixed Speed Adjusting
Screw (SAS). With intermediate link "A" in contact with stopper,
tighten adjusting nut "A" in direction that reduces inner cable free
play. See Fig. 3.
4) Stop turning adjusting nut "A" just before intermediate
link "A" begins to move. Back off adjusting nut "A" 1/2 turn. Inner
cable free play should be 0-.04" (0-1 mm). Tighten lock nut. Ensure
the distance intermediate link "B" begins to move when selector of
actuator turns is 04-.08" (1-2 mm). See Fig. 4.
5) Press accelerator pedal to ensure intermediate links "A"
and "B" operate smoothly. Install actuator cover.
Fig. 1: Adjusting Cruise Control & Accelerator Cables (1991 - 1 Of 4)\
Courtesy of Mitsubishi Motor Co.

Fig. 2: Adjusting Cruise Control & Accelerator Cables (1991 - 2 Of 4)\
Courtesy of Mitsubishi Motor Co.
Fig. 3: Adjusting Cruise Control & Accelerator Cables (1991 - 3 Of 4)\
Courtesy of Mitsubishi Motor Co.

Fig. 4: Adjusting Cruise Control & Accelerator Cables (1991 - 4 Of 4)\
Courtesy of Mitsubishi Motor Co.
1992
Remove link protector. Loosen lock nut. Hold link "A" so that
it touches link "B". Adjust free play by turning adjusting nut until
free play is .04-.08" (1-2 mm). Tighten lock nut. See Fig. 5.
Fig. 5: Adjusting Cruise Control Cable (1992)
Courtesy of Mitsubishi Motor Co.
DIAGNOSIS & TESTING

CRUISE CONTROL SWITCH FUNCTION TEST
NOTE: If vehicle speed decreases approximately 9 MPH below set
speed, set speed will be cancelled.
1) Cruise control switch is part of multifunction switch
mounted on steering column. To operate cruise control system, turn
ignition on. Turn cruise control switch to ON position. Ensure switch
indicator light comes on.
NOTE: Speed will not set beyond system limit of 90 MPH.
2) With cruise control switch in ON position, drive vehicle
between 25 and 90 MPH. Press and release SET button. Vehicle speed
should stay at set speed. Instrument cluster cruise indicator light
should come on. To increase set speed, turn control switch to RESUME
position and hold until new set speed is reached.
3) To lower set speed, press SET button and hold until new
set speed is reached. To return to set speed after cancellation, move
resume switch from ON to OFF position. Vehicle speed should return to
previous setting before cancellation. Set speed should cancel when any
of the following occurs:
* Brake pedal is pressed.
* Clutch pedal is pressed.
* Transmission is shifted to Neutral or Park.
* Cruise control main switch is turned off.
* Ignition switch is turned off.
SELF-DIAGNOSTICS
1) Self-diagnostics should be performed when cruise control
cancels without the driver using normal cancel modes. Diagnosis
connector is located on right side of fuse box. Use analog voltmeter
or Multi-Use Tester (MB991341) for code retrieval.
2) Use multi-use tester according to operating instructions
provided with tester. Connect leads of analog voltmeter between cruise
control terminal and ground terminal of self-diagnostic connector. See
Fig. 6 . Read voltmeter needle sweeps to determine trouble code.
NOTE: On 1991 models, codes No. 13, 14, 15, 16 and 17 will be
displayed whether malfunction is present or not.
3) Once trouble codes have been displayed, see SELF-
DIAGNOSTIC CODE CHART to determine appropriate CIRCUIT TEST. See
Fig. 7 or 8.
4) To clear trouble codes, either disconnect battery cable or
turn ignition on. Turn main cruise control switch and set switch to ON
position. Within one second turn resume switch to ON position.
5) Hold stoplight switch and cruise control switch in ON
position for more than 5 seconds. Verify codes are cleared.
Fig. 6: Identifying Self-Diagnostic Connector Terminals
Courtesy of Mitsubishi Motor Co.