MITSUBISHI MONTERO 1991 Service Manual

Bracket cracked, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket holes elongated,
affecting performance .. A .. Require repair or replacement.
Bracket holes elongated,
not affecting
performance ............ .. ........ No service suggested or
required.
Bracket loose, affecting
performance ............ A .. Require repair or replacement.
Bracket loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket missing ......... C ............ Require replacement.
Connection damaged ...... B .. Require repair or replacement.
Contaminated, affecting
performance ............ A ............ Require replacement.
Corroded internally ..... 1 ............ Suggest replacement.
Dessicant bag
deteriorated ........... A ........ (1) Require replacement.
Further inspection required.
Dessicant at the end of
its useful life
(saturated
with moisture) ......... 1 .. Suggest repair or replacement.
Filter screen torn ...... A .. Require replacement of screen.
Fitting damaged ......... B .. Require repair or replacement.
Fusible plug leaking .... A .... Require replacement of plug.
Inoperative ............. A ........... ( 2) Require repair or
replacement.
Leaking ................. A .. Require repair or replacement.
Pressure relief device
leaking ................ A . Require replacement of pressure
relief device.
Restricted .............. A .. Require repair or replacement.
Sight glass no longer
transparent ............ 2 ... Suggest replacement of drier.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Tubing connection
leaking ................ A .. Require repair or replacement.
( 1) - Inspect system to determine effects of dessicant bag
deterioration.
( 2) - Inoperative includes intermittent operation or out of
OEM specification.









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WATER PUMPS (ELECTRIC AUXILIARY)
WATER PUMP (ELECTRIC AUXILIARY) INSPECTION








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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.

Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted,
affecting performance .. A ........... (1) Require repair or
replacement.
Connector melted, not
affecting performance .. 2 ........... ( 1) Suggest repair or
replacement.
Connector missing ....... C ............ Require replacement.
Inoperative ............. A ........ ( 2) Require replacement.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 ............ Suggest replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Vibration ............... 1 .. Suggest replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Inoperative includes intermittent operation or out of
OEM specification.









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WIRING HARNESSES AND CONNECTORS
WIRING HARNESS AND CONNECTOR INSPECTION








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Condition Code Procedure
Application incorrect ... B .. Require repair or replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Circuit open ............ A .. Require repair or replacement.
Circuit resistance
(voltage drop) out of

specification .......... A .. Require repair or replacement.
Circuit shorted ......... A .. Require repair or replacement.
Connector melted,
affecting performance .. A ........... (1) Require repair or
replacement.
Connector melted, not
affecting performance .. 2 ........... ( 1) Suggest repair or
replacement.
Connector missing ....... C ............ Require replacement.
Diode open .............. A .. Require repair or replacement.
Diode shorted ........... A .. Require repair or replacement.
Insulation damaged,
conductors exposed ..... A .. Require repair or replacement.
Insulation damaged,
conductors not exposed . 1 ............ Suggest replacement.
Protective shield
(conduit) melted ....... B ........ ( 1) Require replacement.
Protective shield
(conduit) missing ...... C ............ Require replacement.
Routed incorrectly ...... B ................. Require repair.
Secured incorrectly ..... B ................. Require repair.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Voltage drop out of
specification .......... A .. Require repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.









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\003
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

system is in operation. This high pressure could rupture can
or fitting at safety can valve, resulting in damage and
personal injury.
CONNECTING LINES & FITTINGS
A new "O" ring should be used in all instances when
connecting lines and fittings (dip "O" ring in clean refrigeration oil
and make certain it is not twisted during installation). Always use
two wrenches to avoid twisting or distorting lines and fittings,
tighten coupling nuts securely.
PLACING SYSTEM IN OPERATION
After component replacement and/or system servicing has been
completed and all connections have been made, proceed as follows:
1) Evacuate the system using a vacuum pump.
2) Charge the system with new R-12 (refrigerant) according t\
o
each individual vehicle as outlined in the
GENERAL COOLING SYSTEM SERVICING article. Also see Refrigerant
Capacity in this Section.
3) Leak test the system, with particular attention to all new
connections and components.
4) Make a performance test of the system. Never assume that a
recharging has automatically corrected a problem.
COMPRESSOR REMOVAL INFORMATION - ISOLATION METHOD
On systems which have compressors equipped with stem-type
service valves (Tecumseh), it is possible to isolate the compressor
for removal.
Isolating
Turn both high and low pressure manual valves to extreme
clockwise (front seat) position. Loosen cap on high pressure manual
valve connection to compressor and allow gas to escape until
compressor is relieved of pressure.
COMPRESSOR REMOVAL INFORMATION - DISCHARGE METHOD
This procedure is to be used on vehicles which have
compressor equipped with Schrader service valves. In these cases, the
compressor cannot be isolated and the system must be discharged, using
approved refrigerant recovery/recycling equipment, prior to compressor
removal.

\003
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

minutes. Repeat this step several times for about one hour. This helps
remove air from engine oil.
IGNITION TIMING
NOTE: Perform all adjustments with engine at normal operating
temperature, cooling fan and accessories off, transmission
in Park or Neutral, and front wheels in straight-ahead
position. Set curb idle speed to specification. See IDLE
SPEED SPECIFICATIONS table under IDLE SPEED & MIXTURE.
IGNITION TIMING
1) Locate ignition timing adjustment connector. See IGNITION
TIMING ADJUSTMENT CONNECTOR LOCATION table. Connect jumper wire
between ignition timing adjustment connector and ground. Check
ignition basic timing.
2) If ignition basic timing is not within specification,
loosen distributor (or crank angle sensor on engines with dual coil
assembly) and rotate to adjust timing if necessary. See IGNITION
TIMING SPECIFICATIONS table. Disconnect jumper wire from ignition
timing adjustment connector.
IGNITION TIMING SPECIFICATIONS TABLE (Degrees BTDC@RPM)









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Application (1) Basic (1) (2) Actual
1.5L
Colt, Colt 200
Mirage & Summit ....... 5@650-850 ........ 10@650-850
1.6L
Mirage ................. 5@650-850 ......... 8@650-850
1.8L
Eclipse ................ 5@600-800 ........ 10@600-800
2.0L
Colt Vista &
Galant (VIN V) ........ 5@600-800 ........ 10@600-800
Eclipse ................ 5@650-850 ......... 8@650-850
Galant
(VIN R) ............... 5@650-850 ......... 8@650-850
(VIN U) ............... 5@650-850 ........ 12@650-850
2.4L
Pickup & Ram-50 ........ 5@650-850 ......... 8@650-850
3.0L
Montero, Pickup, Ram-50
Stealth & 3000GT ...... 5@600-800 ........ 15@600-800
(1) - Transmission in Park or Neutral.
(2) - Actual timing may fluctuate.









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IGNITION TIMING ADJUSTMENT CONNECTOR LOCATION TABLE








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Application (1)(2) Wire Color Locati\
on
Colt, Colt Vista, Colt 200,
Mirage & Summit
1.5L, 1.6L & 2.0L ................ Yellow/Red ............. (3)\
Eclipse
1.8L & 2.0L (Except Turbo) ........ Yellow/Red ............. (4\
)
2.0L Turbo ....................... Yellow/Black ............ (4)\
Galant

2.0L .............................. Yellow/Red ............. (5)\
Montero
3.0L ............................. White/Yellow ............ (4)\
Pickup & Ram-50
2.4L .............................. Black/Blue ............. (6)\
3.0L ............................. White/Yellow ............ (6)\
Stealth (SOHC)
3.0L ............................. White/Yellow ............ (4)\
Stealth & 3000GT (DOHC)
3.0L (Non-Turbo) ................. Black/Green ............. (4\
)
3.0L (Turbo) ..................... White/Yellow ............ (4\
)
(1) - Remove waterproof female connector (if equipped) for access to\
wire.
(2) - Ground connector at wire end for basic timing adjustment.
(3) - On main wiring harness, near center of firewall.
(4) - On main wiring harness, near wiper motor on firewall.
(5) - On main wiring harness, near master cylinder on firewall.
(6) - Between right shock tower and firewall.
(7) - Near front of right shock tower.









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IDLE SPEED & MIXTURE
NOTE: Perform adjustments with engine at normal operating
temperature, cooling fan and accessories off, transmission
in Park or Neutral, and front wheels in straight-ahead
position.
CURB (SLOW) IDLE SPEED
NOTE: Curb idle speed is controlled by Idle Speed Control (ISC)
motor. Adjustment is usually not necessary. For curb idle
speed specifications, see IDLE SPEED SPECIFICATIONS table
under BASIC IDLE SPEED.
1) Check ignition timing and adjust if necessary. Run engine
at 2000-3000 RPM for more than 5 seconds. Allow engine to idle for 2
minutes. Check curb idle speed.
2) If curb idle speed is not within specification, check ISC
system. If ISC system is okay, adjust basic idle speed. See BASIC IDLE
SPEED.
BASIC IDLE SPEED
NOTE: ALWAYS check TPS adjustment after adjusting basic idle
speed. See THROTTLE POSITION SENSOR (TPS).
BASIC IDLE SPEED TEST APPLICATION TABLE









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Application Test
1.5L
Colt, Colt 200,
Mirage & Summit ............. TEST NO. 1
1.6L
Mirage ....................... TEST NO. 2
1.8L
Eclipse ...................... TEST NO. 1
2.0L (VIN V)
Colt Vista & Galant .......... TEST NO. 1
2.0L (VIN R & U)

Eclipse & Galant ............. TEST NO. 2
2.4L
Pickup & Ram-50 .............. TEST NO. 1
3.0L
Montero, Pickup, Ram-50,
Stealth & 3000GT ............ TEST NO. 2









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Test No. 1
1) Loosen throttle cable. Turn ignition on for more than 15
seconds. DO NOT start engine. Turn ignition off. This should fully
retract ISC motor plunger.
2) On 2.0L Galant (VIN V), connect jumper wire between
ignition timing adjustment connector and ground. See IGNITION TIMING
ADJUSTMENT CONNECTOR LOCATION table under IGNITION TIMING.
3) On all models, disconnect harness connector(s) from Idle
Speed Control (ISC) motor. Ensure ISC plunger is in fully retracted
position. Unscrew fixed Speed Adjusting Screw (SAS) until throttle
valve is fully closed. See Fig. 1.
CAUTION: When cleaning throttle body, plug air by-pass hole in
throttle body to prevent solvent from entering passage.
4) Start engine. Check basic idle speed. See IDLE SPEED
SPECIFICATIONS table. If basic idle speed is within specification, go
to step 7). If basic idle speed is not within specification, remove
air intake hose and clean throttle body. Reconnect air intake hose.
Recheck basic idle speed.
5) If basic idle speed is still not within specification
after cleaning throttle body, adjust basic idle speed by turning idle
speed adjusting screw. See Fig. 1. After adjusting basic idle speed,
turn fixed SAS screw clockwise until engine speed begins to increase.
6) Turn fixed SAS screw counterclockwise until engine speed
decreases. Turn fixed SAS screw counterclockwise an additional 1/2
turn from point at which engine speed no longer decreases. Turn off
engine.
7) Adjust throttle cable. Reconnect harness connector(s) at
ISC motor. Start engine. Operate engine for about 5 minutes. Ensure
engine idles within curb idle speed specification. See IDLE SPEED
SPECIFICATIONS table.
8) Turn ignition off. Disconnect negative battery cable for
at least 10 seconds to clear diagnostic trouble code. Reconnect
negative battery cable. Operate engine at idle for about 5 minutes to
ensure engine idles smoothly.
Test No. 2
1) Locate ignition timing adjustment connector. See IGNITION
TIMING ADJUSTMENT CONNECTOR LOCATION table under IGNITION TIMING.
Connect jumper wire between ignition timing adjustment connector and
ground.
2) Locate diagnostic connector under instrument panel.
Connect jumper wire between diagnostic connector terminal No. 10
(White wire) and ground. See Fig. 3. Start engine. Check basic idle
speed. See IDLE SPEED SPECIFICATIONS table. If basic idle speed is
within specification, go to step 9). If basic idle speed is not within
specification, go to step 3).
3) Remove air intake hose. Check throttle body. If throttle
body contains deposits, go to next step. If throttle body is clean,
disconnect jumper wires connected in steps 1) and 2). On all models
except Eclipse, Galant and Mirage, go to step 6). On Eclipse, Galant
and Mirage, go to step 5).
CAUTION: When cleaning throttle body, plug air by-pass hole in