break MITSUBISHI MONTERO 1991 User Guide

Melted, not affecting
performance ............ 2 ........ (1) 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.
( 1) - Determine cause and correct prior to repair or
replacement of part.









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FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS
FUSE, FUSIBLE LINK AND CIRCUIT BREAKER INSPECTION








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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Blown ................... A ........ ( 1) Require replacement.
Corroded, affecting
performance ............ A .. Require repair or replacement.
Corroded, not affecting
performance ............ 2 .. Suggest repair or replacement.
Cracked, affecting
performance ............ A .. Require repair or replacement.
Cracked, not affecting
performance ............ 1 .. Suggest repair or replacement.
Inoperative ............. A ........ ( 2) Require replacement.
Insulation damaged,
conductors exposed ..... A .. Require repair or replacement.
Insulation damaged,
conductors not exposed . 1 ............ Suggest replacement.
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.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Inoperative includes intermittent operation.

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FUSIBLE LINKS
See FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS .
GAUGES
NOTE: Includes odometers, speedometers and tachometers (except
cable-driven).
GAUGE 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 ........ A ........... ( 1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Leaking ................. A ............ Require replacement.
Lens broken ............. A ........... ( 2) Require repair or
replacement.
Lens cloudy ............. 2 ........... ( 2) Suggest repair or
replacement.
Lens missing ............ C ........... ( 2) Require repair or
replacement.
Malfunctioning .......... A ........... ( 3) Require repair or
replacement.
Mechanical head noisy ... 2 .. Suggest repair or 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.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - If lens is available as a separate part, require
replacement of lens only.
( 3) - Includes inoperative, intermittent operation, failure
to perform all functions, out of OEM specification,
or out of range.









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On cast cylinder heads, if warpage exceeds .003" (.08 mm)
in a 6" span, or .006" (.15 mm) over total length, cylinder head must
be resurfaced. On most aluminum cylinder heads, if warpage exceeds .
002" (.05 mm) in any area, cylinder head must be resurfaced. Warpage
specification may vary with manufacturer.
Cylinder head thickness should be measured to determine
amount of material which can be removed before replacement is
required. Cylinder head thickness must not be less than manufacturer's
specifications.
If cylinder head required resurfacing, it may not align
properly with intake manifold. On "V" type engines, misalignment is
corrected by machining intake manifold surface that contacts cylinder
head. Cylinder head may be machined on surface that contacts intake
manifold.
Using oil stone, remove burrs or scratches from all sealing
surfaces.
VALVE SPRINGS
Inspect valve springs for corroded or pitted valve spring
surfaces which may lead to breakage. Polished spring ends caused by
a rotating spring, indicates that spring surge has occurred. Replace
springs showing evidence of these conditions.
Inspect valve springs for squareness using a 90 degree
straightedge. See Fig. 4. Replace valve spring if out-of-square
exceeds manufacturer's specification.
Fig. 4: Checking Valve Spring Squareness - Typical
This Graphic For General Information Only
Using vernier caliper, measure free length of all valve
springs. Replace springs if not within specification. Using valve

using ridge reamer. DO NOT remove an excessive amount of material.
Ensure ridge is completely removed.
PISTON & CONNECTING ROD REMOVAL
Note top of piston. Some pistons may contain a notch, arrow
or be marked "FRONT". Piston must be installed in proper direction to
prevent damage with valve operation.
Check that connecting rod and cap are numbered for cylinder
location and which side of cylinder block the number faces. Proper cap
and connecting rod must be installed together. Connecting rod cap must
be installed on connecting rod in proper direction to ensure bearing
lock procedure. Mark connecting rod and cap if necessary. Pistons must
be installed in original location.
Remove cap retaining nuts or bolts. Remove bearing cap.
Install stud protectors on connecting rod bolts. This protects
cylinder walls from scoring during removal. Ensure proper removal of
ridge. Push piston and connecting rod from cylinder. Connecting rod
boss can be tapped with a wooden dowel or hammer handle to aid in
removal.
PISTON & CONNECTING ROD
Disassembly
Using ring expander, remove piston rings. Remove piston pin
retaining rings (if equipped). On pressed type piston pins, special
fixtures and procedures according to manufacturer must be used to
remove piston pins. Follow manufacturer's recommendations to avoid
piston distortion or breakage.
Cleaning
Remove all carbon and varnish from piston. Pistons and
connecting rods may be cleaned in cold type chemical tank. Using ring
groove cleaner, clean all deposits from ring grooves. Ensure all
deposits are cleaned from ring grooves to prevent ring breakage or
sticking. DO NOT attempt to clean pistons using wire brush.
Inspection
Inspect pistons for nicks, scoring, cracks or damage in ring
areas. Connecting rod should be checked for cracks using Magnaflux
procedure. Piston diameter must be measured in manufacturers specified
area.
Using telescopic gauge and micrometer, measure piston pin
bore of piston in 2 areas, 90 degrees apart. This is done to check
diameter and out-of-round.
Install proper bearing cap on connecting rod. Ensure bearing
cap is installed in proper location. Tighten bolts or nuts to
specification. Using inside micrometer, measure inside diameter in 2
areas, 90 degrees apart.
Connecting rod I.D. and out-of-round must be within
specification. Measure piston pin bore I.D. and piston pin O.D. All
components must be within specification. Subtract piston pin diameter
from piston pin bore in piston and connecting rod to determine proper
fit.
Connecting rod length must be measured from center of
crankshaft journal inside diameter to center of piston pin bushing
using proper caliper. Connecting rods must be the same length.
Connecting rods should be checked on an alignment fixture for bent or
twisted condition. Replace all components which are damaged or not
within specification.
PISTON & CYLINDER BORE FIT

Ensure cylinder is checked for taper, out-of-round and
properly honed prior to checking piston and cylinder bore fit. See
CYLINDER BLOCK in this article. Using dial bore gauge, measure
cylinder bore. Measure piston at right angle to piston pin in center
of piston skirt area. Subtract piston diameter from cylinder bore
diameter. The difference is piston-to-cylinder clearance. Clearance
must be within specification. Mark piston for proper cylinder
location.
ASSEMBLING PISTON & CONNECTING ROD
Install proper fitted piston on connecting rod for proper
cylinder. Ensure piston marking on top of piston marked is in
correspondence with connecting rod and cap number. See Fig. 14.
Fig. 14: Piston Pin Installation - Typical
This Graphic For General Information Only
Lubricate piston pin and install in connecting rod. Ensure
piston pin retainers are fully seated (if equipped). On pressed type
piston pins, follow manufacturer's recommended procedure to avoid
distortion or breakage.
CHECKING PISTON RING CLEARANCES

Piston rings must be checked for side clearance and end gap.
To check end gap, install piston ring in cylinder which it is to be
installed. Using an inverted piston, push ring to bottom of cylinder
in smallest cylinder diameter.
Using feeler gauge, check ring end gap. See Fig. 15. Piston
ring end gap must be within specification. Ring breakage will occur
with insufficient ring end gap.
On some manufacturers, insufficient ring end gap may be
corrected by using a fine file while other manufacturers recommend
using another ring set. Mark rings for proper cylinder installation
after checking end gap.
Fig. 15: Checking Piston Ring End Gap - Typical
This Graphic For General Information Only
For checking side clearance, install rings on piston. Using
feeler gauge, measure clearance between piston ring and piston ring
land. Check side clearance in several areas around piston. Side
clearance must be within specification.
If side clearance is excessive, piston ring grooves can be
machined to accept oversized piston rings (if available). Normal
practice is to replace piston.

damaged.
Pump cover wear is measured using a straightedge and feeler
gauge. Pump is to be replaced if warpage or wear exceeds
specifications or mating surface of pump cover is scratched or
grooved.
Fig. 33: Measuring Oil Pump Gear Cavity - Typical
This Graphic For General Information Only
BREAK-IN-PROCEDURE
* PLEASE READ THIS FIRST *
NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
ENGINE PRE-OILING
Engine pre-oiling should be done prior to operation to
prevent engine damage. A lightly oiled pump will cavitate unless oil
pump cavities are filled with engine oil or petroleum jelly.

Engine pre-oiling can be done using pressure oiler (if
available). Connect pressure oiler to cylinder block oil passage
such as oil pressure sending unit. Operate pressure oiler long enough
to ensure correct amount of oil has filled crankcase. Check oil level
while pre-oiling.
If pressure oiler is not available, disconnect ignition
system. Remove oil pressure sending unit and replace with oil pressure
test gauge. Using starter motor, rotate engine starter until gauge
shows normal oil pressure for several seconds. DO NOT crank engine
for more than 30 seconds to avoid starter motor damage.
Ensure oil pressure has reached the most distant point from
the oil pump. Reinstall oil pressure sending unit. Reconnect ignition
system.
INITIAL START-UP
Start the engine and operate engine at low speed while
checking for coolant, fuel and oil leaks. Stop engine. Recheck coolant
and oil level. Adjust if necessary.
CAMSHAFT
Break-in procedure is required when a new or reground
camshaft has been installed. Operate and maintain engine speed between
1500-2500 RPM for approximately 30 minutes. Procedure may vary due to
manufacturers recommendations.
PISTON RINGS
Piston rings require a break-in procedure to ensure seating
of rings to cylinder walls. Serious damage may occur to rings if
correct procedures are not followed.
Extremely high piston ring temperatures are produced obtained
during break-in process. If rings are exposed to excessively high RPM
or high cylinder pressures, ring damage can occur. Follow piston ring
manufacturer's recommended break-in procedure.
FINAL ADJUSTMENTS
Check or adjust ignition timing and dwell (if applicable).
Adjust valves (if necessary). Adjust carburetion or injection idle
speed and mixture. Retighten cylinder heads (if required). If
cylinder head or block is aluminum, retighten bolts when engine is
cold. Follow the engine manufacturer's recommended break-in procedure
and maintenance schedule for new engines.
NOTE: Some manufacturer's require that head bolts be retightened
after specified amount of operation. This must be done to
prevent head gasket failure.

loose .................. A ... Require repair or replacement
of injection tube or
replacement of catalytic
converter.
Air injection tube
restricted ............. A ... Require repair or replacement
of injection tube or
replacement of catalytic
converter.
Air injection tube
threads damaged ........ A ... Require repair or replacement
of injection tube or
replacement of catalytic
converter.
Air injection tube
threads stripped
(threads missing) ...... A ... Require repair or replacement
of injection tube or
replacement of catalytic
converter.
Body cracked ............ B .. Require repair or replacement.
Converter empty ......... A .. Require repair or replacement.
Converter fill plug
missing ................ C .. Require repair or replacement.
Converter missing ....... C ............ Require replacement.
Exhaust gases leaking ... A .. Require repair or replacement.
Flanges leaking ......... A ... Require repair or replacement
of flanges.
Inlet pipes cracked ..... B .. Require repair or replacement.
Internal rattle (except
pellet-type) ........... 2 .......... (1) Further inspection
required.
Mounting brackets that
are part of converter
broken ................. A .. Require repair or replacement.
Obvious overheating ..... .. ......... ( 2) Require testing of
converter.
Outlet pipes cracked .... B .. Require repair or replacement.
Pieces of catalyst
material found
downstream ............. 1 ............ Suggest replacement.
Plugged ................. A ........ ( 3) Require replacement.
Testing has determined
that existing converter
has been lead-poisoned,
contaminated, or failed
testing ................ A .. Require repair or replacement.
( 1) - If the converter is breaking up, suggest converter
replacement. If an object has fallen into the converter,
remove the object.
( 2) - Overheating is caused by something other than the
converter. Further diagnosis is required to determine
the cause of the overheating.
( 3) - Determine cause and correct to ensure that new converter
will not become plugged.









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EXHAUST AND TAIL PIPES
NOTE: For pipes with resonators, also see MUFFLERS AND RESONATORS.
EXHAUST AND TAIL PIPE INSPECTION

FR O NT S A FE TY B ELT B UCKLE R ELE A SE B UTTO N C AN B REA K
1991 M it s u bis h i M onte ro
NHTSA RECALL BULLETIN
Model(s): 1986 Mitsubishi Cordia
1986 Mitsubishi Galant
1986 Mitsubishi Mirage
1986 Mitsubishi Montero
1986 Mitsubishi Pickup
1986 Mitsubishi Starion
1987 Mitsubishi Cordia
1987 Mitsubishi Galant
1987 Mitsubishi Mirage
1987 Mitsubishi Montero
1987 Mitsubishi Pickup
1987 Mitsubishi Van/Wagon
1988 Mitsubishi Cordia
1988 Mitsubishi Galant
1988 Mitsubishi Mirage
1988 Mitsubishi Montero
1988 Mitsubishi Pickup
1988 Mitsubishi Van/Wagon
1989 Mitsubishi Galant
1989 Mitsubishi Mirage
1989 Mitsubishi Montero
1989 Mitsubishi Pickup
1989 Mitsubishi Sigma
1989 Mitsubishi Van/Wagon
1990 Mitsubishi Eclipse
1990 Mitsubishi Mirage
1990 Mitsubishi Montero
1990 Mitsubishi Pickup
1990 Mitsubishi Sigma
1990 Mitsubishi Van/Wagon
1991 Mitsubishi 3000GT
1991 Mitsubishi Eclipse
1991 Mitsubishi Mirage
1991 Mitsubishi Montero
1991 Mitsubishi Pickup
Campaign No: 95V103004
Number of Affected Vehicles: 658000
Beginning Date of Manufacture: 1985 APR
Ending Date of Manufacture: 1991 JUL
VEHICLE DESCRIPTION:
Passenger vehicles and light duty trucks and vans equipped with safety
belts made by Takata Corporation.
SYSTEM:
Seat belts; belt buckles.
FAULT:
Fastener, Thread failure.
DESCRIPTION OF DEFECT:
The front safety belt buckle release buttons can break. These red
plastic release buttons are marked "PRESS." If a button breaks,
pieces can fall into the buckle assembly causing the buckle to operate