length MITSUBISHI MONTERO 1991 User Guide
Page 33 of 1333
OIL PRESSURE
Oil pressure should be at least 11.4 psi (.8 kg/cm) at idle
and engine oil temperature of 167-194F (75-90C).
OIL PUMP
Removal
Remove timing belt and crankshaft sprocket. See TIMING BELT
under REMOVAL & INSTALLATION. Remove oil pan. See OIL PAN under
REMOVAL & INSTALLATION. Remove oil filter and mounting bracket. Remove
oil pump and gasket from cylinder block. Note bolt length and location
for installation.
Disassembly & Inspection
1) Disassemble pump, and check for scoring and cracks.
Install rotors in pump body. Check clearance between driven rotor and
pump body. See OIL PUMP SPECIFICATIONS table. Place straightedge
across pump body to check rotor side clearance.
2) Check clearance between straightedge and both rotors.
Replace rotor set or pump assembly if not within specification. Ensure
relief valve slides freely in pump body bore. Inspect relief valve
spring for damage.
OIL PUMP SPECIFICATIONS TABLE
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Application In. (mm)
Driven Rotor-To-Pump Body ........ .0039-.0071 (.099-.180)
Rotor Side Clearance ............. .0016-.0037 (.041-.094)
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Reassembly & Installation
1) Reassemble pump. Tighten pump rear cover bolts to
specification. See appropriate TORQUE SPECIFICATIONS table in this
article. Install oil pump and gasket. Ensure splined teeth of oil pump
align with crankshaft. Install bolts, and tighten to specification.
2) If oil seal was removed, coat new seal with grease. Using
Seal Installer (MD998717), install seal in oil pump until flush with
case. Install remaining components.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLE (MONTERO & PICKUP) \
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Application Ft. Lbs. (N.m)
Air Intake Plenum Stay Bolts ............... 11-14 (15-19)
Camshaft Bearing Cap Bolt .................. 14-15 (19-20)
Camshaft Sprocket Bolt ..................... 58-72 (79-98)
Connecting Rod Nut ......................... 37-38 (50-52)
Crankshaft Pulley Bolt
Montero .............................. 108-116 (146-157)
Pickup ............................... 130-137 (176-186)
Cylinder Head Bolt ( 1)
Cold Engine .............................. 65-72 (88-98)
Drive Plate Bolt ........................... 53-55 (72-75)
Exhaust Manifold Nut ....................... 11-16 (15-22)
Flywheel Bolt .............................. 53-55 (72-75)
Intake Manifold Bolts ...................... 11-15 (15-20)
Left Engine Support Bracket Bolt ........... 15-21 (20-30)
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CRANKSHAFT, MAIN & CONNECTING
ROD BEARINGS SPECIFICATIONS
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS TABLE
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Application In. (mm)
Crankshaft
End Play
Standard ...................... .0020-.0098 (.050-.250)
Limit ...................................... .012 (.30)
Main Bearings
Journal Diameter ........................... 2.36 (59.9)
Journal Out-Of-Round
SOHC ..................................... .0002 (.005)
DOHC .................................... .00012 (.003)
Journal Taper ............................. .0002 (.005)
Oil Clearance
Standard
SOHC ........................ .0008-.0019 (.020-.048)
DOHC ........................ .0007-.0017 (.018-.043)
Limit ...................................... .004 (.10)
Connecting Rod Bearings
Journal Diameter ......................... 1.965 (49.91)
Journal Out-Of-Round
SOHC ..................................... .0002 (.005)
DOHC .................................... .00012 (.003)
Journal Taper ............................. .0002 (.005)
Oil Clearance
Standard ...................... .0006-.0018 (.015-.046)
Limit ...................................... .004 (.10)
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CONNECTING RODS SPECIFICATIONS
CONNECTING RODS TABLE \
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Application In. (mm)
Maximum Bend .................................. .002 (.05)
Maximum Twist (Total Rod Length) .............. .004 (.10)
Side Play
Standard ....................... .0039-.0099 (.099-.251)
Limit ....................................... .016 (.41)
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PISTONS, PINS & RINGS SPECIFICATIONS (SOHC)
PISTONS, PINS & RINGS TABLE (SOHC) \
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Application In. (mm)
Pistons
Clearance ...................... .0008-.0016 (.020-.040)
Diameter ................................. 3.587 (91.11)
Pins
Piston Fit ......................................... ( 1)
Rod Fit ............................................ ( 2)
Rings
No. 1
End Gap
Standard .................... .0118-.0177 (.300-.450)
Limit .................................... .031 (.79)
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VALVES & VALVE SPRINGS SPECIFICATIONS (SOHC)
VALVES & VALVE SPRINGS TABLE (SOHC) \
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Application Specification
Intake Valves
Face Angle ..................................... 45-45.5
Minimum Margin ........................... .028" (.71 mm)
Standard Length ...................... 4.055" (103.00 mm)
Stem Diameter ............. .3134-.3140" (7.960-7.976 mm)
Exhaust Valves
Face Angle ..................................... 45-45.5
Minimum Margin .......................... .059" (1.50 mm)
Standard Length ...................... 4.043" (102.70 mm)
Stem Diameter ............. .3122-.3130" (7.930-7.950 mm)
Valve Springs
Free Length
Standard ............................. 1.988" (50.50 mm)
Limit ................................ 1.949" (49.50 mm)
Installed Height ...................... 1.591" (40.41 mm)
Out-Of-Square
Standard ............................................ 2
Limit ............................................... 4
Lbs. @ In. (kg @ mm)
Pressure
Valve Closed ..................... 74@1.591 (33.6@40.41)
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VALVES & VALVE SPRINGS SPECIFICATIONS (DOHC)
VALVES & VALVE SPRINGS TABLE (DOHC) \
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Application Specification
Intake Valves
Face Angle ..................................... 45-45.5
Minimum Margin ........................... .019" (.48 mm)
Standard Length ...................... 4.185" (106.30 mm)
Stem Diameter ........................... .260" (6.60 mm)
Exhaust Valves
Face Angle ..................................... 45-45.5
Minimum Margin ........................... .039" (.99 mm)
Standard Length ...................... 4.150" (105.41 mm)
Stem Diameter ........................... .260" (6.60 mm)
Valve Springs
Free Length
Standard ............................. 1.846" (46.89 mm)
Limit ................................ 1.807" (45.90 mm)
Installed Height ...................... 1.492" (37.90 mm)
Out-Of-Square
Standard ............................................ 2
Limit ............................................... 4
Lbs. @ In. (kg @ mm)
Pressure
Valve Closed ..................... 62@1.492 (28.1@37.90)
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CYLINDER HEAD SPECIFICATIONS (SOHC)
CYLINDER HEAD TABLE (SOHC) \
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Application Specification
Cylinder Head Height ................... 3.307" (84.00 mm)
Maximum Warpage ........................... .008" (.20 mm)
Valve Seats (Intake & Exhaust)
Seat Angle ......................................... 45
Seat Width .................... .035-.051" (.90-1.30 mm)
Seat Bore Diameter ....... 1.732-1.742" (44.00-44.25 mm)
Valve Guides
Intake Valve
Valve Guide Cylinder Head
Bore I.D. ............. .5118-.5189" (13.00-13.18 mm)
Valve Guide Length ..................... 1.732" (44 mm)
Stem-To-Guide Clearance
Standard ................ .0012-.0024" (.030-.060 mm)
Limit ................................ .004" (.10 mm)
Exhaust Valve
Valve Guide Cylinder Head
Bore I.D. ............. .5118-.5189" (13.00-13.18 mm)
Valve Guide Length ..................... 1.890" (48 mm)
Stem-To-Guide Clearance
Standard ................ .0020-.0035" (.050-.090 mm)
Limit ................................ .006" (.15 mm)
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CYLINDER HEAD SPECIFICATIONS (DOHC)
CYLINDER HEAD TABLE (DOHC) \
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Application Specification
Cylinder Head Height .................... 5.20" (132.1 mm)
Maximum Warpage ........................... .008" (.20 mm)
Valve Seats (Intake & Exhaust)
Seat Angle ......................................... 45
Seat Width .................... .035-.051" (.90-1.30 mm)
Seat Bore Diameter ....... 1.417-1.427" (35.99-36.25 mm)
Valve Guides
Intake Valve
Valve Guide Cylinder Head
Bore I.D. ............. .5118-.5189" (13.00-13.18 mm)
Valve Guide
Installed Height ................... .689" (17.50 mm)
Stem-To-Guide Clearance
Standard ................ .0008-.0020" (.020-.051 mm)
Limit .............................. .0039" (.099 mm)
Exhaust Valve
Valve Guide Cylinder Head
Bore I.D. ............. .5118-.5189" (13.00-13.18 mm)
Valve Guide
Installed Height ................... .689" (17.50 mm)
Valve Stem-To-Guide
Clearance
Standard ............... .0020-.0035" (.051-.089 mm)
Limit ............................. .0047" (.119 mm)
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CAMSHAFT SPECIFICATIONS (SOHC)
Page 209 of 1333
length. If spring length is not 6.97-7.09 in. (177-180 mm), adjust
cable or support until correct length is obtained. See Fig. 1.
Fig. 1: Testing LSPV Spring Length (Pickup & Ram-50)
Courtesy of Mitsubishi Motor Sales of America.
MASTER CYLINDER PUSH ROD
Check and adjust clearance between back of master cylinder
piston and power brake push rod. See PUSH ROD CLEARANCE SPECIFICATIONS
table. See Fig. 2. After adjusting push rod clearance, adjust pedal
height, and bleed brake system.
Fig. 2: Adjusting Push Rod Clearance
Courtesy of Mitsubishi Motor Sales of America.
PUSH ROD CLEARANCE SPECIFICATIONS TABLE
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5) Remove the LSPV load-sensing spring. Slowly depress the
brake pedal. Check the readings on the pressure gauges. Refer to the
LSPV PRESSURE SPECIFICATIONS table.
6) Install LSPV load-sensing spring. Load weight into rear of
vehicle until measured spring length distance is 7.0" (178 mm) with
lever slightly pressed in. See Fig. 1.
7) Slowly depress brake pedal. Check readings on pressure
gauges. See LSPV PRESSURE SPECIFICATIONS table. If fluid pressure is
not within specification, ensure all other brake system components are
okay. If other components are okay, replace LSPV assembly.
LSPV PRESSURE SPECIFICATIONS (PICKUP & RAM-50)
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Application Inlet Pressure Outlet Pressure
psi (kg/cm) psi (kg/cm)
Load-Sensing Spring
Removed ........... 853 (60) ......... 242-327 (17-23)
Installed ........ 1991 (140) .... ( 1) 299-583 (21-40)
( 1) - On vehicles with 2WD and heavy-duty suspension,
outlet pressure is 526-697 psi (37-49 kg/cm
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PROPORTIONING VALVE (NON-LOAD-SENSING) (MONTERO)
Pressure Test
1) Connect pressure gauges to input and output ports of the
proportioning valve. See Fig. 5. Bleed brake hydraulic system. Refer
to BLEEDING BRAKE SYSTEM .
2) Slowly depress brake pedal. Check readings on pressure
gauges. See the PROPORTIONING VALVE PRESSURE SPECIFICATIONS table. If
fluid pressures are not within specification, replace proportioning
valve.
Fig. 5: Connecting Pressure Gauges to Proportioning Valve (Typical)
Courtesy of Mitsubishi Motor Sales of America.
PROPORTIONING VALVE PRESSURE SPECIFICATIONS (MONTERO)
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INNER SHAFT SPECIFICATIONS \
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Application In. (mm)
Shaft O.D.
Bearing Area ................ 1.38 (35.0)
Center Area ................. 1.24 (31.4)
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INSTALLATION
1) If oil seal replacement is necessary, install new oil seal
in differential carrier using Oil Seal Installer (MB990934-01) and
Handle (MB990938-01). Coat seal lips with grease. Install housing
tube. Using Seal Installer (MB990955) and Handle (C-4171), install n\
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dust seal in housing tube. Dust seal must be even with housing tube.
Coat seal lip with grease.
2) Using a pipe with O.D. of 2.95" (74.3 mm), wall thickness\
of .16" (4.0 mm) and with overall length of 1.97" (50.0 mm), install\
dust cover on shaft. Coat inside of dust cover with grease. Press
bearing on shaft. Install new circlip on inner shaft. Drive inner
shaft into differential. Use care not to damage oil seal.
DRIVE AXLES & BEARINGS OVERHAUL
NOTE: References to BJ refer to Birfield Joint and DOJ to Double
Offset Joint.
DISASSEMBLY
1) Remove boot bands. Remove circlip from DOJ outer race.
Separate drive axle from DOJ outer race. Remove balls from DOJ cage.
Remove DOJ cage from DOJ inner race in direction of BJ. See Fig. 2.
Fig. 2: Exploded View of Drive Axles
Courtesy of Chrysler Motors.
2) Remove snap ring from drive axle shaft. Remove DOJ inner
race from shaft. Remove circlip from shaft. Wrap tape around splines
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of shaft to prevent boot damage during removal.
3) Remove DOJ boot. Note size of boot. Remove dust cover from
shaft. Straighten BJ boot protector and remove protector band. Move
boot protector toward BJ side of shaft and remove. Remove BJ boot.
CAUTION: Drive axle and BJ are serviced as a unit. DO NOT
disassemble BJ and drive axle.
REASSEMBLY
1) Coat shaft with light coat of grease. Wrap splines with
tape. Install BJ boot, bands and DOJ boot on shaft. Ensure correct
size boot is installed in proper location.
2) Boot bands must be installed so lever is pulled toward
rear of vehicle when band is tightened. Pack proper amount of grease
in BJ and BJ boot. See GREASE APPLICATION table.
3) Place DOJ cage on shaft with smaller diameter installed
first. Install circlip, DOJ inner race, and snap ring on shaft. Apply
grease to DOJ inner race and cage. Install balls into cage.
4) Apply proper amount of grease to outer DOJ race. Install
shaft into DOJ outer race. Apply proper amount of grease to DOJ outer
race and install circlip. See GREASE APPLICATION table.
5) Place DOJ boot over DOJ outer race. Install boot bands so
lever is pulled toward rear of vehicle when band is tightened. Adjust
DOJ boot bands to have proper distance between centerline of boot
bands. See BOOT BAND SPECIFICATIONS table. This distance is necessary
to control air in DOJ boot. Tighten boot bands.
6) Install boot protector and band. Install dust cover on
shaft. Use a pipe with O.D. of 2.68" (68.0 mm), wall thickness of .09"\
(2.3 mm) and with overall length of 6.70" (170.1 mm) to install dust\
cover.
GREASE APPLICATION
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Application Ozs. (g)
BJ Boot
Montero
3.0L Engine .................. 4.6 (130)
All Others .................... 3.9 (110)
DOJ Outer Race
Montero
3.0L Engine ................... 2.3 (60)
All Others ..................... 1.9 (55)
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BOOT BAND SPECIFICATIONS \
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Application In. (mm)
All Models .......... 3.03-3.27 (76.9-83.0)
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DIFFERENTIAL DISASSEMBLY
1) Remove differential carrier from vehicle. See DIFFERENTIAL
CARRIER R & I in this article. Remove cover. Mark bearing caps for
reassembly reference. Remove bearing caps. Remove differential case
assembly from carrier.
CAUTION: Ensure adjusting spacers, bearing caps, gears and side
bearings are marked for reassembly reference. Components
Page 436 of 1333
NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
REMOVAL
Remove intake and exhaust manifolds and valve cover. Cylinder
head and camshaft carrier bolts (if equipped), should be removed only
when the engine is cold. On many aluminum cylinder heads, removal
while hot will cause cylinder head warpage. Mark rocker arm or
overhead cam components for location.
Remove rocker arm components or overhead cam components.
Components must be installed in original location. Individual design
rocker arms may utilize shafts, ball-type pedestal mounts or no rocker
arms. For all design types, wire components together and identify
according to the corresponding valve. Remove cylinder head bolts.
Note length and location. Some applications require cylinder head
bolts be removed in proper sequence to prevent cylinder head damage.
See Fig. 1 . Remove cylinder head.
Fig. 1: Typical Cylinder Head Tightening or Loosening Sequence
This Graphic For General Information Only
INSTALLATION
Ensure all surfaces and head bolts are clean. Check that head
bolt holes of cylinder block are clean and dry to prevent block damage
when bolts are tightened. Clean threads with tap to ensure accurate
bolt torque.
Install head gasket on cylinder block. Some manufacturer's
may recommend sealant be applied to head gasket prior to installation.
Note that all holes are aligned. Some gasket applications may be
marked so certain area faces upward. Install cylinder head using care
not to damage head gasket. Ensure cylinder head is fully seated on
cylinder block.
Some applications require head bolts be coated with sealant
prior to installation. This is done if head bolts are exposed to water
passages. Some applications require head bolts be coated with light
coat of engine oil.
Page 437 of 1333
Install head bolts. Head bolts should be tightened in proper
steps and sequence to specification. See Fig. 1. Install remaining
components. Tighten all bolts to specification. Adjust valves if
required. See VALVE ADJUSTMENT in this article.
NOTE: Some manufacturers require that head bolts be retightened
after specified amount of operation. This must be done to
prevent head gasket failure.
VALVE ADJUSTMENT
Engine specifications will indicate valve train clearance and
temperature at which adjustment is to be made on most models. In most
cases, adjustment will be made with a cold engine. In some cases, both
a cold and a hot clearance will be given for maintenance convenience.
On some models, adjustment is not required. Rocker arms are
tightened to specification and valve lash is automatically set. On
some models with push rod actuated valve train, adjustment is made at
push rod end of rocker arm while other models do not require
adjustment.
Clearance will be checked between tip of rocker arm and tip
of valve stem in proper sequence using a feeler gauge. Adjustment is
made by rotating adjusting screw until proper clearance is obtained.
Lock nut is then tightened. Engine will be rotated to obtain all valve
adjustments to manufacturer's specifications.
Some models require hydraulic lifter to be bled down and
clearance measured. Different length push rods can be used to obtain
proper clearance. Clearance will be checked between tip of rocker arm
and tip of valve stem in proper sequence using a feeler gauge.
On overhead cam engines designed without rocker arms actuate
valves directly on a cam follower. A hardened, removable disc is
installed between the cam lobe and lifter. Clearance will be checked
between cam heel and adjusting disc in proper sequence using a feeler
gauge. Engine will be rotated to obtain all valve adjustments.
On overhead cam engines designed with rocker arms, adjustment
is made at push rod end of rocker arm. Ensure that the valve to be
adjusted is riding on the heel of the cam on all engines. Clearance
will be checked between tip of rocker arm and tip of valve stem in
proper sequence using a feeler gauge. Adjustment is made by rotating
adjusting screw until proper clearance is obtained. Lock nut is then
tightened. Engine will be rotated to obtain all valve adjustments to
manufacturer's specifications.
CYLINDER HEAD OVERHAUL
* 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.
DISASSEMBLY
Mark valves for location. Using valve spring compressor,
compress valve springs. Remove valve locks. Carefully release spring
compressor. Remove retainer or rotator, valve spring, spring seat and
valve. See Fig. 2.