MITSUBISHI MONTERO 1991 Service Manual

Maximum Refinish Diameter ..................... 10.1 (257)
Wheel Cylinder Diameter
Montero ................................... .875 (22.22)
Pickup & Ram-50
2WD ..................................... .937 (23.80)
4WD ..................................... .875 (22.22)
Discard Diameter ........................... 10.12 (257.0)
(1) - Information is not available.









\









\









\









\









\









\






TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLE








\









\









\









\









\









\






Application Ft. Lbs. (N.m)
Caliper Guide or Lock Pin Bolt
Guide Pin Bolt ........................... 29-36 (40-49)
Lock Pin Bolt ............................ 23-30 (31-41)
Caliper Mounting Bolts ..................... 58-72 (79-98)
Front Wheel Bearing Nut .............................. ( 1)
Rotor-To-Hub Bolts Or Nuts
Pickup (2WD) ............................ 34-38 (46-52)
All Others ............................... 36-43 (49-58)
INCH Lbs. (N.m)
Master Cylinder-To-Power Brake Unit Nut .... 72-108 (8-12)
( 1) - See FRONT BRAKE ROTOR under REMOVAL & INSTALLATION.









\









\









\









\









\









\

CO M PU TE R R ELE A R N P R O CED URES

1991 M it s u bis h i M onte ro
GENERAL INFORMATION
Computer Relearn Procedures
All Models
* PLEASE READ THIS FIRST *
The following general procedures are to be used if
driveability problems are encountered after power loss or battery has
been disconnected. These procedures may provide an aid in eliminating
these problems.
To reduce the possibility of complaints, after any service
which requires battery power to be disconnected, vehicle should be
road tested.
COMPUTER RELEARN PROCEDURES
Vehicles equipped with engine or transmission computers may
require a relearn procedure after vehicle battery is disconnected.
Many vehicle computers memorize and store vehicle operation patterns
for optimum driveability and performance. When vehicle battery is
disconnected, this memory is lost. The computer will use default data
until new data from each key start is stored. As computer memorizes
vehicle operation for each new key start, driveability is restored.
Vehicle computers may memorize vehicles operation patterns for 40 of
more key starts.
Customers often complain of driveability problems during
relearn stage because vehicle acts differently then before being
serviced. Depending on type and make of vehicle and how it is
equipped, the following complaints (driveability problems) may exist:
* Harsh Or Poor Shift Quality
* Rough Or Unstable Idle
* Hesitation Or Stumble
* Rich Or Lean Running
* Poor Fuel Mileage
These symptoms and complaints should disappear after a number
of drive cycles have been memorized. To reduce the possibility of
complaints, after any service which requires battery power to be
disconnected, vehicle should be road tested. If a specific relearn
procedure is not available, the following procedure may be used:
Automatic Transmission
* Set parking brake, start engine in "P" or "N" position.
Warm-up vehicle to normal operating temperature or until
cooling fan cycles.
* Allow vehicle to idle for one minute in "N" position. Select
"D" and allow engine to idle for one minute.
* Accelerate at normal throttle position (20-50%) until vehicle
shifts into top gear.
* Cruise at light to medium throttle.
* Decelerate to a stop, allowing vehicle to downshift, and use
brakes normally.
* Process may be repeated as necessary.
Manual Transmission

* Place transmission in Neutral position.
* Ensure emergency brake has been set and all accessories
are turned off.
* Start engine and bring to normal operating temperature.
* Allow vehicle to idle in Neutral for one minute.
* Initial relearn is complete: process will be completed during
normal driving.
Some manufacturers identify a specific relearn procedure
which will help establish suitable driveability during relearn stage.
These procedures are especially important if vehicle is equipped with
and electronically controlled automatic transmission or transaxle.
Always complete procedure before returning vehicle to customer.

CO OLIN G S YSTE M S PEC IF IC ATIO NS

1991 M it s u bis h i M onte ro
1991 ENGINE COOLING
Mitsubishi Cooling System Specifications
Mitsubishi: Eclipse, Galant, Mirage,
Montero, Pickup, Precis, 3000GT
COOLING SYSTEM SPECIFICATIONS
COOLING SYSTEM SPECIFICATIONS TABLE








\









\









\









\









\









\









\







Application Specification
Coolant Replacement Interval ............. 30,000 Miles or 24 Months
Coolant Capacity
(Includes Heater & Reserve Tank)
Eclipse
1.8L .......................................... 6.6 qts. (6.2L)\
2.0L .......................................... 7.6 qts. (7.2L)\
Galant .......................................... 7.6 qts. (7.2L)\
Montero ........................................ 10.0 qts. (9.5L)\
Pickup
2WD
Automatic Transmission ....................... 6.4 qts. (6.1L)\
Manual Transmission .......................... 6.3 qts. (6.0L)\
4WD ........................................... 8.9 qts. (8.4L)\
Precis .......................................... 5.6 qts. (5.3L)\
3000GT .......................................... 8.8 qts. (8.3L)\
Pressure Cap ............................................. 11-15 psi
Thermostat Opens
Except 3000GT
Starts ............................................. 190
F (88C)
Fully Open ........................................ 212F (100C)
3000GT
Starts ............................................. 170
F (77C)
Fully Open ......................................... 190F (88C)








\









\









\









\









\









\









\

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.

Fig. 7: 1991 Self-Diagnostic Code Chart
Courtesy of Mitsubishi Motor Co.
Fig. 8: 1992 Self-Diagnostic Code Chart
Courtesy of Mitsubishi Motor Co.
SYSTEM INPUT TESTS
1991
1) System input tests should be performed if no trouble codes
are stored when performing SELF-DIAGNOSTICS.