belt MITSUBISHI MONTERO 1991 Workshop Manual

AIR PLENUM INSPECTION








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Condition Code Procedure
Integrated air or fuel
control components
inoperative ............ A ........... (1) Require repair or
replacement.
Internal air or fuel
components damaged,
affecting performance .. A ... Require repair or replacement
of component.
Internal air or fuel
components damaged, not
affecting performance .. .. ........ No service suggested or
required.
Internal air or fuel
components missing ..... C .......... Require replacement of
component.
Leaking ................. A .. Require repair or replacement.
Restricted .............. A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A .. Require repair or replacement.
( 1) - Inoperative includes intermittent operation or out of
OEM specification.









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AIR PUMP BELTS
AIR PUMP BELT INSPECTION








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Condition Code Procedure
Alignment incorrect ..... B .......... ( 1) Further inspection
required.
Cracked ................. 1 ............ Suggest replacement.
Frayed .................. 1 ............ Suggest replacement.
Maintenance intervals ... 3 ... Suggest replacement to comply
with vehicle OEM recommended
service intervals.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .......... ( 2) Further inspection
required.
Plies separated ......... A ............ Require replacement.
Tension out of
specification .......... B ........... Require adjustment or
replacement.
Worn beyond adjustment
range .................. B ............ Require replacement.
Worn so it contacts bottom
of pulley .............. A ............ Require replacement.
( 1) - Determine cause of incorrect alignment and require repair.
( 2) - Determine cause of noise and suggest repair.









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AIR PUMPS (ELECTRIC-DRIVEN)
AIR PUMP (ELECTRIC-DRIVEN) INSPECTION








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BATTERY TRAY AND HOLD DOWN HARDWARE INSPECTION








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Condition Code Procedure
Battery improperly
secured ................ 2 ................. Suggest repair.
Bent, affecting
performance ............ A .. Require repair or replacement.
Bent, not affecting
performance ............ .. ....... No service suggested or
required.
Broken, affecting
performance ............ A .. Require repair or replacement.
Broken, not affecting
performance ............ .. ....... No service suggested or
required.
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.
Missing ................. C ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Water drain clogged ..... A ................. Require repair.









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BATTERY WIRES
See BATTERY CABLES, WIRES AND CONNECTORS .
BELT-DRIVEN AIR PUMPS
BELT-DRIVEN AIR PUMP 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.
Inoperative ............. A ........ ( 1) Require replacement.
Leaking ................. A ............ Require replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 ............ Suggest replacement.
Pulley alignment
incorrect .............. B .. Require repair or replacement.
Pulley bent ............. A ............ Require replacement.
Pulley cracked .......... A ............ Require replacement.
Pulley loose ............ A .. Require repair or replacement.
Pulley missing .......... C ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads

missing) ............... A .. Require repair or replacement.
(1) - Inoperative includes intermittent operation or out of
OEM specification.









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BELT IDLER ASSEMBLIES (ACCESSORY AND CAM BELTS)
BELT IDLER ASSEMBLY (ACCESSORY AND CAM BELT) INSPECTION








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Condition Code Procedure
Alignment 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.
Bearings worn ........... 1 ............ Suggest replacement.
Cracked ................. 2 ............ Suggest replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 ............ Suggest replacement.
Seized .................. A .. Require repair or replacement.









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BELT TENSIONERS (ACCESSORY AND CAM BELTS)
BELT TENSIONER (ACCESSORY AND CAM BELT) INSPECTION








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Condition Code Procedure
Alignment 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.
Bearings worn ........... 1 ............ Suggest replacement.
Belt tension incorrect .. B ... Require adjustment or repair.
Cracked ................. 2 ............ Suggest replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 ............ Suggest replacement.
Pulley damaged, affecting
belt life .............. A ............ Require replacement.
Seized .................. A .. Require repair or replacement.









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BOOST CONTROL MECHANISMS
See WASTE GATES AND BOOST CONTROL MECHANISMS .
CAMSHAFT POSITION SENSORS
CAMSHAFT POSITION SENSOR INSPECTION

Threads stripped (threads
missing) ............... A ............ Require 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. Some components may be serviceable;
check for accepted cleaning procedure.









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TIMING BELT SPROCKETS
TIMING BELT SPROCKET INSPECTION








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Condition Code Procedure
Alignment incorrect ..... B ................. Require repair.
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.
Bent .................... A ............ Require replacement.
Cracked ................. A ............ Require replacement.
Key damaged ............. A ............ Require replacement.
Loose ................... A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Pulley damaged, affecting
belt life .............. A ............ Require replacement.
Sprocket damaged,
affecting belt life .... A .. Require repair or replacement.
Sprocket loose .......... B .. Require repair or replacement.
Sprocket-to-shaft
alignment incorrect ..... B .. Require repair or replacement.









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TIMING BELTS
TIMING BELT INSPECTION








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Condition Code Procedure
Adjustment incorrect .... 2 ......... ( 1) Suggest adjustment.
Alignment incorrect ..... B ........... ( 2) Further inspection
required.
Broken .................. A ............ Require replacement.
Cam timing out of
specification .......... B ................. Require repair.
Cracked ................. 1 ............ Suggest replacement.
Fluid-soaked ............ 1 ... Suggest replacement. Further
inspection required.
Frayed .................. 1 ............ Suggest replacement.
Maintenance intervals ... 3 ... Suggest replacement to comply
with vehicle OEM recommended

service intervals.
Missing ................. C ........ (3) Require replacement.
Noisy ................... 2 .......... ( 4) Further inspection
required.
See note below.
Plies separated ......... A ............ Require replacement.
Tension out of
specification .......... B ........... Require adjustment or
replacement.
Teeth missing ........... A ............ Require replacement.
( 1) - Inspect belt tensioners, pulleys, and cover.
( 2) - Determine cause of incorrect alignment and require repair.
( 3) - CAUTION: Internal engine damage may result from timing
belt damage/failure.
( 4) - Determine cause of noise and suggest repair.









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TORQUE STRUTS
TORQUE STRUT 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.
Binding ................. A ............ Require replacement.
Body dented ............. A .......... ( 1) Further inspection
required.
Body punctured .......... A ............ Require replacement.
Bushing deteriorated,
affecting performance .. A ............ Require replacement.
Bushing deteriorated, not
affecting performance .. .. ........ No service suggested or
required.
Bushings missing ........ C ............ Require replacement.
Bushings separated from
mounting eye ........... 1 ............ Suggest replacement.
Damping (none) .......... A ............ Require replacement.
Leaking oil, enough for
fluid to be running down
the body ............... A ............ Require replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .......... ( 2) Further inspection
required.
Piston rod bent ......... A ............ Require replacement.
Piston rod broken ....... A ............ Require replacement.
Seized .................. A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Require replacement of units where dents restrict strut
piston rod movement. If dents don't restrict movement, no
service is suggested or required.
( 2) - If noise is isolated to shock or strut, suggest replacement.

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

improperly.
CONSEQUENCE OF DEFECT:
The safety belts would not provide adequate protection to an occupant
in a vehicle crash.
CORRECTIVE ACTION:
Owners should promptly check the condition and operation of both front
safety belt buckles and carefully inspect the red release button for
any breaks or cracks. They should ensure that both buckles are
operating properly by inserting each latch plate into its buckle,
tugging on the belt to make sure the latch is securely locked, and
then pressing the release button. The latch plate should pop out of
the buckle when the button is pressed. If either release button shows
a sign of breaking or cracking or if either buckle fails to operate
properly, owners should promptly contact their authorized dealer to
schedule an appointment to have the buckle replaced or repaired, free
of charge. The manufacturer is developing a remedy designed to prevent
failure of the buttons that are not currently broken.
NOTE:
If your vehicle is presented to an authorized dealer on an agreed upon
service date and the remedy is not provided free of charge within a
reasonable time, please contact Mitsubishi at 1-800-222-0037. Also
contact the National Highway Traffic Safety Administration's Auto
Safety Hotline at 1-800-424-9393.
ADDITIONAL INFORMATION:
The National Highway Traffic Safety Administration operates Monday
through Friday from 8:00 AM to 4:00 PM, Eastern Time. For more
information call (800) 424-9393 or (202) 366-0123. For the hearing
impaired, call (800) 424-9153.

\00398V 311000: F R O NT S EA T B ELTS

1991 M it s u bis h i M onte ro
NHTSA RECALL BULLETIN
Model(s): 1986-88 Mitsubishi Cordia
1986-91 Mitsubishi Galant
1986-91 Mitsubishi Mirage
1986-91 Mitsubishi Montero
1986-91 Mitsubishi Pickup
1986 Mitsubishi Starion
1990-91 Mitsubishi Eclipse
1990 Mitsubishi Sigma
1991 Mitsubishi 3000GT
Campaign No: 98V311000
Number of Affected Vehicles: 53162
VEHICLE DESCRIPTION:
Passenger vehicles sold in the Caribbean.
DESCRIPTION OF DEFECT:
In the front passenger seat of these vehicles, which are equipped with
Takata belt buckles, the seat belt release buttons, which are made of
ABS plastic material and marked "press," can break, allowing pieces to
fall into the buckle assembly.
CONSEQUENCE OF DEFECT:
If pieces fall into the buckle assembly, the buckle may not operate
properly, failing to properly restrain an occupant in the event of a
crash.
CORRECTIVE ACTION:
Dealers will repair the front seat belt buckles.
OWNER NOTIFICATION:
Owner notification is expected to begin during early January 1999.
Owners who take their vehicles to an authorized dealer on an agreed
upon service date and do not receive the free remedy within a
reasonable time should contact Mitsubishi Of Caribbean at 1-787-251-
8716. Also contact the National Highway Traffic Safety
Administration's Auto Safety Hotline at 1-888-dash-2-dot (1-888-327-
4236).
ADDITIONAL INFORMATION:
The National Highway Traffic Safety Administration operates Monday
through Friday from 8:00 AM to 4:00 PM, Eastern Time. For more
information call (800) 424-9393 or (202) 366-0123. For the hearing
impaired, call (800) 424-9153.

GEN ER AL C O OLIN G S YSTE M S ER VIC IN G

1991 M it s u bis h i M onte ro
GENERAL INFORMATION
General Cooling System Servicing
* PLEASE READ THIS FIRST *
The following article is for general information only.
Information may not apply to all years, makes and models. See specific
article in the ENGINE COOLING section.
DESCRIPTION
The basic liquid cooling system consists of a radiator, water
pump, thermostat, electric or belt-driven cooling fan, pressure cap,
heater, and various connecting hoses and cooling passages in the block
and cylinder head.
MAINTENANCE
DRAINING
Remove radiator cap and open heater control valve to maximum
heat position. Open drain cocks or remove plugs in bottom of radiator
and engine block. In-line engines usually have one plug or drain cock,
while "V" type engines will have 2, one in each bank of cylinders.
CLEANING
A good cleaning compound removes most rust and scale. Follow
manufacturer's instructions in the use of cleaner. If considerable
rust and scale has to be removed, cooling system should be flushed.
Clean radiator air passages with compressed air.
FLUSHING
CAUTION: Some manufacturers use an aluminum and plastic radiator.
Flushing solution must be compatible with aluminum.
Back Flushing
Back flushing is an effective means of removing cooling
system rust and scale. The radiator, engine and heater core should be
flushed separately.
Radiator
To flush radiator, connect flushing gun to water outlet of
radiator and disconnect water inlet hose. To prevent flooding engine,
use a hose connected to radiator inlet. Use air in short bursts to
prevent damage to radiator. Continue flushing until water runs clear.
Engine
To flush engine, remove thermostat and replace housing.
Connect flushing gun to water outlet of engine. Flush using short air
bursts until water runs clean.
Heater Core
Flush heater core as described for radiator. Ensure heater
control valve is set to maximum heat position before flushing heater.

Parking Brake Switch ...................... Analog Instrument Panels
Park Lights ........................................ Exterior Lights
Park/Neutral Position Switch .............................. Starters
Engine Performance
Anti-Theft System
Body Control Module
Perimeter Lighting Control Relay ................... Exterior Lights
Power Amplifier ..................................... Power Antennas
Power Antenna Module ................................ Power Antennas
Power Antenna Motor ................................. Power Antennas
Power Distribution Center ....................... Power Distribution
Generators & Regulators
Starters
Power Door Lock Motors ............................ Power Door Locks
Power Mirror Motors .................................. Power Mirrors
Memory Systems
Power Sliding Door Controller .............. Power Sliding Side Door
Power Seat Motors ...................................... Power Seats
Memory Systems
Power Steering Pressure Switch .................. Engine Performance
Power Top Motor .............................. Power Convertible Top
Power Top Relay(s) ........................... Power Convertible Top\
Powertrain Control Module ....................... Engine Performance
Analog Instrument Panels
Cruise Control Systems
Data Link Connectors
Generators & Regulators
Starters
Power Window Motors .................................. Power Windows
Power Window Relay(s) ................................ Power Windows\
Radiator Fan Motor(s) ........................ Electric Cooling Fans\
Radiator Fan Relay(s) ........................... Engine Performance\
Electric Cooling Fans
Rainsense Module .............................. Wiper/Washer Systems
Raise Relay .................................. Power Convertible Top
Remote Anti-Theft Personality (RAP) Module ....... Anti-Theft System\
Starters
Warning Systems
Seat Belt Pretensioners ................... Air Bag Restraint System
Seat Belt Retractor Solenoid .................... Passive Restraints
Seat Belt Switch .......................... Air Bag Restraint System
Passive Restraints
Shift Interlock Solenoid ................... Shift Interlock Systems
Shift Lock Actuator ........................ Shift Interlock Systems
Side Marker Lights ................................. Exterior Lights
SIR Coil Assembly (Clockspring) ........... Air Bag Restraint System\
Slip Ring (Clockspring) ................... Air Bag Restraint System\
Steering Column Switches
SRS Control Module ........................ Air Bag Restraint System
Starter Motor ............................................. Starters
Starter Interrupt Relay ................................... Starters
Starter Solenoid .......................................... Starters
Starter Relay ............................................. Starters
Steering Wheel Position Sensor .................... Anti-Lock Brakes
Stoplights ......................................... Exterior Lights
Stoplight Switch ................................ Engine Performance
Cruise Control Systems
Anti-Lock Brakes
Sun Roof ECU ........................................ Power Sun Roof
Sun Roof Motor ...................................... Power Sun Roof
Sun Roof Position Sensor ............................ Power Sun Roof
Taillights ......................................... Exterior Lights
Throttle Position (TP) Sensor ................... Engine Performance\