MITSUBISHI MONTERO 1991 Service Manual

Application Terminals Ohms
Montero ............... No. 1 & 2 ......... 55
Pickup & Ram-50 ........ 7V & TU ....... 49-61









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VOLTMETER
Resistance Test (Montero)
Using an ohmmeter, measure resistance between voltmeter
terminals. See Fig. 9. Resistance should be 380-460 ohms.
Fig. 9: Identifying Voltmeter Resistance Test Terminals (Montero)
Courtesy of Mitsubishi Motor Sales of America.
Voltage Test (Pickup & Ram-50)
Using a voltmeter, connect positive lead to terminal No. 7 of
fuse box, and ground negative terminal. Crank engine and compare
readings of vehicle voltmeter to testing voltmeter. Voltage variation
should not exceed 0.5 volt (plus or minus). Replace voltmeter if
voltage reading is not as specified.
REMOVAL & INSTALLATION
INSTRUMENT CLUSTER
Removal & Installation (Montero)
1) Remove instrument cluster cover. Remove screws from bottom
of instrument cluster. Remove bolt from upper part of cluster.
2) Disconnect speedometer cable from back of instrument
cluster by pushing stopper of plug on speedometer cable side of
connection. Pull cluster out part way. Disconnect all connectors
attaching cluster. Remove cluster. See Fig. 10. To install, reverse
removal procedure.

Fig. 10: Identifying Instrument Cluster Components (Montero)
Courtesy of Mitsubishi Motor Sales of America.
Removal & Installation (Pickup & Ram-50)
1) Disconnect negative battery cable. Remove heater fan

switch knob, heater control knobs and radio knobs. Remove instrument
cluster bezel. Remove mounting screws from 4 corners of cluster.
2) Disconnect speedometer cable and connectors from back of
cluster. Remove cluster assembly. See Fig. 11 or Fig. 12. To install,
reverse removal procedure.
Fig. 11: Instrument Cluster Component ID (Pickup & Ram-50 W/Tach)
Courtesy of Mitsubishi Motor Sales of America.
Fig. 12: Instrument Cluster Component ID (Pickup & Ram-50 W/O Tach)
Courtesy of Mitsubishi Motor Sales of America.
SPEEDOMETER CABLE

NOTE: When routing speedometer cable, DO NOT bend cable sharply.
Minimum bending radius is 6" (150 mm). Speedometer cable
length varies with transmission type.
Removal
Disconnect speedometer cable from transmission or transaxle.
Remove instrument cluster from instrument panel. See
INSTRUMENT CLUSTER under REMOVAL & INSTALLATION. Disconnect
speedometer cable from instrument cluster and/or adapter (if
equipped). Remove speedometer cable from firewall grommet.
Installation
Install new cable. Insert cable until stopper seats properly
in groove on rear of speedometer housing. Pull speedometer cable
through firewall grommet until cable marking is visible from engine
compartment. Install adapter onto speedometer cable (if equipped).
Install instrument cluster. See INSTRUMENT CLUSTER under REMOVAL &
INSTALLATION. Install cable onto transmission or transaxle. Check for
proper operation.
NOTE: An improperly installed cable can cause fluctuating meter,
noise or damaged harness inside instrument panel.
WIRING DIAGRAMS
See appropriate chassis wiring diagram in the WIRING DIAGRAMS
Section.

IN TE R FE R EN CE V ER IF IC ATIO N C HEC K F O R O HC E N G IN E
1991 Mitsubishi Montero
Maintenance & Service Information
1983-96 Mitsubishi - Timing Belt Information
Cordia, Diamante, Eclipse, Expo, Expo LRV, Galant, Mirage,
Montero, Pickup, Precis, Sigma, Tredia, Van, 3000GT
TIMING BELT INTERFERENCE VERIFICATION INFORMATION
TIMING BELT INTERFERENCE CAUTION
NOTE: CAMSHAFT DRIVE BELTS OR TIMING BELTS - The condition of
camshaft drive belts should always be checked on vehicles
which have more than 50,000 miles. Although some
manufacturers do not recommend replacement at a specified
mileage, others require it at 60,000-100,000 miles. A
camshaft drive belt failure may cause extensive damage to
internal engine components on most engines, although some
designs do not allow piston-to-valve contact. These designs
are often called "Free Wheeling". Many manufacturers changed
their maintenance and warranty schedules in the mid-1980's to
reflect timing belt inspection and/or replacement at
50,000-60,000 miles. Most service interval schedules shown in
this section reflect these changes. Belts or components
should be inspected and replaced if any of the following
conditions exist:
* Crack Or Tears In Belt Surface
* Missing, Damaged, Cracked Or Rounded Teeth
* Oil Contamination
* Damaged Or Faulty Tensioners
* Incorrect Tension Adjustment
TIMING BELT INTERFERENCE CHECK MENU
TIMING BELT INTERFERENCE VERIFICATION TABLE ( 1)








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Replacement Interval
Application Engine (Miles)
Passenger Cars
Cordia
1983-88 .......... 1.8L 4-Cyl. ............ ( 4) 60,000
2.0L 4-Cyl. ............ ( 4) 60,000
Diamante
1992-96 ...... ( 2) 3.0L V6 (DOHC) ............. 60,000
3.0L V6 (SOHC) ........... ( 4) 60,000
Eclipse
1990-94 .......... 1.8L 4-Cyl. ............ ( 4) 60,000
1990-95 ....... ( 2) 2.0L 4-Cyl. ........... ( 4) 60,000
1990-94 ... ( 2) 2.0L 4-Cyl. Non-Turbo ..... ( 4) 60,000
1990-96 ..... ( 2) 2.0L 4-Cyl. Turbo ....... ( 4) 60,000
1996 ........... ( 2) 2.4L 4-Cyl. .......... ( 4) 60,000
Expo
1992-95 .......... 1.8L 4-Cyl. ................ 60,000
( 2) 2.4L 4-Cyl. .......... ( 4) 60,000
Expo LRV
1995 ............. 1.8L 4-Cyl. ................ 60,000
( 2) 2.4L 4-Cyl. .......... ( 4) 60,000
Galant

1985-87 ........ (2) 2.4L 4-Cyl. .......... ( 4) 60,000
1988 ............... 3.0L V6 .............. ( 3) 60,000
1989-93 .... ( 2) 2.0L 4-Cyl. (DOHC) ....... ( 4) 60,000
2.0L 4-Cyl. (SOHC) ........ ( 4) 60,000
1994-96 .... ( 2) 2.4L 4-Cyl. (DOHC) ....... ( 4) 60,000
2.4L 4-Cyl. (SOHC) ........ ( 4) 60,000
Mirage
1985-96 ........ ( 2) 1.5L 4-Cyl. .............. 60,000
1985-88 ..... ( 2) 1.6L 4-Cyl. Turbo ........... 60,000
1989, 1991 ..... ( 2) 1.6L 4-Cyl. .............. 60,000
1993-96 ........... 1.8L 4-Cyl ................ 60,000
Precis
1987-93 ........ ( 2) 1.5L 4-Cyl. .............. 60,000
Sigma
1989-90 ............ 3.0L V6 .............. ( 3) 60,000
Tredia
1983-88 .......... 1.8L 4-Cyl. ............ ( 4) 60,000
2.0L 4-Cyl. ............ ( 4) 60,000
3000GT
1991-96 .......... ( 2) 3.0L V6 ................ 60,000
Light Trucks
Montero
1985-96 ............ 3.0L V6 .............. ( 3) 60,000
1994-96 ............ 3.5L V6 .............. ( 3) 60,000
Pickup
1983-89 ........... 2.0L 4-Cyl. ........... ( 3) 60,000
1983-86 ... ( 2) 2.3L 4-Cyl. Turbo Diesel .. ( 4) 60,000
1990-96 ........... 2.4L 4-Cyl. ........... ( 4) 60,000
3.0L V6 .............. ( 3) 60,000
Van
1987-90 ........... 2.4L 4-Cyl. ........... ( 4) 60,000
( 1) - Other interference engine applications may exist which
are not indicated here.
( 2) - Interference engine. Check for possible damage to
piston(s) or valve(s) if there has been a timing belt
failure.
( 3) - Although the vehicle manufacturer does not recommend a
specific scheduled maintenance interval, aftermarket
belt manufacturers suggest the belt be replaced at
60,000 mile intervals.
( 4) - Vehicle manufacturer recommends replacing all belts at
the same time.









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JA C KIN G & H O IS TIN G

1991 M it s u bis h i M onte ro
1991 WHEEL ALIGNMENT
Jacking & Hoisting
Chrysler Motors: Ram-50
Mitsubishi: Montero, Pickup
JACKING & HOISTING
NOTE: The following illustrations DO NOT represent the exact
structure of vehicle's frame, underbody or body outline.
Illustrations are given to provide reference points for the
mechanic.
FRAME & UNDERBODY
The following illustrations indicate points for jacking and
hoisting vehicle. These points are indicated by shaded areas on the
frame and underbody. See Fig. 1.
OUTERBODY
Points on the outline of body were designated to be used
specifically with vehicle's own jack. See Fig. 2. If floor jack or
hoist is used at these points, use extreme care to avoid damaging
outer body shell. See Fig. 2 or 3.
Fig. 1: Jacking & Hoisting Points (Typical)

Fig. 2: Jacking & Hoisting Points (Montero)
Courtesy of Mitsubishi Motor Sales of America.
Fig. 3: Jacking & Hoisting Points (Pickup & Ram-50)
Courtesy of Mitsubishi Motor Sales of America.

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L - W IR IN G D IA G RAM S

1991 M it s u bis h i M onte ro
1991 ENGINE PERFORMANCE
Wiring Diagrams
Chrysler Motors: Colt, Colt 200, Colt Vista,
Ram-50, Stealth, Summit,
Mitsubishi: Eclipse, Galant, Mirage, Montero,
Pickup, 3000GT
Fig. 1: Wiring Diagram (Colt, Colt 200, Mirage & Summit 1.5L)

Fig. 2: Wiring Diagram (Colt Vista 2.0L)