automatic transmission MITSUBISHI MONTERO 1991 Service Manual
Page 2 of 1333
* Wrap shop towels around fuel return and high pressure hoses
to prevent fuel splashing on engine. Disconnect fuel return
hose and high pressure fuel hose to drain any residual fuel.
ENGINE
Removal (Montero & Pickup)
1) Remove hood. Drain cooling system, and remove radiator.
Remove skid plate and splash shields. Release fuel system pressure.
See FUEL PRESSURE RELEASE under REMOVAL & INSTALLATION. Disconnect
negative battery cable.
2) Remove air cleaner ducts. Remove accessory drive belts.
Remove and support A/C compressor and power steering pump. DO NOT
disconnect hoses from compressor or pump. Disconnect oil cooler hoses.
Cover fuel hose using shop towel, and disconnect high pressure fuel
hose and "O" ring. Remove fuel return hose.
3) Label and disconnect all vacuum hoses. Disconnect cooling
system hoses. Label and disconnect all electrical connections from
engine. Remove heat shield from motor mounts. Remove motor mount
bolts. Ensure all hoses and wires are disconnected and set aside.
4) Disconnect exhaust pipe from exhaust manifolds. Remove
starter. Attach engine hoist to engine. Support transmission.
Disconnect engine from transmission. See appropriate article in
CLUTCHES or TRANSMISSION SERVICING. Remove engine.
Installation (Montero & Pickup)
To install, reverse removal procedure. Install new "O" ring
on fuel line. Install new exhaust gaskets and nuts. See TORQUE
SPECIFICATIONS (MONTERO & PICKUP) table at end of article. Adjust
fluid levels.
Removal (3000GT)
1) Release fuel pressure. See FUEL PRESSURE RELEASE under
REMOVAL & INSTALLATION. Remove hood. Remove cruise control vacuum pump
and linkage. On turbo models, remove necessary turbo air intake hoses
and pipes. On all other models, remove air cleaner hoses.
2) On all models, drain cooling system. Drain engine oil and
transaxle oil. Remove heater hoses and radiator hoses. Remove
transaxle assembly. See appropriate article in CLUTCHES or
TRANSMISSION SERVICING.
3) Remove radiator. Label and disconnect all vacuum hoses.
Label and disconnect all electrical connections and harnesses from
engine. Remove accessory drive belts.
4) Remove and support A/C compressor and power steering pump.
DO NOT disconnect hoses from compressor or pump. Cover fuel hose using
shop towel, and disconnect high pressure fuel hose and "O" ring.
Remove fuel return hose.
5) On turbo models, disconnect oil cooler and vacuum hoses.
On all models, remove motor mount bolts and brackets. Ensure all hoses
and wires are disconnected and set aside. Attach engine hoist to
engine. Remove engine.
Installation
To install, reverse removal procedure. Install new "O" ring
on fuel line. Install new exhaust gaskets and nuts. See TORQUE
SPECIFICATIONS (3000GT) table at end of article. Adjust fluid levels.
UPPER INTAKE MANIFOLD
Removal (Montero & Pickup)
1) Remove air intake hose. See Fig. 1. Remove accelerator
cable adjusting bolts. On models equipped with automatic transmission,
remove throttle control cable. On all models, remove accelerator
Page 34 of 1333
Main Bearing Cap Bolt ...................... 55-61 (75-83)
Oil Pick-Up Tube Bolt ...................... 11-15 (15-20)
Rear Engine Support
Bracket-To-Engine Bolt .................... 13-18 (18-25)
Relief Valve Plug .......................... 29-36 (39-49)
Right Engine Support Bracket Bolt
10x22 mm ................................. 25-36 (34-49)
12x22 mm & 12x32 mm ...................... 47-61 (64-83)
Rocker Shaft ............................... 14-15 (19-20)
Timing Belt Tensioner Bolt ................. 16-21 (22-29)
Water Pump Bolt ............................ 14-20 (19-27)
INCH Lbs. (N.m)
Delivery Pipe Bolt ......................... 84-108 (9-12)
Distributor Adapter Bolt .................. 108-132 (12-15)
Oil Filter Bracket Bolt .................. 108-120 (12-14)
Oil Pan Bolt ................................. 48-60 (5-7)
Oil Pump Cover Bolt ........................ 72-108 (8-12)
Oil Pump Mounting Bolt ................... 108-120 (12-14)
Rear Seal Case Bolt ........................ 84-108 (9-12)
Rocker Cover Bolt ............................ 72-84 (8-9)
Throttle Body Bolt ......................... 84-108 (9-12)
Timing Belt Cover Bolt ..................... 84-108 (9-12)
Transmission Mounting Plate Bolt ........... 84-108 (9-12)
( 1) - Tighten in 2 steps using proper sequence.
See Fig. 4.
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TORQUE SPECIFICATIONS TABLE (3000GT) \
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Application Ft. Lbs. (N.m)
Air Intake Plenum Stay Bolts ..................... 13 (18)
Automatic Tensioner Bolt ......................... 17 (23)
Camshaft Bearing Cap Bolt ........................ 15 (20)
Camshaft Sprocket Bolt ........................... 65 (88)
Connecting Rod Nut ............................... 38 (52)
Crankshaft Pulley Bolt
SOHC ................................. 108-116 (146-157)
DOHC ................................. 130-137 (176-186)
Cylinder Head Bolt ( 1)
SOHC ................................... 76-83 (103-113)
DOHC
Non-Turbo ............................. 76-83 (103-113)
Turbo ................................. 87-94 (118-127)
Distributor Adapter Bolt ......................... 11 (15)
Drive Plate Bolt ................................. 55 (75)
Engine Support Bracket Bolt
Except 10x40 mm ........................ 76-83 (103-113)
10x40 mm ................................. 47-54 (63-73)
Exhaust Manifold Nut ............................. 13 (18)
Flywheel Bolt .................................... 55 (75)
Intake Manifold Bolt
Lower Manifold
Non-Turbo ............................... 11-15 (15-20)
Turbo .................................... 9-11 (12-15)
Upper Manifold ................................. 13 (18)
Main Bearing Cap Bolt ............................ 58 (79)
Oil Filter Bracket Bolt .......................... 11 (15)
Oil Pick-Up Tube Bolt ............................ 14 (19)
Oil Pump Mounting Bolt ........................... 11 (15)
Page 222 of 1333
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
Page 223 of 1333
* 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.
Page 224 of 1333
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 \
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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) \
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Page 289 of 1333
\003
* D RIV ETR AIN S YSTE M S U NIF O RM IN SPEC TIO N G UID ELIN ES *
1 991 M it s u bis h i M onte ro
GENERAL INFORMATION
Drivetrain/Transmission Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Drive/Power Train Assemblies
AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLIES
DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES
MANUAL TRANSMISSION/TRANSAXLE ASSEMBLIES
TRANSFER CASE ASSEMBLIES
Drive/Power Train Components
ACTUATORS (ELECTRICAL)
ACTUATORS (VACUUM)
AXLES
BEARINGS AND RACES
BELL CRANKS
BELL HOUSINGS
BUSHINGS (EXTERNAL)
CABLES (SPEEDOMETER)
CABLES (TV, DETENT AND SHIFT)
CARRIER BEARINGS
CLUTCH CABLES AND CABLE HOUSINGS
CLUTCH DISCS (MANUAL TRANSMISSION)
CLUTCH FORKS
CLUTCH LINKAGES (MECHANICAL)
CLUTCH MASTER CYLINDERS
CLUTCH PEDALS
CLUTCH PIVOTS
CLUTCH PRESSURE PLATES
CLUTCH RELEASE BEARINGS
CLUTCH SLAVE CYLINDERS (CONCENTRIC)
CLUTCH SLAVE CYLINDERS (CONVENTIONAL OR EXTERNAL)
COMPANION FLANGES
CONNECTORS
COOLER BYPASS VALVES
COOLER LINES
COOLERS
CV JOINTS
DIP STICK TUBES
DIP STICKS (FLUID LEVEL INDICATORS)
DOWEL PINS, GUIDES AND PILOT HOLES
DRIVE SHAFT FLANGES
DRIVE SHAFTS AND HALF SHAFTS
DUST BOOTS
ENGINE MOUNTS
EXCITER RINGS
FILLER TUBES
FILTERS AND SCREENS
Page 294 of 1333
NOTE: Whenever transmission or drivetrain service is performed
that affects the suspension alignment, for example,
removing the engine cradle, it is required that the
alignment be checked and corrected if necessary.
AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLIES
AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLY INSPECTION \
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Condition Code Procedure
Any internal component
failure that requires
removal of the assembly
from the vehicle for
service. ( 1) ........... A ........... ( 2) Require repair or
replacement of the automatic
transmission/transaxle
assembly.
( 1) - It is Required that the torque converter and all other
failure related components be inspected for cause and
condition.
( 2) - For components not requiring removal of the assembly,
refer to the component listing in this document.
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DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES
NOTE: Does not include half shafts.
DIFFERENTIAL AND FINAL DRIVE ASSEMBLY INSPECTION
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Condition Code Procedure
Any internal component
failure that requires
removal of the assembly
from the vehicle for
service. ( 1) ........... A ... Require repair or replacement
of the differential assembly.
( 1) - For components not requiring removal of the assembly,
refer to the component listing in this document.
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MANUAL TRANSMISSION/TRANSAXLE ASSEMBLIES
MANUAL TRANSMISSION/TRANSAXLE ASSEMBLY INSPECTION \
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Condition Code Procedure
Any internal component
failure that requires
removal of the assembly
from the vehicle for
service. ( 1) ........... A ... Require repair or replacement
of the manual
transmission/transaxle
assembly.
( 1) - For components not requiring removal of the assembly,
Page 667 of 1333
Application Mile Service Mile Service
1983-86 2.6L 4-Cylinder
Automatic Transmission .... 7.9 (8.2) ................. 5.2
Manual Transmission ....... 6.9 (7.2) ................. 5.2
1987-90 2.6L 4-Cylinder
Automatic Transmission .... 7.9 (8.9) ................. 2.6
Manual Transmission ....... 6.9 (7.9) ................. 2.6
1989-96 3.0L V6
Automatic Transmission .... 6.1 (10.6) ................ 2.6
Manual Transmission ....... 5.1 (9.6) ................. 2.6
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LUBRICATION SPECIFICATIONS
LUBRICATION SPECIFICATIONS TABLE\
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Application Fluid Specifications
Brake & Clutch Fluid ........................... DOT 3 Or DOT 4
Engine Coolant ............. Ethylene-Glycol Antifreeze Coolant
Engine Oil ( 1)
Minimum Temperature
Greater Than 32
\bF (0\bC) ..... SAE 20W-40 Or 20W-50 API SG/CD
Greater Than -10\bF (-23\bC) .. SAE 10W-30 Or 10W-40 API SG/CD
Maximum Temperature
Less Than 60
\bF (16\bC) ......... SAE 5W-30 Or 5W-40 API SG/CD
Front Axle & Conventional Rear Axle
Minimum Temperature
Greater Than -10
\bF (-23\bC) ..... SAE 85W-90, 80W-90 API GL-5
Maximum Temperature
Less Than -30
\bF (-34\bC) ................... SAE 75W API GL-5
Power Steering Fluid ........................... Dexron-IIE ATF
Rear Axle (With Limited
Slip Differential) ........... Hypoid Gear Oil (8149630EX) Or
Equivalent
Transmission
Automatic .................................... Dexron-IIE ATF
Manual Transaxle &
Transfer Case (4WD) ........... SAE 75W-85W, 75W-90 API GL-5
( 1) - Since temperature ranges for different oil grades overlap,
brief fluctuations in outside temperatures are no cause for
concern.
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FLUID CAPACITIES
FLUID CAPACITIES TABLE\
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Application Quantity
A/C System R-12 Refrigerant
1983-87 .......................................... 24-26 Ozs.
1988-91 ............................................. 32 Ozs.
1992-93 ............................................. 28 Ozs.
A/C System R-134a Refrigerant ( 1)
1994-96 .......................................... 21-23 Ozs.
Automatic Transmission
1984-86 ................................. ( 2) 7.2 Qts. (6.8L)
1987-93 ..................................... 7.6 Qts. (7.2L)
1994-96 (3.0L SOHC) ......................... 7.6 Qts. (7.2L)
Page 705 of 1333
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Fluid Levels
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Braking System
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Drive Shaft Boots
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Replace
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Engine Oil
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Oil Filter
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Lubrication Specifications
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Application Specification
Brake & Clutch Fluid ............................ DOT 3 Or DOT 4
Engine Coolant .............. Ethylene-Glycol Antifreeze Coolant
Engine Oil (
1)
Minimum Temperature
Greater Than 32
F (0
C) ...... SAE 20W-40 Or 20W-50 API SG/CD
Greater Than -10
F (-23
C) ..... SAE 10W-30, 10W-40 API SG/CD
Maximum Temperature
Less Than 60
F (16
C) .......... SAE 5W-30 Or 5W-40 API SG/CD
Front Axle & Conventional Rear Axle
Minimum Temperature
Greater Than -10
F (-23
C) ........... SAE 90, 85W-90, 80W-90
API GL-5
Maximum Temperature
Less Than -30
F (-34
C) .................... SAE 75W API GL-5
Power Steering Fluid ............................. Dexron-II ATF
Rear Axle (With Limited
Slip Differential) ............ Hypoid Gear Oil (8149630EX) Or
Equivalent
Transmission
Automatic ...................................... Dexron-II ATF
Manual Transaxle &
Transfer Case (4WD) ................. SAE 75W-85W, 75W-90 API
GL-4 Or GL-5
(
1) - Since temperature ranges for different oil grades overlap,
brief fluctuations in outside temperatures are no cause for
concern.
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Fluid Capacities
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Application Quantity
Automatic Transmission
1987-93 ...................................... 7.6 Qts. (7.2L)
1994 (3.0L SOHC) ............................. 7.6 Qts. (7.2L) \
1994 (3.0L DOHC & 3.5L) ...................... 9.0 Qts. (8.5L) \
1995 ......................................... 7.9 Qts. (7.5L)
Cooling System
1987-88 ...................................... 8.5 Qts. (8.0L)
1989-95
2.6L ........................................ 9.7 Qts. (9.2L)
3.0L ....................................... 10.0 Qts. (9.5L)
1994-95
3.5L ....................................... 10.0 Qts. (9.5L)
Differential
1987-88 ...................................... 1.9 Qts. (1.8L)
Page 707 of 1333
Service Or Inspect
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Verify Last Major Service Was Performed
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Valve Clearance (Jet Valve Only)
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Manual Transmission Oil & Transfer Case
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Carburetor Choke Mechanism & Linkage (If Equipped)
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Disc Brake Pads
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Drum Brake Linings & Rear Wheel Cylinders
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Brake Hoses
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Fuel & Vapor Hoses
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Steering Linkage Seals & Drive Shaft Boots
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Lubricate Ball Joint
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Power Steering Fluid (If Equipped)
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Power Steering Hoses (If Equipped)
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Lubricate Front Wheel Bearing
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Drive Axle Fluid (Without Limited-Slip Differential)
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Lubricate Drive Shaft Joints
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Exhaust System
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Lubricate Upper Control Arm Bushings
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Drive Belt (Water Pump & Alternator)
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Replace
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Air Filter
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Spark Plugs
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Drive Axle Fluid (With Limited-Slip Differential)
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Automatic Transmission & Transfer Case Fluids
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Engine Oil & Filter
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Engine Coolant
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Lubrication Specifications
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Application Specification
Brake & Clutch Fluid ............................ DOT 3 Or DOT 4
Engine Coolant .............. Ethylene-Glycol Antifreeze Coolant
Engine Oil (
1)
Minimum Temperature
Greater Than 32
F (0
C) ...... SAE 20W-40 Or 20W-50 API SG/CD
Greater Than -10
F (-23
C) ..... SAE 10W-30, 10W-40 API SG/CD
Maximum Temperature