drain bolt MITSUBISHI MONTERO 1991 User Guide
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 1991, Model line: MONTERO, Model: MITSUBISHI MONTERO 1991Pages: 1333, PDF Size: 24.61 MB
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recovery/recycling equipment. Remove glove box with lower frame
attached. Loosen duct joint bolt to free duct joint. Disconnect A/C
switch harness. Disconnect evaporator drain hose.
2) Disconnect refrigerant lines at firewall side of engine
compartment. Remove evaporator top attaching bolts in passenger
compartment. Remove evaporator assembly. See Fig. 12 or 13. To
install, reverse removal procedure.
Fig. 12: Exploded View of Front Evaporator (Montero)
Courtesy of Mitsubishi Motor Sales of America.
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![MITSUBISHI MONTERO 1991 User Guide TORQUE SPECIFICATIONS
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TORQUE SPECIFICATIONS
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Application Ft. Lbs. (N.m)
Bearing Cap Bolt ...................... 40-47 (54-64)
Brake Caliper Bolt .................... 58-72 (79-98)
Carrier-to-Housing Tube Bolt .......... 58-72 (79-98)
Cover Bolt ............................ 11-16 (15-22)
Drain Plug ............................ 43-51 (58-69)
Fill Plug ............................. 29-43 (39-58)
Front Crossmember Bolt ............... 72-87 (98-118)
Hub Cover ............................. 13-25 (18-34)
Knuckle-to-Ball Joint Nut
Upper ............................... 43-65 (58-88)
Lower ............................ 87-130 (118-176)
Mount Bracket-to-Frame Bolt .......... 58-80 (79-108)
Mount Bracket-to-Housing Tube Bolt ... 58-72 (79-98)
Pinion Flange Nut
2.4L & 2.6L ..................... 116-159 (157-216)
3.0L ............................ 137-181 (186-245)
Drive Shaft Flange Bolt ............... 36-43 (49-58)
Right Drive Axle-to-Inner Shaft Bolt .. 36-43 (49-58)
Ring Gear-to-Case Bolt ................ 58-65 (79-88)
Tie Rod-to-Knuckle Nut ...................... 33 (45)
Wheel Lug Nuts
Montero ............................ 72-87 (98-188)
Pick-Up .......................... 87-101 (118-137)
INCH Lbs. (N.m)
Undercover-to-Frame
Bolts (Montero) ................. 84-108 (9.5-12.2)
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![MITSUBISHI MONTERO 1991 User Guide TESTING SPECIFICATIONS \
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Application Ft. Lbs. (N.m)")
TESTING SPECIFICATIONS \
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Application Ft. Lbs. (N.m)
Montero & Pickup ............................ 25 (34)
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REMOVAL & INSTALLATION
AXLE SHAFTS
Removal
1) Block front wheels. Raise and support rear axle housing.
Remove brake drum. See Fig. 1. Remove parking brake cable attaching
bolts. Remove connection for parking brake cable end and rear brake
assembly. Drain brake fluid from bleeder screw at left side of rear
brake and disconnect brake tubes.
2) On all models, remove flange nuts and rear axle shaft
assembly. Use Puller (MB990241) and Slide Hammer (MB990211) if
necessary. DO NOT damage oil seal. Remove shim(s) and "O" ring.
Replace if necessary.
Fig. 1: Exploded View of Axle Shaft
Courtesy of Chrysler Motors.
Installation
1) Insert a new "O" ring and a shim of .04" (1.0 mm)
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thickness into left side axle housing. Install left axle shaft
assembly into axle housing and tighten nuts to specification. See
TORQUE SPECIFICATIONS table at the end of this article.
2) Install right axle shaft assembly into axle housing
WITHOUT a shim or "O" ring. Temporarily tighten nuts in diagonal
sequence to 51.6 INCH lbs. (5.8 N.m) in 2 stages. Measure clearance
between bearing case and rear axle housing end with a feeler gauge.
3) Select shims equal to the sum of the thickness of the
measured clearance plus .0020-.0079" (.05-.20 mm). Remove right axle
shaft and install the selected shim(s) and "O" ring into right axle
housing end. Install right axle shaft assembly into rear axle housing.
Tighten nuts in diagonal sequence to specification. See TORQUE
SPECIFICATIONS table.
4) Using dial indicator, check end play of axle shaft. End
play must be .0020-.0079" (.05-.20 mm). If end play is not within
specification, change shim(s) to obtain correct end play. Reverse
removal procedure to install remaining components. Adjust parking
brake and bleed brake system.
DIFFERENTIAL CARRIER
Removal
Raise and support vehicle. Drain gear oil. Mark drive shaft
flange-to-pinion flange position. Remove drive shaft. Remove axle
shafts. See AXLE SHAFTS under REMOVAL & INSTALLATION. Support
differential carrier with jack. Remove differential carrier retaining
nuts. Remove differential carrier.
Inspection
Inspect for leakage at vent plug, differential carrier
companion flange and where carrier joins axle housing.
Installation
Apply sealant to axle housing surface. To install, reverse
removal procedure. Align marks on drive shaft and pinion flange.
DRIVE SHAFT
Removal
Make match marks on drive shaft yoke flange and pinion
flange. Remove bolts. Remove drive shaft from vehicle.
Installation
To install, reverse removal procedure. Ensure match marks are
aligned. Tighten bolts to specification. See TORQUE SPECIFICATIONS
table at end of article.
OVERHAUL
AXLE SHAFTS
Disassembly
1) Mount backing plate and axle shaft assembly in soft-jawed
vise. Bend over axle shaft bearing lock washer. Using Spanner Wrench
(MD990785), remove lock nut from axle shaft. Remove washers. Reinstall\
lock nut on axle shaft approximately 3 turns.
2) Attach Bearing Puller (MB990787-01) to rear of backing
plate to remove bearing case from axle shaft. See Fig. 2. Using equal
pressure to avoid binding, tighten puller nuts diagonally to remove
bearing case. Using hammer and drift, remove bearing outer race from
bearing case. Remove oil seal from end of axle housing with Slide
Hammer and Adapter (MB990211).
Page 284 of 1333
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TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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Application Ft. Lbs. (N.m)\
Axle Bearing Lock Nut (Montero) .................. 130-159 (176-216\
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Bearing Cap Bolt ..................................... 40-47 (54-64)\
Bearing Case-To-Axle Housing Bolt .................... 36-43 (49-58)\
Brake Tube Flare Nut ................................. 10-12 (14-16)\
Differential Carrier-To-Axle Housing Nut
2.4L (2WD) ......................................... 18-22 (24-30\
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3.0L (4WD) ......................................... 29-40 (39-54\
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Drain Plug ........................................... 43-50 (58-68)\
Filler Plug .......................................... 29-43 (39-58)\
Lock Plate Bolt ...................................... 11-16 (15-22)\
Pinion Flange Nut ................................ 137-181 (186-245)\
Drive Shaft-To-Flange Bolt ........................... 36-43 (49-58)\
Ring Gear Bolt ....................................... 58-65 (79-88)\
Side Bearing Lock Plate Bolts ........................ 11-16 (15-22)\
Wheel Lug Nut
Montero ........................................... 72-87 (98-118)\
Pickup .......................................... 87-101 (118-137)\
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Bolt loose .............. A ........... Require tightening or
replacement of bolts.
Bolt missing ............ C ... Require replacement of bolts.
Corroded, affecting
sealability ............ A .. Require repair or replacement.
Cylinder head threads
stripped ............... A ... Require repair or replacement
of cylinder head.
Gasket leaking .......... A ........... Require tightening or
replacement of gasket.
Heat stove bent ......... B ........... (1) Require repair or
replacement of stove.
Heat stove broken ....... A ......... ( 1) Require replacement
of stove.
Heat stove corroded,
affecting structural
integrity .............. 1 ......... ( 1) Suggest replacement
of stove.
Heat stove missing ...... C ......... ( 1) Require replacement
of stove.
Manifold broken ......... A .. Require repair or replacement.
Manifold cracked ........ B .. Require repair or replacement.
Manifold warped ......... A .. Require repair or replacement.
Out of specification .... B .. Require repair or replacement.
Stud broken ............. A .... Require replacement of stud.
Stud missing ............ C .... Require replacement of stud.
Stud threads damaged .... A ... Require repair or replacement
of stud.
Stud threads stripped
(threads missing) ...... A .... Require replacement of stud.
( 1) - Stove may not be available separately; this may require
replacement of manifold.
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MECHANICAL EFE DEVICES
See HEAT RISERS (MECHANICAL EFE DEVICES) .
MUFFLERS AND RESONATORS
MUFFLER AND RESONATOR INSPECTION \
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Condition Code Procedure
Body shell distorted,
affecting performance or
structural integrity ... A ............ Require replacement.
Corrosion hole .......... A ............ Require replacement.
Missing ................. C ............ Require replacement.
Mounting bracket broken . A .. Require repair or replacement.
Mounting bracket
cracked ................ B .. Require repair or replacement.
Nipple cracked .......... A .. Require repair or replacement.
Nipple loose ............ B ............ Require replacement.
Outer wrap peeling
(exhaust not leaking) .. 1 ............ Suggest replacement.
Plugged ................. A ............ Require replacement.
Puncture (other than a
drain hole) ............ A ............ Require replacement.
Rattling or knocking noise
from inside muffler .... B ............ Require replacement.
Seam open (exhaust
Page 611 of 1333
Removal (Montero)
1) Move temperature control lever to WARM position. Drain
coolant from vehicle. Disconnect heater hoses from heater unit. See
Fig. 1.
2) Remove lap heater ducts. Remove hood release bracket.
Using screwdriver, release tabs and remove left and right demister
grilles. Remove glove box frame attaching screws, and remove glove
box. Remove passenger lap heater duct.
3) Using screwdriver and shop towel, carefully pry at top
center of instrument cluster cover, and remove cover. Remove 2 screws
at bottom of instrument panel and one bolt at top of instrument panel.
Gently pull instrument cluster out, and disconnect speedometer cable
and electrical connections. Remove instrument cluster.
4) Remove 4 screws, and disconnect electrical connections on
back of instrument cluster. Remove instrument cluster. Handle
instrument cluster carefully. Instrument cluster can be damaged if
dropped.
5) Remove center console knobs and side screw plugs. Remove
screws, disconnect electrical connections and remove console. Remove 6
bolts and console bracket (center dash reinforcement). Disconnect
radio connections while removing console bracket.
6) Remove horn pad and steering wheel retaining nut. Mark
steering wheel and steering shaft for reassembly reference. Using
steering wheel puller, remove steering wheel.
7) Using screwdriver, carefully pry out dash plug at upper
center of dash panel. Remove 3 upper dash mounting nuts, one upper
screw above steering column, and 2 lower mounting screws. Remove dash
panel.
8) Remove control cables at heater unit. Remove heater unit
attaching screws. Remove heater ducts. Remove heater unit. Remove
heater control lever arm.
9) Remove heater control valve cover. Remove heater pipe and
heater control valve. Disconnect control arm linkage. Remove control
arm. Remove heater core by moving it sideways.
Installation
1) To install, reverse removal procedure. Insert heater hoses
fully into pipes, and clamp securely to prevent leaks. Connect heater
hoses with 1-1.2" (25-30 mm) overlap on outlet.
2) When filling radiator with coolant, first open heater
control valve fully and run engine to circulate coolant and discharge
air from inside heater and engine cooling system. Stop engine, and add
coolant.
3) Adjust all control cables. When installing heater hose
grommets, apply sealer. After installing heater control assembly,
ensure each lever operates smoothly.
Removal (Pickup & Ram-50)
1) Disconnect battery ground cable. Place heater control
lever to far right. Drain coolant. Using trim stick, pry out hazard
switch and remove electrical connection. Remove 4 instrument cluster
cover screws, and remove cover. Remove 4 instrument cluster screws.
Tilt instrument cluster out, and disconnect speedometer cable and
electrical connections. Remove cluster.
2) Remove fuse box cover and fuse box assembly. Remove glove
box. Remove defroster air ducts. Disconnect heater control cables.
Using trim stick, pry under and remove speaker grilles. Remove clock
or coin box in center of dash. Remove center dash hole cover (located
above clock).
3) Remove 2 center support cover screws, and remove cover.
Remove shift knob and 6 console attaching screws. Remove console.
Ensure all electrical connections are free of dash panel. Remove 3 top
nuts, one bolt above steering column, and side and lower attaching
Page 689 of 1333
FUEL SYSTEM PRESSURE RELEASE
WARNING: ALWAYS relieve fuel pressure before disconnecting any fuel
injection-related component. DO NOT allow fuel to contact
engine or electrical components.
1) On Colt and Mirage, remove rear seat cushion. On all
models, disconnect fuel pump harness connector at fuel tank.
2) Start engine. Let engine run until it stops. Turn ignition
off. Disconnect negative battery terminal. Connect fuel pump harness
connector.
FUEL PUMP
Removal & Installation
1) Fuel pump assembly is located inside fuel tank. Release
fuel pressure from system. See FUEL SYSTEM PRESSURE RELEASE. Raise
vehicle on hoist. Drain fuel into suitable container. Disconnect
electrical connectors and fuel hoses at fuel tank.
2) Remove fuel filler hose from fuel tank. Remove nuts
securing fuel tank. Remove fuel tank from vehicle and remove fuel pump
assembly. To install, reverse removal procedure. Tighten nuts to
specification. See TORQUE SPECIFICATION table.
FUEL RAILS & INJECTORS (PFI)
Use a rag to cover fuel hose connection before disconnecting
high pressure fuel hose at fuel rail. Some residual fuel pressure may
still be in system.
Removal (Except Pickup & Ram-50 2.4L)
1) On all models, relieve fuel pressure. See
FUEL SYSTEM PRESSURE RELEASE . Disconnect negative battery cable. On
Montero, Pickup, Ram-50, Stealth and 3000GT 3.0L, disconnect air
intake plenum. On Eclipse, disconnect PCV valve hose.
2) On Colt Vista, disconnect coolant temperature sensor
connector, idle speed control servo connector and brake booster vacuum
hose. On all models, disconnect high pressure fuel hose at fuel rail.
3) Disconnect fuel return hose. Disconnect vacuum hoses. On
Eclipse, Colt and Colt 200, disconnect throttle cable clamp. Remove
center cover. On all models, disconnect injector electrical
connectors. Remove fuel rail bolts and lift fuel rail and injectors
from engine.
Installation
To install, reverse removal procedure. Tighten bolts to
specifications. See TORQUE SPECIFICATIONS table.
Removal (Pickup & Ram-50 2.4L)
1) Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELEASE.
Disconnect negative battery cable. Drain coolant. On all models,
disconnect air intake hose. Disconnect breather hose (if applicable)
and vacuum hoses.
2) Disconnect coolant lines as necessary for clearance.
Disconnect injector electrical connectors. Position all lines, hoses
and electrical connectors out of way. Disconnect throttle and/or
kickdown cables. Remove throttle body assembly and position it out of
the way.
3) Disconnect high pressure fuel hose at fuel rail.
Disconnect fuel return line and vacuum line connection at fuel rail.
Remove fuel rail bolts and lift fuel rail and injectors from engine.
Page 692 of 1333
Courtesy of Mitsubishi Motor Sales of America.
2) Disconnect air intake hose and vacuum hoses. Remove air
hose and air outlet housing. Remove heat protectors. Disconnect
exhaust pipe. Remove power steering oil pump and bracket. Remove
engine hanger bracket. Disconnect oil inlet pipe.
3) Disconnect coolant hose and tubes. Remove nuts and bolts
securing exhaust manifold. Remove exhaust manifold and gaskets.
Disconnect oil return pipe. Remove turbocharger assembly.
Removal (Stealth & 3000GT Front)
1) Disconnect negative battery cable. Drain engine oil and
coolant. Remove radiator. Disconnect exhaust pipe. Remove air intake
hose, air hoses and air pipe. Remove alternator and belt. Remove oil
dipstick guide.
2) Remove heat protector. Disconnect oxygen sensor electrical
connector. Remove oil return pipe. Remove turbocharger support bracket
and remove turbocharger from exhaust manifold. See Fig. 10.
Fig. 10: Removing Front Turbocharger (Stealth & 3000GT)
Courtesy of Mitsubishi Motor Sales of America.
Removal (Stealth & 3000GT Rear)
1) Disconnect battery cables and remove battery. Drain engine
oil and coolant. Remove accelerator cable. Remove air hose, air pipe
and heat protectors. Disconnect clutch booster vacuum hose. Remove air
Page 694 of 1333
Fuel Tank Drain Plug ....................... 11-18 (15-24)
Exhaust Manifold-To-Engine Nuts ............ 18-22 (24-30)
Exhaust Manifold-To-Turbocharger Bolts ..... 40-47 (54-64)
Exhaust Pipe Bolts ......................... 22-29 (30-39)
Oil Pipe-To-Engine ......................... 10-14 (14-19)
Oxygen (O2) Sensor ......................... 29-36 (39-49)
Plenum-To-Intake Manifold Bolts ............ 11-15 (15-20)
Water Pipe-To-Turbocharger
Except Stealth & 3000GT .................. 25-36 (34-49)
Stealth & 3000GT ............................... 22 (30)
INCH Lbs. (N.m)
Fuel Rail Bolts .......................... 84-108 (10-12)
Heat Protector Bolts ..................... 108-132 (12-15)
ISC Switch Screws ........................ 20-54 (2.5-4.5)
TPS Switch Screws ........................ 13-20 (1.5-2.5)
Wastegate Actuator Bolts ................... 84-108 (9-12)
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