engine MITSUBISHI MONTERO 1991 Service Manual
[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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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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\003
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)
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4 * High
5 * Premium
7 - Body Type
1 * 5-Door Wagon
2 * 2-Door Canvas Top
3 * 2-Door Metal Top (1983-86)
3 * 3-Door Metal Top Or Van (1987 & Newer Models)
8 - Engine Type
E * 2.6L 4-Cylinder
H * 3.0L V6
M * 3.5L V6
S * 3.0L V6
7 * 2.6L 4-Cylinder (1983)
9 - VIN Check Digit
* 1 Through 9 Or X
10 - Vehicle Model Year
D * 1983
E * 1984
F * 1985
G * 1986
H * 1987
J * 1988
K * 1989
L * 1990
M * 1991
N * 1992
P * 1993
R * 1994
S * 1995
T * 1996
11 - Assembly Plant
Y * Ohye, Japan (1983)
Y * Nagoya, Japan (1984)
J * Nagoya, Japan (1985-96)
12 - Transmission Code (1983-85)
4 * 5-Speed M/T (1984-85 Federal Vehicles)
5 * 5-Speed M/T (1984-85 California Vehicles)
7 * 5-Speed M/T (1983 Federal Vehicles)
7 * A/T (1984-85 Federal Vehicles)
8 * A/T (1984-85 California Vehicles)
12-17 - Serial Number (1986-96)
* Sequential Production Number
13-17 - Serial Number (1983-85)
* Sequential Production Number
MAINTENANCE SERVICE INFORMATION
SEVERE & NORMAL SERVICE DEFINITIONS
NOTE: Use the Severe Service schedule if the vehicle to be serviced
is operated under ANY (one or more) of these conditions:
Service is recommended at mileage intervals based on vehicle
operation. Service schedules are based on the following primary
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operating conditions.
Normal Service
* Driven More Than 10 Miles Daily
* No Operating Conditions From Severe Service Schedule
Severe Service (Unique Driving Conditions)
* Short Trips In Freezing Temperatures
* Towing Or Commercial Use
* Driving Off-Road Or In Salty Or Sandy Areas
* Severe Dust Conditions
* Hot Weather, Stop-And-Go Driving
* Extensive Idling
CAMSHAFT TIMING BELT
CAUTION: Failure to replace a faulty camshaft timing belt may result
in serious engine damage.
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 belt 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 in
this manual reflect these changes.
Belts or components should be inspected and replaced if any
of the following conditions exist:
* Cracks Or Tears In Belt Surface
* Missing, Damaged, Cracked Or Rounded Teeth
* Oil Contamination
* Damaged Or Faulty Tensioners
* Incorrect Tension Adjustment
Replace camshaft timing belt at 60,000 mile intervals.
SERVICE POINT LOCATIONS
Fig. 1: Service Point Locations (1983-86 2.6L 4-Cylinder Engine)
Courtesy of Mitsubishi Motor Sales of America.
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Fig. 2: Service Point Locations (1987-91 2.6L 4-Cylinder Engine)
Courtesy of Mitsubishi Motor Sales of America.
Fig. 3: Service Point Locations (1987-91 3.0L V6 Engine)
Courtesy of Mitsubishi Motor Sales of America.
Fig. 4: Service Point Locations (1992 3.0L V6 Engine)
Courtesy of Mitsubishi Motor Sales of America.
INFORMATION LABEL LOCATIONS
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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)
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1994-96 (3.0L DOHC & 3.5L) .................. 9.0 Qts. (8.5L)
Cooling System
1983-88 ..................................... 8.5 Qts. (8.0L)
1989-96
2.6L ....................................... 9.7 Qts. (9.2L)
3.0L ...................................... 10.0 Qts. (9.5L)
3.5L ...................................... 10.0 Qts. (9.5L)
Differential
1983-88 ..................................... 1.9 Qts. (1.8L)
1989-93
2.6L ....................................... 1.9 Qts. (1.8L)
3.0L ....................................... 2.7 Qts. (2.6L)
1994-96
3.0L & 3.5L ................................ 2.7 Qts. (2.6L)
Engine Oil
1983-86 ..................................... 6.0 Qts. (5.8L)
1987 ........................................ 5.2 Qts. (5.0L)
1988 ........................................ 5.0 Qts. (4.8L)
1989-91 ..................................... 5.5 Qts. (5.3L)
1992-96 ..................................... 5.2 Qts. (4.9L)
Power Steering ................................ 1.1 Qts. (1.0L)
Fuel Tank
1983-88 .................................... 15.9 Gals. (60L)
1989-90
2.6L 2-Door ............................... 15.9 Gals. (60L)
3.0L 2-Door ............................... 19.9 Gals. (75L)
2.6L & 3.0L 4-Door .......................... 24 Gals. (92L)
1991-96 ...................................... 24 Gals. (92L)
Manual Transmission
1983-91 ..................................... 2.3 Qts. (2.2L)
1992 ........................................ 2.4 Qts. (2.3L)
1993-96 ..................................... 2.6 Qts. (2.5L)
Transfer Case
1983-91 ..................................... 2.3 Qts. (2.2L)
1992-96 ..................................... 2.4 Qts. (2.3L)
(1) - Use of R12 in a R134a system will result in SEVERE DAMAGE.
( 2) - 1983 model equipped with manual transmission only.
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WHEEL & TIRE SPECIFICATIONS
Tire specifications are imprinted on the tire side wall. The
recommended cold tire inflation pressures are listed on a label
attached to the rear face of the driver's door. These pressures
provide the best combination of ride comfort, tire wear and stability
under normal conditions.
CAUTION: DO NOT mix tires of different design such as radial ply
with bias or bias-belted tires. Mixing tire types will
adversely affect road handling and may lead to loss of
vehicle control. When using snow tires, they must be used
in set of four for maneuverability and safety. DO NOT use
tire chains on front wheels.
TIRE & WHEEL SPECIFICATIONS TABLE
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Wheel Size Tire Size
1983-86
15 x 6JJ (Steel) .............................. 215 SR15
1987-88
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2.6L Engine ........................................... 45
2.6L Optional ......................................... 45
3.0L V6 ........................................... (1) 24
3.5L V6 ........................................... ( 1) 24
( 1) - Check hood clearance on 1986 and newer models.
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CAUTIONS & WARNINGS
SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG SYSTEM
NOTE: See the AIR BAG RESTRAINT SYSTEM article in the
ACCESSORIES/SAFETY EQUIPMENT Section.
The SRS has no user-servicable parts. Always have servicing
done by an authorized dealer.
When performing maintenance on air bag equipped vehicles
always observe proper safety precautions.
WARNING: To avoid injury from accidental air bag deployment, read and
carefully follow all warnings and service precautions. See
appropriate AIR BAG RESTRAINT SYSTEM article in the
ACCESSORIES/SAFETY EQUIPMENT section.
CAUTION: Disconnect negative battery cable before servicing any air
bag system, steering column or passenger side dash
component. After any repair, turn ignition key to the ON
position from passenger's side of vehicle in case of
accidental air bag inflation
ANTI-LOCK BRAKE SYSTEM (ABS)
CAUTION: Never mix different diameter tires. On loose or uneven
surfaces, the ABS system may require longer stopping
distances than conventional brake systems. Exercise caution
when removing mud or snow from the wheels so as not to
damage the ABS wiring or speed sensors.
BATTERY WARNING
WARNING: When battery is disconnected, vehicles equipped with
computers may lose memory data. When battery power is
restored, driveability problems may exist on some vehicles.
These vehicles may require a relearn procedure. See
appropriate COMPUTER RELEARN PROCEDURES article in the
GENERAL INFORMATION section below.
REPLACING BLOWN FUSES
Before replacing a blown fuse, remove ignition key, turn off
all lights and accessories to avoid damaging the electrical system. Be
sure to use fuse with the correct indicated amperage rating. The use
of an incorrect amperage rating fuse may result in a dangerous
electrical system overload.
BRAKE PAD WEAR INDICATOR
Indicator will cause a squealing or scraping noise, warning
that brake pads need replacement.
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CATALYTIC CONVERTER
Continued operation of vehicle with a severe malfunction
could cause converter to overheat, resulting in possible damage to
converter and vehicle.
COOLANT (PROPYLENE-GLYCOL FORMULATIONS)
CAUTION: To avoid possible damage to vehicle use only ethylene-glycol
based coolants with a mixture ratio from 44-68% anti-freeze.
DO NOT use 100% anti-freeze as it will cause the formation
of cooling system deposits. This results in coolant
temperatures of over 300
\b F (149\bC) which can melt plastics.
100% anti-freeze has a freeze point of only -8\b F (-22\bC).
CAUTION: Propylene-Glycol Mixtures has a smaller temperature range
than Ethylene-Glycol. The temperature range (freeze-boil)
of a 50/50 Anti-Freeze/Water Mix is as follows:
Propylene-Glycol -26
\b F (-32\bC) - 257\b F (125\bC)
Ethylene-Glycol -35\b F (-37\bC) - 263\b F (128\bC)
CAUTION: Propylene-Glycol/Ethylene-Glycol Mixtures can cause the
destabilization of various corrosion inhibitors. Also
Propylene-Glycol/Ethylene-Glycol has a different specific
gravity than Ethylene-Glycol coolant, which will result in
inaccurate freeze point calculations.
ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS
WARNING: Many solid state electrical components can be damaged by
static electricity (ESD). Some will display a warning label,
but many will not. Discharge personal static electricity by
touching a metal ground point on the vehicle prior to
servicing any ESD sensitive component.
ENGINE OIL
CAUTION: Never use non-detergent or straight mineral oil.
FUEL SYSTEM SERVICE
WARNING: Relieve fuel system pressure prior to servicing any fuel
system component (fuel injection models).
HALOGEN BULBS
WARNING: Halogen bulbs contain pressurized gas which may explode if
overheated. DO NOT touch glass portion of bulb with bare
hands. Eye protection should be worn when handling or working
around halogen bulbs.
RADIATOR CAP
CAUTION: Always disconnect the fan motor when working near the
radiator fan. The fan is temperature controlled and could
start at any time even when the ignition key is in the OFF
position. DO NOT loosen or remove radiator cap when cooling
system is hot.
RADIATOR FAN
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WARNING: Keep hands away from radiator fan. Fan is controlled by a
thermostatic switch which may come on or run for up to
15 minutes even after engine is turned off.
WARRANTY INFORMATION
CAUTION: Always refer to customer's copy of warranty information for
specific model application and/or coverage limitations.
NEW VEHICLE LIMITED WARRANTY
Covers all manufacturer-installed parts and components for
any repairs, replacements or adjustments needed to correct defects in
materials or workmanship under normal use and maintenance for 36
months or 36,000 miles, whichever comes first, from date of delivery
to the first retail buyer or first date of use.
POWERTRAIN LIMITED WARRANTY
Upon expiration of New Vehicle Limited Warranty, this
warranty covers powertrain against defects in materials or workmanship
up to a maximum of 36 months or 50,000 miles, whichever occurs first.
On 1991-96 models, warranty period is extended to 5 years or 60,000
miles, whichever occurs first. See copy of warranty for specific
components covered.
BATTERY WARRANTY
Covers replacement of original battery for 12 months or 12,
000 miles, whichever occurs first.
AIR CONDITIONER WARRANTY
Covers manufacturer's air conditioners for 36 months or 36,
000 miles, whichever occurs first. Air conditioner refrigerant charge
is covered for the first 12 months or 12,000 miles, whichever occurs
first. On 1992-96 models, refrigerant is covered only as part of a
warranty repair.
ANTI-CORROSION PERFORATION LIMITED WARRANTY
Covers any body sheet metal panel found to have developed
perforation (rust-through) due to corrosion for 5 years regardless of
mileage. Outer panel coverage extends to 7 years or 100,000 miles,
whichever occurs first, on 1992-96 models.
EMISSION SYSTEM DEFECT WARRANTY (EXCEPT CALIFORNIA)
Warrants that the vehicle was designed, built and equipped to
conform at the time of sale with all applicable U.S. emission
standards. Covers any repairs needed to correct defects in materials
or workmanship which would cause the vehicle not to meet these
standards for 5 years or 50,000 miles, whichever occurs first.
EMISSION SYSTEM PERFORMANCE WARRANTY (EXCEPT CALIFORNIA)
Covers all repairs, adjustments, or replacements if vehicle
has been maintained in accordance with the prescribed scheduled
maintenance instructions and fails to conform to applicable emission
standards and such failure results or will result in the vehicle owner
having to bear any penalty or other sanctions under local, state or