length MITSUBISHI MONTERO 1991 Owner's Manual

On cast cylinder heads, if warpage exceeds .003" (.08 mm)
in a 6" span, or .006" (.15 mm) over total length, cylinder head must
be resurfaced. On most aluminum cylinder heads, if warpage exceeds .
002" (.05 mm) in any area, cylinder head must be resurfaced. Warpage
specification may vary with manufacturer.
Cylinder head thickness should be measured to determine
amount of material which can be removed before replacement is
required. Cylinder head thickness must not be less than manufacturer's
specifications.
If cylinder head required resurfacing, it may not align
properly with intake manifold. On "V" type engines, misalignment is
corrected by machining intake manifold surface that contacts cylinder
head. Cylinder head may be machined on surface that contacts intake
manifold.
Using oil stone, remove burrs or scratches from all sealing
surfaces.
VALVE SPRINGS
Inspect valve springs for corroded or pitted valve spring
surfaces which may lead to breakage. Polished spring ends caused by
a rotating spring, indicates that spring surge has occurred. Replace
springs showing evidence of these conditions.
Inspect valve springs for squareness using a 90 degree
straightedge. See Fig. 4. Replace valve spring if out-of-square
exceeds manufacturer's specification.
Fig. 4: Checking Valve Spring Squareness - Typical
This Graphic For General Information Only
Using vernier caliper, measure free length of all valve
springs. Replace springs if not within specification. Using valve

Fig. 6: Measuring Valve Stem-to-Guide Clearance - Typical
This Graphic For General Information Only
Lower valve approximately 1/16" below valve seat. Push valve
stem against valve guide as far as possible. Adjust dial indicator to
zero. Push valve stem in opposite direction and note reading.
Clearance must be within specification.
If valve guide clearance exceeds specification, valves with
oversize stems may be used or valve guide must be replaced. On some
applications, a false guide is installed, then reamed to proper
specification. Valve guide reamer set is used to ream valve guide to
obtain proper clearance for new valve.
Reaming Valve Guide
Select proper reamer for valve stem. Reamer must be of
proper length to provide clean cut through entire length of valve
guide. Install reamer in valve guide and rotate to cut valve guide.
See Fig. 7 .

using ridge reamer. DO NOT remove an excessive amount of material.
Ensure ridge is completely removed.
PISTON & CONNECTING ROD REMOVAL
Note top of piston. Some pistons may contain a notch, arrow
or be marked "FRONT". Piston must be installed in proper direction to
prevent damage with valve operation.
Check that connecting rod and cap are numbered for cylinder
location and which side of cylinder block the number faces. Proper cap
and connecting rod must be installed together. Connecting rod cap must
be installed on connecting rod in proper direction to ensure bearing
lock procedure. Mark connecting rod and cap if necessary. Pistons must
be installed in original location.
Remove cap retaining nuts or bolts. Remove bearing cap.
Install stud protectors on connecting rod bolts. This protects
cylinder walls from scoring during removal. Ensure proper removal of
ridge. Push piston and connecting rod from cylinder. Connecting rod
boss can be tapped with a wooden dowel or hammer handle to aid in
removal.
PISTON & CONNECTING ROD
Disassembly
Using ring expander, remove piston rings. Remove piston pin
retaining rings (if equipped). On pressed type piston pins, special
fixtures and procedures according to manufacturer must be used to
remove piston pins. Follow manufacturer's recommendations to avoid
piston distortion or breakage.
Cleaning
Remove all carbon and varnish from piston. Pistons and
connecting rods may be cleaned in cold type chemical tank. Using ring
groove cleaner, clean all deposits from ring grooves. Ensure all
deposits are cleaned from ring grooves to prevent ring breakage or
sticking. DO NOT attempt to clean pistons using wire brush.
Inspection
Inspect pistons for nicks, scoring, cracks or damage in ring
areas. Connecting rod should be checked for cracks using Magnaflux
procedure. Piston diameter must be measured in manufacturers specified
area.
Using telescopic gauge and micrometer, measure piston pin
bore of piston in 2 areas, 90 degrees apart. This is done to check
diameter and out-of-round.
Install proper bearing cap on connecting rod. Ensure bearing
cap is installed in proper location. Tighten bolts or nuts to
specification. Using inside micrometer, measure inside diameter in 2
areas, 90 degrees apart.
Connecting rod I.D. and out-of-round must be within
specification. Measure piston pin bore I.D. and piston pin O.D. All
components must be within specification. Subtract piston pin diameter
from piston pin bore in piston and connecting rod to determine proper
fit.
Connecting rod length must be measured from center of
crankshaft journal inside diameter to center of piston pin bushing
using proper caliper. Connecting rods must be the same length.
Connecting rods should be checked on an alignment fixture for bent or
twisted condition. Replace all components which are damaged or not
within specification.
PISTON & CYLINDER BORE FIT

Fig. 18: Measuring Connecting Rod Side Clearance - Typical
This Graphic For General Information Only
Check for improper bearing installation, wrong bearing cap
or insufficient bearing clearance if side clearance is insufficient.
Connecting rod may require machining to obtain proper clearance.
Excessive clearance usually indicates excessive wear at crankshaft.
Crankshaft must be repaired or replaced.
MAIN & CONNECTING ROD BEARING CLEARANCE
Plastigage Method
Plastigage method may be used to determine bearing clearance.
Plastigage can be used with an engine in service or during reassembly.
Plastigage material is oil soluble.
Ensure journals and bearings are free of oil or solvent.
Oil or solvent will dissolve material and false reading will be
obtained. Install small piece of Plastigage along full length of
bearing journal. Install bearing cap in original location. Tighten
bolts to specification.
CAUTION: DO NOT rotate crankshaft while Plastigage is installed.
Bearing clearance will not be obtained if crankshaft is
rotated.
Remove bearing cap. Compare Plastigage width with scale on
Plastigage container to determine bearing clearance. See Fig. 19.
Rotate crankshaft 90 degrees. Repeat procedure. this is done to check
journal eccentricity. This procedure can be used to check oil
clearance on both connecting rod and main bearings.

length of cylinder block at several points.
If warpage exceeds specifications, deck must be resurfaced.
If warpage exceeds manufacturer's maximum tolerance for material
removal, replace block.
DECK HEIGHT
Distance from the crankshaft centerline to the block
deck is termed the deck height. Measure and record front and rear main
journals of crankshaft. To compute this distance, install crankshaft
and retain with center main bearing and cap only. Measure distance
from the crankshaft journal to the block deck, parallel to the
cylinder centerline.
Add one half of the main bearing journal diameter to distance
from crankshaft journal to block deck. This dimension should be
checked at front and rear of cylinder block. Both readings should be
the same.
If difference exceeds specifications, cylinder block must be
repaired or replaced. Deck height and warpage should be corrected at
the same time.
MAIN BEARING BORE & ALIGNMENT
For checking main bearing bore, remove all bearings from
cylinder block and main bearing caps. Install main bearing caps in
original location. Tighten bolts to specification. Using inside
micrometer, measure main bearing bore in 2 areas 90 degrees apart.
Determine bore size and out-of-round. If diameter is not within
specification, block must be align-bored.
For checking alignment, place a straightedge along centerline
of main bearing saddles. Check for clearance between straightedge and
main bearing saddles. Block must be align-bored if clearance is
present.
EXPANSION PLUG REMOVAL & INSTALLATION
Removal
Drill a hole in the center of expansion plug. Remove with
screwdriver or punch. Use care not to damage sealing surface.
Installation
Ensure sealing surface is free of burrs. Coat expansion plug
with sealer. Use a wooden dowel or pipe of slightly smaller diameter,
install expansion plug. Ensure expansion plug is evenly located.
OIL GALLERY PLUG REMOVAL & INSTALLATION
Removal
Remove threaded oil gallery plugs using the appropriate
wrench. Soft, press-in plugs are removed by drilling into plug and
installing a sheet metal screw. Remove plug with slide hammer or
pliers.
Installation
Ensure threads or sealing surface is clean. Coat threaded oil
gallery plugs with sealer and install. Replacement soft press-in plugs
are driven in place with a hammer and drift.
CAMSHAFT
* PLEASE READ THIS FIRST *

Fig. 31: Measuring Rotor Clearance - Typical
This Graphic For General Information Only
Install rotors in pump body. Position straightedge across
pump body. Using feeler gauge, measure clearance between rotors and
straightedge. Pump cover wear is measured using a straightedge and
feeler gauge. Replace pump if clearance exceeds specification.
GEAR TYPE
Oil pump gears must be marked for location prior to removal.
See Fig. 32 . Remove gears from pump body. Inspect gears for pitting
or damage. Inspect cover for grooving or wear.
Fig. 32: Typical Gear Type Oil Pump
This Graphic For General Information Only
Measure gear diameter and length. Measure gear housing cavity
depth and diameter. See Fig. 33. Replace components if worn or

HO W T O U SE S YSTE M W IR IN G D IA G RAM S
1991 M it s u bis h i M onte ro
GENERAL INFORMATION
Using Wiring Diagrams
All Models
INTRODUCTION
This CD obtains wiring diagrams and technical service
bulletins, containing wiring diagram changes from the domestic and
import manufacturers. These are checked for accuracy and are all
redrawn into a consistent format for easy use.
In the past, when cars were simpler, diagrams were simpler.
All components were connected by wires and diagrams seldom exceeded 4
pages in length. Today, some wiring diagrams require more than 16
pages. It would be impractical to expect a service technician to trace
a wire from page 1 across every page to page 16.
Removing some of the wiring maze reduces eyestrain and time
wasted searching across several pages. Today the majority of
these

diagrams follow a much improved format, which permits space for
internal switch details.
Wiring diagrams are drawn in a "top-down" format. The
diagrams are drawn with the power source at the top of the diagram and
the ground point at the bottom of the diagram. Components locations
are identified on the wiring diagrams. Any wires that don't connect
directly to a component are identified on the diagram to indicate
where they go.
COLOR ABBREVIATIONS
COLOR ABBREVIATIONS TABLE








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Color Normal Optional
Black ................ BLK .......................... BK
Blue ................. BLU .......................... BU
Brown ................ BRN .......................... BN
Clear ................ CLR .......................... CR
Dark Blue .......... DK BLU ...................... DK BU
Dark Green ......... DK GRN ...................... DK GN
Green ................ GRN .......................... GN
Gray ................. GRY .......................... GY
Light Blue ......... LT BLU ...................... LT BU
Light Green ........ LT GRN ...................... LT GN
Orange ............... ORG .......................... OG
Pink ................. PNK .......................... PK
Purple ............... PPL .......................... PL
Red .................. RED .......................... RD
Tan .................. TAN .......................... TN
Violet ............... VIO .......................... VI
White ................ WHT .......................... WT
Yellow ............... YEL .......................... YL









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IDENTIFYING WIRING DIAGRAM ABBREVIATIONS
NOTE: Abbreviations used on these diagrams are normally
self-explanatory. If necessary see ABBREVIATIONS

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.

1) Check drive gear and slide gear splines for damage. Check
cam portion of retainer "A" for wear or damage. Check cam for wear and
damage. Check slide gear and housing tooth surfaces for damage. Check
retainer "B" and housing contact surfaces for wear and damage.
2) Check brake assembly thickness. See Fig. 2. Assemble brake
"A" and brake "B". Using slide calipers, measure thickness of
assembled brake at both brake "A" lugs.
3) Standard thickness is .413" (10.49 mm). Minimum thickness\
is .378" (9.60 mm). If measured thickness is less than minimum
thickness, replace brake "A" and brake "B".
4) Check length of return spring. Measure length "A" of
spring. Ensure length "A" is 1.38" (35.1 mm). See Fig. 3. If length
"A" is NOT as specified, replace return spring.
5) Check length of shift spring. Measure length "B" of
spring. Ensure length "B" is 1.18" (30.0 mm). See Fig. 3. If length
"B" is NOT as specified, replace shift spring.
Reassembly Pack grooves of retainer "B" with multipurpose
grease and apply grease to attaching surfaces of all components. To
complete assembly, reverse disassembly procedure.
Fig. 2: Measuring Brake Assembly Thickness
Courtesy of Chrysler Motors.

Fig. 3: Measuring Lengths of Return Spring & Shift Spring
Courtesy of Chrysler Motors.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)
Hub Cover ........................... 13-25 (18-34)
Locking Hub Bolts ................... 36-43 (49-58)









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