MITSUBISHI MONTERO 1991 Service Manual
Manufacturer: MITSUBISHI, Model Year: 1991, Model line: MONTERO, Model: MITSUBISHI MONTERO 1991Pages: 1333, PDF Size: 24.61 MB
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Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Worn close to the end of
its useful life ........ 1 ............ Suggest replacement.
Worn, affecting
performance ............ A ............ Require replacement.
(1) - Inoperative includes intermittent operation.
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SPEEDOMETER/ODOMETER HEADS (MECHANICAL)
SPEEDOMETER/ODOMETER HEAD (MECHANICAL) INSPECTION \
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Lens broken ............. A ........... ( 1) Require repair or
replacement.
Lens cloudy ............. 2 ........... ( 1) Suggest repair or
replacement.
Lens missing ............ C ........... ( 1) Require repair or
replacement.
Malfunctioning .......... A ........... ( 2) Require repair or
replacement.
Noisy ................... 2 .. Suggest repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - If lens is available as a separate part, require
replacement of lens only.
( 2) - Includes inoperative, intermittent operation, failure
to perform all functions, out of OEM specification, or
out of range.
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SPEEDOMETERS AND ODOMETERS (ELECTRONIC)
SPEEDOMETER AND ODOMETER (ELECTRONIC) INSPECTION \
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
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type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... (1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Leaking ................. A ............ Require replacement.
Lens broken ............. A ........... ( 2) Require repair or
replacement.
Lens cloudy ............. 2 ........... ( 2) Suggest repair or
replacement.
Lens missing ............ C ........... ( 2) Require repair or
replacement.
Malfunctioning .......... A ........... ( 3) Require repair or
replacement.
Mechanical head noisy ... 2 .. Suggest repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - If lens is available as a separate part, require
replacement of lens only.
( 3) - Includes inoperative, intermittent operation, failure
to perform all functions, out of OEM specification,
or out of range.
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SWITCHES
SWITCH INSPECTION \
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Binding, affecting
performance ............ A .. Require repair or replacement.
Binding, not affecting
performance ............ 2 .. Suggest repair or replacement.
Broken .................. A .. Require repair or replacement.
Burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Burned, not affecting
performance ............ 2 ........... ( 1) Suggest repair or
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replacement.
Cracked, affecting
performance ............ A .. Require repair or replacement.
Cracked, not affecting
performance ............ 1 .. Suggest repair or replacement.
Leaking ................. A .. Require repair or replacement.
Malfunctioning .......... A ........... (2) Require repair or
replacement.
Melted, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Melted, not affecting
performance ............ 2 ........... ( 1) Suggest repair or
replacement.
Missing ................. C ............ Require replacement.
Out of adjustment ....... B .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Won't return ............ A .. Require repair or replacement.
Worn .................... 1 ............ Suggest replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Includes inoperative, intermittent operation, or
failure to perform all functions.
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TONE WHEELS
See TOOTHED RINGS (TONE WHEELS) .
TOOTHED RINGS (TONE WHEELS)
If the toothed ring requires replacement and cannot be
replaced as a separate component, replace the assembly of which the
ring is a part.
TOOTHED RING (TONE WHEEL) INSPECTION
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Condition Code Procedure
Alignment incorrect ..... B .. Require repair or replacement.
Bent .................... B ............ Require replacement.
Contaminated, affecting
performance ............ A .... Require repair. Identify and
correct cause.
Cracked ................. B ............ Require replacement.
Loose ................... A ..... Require replacement of worn
parts.
Missing ................. C ............ Require replacement.
Number of teeth
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incorrect .............. B ............ Require replacement.
Teeth broken ............ A ............ Require replacement.
Teeth damaged, affecting
performance ............ A ............ Require replacement.
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TORQUE CONVERTERS
TORQUE CONVERTER INSPECTION \
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Condition Code Procedure
Converter clutch lock-up
operation is faulty .... A ............ Require replacement.
Cover shell damaged,
affecting performance .. A ............ Require replacement.
Does not meet stall speed
specification .......... B ............ Require replacement.
End play exceeds
specifications ......... B ............ Require replacement.
Hub broken .............. A ............ Require replacement.
Hub cracked ............. A ............ Require replacement.
Internal component
failure ................ A ............ Require replacement.
Leaking ................. A .. Require repair or replacement.
Pilot broken ............ A ............ Require replacement.
Pilot worn, affecting
performance ............ A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Weights missing ......... C ............ Require replacement.
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TRANSAXLE MOUNTS
See MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION) .
TRANSDUCERS (TRANSMISSION)
See SENSORS.
TRANSMISSION COOLERS
TRANSMISSION COOLER INSPECTION \
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Condition Code Procedure
Air flow obstruction .... A ................. Require repair.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A .. Require repair or replacement
of hardware.
Connection leaking ...... A .. Require repair or replacement.
Contaminated ............ A .. Require repair or replacement.
Corroded ................ 1 .. Suggest repair or replacement.
Fins damaged, affecting
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performance ............ A .. Require repair or replacement.
Fins damaged, not
affecting performance .. .. ........ No service suggested or
required.
Internal restrictions ... B .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A .. Require repair or replacement.
Tubes damaged, affecting
performance ............ A .. Require repair or replacement.
Tubes damaged, not
affecting performance .. .. ........ No service suggested or
required.
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TRANSMISSION MOUNTS
See MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION) .
TRANSMISSION PANS
TRANSMISSION PAN INSPECTION \
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Condition Code Procedure
Bent, interfering with
filter or other internal
components ............. A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
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TRANSMISSION RANGE INDICATORS (PRNDL)
TRANSMISSION RANGE INDICATOR (PRNDL) INSPECTION \
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Condition Code Procedure
Binding ................. A .. Require repair or replacement.
Broken .................. A .. Require repair or replacement.
Components missing ...... C .. Require replacement of missing
components.
Loose, affecting
performance ............ A .. Require repair or replacement.
Out of adjustment ....... A ................. Require repair.
Worn, affecting
performance ............ A .. Require repair or replacement.
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TUBES
See HOSES, LINES AND TUBES .
UNIVERSAL JOINTS (CARDON OR CROSS TYPE)
UNIVERSAL JOINT (CARDON OR CROSS TYPE) INSPECTION \
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
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Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Bearing cap distorted ... B ............ Require replacement.
Binding ................. A ............ Require replacement.
Cross (trunion) worn,
affecting performance .. A ............ Require replacement.
Double cardon centering
ball damaged ........... A ............ Require replacement.
Double cardon centering
ball worn, affecting
performance ............ A ............ Require replacement.
Double cardon centering
spring broken .......... A ............ Require replacement.
Double cardon centering
spring missing ......... C ............ Require replacement.
Double cardon centering
spring weak ............ A ............ Require replacement.
End cap seal cracked .... 2 ............ Suggest replacement.
End cap seal missing .... C .... Require replacement of seal.
Grease fitting broken ... A ...... (1) Require replacement of
grease fitting.
Grease fitting missing .. C ...... ( 2) Require replacement of
grease fitting.
Rust-colored powder around
end cap seals .......... A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Worn, affecting
performance ............ A ............ Require replacement.
( 1) - A broken grease fitting does not require replacement
of the U-Joint.
( 2) - A missing grease fitting does not require replacement
of the U-Joint.
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VACUUM CONTROLS
See ACTUATORS (VACUUM) .
VACUUM HOSES
See HOSES, LINES AND TUBES .
VACUUM MOTORS
See ACTUATORS (VACUUM) .
VACUUM-OPERATED SWITCHES
See SWITCHES.
VEHICLE SPEED SENSORS
See SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE) .
VENTS
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![MITSUBISHI MONTERO 1991 Service Manual VENT INSPECTION \
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Condition Code](/img/19/57332/w960_57332-326.png "MITSUBISHI MONTERO 1991 Service Manual VENT INSPECTION \
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Condition Code")
VENT INSPECTION \
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Condition Code Procedure
Broken .................. A ............ Require replacement.
Missing ................. C ............ Require replacement.
Plugged ................. A ........... (1) Require repair or
replacement.
( 1) - A plugged vent may force fluid past the seal.
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VIBRATION DAMPERS
VIBRATION DAMPER INSPECTION \
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Condition Code Procedure
Broken .................. A ............ Require replacement.
Missing ................. C ............ Require replacement.
Out of position ......... B .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
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WHEEL ATTACHMENT HARDWARE
NOTE: For conditions noted below, also check conditions of
wheel stud holes.
CAUTION: Proper lug nut torque is essential. Follow recommended
torque specifications and tightening sequence. DO NOT
lubricate threads unless specified by the vehicle
manufacturer.
WHEEL ATTACHMENT HARDWARE INSPECTION
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Condition Code Procedure
Bent .................... A ............ Require replacement.
Broken .................. A ........ ( 1) Require replacement.
Loose ................... B ... Require repair or replacement
of affected component.
Lug nut installed
backward ............... B .. Require repair or replacement.
Lug nut mating surface
dished ................. A ..... Require replacement of nut.
Lug nut mating type
incorrect .............. B ..... Require replacement of nut.
Lug nut rounded ......... A . ( 2) Require replacement of nut.
Lug nut seized .......... A . ( 2) Require replacement of nut.
Stud incorrect .......... B .... Require replacement of stud.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Some manufacturers require replacement of all studs on
that wheel if two or more studs or nuts on the same wheel
are broken or missing.
( 2) - Only required if removing wheel.
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![MITSUBISHI MONTERO 1991 Service Manual WHEEL SPEED SENSORS
See SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE) .
WIRING HARNESSES AND CONNECTORS
WIRING HARNESS AND CONNECTOR INSPECTION \](/img/19/57332/w960_57332-327.png "MITSUBISHI MONTERO 1991 Service Manual WHEEL SPEED SENSORS
See SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE) .
WIRING HARNESSES AND CONNECTORS
WIRING HARNESS AND CONNECTOR INSPECTION \")
WHEEL SPEED SENSORS
See SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE) .
WIRING HARNESSES AND CONNECTORS
WIRING HARNESS AND CONNECTOR INSPECTION \
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Condition Code Procedure
Application incorrect ... B .. Require repair or replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A .. Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... ( 1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Insulation damaged,
conductors exposed ..... A .. Require repair or replacement.
Insulation damaged,
conductors not exposed . 1 ............ Suggest replacement.
Open .................... A .. Require repair or replacement.
Protective shield
(conduit) melted ....... 2 ........... ( 1) Suggest repair or
replacement.
Protective shield
(conduit) missing ...... 2 .. Suggest repair or replacement.
Resistance (voltage drop)
out of specification ... A .. Require repair or replacement.
Routed incorrectly ...... B ................. Require repair.
Secured incorrectly ..... B ................. Require repair.
Shorted ................. A .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Transmission connector
leaking ................ .. ..... See TRANSMISSION ASSEMBLY.
Voltage drop out of
specification .......... A .. Require repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
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![MITSUBISHI MONTERO 1991 Service Manual \
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YOKES AND SLIP YOKES
YOKE AND SLIP YOKE INSPECT](/img/19/57332/w960_57332-328.png "MITSUBISHI MONTERO 1991 Service Manual \
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YOKES AND SLIP YOKES
YOKE AND SLIP YOKE INSPECT")
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YOKES AND SLIP YOKES
YOKE AND SLIP YOKE INSPECTION \
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Condition Code Procedure
Bearing cap bore
distorted .............. A .. Require repair or replacement.
Bent .................... A ............ Require replacement.
Bolt holes elongated .... A .. Require repair or replacement.
Bushing or seal surface
worn, affecting
performance ............ A .. Require repair or replacement.
Leaking through soft yoke
plug ................... A ... Require repair or replacement
of soft yoke plug.
Retainer strap bent ..... A .......... Require replacement of
retainer strap.
Slip yoke broken ........ A ............ Require replacement.
Splines worn, affecting
performance ............ A ............ Require replacement.
Splines worn close
to the end of their
useful life ............ 1 ............ Suggest replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
U-bolt damaged, affecting
performance ............ A ............. Require replacement
of U-bolts.
Yoke damaged, affecting
performance ............ A .. Require repair or replacement.
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\003P - E G R F U NCTIO N T E STIN G
1991 M it s u bis h i M onte ro
1989-95 ENGINE PERFORMANCE
Chrysler Motors/Mitsubishi Corp. EGR Function Testing
All Models
EGR FUNCTION TESTING
Colt Wagon 1.8L, Montero (A/T), Raider (A/T), Sigma,
Van/Wagon & All Other Federal Models (Ported EGR Valve)
1) Disconnect Green-striped hose from throttle body and
connect a vacuum pump to hose end. Plug nipple where hose was
connected to throttle body. With engine temperature 122
F (50 C) or
less, and engine idling, apply vacuum to hose. If idle does not change
and vacuum leaks down, system is functioning properly.
2) With engine temperature 176-205
F (80-95 C) and engine
idling, apply 2 in. Hg to hose. If idle does not change, and vacuum
holds, system is functioning properly.
3) Apply 7.7 in. Hg. If vacuum holds and idle becomes
unstable or engine stalls, EGR system is functioning properly.
Montero (M/T), Raider (M/T) & All Other California
Models (Ported EGR Valve)
1) Connect a vacuum tee into Green-striped hose from EGR
valve and connect a vacuum pump to vacuum tee. With engine temperature
68
F (20 C) or less and engine idling, snap throttle opened and
closed. If no change in vacuum reading on vacuum pump gauge is
detected, system is functioning properly.
2) With engine temperature 158
F (70 C) or higher and engine
idling, snap throttle open to race engine. If vacuum is now indicated
on vacuum pump gauge, system is functioning properly.
3) Using a vacuum pump, apply specified vacuum to open EGR
valve. See appropriate EGR VALVE SPECIFICATIONS table. If idle becomes
unstable or engine stalls, EGR system is functioning properly.
EGR VALVE SPECIFICATIONS TABLE (1989 Models)
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Application Closed Open
In. Hg In. Hg
Colt, Colt Wagon,
Mirage ....................... 1.8 ................ 7.7
Colt Vista .................... 2.1 ................ 6.8
Galant, Sigma ................. 1.7 ................ 7.5
Montero, Raider,
Van/Wagon .................... 1.9 ................ 6.7
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EGR VALVE SPECIFICATIONS TABLE (1990 Models)\
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Application Closed Open
In. Hg In. Hg
Colt, Colt 200, Mirage
& Colt Wagon ................. 1.8 ................ 7.7
Colt Vista .................... 2.1 ................ 6.8
Eclipse ....................... 1.8 ................ 8.5
Galant ........................ 1.7 ................ 7.5
Pickup, Ram-50 ................ 1.2 ................ 9.4
Precis ........................ 1.0 ................ 3.3
Sigma ......................... 1.6 ................ 8.7