maintenance MITSUBISHI MONTERO 1991 Workshop 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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Idle Speed Control Actuator ............................... ISC
Mix Control Solenoid .............................. MC Solenoid
Secondary Air Injection System Management Device .... AIR, PAIR
Vacuum Regulator Solenoid .................................. ..
Waste Gate Control Solenoid ................................ ..
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SHROUDS, BAFFLES AND DEFLECTORS
SHROUD, BAFFLE AND DEFLECTOR INSPECTION \
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Condition Code Procedure
Application incorrect,
affecting cooling system
performance ............ A . 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.
Bent, affecting cooling
system performance ..... A . Require repair or replacement.
Blocked, affecting cooling
system performance ..... A . Require repair or replacement.
Broken, affecting cooling
system performance ..... A . Require repair or replacement.
Cracked, affecting cooling
system performance ..... A . Require repair or replacement.
Loose, affecting cooling
system performance ..... A ................ Require repair.
Loose, not affecting
cooling system
performance ............ 2 ................ Suggest repair.
Missing, affecting cooling
system performance ..... C ........... Require replacement.
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SPARK PLUGS
NOTE: You are not required to replace spark plugs in sets.
However, you may suggest replacement of the other plugs
for preventive maintenance.
SPARK PLUG INSPECTION
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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Electrode eroded ........ 1 ............ Suggest replacement.
Fouled .................. A ........... ( 1) Require repair or
replacement.
Gap incorrect ........... B .. Require repair or replacement.
Insulation broken ....... A ............. Require replacement
Insulator cracked ....... A ............ Require replacement.
Leaking compression ..... A .. Require repair or replacement.
Maintenance interval .... 3 ............ Suggest replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
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Threads stripped (threads
missing) ............... A ............ Require replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
(1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Inoperative includes intermittent operation or out of
OEM specification. Some components may be serviceable;
check for accepted cleaning procedure.
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TIMING BELT SPROCKETS
TIMING BELT SPROCKET INSPECTION \
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Condition Code Procedure
Alignment incorrect ..... B ................. 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.
Bent .................... A ............ Require replacement.
Cracked ................. A ............ Require replacement.
Key damaged ............. A ............ Require replacement.
Loose ................... A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Pulley damaged, affecting
belt life .............. A ............ Require replacement.
Sprocket damaged,
affecting belt life .... A .. Require repair or replacement.
Sprocket loose .......... B .. Require repair or replacement.
Sprocket-to-shaft
alignment incorrect ..... B .. Require repair or replacement.
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TIMING BELTS
TIMING BELT INSPECTION \
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Condition Code Procedure
Adjustment incorrect .... 2 ......... ( 1) Suggest adjustment.
Alignment incorrect ..... B ........... ( 2) Further inspection
required.
Broken .................. A ............ Require replacement.
Cam timing out of
specification .......... B ................. Require repair.
Cracked ................. 1 ............ Suggest replacement.
Fluid-soaked ............ 1 ... Suggest replacement. Further
inspection required.
Frayed .................. 1 ............ Suggest replacement.
Maintenance intervals ... 3 ... Suggest replacement to comply
with vehicle OEM recommended
Page 583 of 1333
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* E XH AU ST S YSTE M 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
Exhaust Systems Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
Motorist Assurance Program (MAP)
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS
Exhaust
CATALYTIC CONVERTERS
EXHAUST AND TAIL PIPES
EXHAUST CONNECTIONS
HANGERS
HEAT RISERS (MECHANICAL EFE DEVICES)
HEAT SHIELDS
MANIFOLDS (CAST AND TUBE TYPE)
MECHANICAL EFE DEVICES
MUFFLERS AND RESONATORS
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt
(1) a Pledge of Assurance to their Customers and (2) the Motorist
Assurance Program Standards of Service. All participating service
providers have agreed to subscribe to this Pledge and to adhere to the
promulgated Standards of Service demonstrating to their customers that
they are serious about customer satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection communication standards
are continually re-published. In addition to these, standards for
Drive Train and Transmissions have recently been promulgated.
Participating shops utilize these Uniform Inspection & Communication
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Standards as part of the inspection process and for communicating
their findings to their customers.
The Motorist Assurance Program continues to work
cooperatively and proactively with government agencies and consumer
groups toward solutions that both benefit the customer and are
mutually acceptable to both regulators and industry. We maintain the
belief that industry must retain control over how we conduct our
business, and we must be viewed as part of the solution and not part
of the problem. Meetings with state and other government officials
(and their representatives), concerned with auto repair and/or
consumer protection, are conducted. Feedback from these sessions is
brought back to the association, and the program adjusted as needed.
To assure auto repair customers recourse if they were not
satisfied with a repair transaction, the Motorist Assurance Program
offers mediation and arbitration through MAP/BBB-CARE and other non-
profit organizations. MAP conducted pilot programs in twelve states
before announcing the program nationally in October, 1998. During the
pilots, participating repair shops demonstrated their adherence to the
Pledge and Standards and agreed to follow the UICS in communicating
the results of their inspection to their customers. To put some
"teeth" in the program, an accreditation requirement for shops was
initiated. The requirements are stringent, and a self-policing method
has been incorporated which includes the "mystery shopping" of
outlets.
We welcome you to join us as we continue our outreach... with
your support, both the automotive repair industry and your customers
will reap the benefits. Please visit MAP at our Internet site www.
motorist.org or contact us at:
1444 I Street, NW Suite 700
Washington, DC 20005
Phone (202) 712-9042 Fax (202) 216-9646
January 1999
MAP UNIFORM INSPECTION GENERAL GUIDELINES
OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS
It is MAP policy that all exhaust, brake, steering,
suspension, wheel alignment, drive-line, engine performance and
maintenance, and heating, ventilation and air conditioning, and
electrical services be offered and performed under the standards and
procedures specified in these sections.
Before any service is performed on a vehicle, an inspection
of the appropriate system must be performed. The results of this
inspection must be explained to the customer and documented on an
inspection form. The condition of the vehicle and its components will
indicate what services/part replacements may be "Required" or
"Suggested". In addition, suggestions may be made to satisfy the
requests expressed by the customer.
When a component is suggested or required to be repaired or
replaced, the decision to repair or replace must be made in the
customer's best interest, and at his or her choice given the options
available.
This section lists the various parts and conditions that
indicate a required or suggested service or part replacement.
Although this list is extensive, it is not fully inclusive. In
addition to this list, a technician may make a suggestion. However,
any suggestions must be based on substantial and informed experience,
or the vehicle manufacturer's recommended service interval and must be
documented.
Some conditions indicate that service or part replacement is
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1 - Part is close to the end of its useful life (just above
discard specifications, or weak; failure likely to occur
soon, etc.)
2 - To address a customer need, convenience, or request (to
stiffen ride, enhance performance, eliminate noise,
etc.)
3 - To comply with maintenance recommended by the vehicle's
Original Equipment Manufacturer (OEM)
4 - Technician's recommendation based on substantial and
informed experience
NOTE: Suggested services are always optional. When presenting
suggested repairs to the customer, you must present
the facts, allowing the customer to draw their own
conclusions and make an informed decision about how to
proceed.
EXHAUST
SERVICE PROCEDURES REQUIRED AND SUGGESTED FOR PROPER
VEHICLE OPERATION
WARNING: Federal EPA rules prohibit altering an exhaust system in
any way that defeats the emission reduction components of a
vehicle. Be sure to review and adhere to EPA policy on
removing and replacing catalytic converters. Where state or
local laws are stricter, they take precedence over these
guidelines.
NOTE: Some exhaust systems are of a welded design. It is not
required that the entire system be replaced. Determine the
need to replace individual components based on conditions of
component.
CATALYTIC CONVERTERS
CAUTION: Before working on an exhaust system, review EPA
regulations on removing and replacing catalytic converters.
NOTE: Any time a converter has failed, further diagnosis is
required to determine the reason(s) for converter failure.
CATALYTIC CONVERTER INSPECTION
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Condition Code Procedure
Air injection tube
broken ................. A ... Require repair or replacement
of injection tube or
replacement of catalytic
converter.
Air injection tube
burnt .................. A ... Require repair or replacement
of injection tube or
replacement of catalytic
converter.
Air injection tube
leaking ................ A ... Require repair or replacement
of injection tube or
replacement of catalytic
converter.
Air injection tube
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GEN ER AL C O OLIN G S YSTE M S ER VIC IN G
1991 M it s u bis h i M onte ro
GENERAL INFORMATION
General Cooling System Servicing
* PLEASE READ THIS FIRST *
The following article is for general information only.
Information may not apply to all years, makes and models. See specific
article in the ENGINE COOLING section.
DESCRIPTION
The basic liquid cooling system consists of a radiator, water
pump, thermostat, electric or belt-driven cooling fan, pressure cap,
heater, and various connecting hoses and cooling passages in the block
and cylinder head.
MAINTENANCE
DRAINING
Remove radiator cap and open heater control valve to maximum
heat position. Open drain cocks or remove plugs in bottom of radiator
and engine block. In-line engines usually have one plug or drain cock,
while "V" type engines will have 2, one in each bank of cylinders.
CLEANING
A good cleaning compound removes most rust and scale. Follow
manufacturer's instructions in the use of cleaner. If considerable
rust and scale has to be removed, cooling system should be flushed.
Clean radiator air passages with compressed air.
FLUSHING
CAUTION: Some manufacturers use an aluminum and plastic radiator.
Flushing solution must be compatible with aluminum.
Back Flushing
Back flushing is an effective means of removing cooling
system rust and scale. The radiator, engine and heater core should be
flushed separately.
Radiator
To flush radiator, connect flushing gun to water outlet of
radiator and disconnect water inlet hose. To prevent flooding engine,
use a hose connected to radiator inlet. Use air in short bursts to
prevent damage to radiator. Continue flushing until water runs clear.
Engine
To flush engine, remove thermostat and replace housing.
Connect flushing gun to water outlet of engine. Flush using short air
bursts until water runs clean.
Heater Core
Flush heater core as described for radiator. Ensure heater
control valve is set to maximum heat position before flushing heater.
Page 635 of 1333
IN TE R FE R EN CE V ER IF IC ATIO N C HEC K F O R O HC E N G IN E
1991 Mitsubishi Montero
Maintenance & Service Information
1983-96 Mitsubishi - Timing Belt Information
Cordia, Diamante, Eclipse, Expo, Expo LRV, Galant, Mirage,
Montero, Pickup, Precis, Sigma, Tredia, Van, 3000GT
TIMING BELT INTERFERENCE VERIFICATION INFORMATION
TIMING BELT INTERFERENCE CAUTION
NOTE: CAMSHAFT DRIVE BELTS OR TIMING BELTS - 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 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 shown in
this section reflect these changes. Belts or components
should be inspected and replaced if any of the following
conditions exist:
* Crack Or Tears In Belt Surface
* Missing, Damaged, Cracked Or Rounded Teeth
* Oil Contamination
* Damaged Or Faulty Tensioners
* Incorrect Tension Adjustment
TIMING BELT INTERFERENCE CHECK MENU
TIMING BELT INTERFERENCE VERIFICATION TABLE ( 1) \
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Replacement Interval
Application Engine (Miles)
Passenger Cars
Cordia
1983-88 .......... 1.8L 4-Cyl. ............ ( 4) 60,000
2.0L 4-Cyl. ............ ( 4) 60,000
Diamante
1992-96 ...... ( 2) 3.0L V6 (DOHC) ............. 60,000
3.0L V6 (SOHC) ........... ( 4) 60,000
Eclipse
1990-94 .......... 1.8L 4-Cyl. ............ ( 4) 60,000
1990-95 ....... ( 2) 2.0L 4-Cyl. ........... ( 4) 60,000
1990-94 ... ( 2) 2.0L 4-Cyl. Non-Turbo ..... ( 4) 60,000
1990-96 ..... ( 2) 2.0L 4-Cyl. Turbo ....... ( 4) 60,000
1996 ........... ( 2) 2.4L 4-Cyl. .......... ( 4) 60,000
Expo
1992-95 .......... 1.8L 4-Cyl. ................ 60,000
( 2) 2.4L 4-Cyl. .......... ( 4) 60,000
Expo LRV
1995 ............. 1.8L 4-Cyl. ................ 60,000
( 2) 2.4L 4-Cyl. .......... ( 4) 60,000
Galant
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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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MAIN TE N AN CE IN FO RM ATIO N
1991 M it s u bis h i M onte ro
1983-96 MAINTENANCE
Mitsubishi Maintenance Information
Montero
* PLEASE READ THIS FIRST *
NOTE: For scheduled maintenance intervals and the related fluid
capacities, fluid specifications and labor times for major
service intervals, see SCHEDULED SERVICES article below:
* SCHEDULED SERVICES - 1983-86
* SCHEDULED SERVICES - 1987-95
* SCHEDULED SERVICES - 1996
Warranty information and specifications for fluid
capacities, lubrication specifications, wheel and tire size,
and battery type are covered in this article.
MODEL IDENTIFICATION
VIN LOCATION
The Vehicle Identification Number (VIN) is located on the
left side of the dash panel at the base of the windshield. The VIN
chart explains the code characters.
VIN CODE ID EXPLANATION
Numbers preceding the explanations in the legend below refer
to the sequence of characters as listed on VIN identification label.
See VIN example below.
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(VIN) J A 4 F J 4 3 E 1 H J 0 0 0 0 0 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
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1 - Manufacturing Country
J
* Japan
2 - Manufacturer
A * Mitsubishi Motor Corp.
3 - Vehicle Type
4 * Multi-Purpose Vehicle
7 * Truck
4 - GVW & Brake Type
F * 4001-5000 Lbs., Hydraulic Brakes
G * 5001-6000 Lbs., Hydraulic Brakes
5 - Vehicle Line
J, K Or R * Montero
6 - Vehicle Series
2 * Low
3 * Medium
Page 661 of 1333
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