torque 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
Page 690 of 1333
Installation
1) To install, reverse removal procedure. Injectors may be
removed after fuel rail is removed from intake manifold. Use new
insulators and "O" rings when installing injectors.
2) Use spindle oil or gasoline on "O" ring. Install injectors
into fuel rail with a twisting motion. Adjust throttle and kickdown
cable (if applicable). Do not drop injectors while removing or
installing fuel rail.
OXYGEN (O2) SENSOR
Removal & Installation
1) O2 Sensor is mounted in exhaust pipe below exhaust header.
It is equipped with a permanent pigtail which must be protected from
damage when sensor is removed. Ensure sensor is free of contaminants,
avoid using cleaning solvents of any type. Sensor may be difficult to
remove when engine temperature is less than 120
F (48 C).
2) Always use anti-seize compound on threads before
installation. On non-turbo models, remove sensor using Remover
(MD998703). On turbo models, use Remover (MD998748) on Eclipse and
Galant, or Remover (MD998770) on Stealth and 3000GT. Tighten oxygen
sensor to specification. See TORQUE SPECIFICATIONS table.
THROTTLE BODY
Removal
Disconnect air intake hose. Remove accelerator and automatic
speed control cables (if equipped). Disconnect fuel vapor hose,
electrical harness connector, vacuum hose and coolant hoses. Remove
throttle body retaining bolts.
Disassembly
Remove throttle position sensor. Remove idle speed control
motor. Remove throttle bracket and connector bracket (if equipped).
Remove idle position switch and adjusting nut.
NOTE: DO NOT remove throttle valve. DO NOT use cleaning solvents
on throttle position sensor, idle speed control motor or
idle position switch.
Cleaning
Clean all parts except those noted in solvent. Check vacuum
port and passage for clogging. Clean vacuum, vapor and fuel passages
with compressed air.
Reassembly
To reassemble, reverse disassembly procedure.
Installation
To install, reverse removal procedure.
THROTTLE POSITION SENSOR/SWITCH
Removal & Installation
Throttle position sensor/switch is located on throttle body.
Disconnect TPS electrical connector. Remove bolts holding TPS and
remove TPS. To install, reverse removal procedure. Tighten throttle
position sensor/switch to specification. See TORQUE SPECIFICATIONS
table. For adjustment procedure, see ON-VEHICLE ADJUSTMENTS article.
TURBOCHARGERS
Page 693 of 1333
intake hoses and EGR pipe. Disconnect oxygen sensor electrical
connector.
2) Remove oil pipe and EGR valve. Disconnect exhaust fitting
and remove rear heat protector. Remove oil return pipe. Remove
turbocharger assembly. See Fig. 11.
Fig. 11: Removing Rear Turbocharger (Stealth & 3000GT)
Courtesy of Mitsubishi Motor Sales of America.
Inspection
Check turbine and compressor wheels for cracking and other
damage. Make sure turbine and compressor wheels turn smoothly. Check
for oil leakage from turbocharger assembly. Check for proper wastegate
valve operation. See SYSTEM & COMPONENT TESTING article.
Installation
1) To install, reverse removal procedure. Before oil pipe
flare nut (above turbocharger) is installed, pour clean engine oil
into turbocharger. Ensure oil and air hoses are properly installed and
securely clamped.
2) Use new gaskets. Adjust accelerator cable (if necessary).\
Refill engine oil and coolant. Check for oil and coolant leaks.
Tighten all bolts to specification. See TORQUE SPECIFICATIONS table.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLE\
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Applications Ft. Lbs. (N.m)
Fuel Tank Nuts ............................. 15-22 (20-30)
Page 741 of 1333
No. 3 Wire ....................... 12,000
No. 4 Wire ....................... 14,000
3.0L (VIN B & C)
Coil Wire ...................... Not Used
No. 1 Wire ......................... 8600
No. 2 Wire ....................... 13,900
No. 3 Wire ......................... 6400
No. 4 Wire ....................... 11,500
No. 5 Wire ......................... 4500
3.0L (VIN S)
Coil Wire .......................... 3000
No. 1 Wire ......................... 9000
No. 2 Wire ......................... 8500
No. 3 Wire ....................... 10,000
No. 4 Wire ......................... 9000
No. 5 Wire ....................... 12,000
No. 6 Wire ....................... 10,000
No. 6 Wire ....................... 11,700
(1) - See A - ENGINE/VIN ID article in the
ENGINE PERFORMANCE Section for VIN
information.
( 2) - Information not available from mfg.
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SPARK PLUGS
SPARK PLUG TYPE \
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Application Nippondenso No.
1.5L (VIN A) .................... W20EPR-11
1.6L (VIN Y) .................... W20EPR-11
1.8L (VIN T) .................... W20EPR-11
2.0L (VIN R) ....................... W20EPR
2.0L (VIN U & V) ................ W20EPR-11
2.4L (VIN W) .................... W20EPR-11
3.0L (VIN B & C) ............... PK20PR-P11
3.0L (VIN S) .................... W16EPR-11
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SPARK PLUG SPECIFICATIONS \
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Gap Torque
Application In. (mm) Ft. Lbs. (N.m\
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2.0L (VIN R & U) ....... .028-.031 (.7-.8) ......... 15-21 (20-\
30)
All Others ............ .039-.043 (1.0-1.1) ........ 15-21 (20-30\
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FIRING ORDER & TIMING MARKS
WARNING: On the 3.0L V6, the firing order and the spark plug
connection order on the top of the distributor do not match.
Circuits internal to the distributor cap differ from the
external spark plug wire connections. This is intentional and
is done to avoid spark plug wires crossover. See Fig. 3.
Page 766 of 1333
LOWER BALL JOINT
Place ball joint in soft-jawed vise. Install dial indicator,
with stem resting on end of ball joint stud. Measure ball joint stud
end play. Replace ball joint if end play exceeds .02" (.5 mm).
UPPER BALL JOINT
1) With ball joint disconnected from steering knuckle, place
nut on ball joint stud. Using INCH lb. torque wrench, measure starting
torque required to rotate ball joint stud.
2) Starting torque must be 7-30 INCH lbs. (.8-3.4 N.m). If
starting torque is not within specification, replace ball joint
(Montero) or upper arm (Ram-50 and Pickup). For ball joint replaceme\
nt
on Montero, see UPPER BALL JOINT under REMOVAL & INSTALLATION.
WHEEL BEARINGS ADJUST
PRELOAD
1) Remove locking hub assembly. See LOCKING HUB under REMOVAL
& INSTALLATION. Remove lock washer-to-lock nut bolts and lock washer.
Remove brake caliper to ensure brake pads are not contacting rotor.
2) Using Socket (MB990954-01) and torque wrench, rotate fron\
t
hub and tighten lock nut to 95-145 ft. lbs. (129-197 N.m) to seat
bearings. Loosen nut.
3) Retighten nut to 18 ft. lbs. (24 N.m) and loosen 30-40
degrees. After setting preload, check hub turning resistance and axial
play.
HUB TURNING RESISTANCE & AXIAL PLAY
1) Using INCH lb. torque wrench or spring scale attached to
wheel stud, measure hub turning resistance. Turning resistance should
be 1-4 lbs. (.45-1.8 kg) if measured with spring scale or 2.6-11.3
INCH lbs. (.3-1.3 N.m) if measured with torque wrench.
2) Using dial indicator, check front hub axial play. Axial
play should be .002" (.05 mm) or less. Adjust wheel bearing so turning\
resistance and axial play are within specification. If turning
resistance and axial play cannot be adjusted to specifications, check
wheel bearing condition and installation. Install lock washer.
3) If lock washer and lock nut holes are not aligned, align
holes by loosening lock nut a maximum of 40 degrees. Install lock
washer bolts to lock nut. Tighten lock washer bolts. Install locking
hub.
LOWER BALL JOINT R & I
REMOVAL
1) Raise and support vehicle. Remove wheel assembly. Support
lower control arm enough to release torsion bar tension. Loosen but DO
NOT remove lower ball joint-to-steering knuckle nut.
2) Using ball joint separator, separate ball joint from
steering knuckle. Remove ball joint nut from steering knuckle. Remove
ball joint-to-lower control arm bolts. Remove ball joint.
INSTALLATION
Page 767 of 1333
Lubricate ball joint with SAE J310 NLGI No. 2 grease. Apply
semi-drying sealant to ball joint grooves. Reverse removal procedure
to complete installation. Tighten bolts to specification. See TORQUE
SPECIFICATIONS table at end of article.
NOTE: On Ram-50 and Pickup, replace upper control arm if ball
joint is defective.
UPPER BALL JOINT R & I (MONTERO)
REMOVAL
Remove snap ring and dust cover together from ball joint. See
Fig. 1 . Use Ball Joint Remover/Installer (MB990799-01 and MB990800-01)
and Clamp (MB990840-01) to press ball joint from control arm. Tighten
clamp to remove ball joint.
INSTALLATION
1) Before installing, align reference mark on ball joint with
center of control arm. Using bushing remover/installers, install ball
joint in control arm. See Fig. 1.
2) Install snap ring on ball joint. Lubricate ball joint with
SAE J310 NLGI No. 2 grease. Apply semi-drying sealant to ball joint
grooves. Install new dust cover and ring.
AUTOMATIC TYPE LOCKING HUB R & I
REMOVAL
1) Place hub must in the FREE position by placing transfer
case lever in 2H position and moving vehicle in Reverse approximately
4-6 feet.
2) Remove cover from locking hub. If necessary, wrap shop
towel around cover and use an oil filter wrench to loosen cover. Raise
and support vehicle. Remove wheel assembly.
3) Using snap ring pliers, remove snap ring and shim from end
of drive axle. See Fig. 2. Using hexagonal wrench, remove locking hub
retaining bolts. Remove locking hub assembly.
Fig. 2: Exploded View of Automatic Locking Hub
Courtesy of Chrysler Motors.
INSTALLATION
Page 768 of 1333
1) Using Socket (MB990954) and torque wrench, rotate front
hub and tighten lock nut to 95-145 ft. lbs. (129-197 N.m) to seat
bearings. Loosen nut. Retighten nut to 18 ft. lbs. (24 N.m) and loosen\
30-40 degrees.
2) Using spring scale attached to wheel stud, measure and
record turning resistance required to rotate hub/rotor assembly before
installing locking hub.
3) Apply semi-drying sealant on locking hub assembly-to-
hub/rotor contact areas. DO NOT apply sealant on outer areas of
hub/rotor assembly, toward brake contact areas.
4) Align locking hub assembly key area with steering knuckle
keyway area. Loosely install locking hub assembly on hub/rotor
assembly. Ensure locking hub assembly fully contacts hub/rotor
assembly.
5) Install locking hub retaining bolts. Tighten to
specification. See TORQUE SPECIFICATIONS table at end of article.
Using spring scale attached to wheel stud, measure turning resistance
required to rotate hub/rotor assembly.
6) Subtract turning resistance measured in step 2) (before
installing locking hub) from turning resistance measured in step 5)
(after installing locking hub). If difference exceeds 3.1 lbs. (14 N)\
,
check for incorrect installation of locking hub assembly or
components.
7) Install shim and snap ring on drive axle. Rotate drive
axle until maximum end play is obtained. Using dial indicator, check
drive axle end play.
8) Drive axle end play should be .008-.020" (.20-.51 mm). If\
end play is not within specification, adjust drive axle end play by
changing axle shaft shim. Install new "O" ring and cover. Tighten
cover to specification. See TORQUE SPECIFICATIONS table at end of
article.
LOWER CONTROL ARM R & I
REMOVAL
1) Raise and support vehicle. Remove wheel assembly. Remove
front skid plate and undercover (if equipped). Remove torsion bar. See\
TORSION BAR under REMOVAL & INSTALLATION. Remove stabilizer bar bolt
from control arm.
2) Remove shock absorber-to-control arm bolts. Loosen but DO
NOT remove lower ball joint-to-steering knuckle nut. Using ball joint
fork, separate lower ball joint from steering knuckle.
3) Remove ball joint stud nut from steering knuckle. Remove
control arm shaft. See Fig. 1. Remove torque arm. Remove lower control
arm pivot bolt. Remove lower control arm.
INSPECTION
1) Inspect control arm for cracks or deformation. Check ball
joints. See BALL JOINT CHECKING under ADJUSTMENTS & INSPECTION.
2) Inspect ball joint dust covers for damage. Replace dust
covers if damaged. Inspect control arm bushing and frame bracket
bushing for damage. Replace if necessary.
3) If frame bracket bushing needs replacing, install Bushing
Remover/Installer (MB990958-01) in bushing. See Fig. 3. Tighten
bushing remover/installer bolt until bushing is removed. Reverse
bushing remover/installer to install bushing.
NOTE: Differential carrier may require relocation to replace left
bracket bushing.
Page 769 of 1333
4) If control arm bushing needs replacing, use press and
Bushing Remover/Installer (MB990883-01). Press bushing from control
arm. See Fig. 4.
5) Coat bushing and control arm with soapy solution. Using
press and bushing remover/installer, press bushing into control arm.
Position bushing so there is equal distance from bushing-to-control
arm at both ends.
6) Reverse bushing remover/installer to install bushing.
Position bushing so there is equal distance from bushing-to-control
arm at both ends.
CAUTION: Tighten lower control arm shaft and pivot bolt to
specification with vehicle at normal operating height.
INSTALLATION
1) To install, reverse removal procedure. Ensure White mark,
located on lower mounting end of shock absorber, faces toward outside
of vehicle. Tighten lower control arm shaft and pivot bolt to
specification with vehicle at normal operating height.
2) Tighten bolts to specification. See TORQUE SPECIFICATIONS
table at end of article. Install new nut on stabilizer bar-to-control
arm bolt. Tighten stabilizer bar-to-control arm bolt until distance
from threaded end of bolt to nut is .24-.31" (6.0-7.8 mm).
Fig. 3: Replacing Bracket Bushing
Courtesy of Mitsubishi Motor Sales of America.
Page 771 of 1333
REMOVAL
Remove skid plate (if equipped). Remove stabilizer bar bolt
from lower control arm. Remove stabilizer bar clamp-to-hanger bolts.
Remove stabilizer bar and bushings. Remove stabilizer bar-to-frame
hangers (if necessary).
INSTALLATION
Inspect bushings for wear. Check stabilizer bar for
deformation. To install, reverse removal procedure. Install stabilizer
bar-to-frame hangers and stabilizer bar-to-control arm bolt using new
nuts. Tighten hanger-to-frame nut and stabilizer bar-to-control arm
nut until distance from threaded end of bolt to nut is .24-.32" (6.1-
8.1 mm).
STEERING KNUCKLE R & I
REMOVAL
1) Raise and support vehicle. Remove wheel assembly. Remove
brake caliper. Remove hub/rotor assembly. See WHEEL BEARINGS under
REMOVAL & INSTALLATION. Remove dust cover from steering knuckle.
2) Disconnect tie rod end from steering knuckle. Loosen
torsion bar anchor arm assembly adjusting nut. Loosen ball joint-to-
steering knuckle nuts. Using ball joint separator, separate ball
joints from steering knuckle.
3) Detach upper and lower ball joints from steering knuckle.
Remove steering knuckle from drive axle. Remove oil seal and spacer
from steering knuckle.
INSPECTION
Inspect steering knuckle for cracks. Inspect spindle and
steering knuckle needle bearing for wear or damage.
INSTALLATION
1) If needle bearing requires replacement, drive bearing from
steering knuckle. Use Bearing Driver (MB990956-01) and Handle
(MB9909938-01) to install needle bearing.
NOTE: DO NOT reuse steering knuckle bearing if removed.
2) Using bearing installer and handle, install new needle
bearing until bearing is even with steering knuckle end face. Apply
SAE J310 NLGI No. 2 grease to bearing roller surface and spacer-to-
steering knuckle contact areas. Install spacer with chamfered side
toward inside of vehicle.
3) Using Seal Installer (MB990985-01) and Handle (MB990938-\
01), install seal in steering knuckle until seal is even with steering
knuckle end face. Apply grease to seal lip area and inside of seal. To
complete installation, reverse removal procedure. Tighten bolts to
specification. See TORQUE SPECIFICATIONS table at end of article.
TORSION BAR R & I
CAUTION: Mark torsion bar and anchor arm location for reassembly
reference before removing.
Page 772 of 1333
REMOVAL
1) Raise and support vehicle. Support lower control arm with
jack stand. Loosen anchor arm adjusting bolt lock nut. On Montero,
remove heat protector from frame (right side only). Loosen anchor bolt\
to release torsion bar tension.
2) Place reference marks on front of torsion bar, torque arm
and torsion bar-to-torque arm for reassembly reference. Remove anchor
arm. See Fig. 1.
3) Remove dust cover from end of torsion bar. On Montero,
remove heat cover (left side only) located between dust cover and
torsion bar. On all models, remove torsion bar.
INSPECTION
Inspect all splined areas for damage. Inspect dust covers for
cracks or damage. Check for bent anchor bolts. Replace components as
necessary.
INSTALLATION
1) Apply grease to splined areas of torsion bar, anchor arm,
torque arm splines, anchor bolt threads and inside of dust cover.
Check for left and right identification marks on torsion bars' ends.
Ensure torsion bars are installed in correct location.
2) Install torsion bar in torque arm, with identification
mark toward front of vehicle. Align mark on torque arm with mating
mark on torsion bar. When installing a new torsion bar, align the
White paint spline with index mark on front torque arm.
3) Install anchor arm on torsion bar so initial length of
adjusting bolt from flat surface of upper and lower half moon washers
is within specification. See Fig. 5.
4) See ANCHOR BOLT INITIAL SPECIFICATIONS table. Ensure upper
control arm rebound stopper is contacting crossmember before adjusting
initial setting.
NOTE: Ensure upper control arm rebound stopper is contacting
crossmember when adjusting initial settings.
Fig. 5: Adjusting Anchor Arm Bolt
Courtesy of Mitsubishi Motor Sales of America.
ANCHOR BOLT INITIAL SPECIFICATIONS TABLE
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Page 773 of 1333
Application In. (mm)
Montero
Left Side .................. 5.3-5.6 (135-142)
Right Side ................. 4.9-5.2 (124-132)
Ram-50 & Pickup
Left Side .................. 5.5-5.8 (140-147)
Right Side ................. 5.3-5.6 (135-142)
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5) After initial torsion bar setting, tighten anchor bolt
adjusting nut to obtain correct final bolt protrusion.
6) On Montero, final bolt protrusion depends upon curb weight
of vehicle. Adjust anchor bolt adjusting nut to obtain final anchor
bolt protrusion. See appropriate FINAL ANCHOR BOLT PROTRUSION table.
FINAL ANCHOR BOLT PROTRUSION TABLE (MONTERO)
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Curb Weight Right Bolt Left Bolt
Lbs. (kg) In. (mm) In. (mm)
2910 (1320) ........... 2.6 (65) .............. 2.2 (55)
3000 (1360) ........... 2.7 (68) .............. 2.2 (55)
3080 (1400) ........... 2.8 (71) .............. 2.3 (57)
3170 (1440) ........... 2.8 (71) .............. 2.4 (59)
3260 (1480) ........... 2.9 (72) .............. 2.5 (62)
3350 (1520) ........... 3.0 (76) .............. 2.5 (62)
3440 (1560) ........... 3.0 (76) .............. 2.6 (65)
3530 (1600) ........... 3.1 (78) .............. 2.6 (65)
3620 (1640) ........... 3.2 (80) .............. 2.7 (68)
3700 (1680) ........... 3.2 (80) .............. 2.8 (71)
3790 (1720) ........... 3.3 (84) .............. 2.9 (72)
3880 (1760) ........... 3.4 (86) .............. 2.9 (72)
3970 (1800) ........... 3.4 (86) .............. 3.0 (76)
4060 (1840) ........... 3.5 (88) .............. 3.1 (78)
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FINAL ANCHOR BOLT PROTRUSION (RAM-50 & PICKUP) \
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Right Bolt Left Bolt
Application In. (mm) In. (mm)
Ram-50 & Pickup ..... 3.39 (86.1) ......... 3.94 (100.1)
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FINAL ANCHOR BOLT PROTRUSION (1992 MONTERO) \
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Right Bolt Left Bolt
Application In. (mm) In. (mm)
Montero ............. 3.15 (80.0) .......... 3.15 (80.0)
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7) To complete installation, reverse removal procedure.
Tighten bolts to specification. See TORQUE SPECIFICATIONS table at end
of article. Place unladed vehicle in normal operating height. Measure
clearance between lower control arm bump stop and bump stop bracket on
frame.
8) On Montero, clearance should be 2.8" (71 mm). On Pickup,
clearance should be 3.1" (78 mm). If clearance measurements are NOT as\
specified, adjust anchor bolt adjusting nut to obtain correct
clearance.