MITSUBISHI MONTERO 1991 Service Manual

meter long with force of one Newton applied). Some conversions are:
* A meter kilogram is about 7.2 foot pounds.
* A foot pound is about 1.4 Newton-meters.
* A centimeter kilogram (cmkg) is equal to .9 inch pounds.
PRESSURE
Pressure is another complicated measurement. Pressure is
described as a force or weight applied to a given area. Our common
unit is pounds per square inch. Metric units can be expressed in
several ways. One is the kilogram per square centimeter (kg/cm
).
Another unit of pressure is the Pascal (force of one Newton on an area
of one square meter), which equals about 4 ounces on a square yard.
Since this is a very small amount of pressure, we usually see the
kiloPascal, or kPa (1000 Pascals). Another common automotive term for
pressure is the bar (used by German manufacturers), which equals 10
Pascals. Thoroughly confused? Try the examples below:
* Atmospheric pressure at sea level is about 14.7 psi.
* Atmospheric pressure at sea level is about 1 bar.
* Atmospheric pressure at sea level is about 1 kg/cm
.
* One pound per square inch is about 7 kPa.
CONVERSION FACTORS
CONVERSION FACTORS
\
\
\
\
\
\
\
 
TO CONVERT TO  MULTIPLY BY 
\b
\
\
\
\
\
 \
\



LENGTH
  

Millimeters (mm) Inches  .03937 

Inches Millimeters  25.4 

Meters (M) Feet  3.28084 

Feet Meters  .3048 

Kilometers(Km) Miles  .62137 
\b
\
\
\
\
\
 \
\



AREA
  

Square Centimeters (cm) Square Inches  .155 

Square Inches Square Centimeters  6.45159 
\b
\
\
\
\
\
 \
\



VOLUME
  

Cubic Centimeters Cubic Inches  .06103 

Cubic Inches Cubic Centimeters  16.38703 

Liters Cubic Inches  61.025 

Cubic Inches Liters  .01639 

Liters Quarts  1.05672 

Quarts Liters  .94633 

Liters Pints  2.11344 

Pints Liters  .47317 

Liters Ounces  33.81497 

Ounces Liters  .02957 
\b
\
\
\
\
\
 \
\



WEIGHT
  

Grams Ounces  .03527 

Ounces Grams  28.34953 

Kilograms Pounds  2.20462 

Pounds Kilograms  .45359 
\b
\
\
\
\
\
 \
\



WORK
  

Centimeter Kilograms Inch Pounds  .8676 

Pounds/Sq. Inch Kilograms/Sq.Centimeter .07031 

Bar Pounds/Sq. Inch  14.504 

Pounds/Sq. Inch Bar  .06895 

Atmosphere Pounds/Sq. Inch  14.696 

Pounds/Sq. Inch Atmosphere  .06805 
\b
\
\
\
\
\
 \
\



TEMPERATURE
  

Centigrade Degrees Fahrenheit Degrees (Cx(9)/5)+32 

Fahrenheit Degrees Centigrade Degrees (F-32)x(5)/9 
\f
\
\
\

\
\

\
\

CONVERSION FACTORS (Cont.)
\
\
\
\
\
\
\
 
INCHES DECIMALS mm

\b
\
\
\
\
\
\
\





1/64 ...................... .016 ........................ .397 

1/32 ...................... .031 ........................ .794 

3/64 ...................... .047 ....................... 1.191 

1/16 ...................... .063 ....................... 1.588 

5/64 ...................... .078 ....................... 1.984 

3/32 ...................... .094 ....................... 2.381 

7/64 ...................... .109 ....................... 2.778 

1/8 ....................... .125 ....................... 3.175 

9/64 ...................... .141 ....................... 3.572 

5/32 ...................... .156 ....................... 3.969 

11/64 ..................... .172 ....................... 4.366 

3/16 ...................... .188 ....................... 4.763 

13/64 ..................... .203 ....................... 5.159 

7/32 ...................... .219 ....................... 5.556 

15/64 ..................... .234 ....................... 5.953 

1/4 ....................... .250 ....................... 6.350 

17/64 ..................... .266 ....................... 6.747 

9/32 ...................... .281 ....................... 7.144 

19/64 ..................... .297 ....................... 7.541 

5/16 ...................... .313 ....................... 7.938 

21/64 ..................... .328 ....................... 8.334 

11/32 ..................... .344 ....................... 8.731 

23/64 ..................... .359 ....................... 9.128 

3/8 ....................... .375 ....................... 9.525 

25/64 ..................... .391 ....................... 9.992 

13/32 ..................... .406 ...................... 10.319 

27/64 ..................... .422 ...................... 10.716 

7/16 ...................... .438 ...................... 11.113 

29/64 ..................... .453 ...................... 11.509 

15/32 ..................... .469 ...................... 11.906 

31/64 ..................... .484 ...................... 12.303 

1/2 ....................... .500 ...................... 12.700 

33/64 ..................... .516 ...................... 13.097 

17/32 ..................... .531 ...................... 13.494 

35/64 ..................... .547 ...................... 13.891 

9/16 ...................... .563 ...................... 14.288 

37/64 ..................... .578 ...................... 14.684 

19/32 ..................... .594 ...................... 15.081 

39/64 ..................... .609 ...................... 15.478 

5/8 ....................... .625 ...................... 15.875 

41/64 ..................... .641 ...................... 16.272 

21/32 ..................... .656 ...................... 16.669 

43/64 ..................... .672 ...................... 17.066 

11/16 ..................... .687 ...................... 17.463 

45/64 ..................... .703 ...................... 17.859 

23/32 ..................... .719 ...................... 18.256 

47/64 ..................... .734 ...................... 18.653 

3/4 ....................... .750 ...................... 19.050 

49/64 ..................... .766 ...................... 19.447 

25/32 ..................... .781 ...................... 19.844 

51/64 ..................... .797 ...................... 20.241 

13/16 ..................... .813 ...................... 20.638 

53/64 ..................... .828 ...................... 21.034 

27/32 ..................... .844 ...................... 21.431 

55/64 ..................... .859 ...................... 21.828 

7/8 ....................... .875 ...................... 22.225 

57/64 ..................... .891 ...................... 22.622 

29/32 ..................... .906 ...................... 23.019 

59/64 ..................... .922 ...................... 23.416 

15/16 ..................... .938 ...................... 23.813 

61/64 ..................... .953 ...................... 24.209 

31/32 ..................... .969 ...................... 24.606 

63/64 ..................... .984 ...................... 25.003 

1 ......................... 1.000 ..................... 25.400 
\f
\
\
\
\
\
\
\


\003
PR E-A LIG NM EN T C HEC KS

1991 M it s u bis h i M onte ro
Wheel Alignment
PRE-ALIGNMENT INSPECTION PROCEDURES
PRE-ALIGNMENT CHECKS
Before making wheel alignment adjustment, perform the
following checks:
1) Tires should be equal in size and runout must not be
excessive. Tires and wheels should be in balance, and inflated to
manufacturer's specifications.
2) Wheel bearings must be properly adjusted. Steering linkage
and suspension must not have excessive looseness. Check for wear in
tie rod ends and ball joints.
3) Steering gear box must not have excessive play. Check and
adjust to manufacturer's specifications.
4) Vehicle must be at curb height with full fuel load and
spare tire in vehicle. No extra load should be on vehicle.
5) Vehicle must be level with floor and with suspension
settled. Jounce front and rear of vehicle several times and allow it
to settle to normal curb height.
6) If steering wheel is not centered with front wheels in
straight-ahead position, correct by shortening one tie rod adjusting
sleeve and lengthening opposite sleeve equal amounts.
7) Ensure wheel lug nuts are tightened to torque
specifications.

\003
N - R EM OVE/IN STA LL/O VER HAU L
1991 Mitsubishi Montero
1991 ENGINE PERFORMANCE
Removal, Overhaul & Installation
Dodge; Colt, Colt 200, Colt Vista, Ram-50, Stealth
Eagle; Summit
Mitsubishi; Eclipse, Galant, Mirage, Montero, Pickup, 3000GT
Plymouth; Colt, Colt 200, Colt Vista
INTRODUCTION
Removal, overhaul and installation procedures (when given by
manufacturer) are covered in this article. If component removal and
installation is primarily an unbolt and bolt-on procedure, only a
torque specification may be furnished.
IGNITION SYSTEM
DISTRIBUTOR
Fig. 1: Exploded View of Distributor (Colt Vista)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Exploded View of Distributor (Colt, Colt 200, Mirage &
Summit 1.5L)
Courtesy of Mitsubishi Motor Sales of America.
Fig. 3: Exploded View of Distributor (Galant 2.0L SOHC)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Exploded View of Distributor (Eclipse 1.8L)
Courtesy of Mitsubishi Motor Sales of America.
Fig. 5: Exploded View of Distributor (Montero & Ram-50 3.0L)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 6: Exploded View of Distributor (Pickup & Ram-50 2.4L)
Courtesy of Mitsubishi Motor Sales of America.
Fig. 7: Exploded View of Distributor (Stealth 3.0L SOHC)
Courtesy of Mitsubishi Motor Sales of America.
FUEL SYSTEM

FUEL SYSTEM PRESSURE RELEASE
WARNING: ALWAYS relieve fuel pressure before disconnecting any fuel
injection-related component. DO NOT allow fuel to contact
engine or electrical components.
1) On Colt and Mirage, remove rear seat cushion. On all
models, disconnect fuel pump harness connector at fuel tank.
2) Start engine. Let engine run until it stops. Turn ignition
off. Disconnect negative battery terminal. Connect fuel pump harness
connector.
FUEL PUMP
Removal & Installation
1) Fuel pump assembly is located inside fuel tank. Release
fuel pressure from system. See FUEL SYSTEM PRESSURE RELEASE. Raise
vehicle on hoist. Drain fuel into suitable container. Disconnect
electrical connectors and fuel hoses at fuel tank.
2) Remove fuel filler hose from fuel tank. Remove nuts
securing fuel tank. Remove fuel tank from vehicle and remove fuel pump
assembly. To install, reverse removal procedure. Tighten nuts to
specification. See TORQUE SPECIFICATION table.
FUEL RAILS & INJECTORS (PFI)
Use a rag to cover fuel hose connection before disconnecting
high pressure fuel hose at fuel rail. Some residual fuel pressure may
still be in system.
Removal (Except Pickup & Ram-50 2.4L)
1) On all models, relieve fuel pressure. See
FUEL SYSTEM PRESSURE RELEASE . Disconnect negative battery cable. On
Montero, Pickup, Ram-50, Stealth and 3000GT 3.0L, disconnect air
intake plenum. On Eclipse, disconnect PCV valve hose.
2) On Colt Vista, disconnect coolant temperature sensor
connector, idle speed control servo connector and brake booster vacuum
hose. On all models, disconnect high pressure fuel hose at fuel rail.
3) Disconnect fuel return hose. Disconnect vacuum hoses. On
Eclipse, Colt and Colt 200, disconnect throttle cable clamp. Remove
center cover. On all models, disconnect injector electrical
connectors. Remove fuel rail bolts and lift fuel rail and injectors
from engine.
Installation
To install, reverse removal procedure. Tighten bolts to
specifications. See TORQUE SPECIFICATIONS table.
Removal (Pickup & Ram-50 2.4L)
1) Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELEASE.
Disconnect negative battery cable. Drain coolant. On all models,
disconnect air intake hose. Disconnect breather hose (if applicable)
and vacuum hoses.
2) Disconnect coolant lines as necessary for clearance.
Disconnect injector electrical connectors. Position all lines, hoses
and electrical connectors out of way. Disconnect throttle and/or
kickdown cables. Remove throttle body assembly and position it out of
the way.
3) Disconnect high pressure fuel hose at fuel rail.
Disconnect fuel return line and vacuum line connection at fuel rail.
Remove fuel rail bolts and lift fuel rail and injectors from engine.

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