MITSUBISHI MONTERO 1991 Service Manual

Manufacturer: MITSUBISHI, Model Year: 1991, Model line: MONTERO, Model: MITSUBISHI MONTERO 1991
Pages: 1333, PDF Size: 24.61 MB

MITSUBISHI MONTERO 1991 Service Manual MONTERO 1991 MITSUBISHI MITSUBISHI https://www.carmanualsonline.info/img/19/57332/w960_57332-0.png MITSUBISHI MONTERO 1991 Service Manual

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Page 731 of 1333

MITSUBISHI MONTERO 1991 Service Manual Fig. 2: 1989-92 Dash Gauges & Warning Lights
Courtesy of Mitsubishi Motor Sales of America, Inc.
OIL PRESSURE WARNING LIGHT

Fig. 2: 1989-92 Dash Gauges & Warning Lights
Courtesy of Mitsubishi Motor Sales of America, Inc.
OIL PRESSURE WARNING LIGHT

Page 732 of 1333

MITSUBISHI MONTERO 1991 Service Manual Light comes on with the ignition switch in the "ON" position
as a bulb check, but should go out shortly after engine is started. If
light remains on or comes on while driving, it indicates lo

Light comes on with the ignition switch in the "ON" position
as a bulb check, but should go out shortly after engine is started. If
light remains on or comes on while driving, it indicates low oil
pressure and possible system malfunction. Have the system checked and
serviced immediately. Do not operate vehicle until cause is located
and corrected.
ALTERNATOR WARNING LIGHT
Light comes on with the ignition switch in the "ON" position
as a bulb check and goes out after engine is started. If light remains
on or comes on while driving, it indicates possible fault in the
electrical charging system. The alternator belt may be loose or
broken. Have the system checked and serviced promptly. Do not drive
vehicle if alternator belt is loose or broken.
"BRAKE" WARNING LIGHT
Light comes on with the ignition switch in the "ON" position
as a bulb check and goes out after engine is started. Light will also
come on with the parking brake fully or partially engaged. If light
remains on or comes on at any other time, it indicates low brake fluid
level in the master cylinder reservoir or the parking brake switch may
be damaged. Have the system checked and serviced immediately if brake
fluid level is low. Do not continue driving if further trouble is
experienced.
"CHECK ENGINE" WARNING LIGHT (IF EQUIPPED)
Light is designed to come on briefly with the ignition switch
in the "ON" position as a bulb check. If light remains on or comes on
while driving, it indicates fault in an exhaust gas related component
and the system is not functioning properly. Have the system checked
and serviced as soon as possible.
"MAINTENANCE REQUIRED" WARNING LIGHT (IF EQUIPPED)
Light comes on at 50,000 miles, 80,000 miles, 100,000 miles
and 120,000 miles (150,000 miles on 1990-91 models) as a service
reminder that it is time for the periodic maintenance of the emission
control system. Have the system inspected and serviced as necessary
when light comes on. Continued operation of vehicle without having
system serviced after warning light comes on may adversely affect
proper performance of the emission control system. Reset warning
light, after the system has been checked, by pushing the reset switch
in front of the combination meter. Remove the warning light bulb after
the last maintenance service at 120,000 miles (150,000 miles on 1990-
91 models).
"A/T TEMPERATURE" WARNING LIGHT (IF EQUIPPED)
Light comes on when the automatic transmission fluid
temperature becomes abnormally high. If light comes on, reduce engine
speed, stop car and put it in "P" (Park) position. Leave engine
running until light goes out. Normal vehicle operation may be resumed
after light has gone out. If light does not go out, have the system
checked and serviced as necessary.
WHEEL LOCK INDICATOR LIGHT (IF EQUIPPED)
Light comes on when automatic free-wheeling hubs are locked.
If ignition is turned off, indicator light will not come on when

Page 733 of 1333

MITSUBISHI MONTERO 1991 Service Manual ignition switch is turned on again until vehicle begins to move, even
if free-wheeling hubs are in locked condition. Light comes on or goes
out by detecting vehicle speed (approximately 3 mph). When v

ignition switch is turned on again until vehicle begins to move, even
if free-wheeling hubs are in locked condition. Light comes on or goes
out by detecting vehicle speed (approximately 3 mph). When vehicle
speed is less than 3 mph, the condition of the automatic free-wheeling
hubs may not agree with the indicator until vehicle speed is
increased. If vehicle has been parked in extremely cold weather in 4WD
mode, the light may remain lit, even after switching to 2WD,
indicating that hubs are still locked.

Page 734 of 1333

$MITSUBISHI MONTERO 1991 Service Manual \003 C - S PEC IF IC ATIO NS 1991 M it s u bis h i M onte ro 1991 ENGINE PERFORMANCE Service & Adjustment Specifications Chrysler Motors: Colt, Colt 200, Colt Vista,$

\003
C - S PEC IF IC ATIO NS

1991 M it s u bis h i M onte ro
1991 ENGINE PERFORMANCE
Service & Adjustment Specifications
Chrysler Motors: Colt, Colt 200, Colt Vista,
Ram-50, Stealth, Summit
Mitsubishi: Eclipse, Galant, Mirage, Montero,
Pickup, 3000GT
INTRODUCTION
Use this article to quickly find specifications related to
servicing and on-vehicle adjustments. This is a quick reference
article for when you are familiar with an adjustment procedure and
only need a specification.
CAPACITIES
BATTERY SPECIFICATIONS\
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Application Amp. Hr. Rating
Colt, Mirage & Summit
Type 1 ............................... 48
Type 2 ............................... 36
Colt Vista ............................. 36
Colt 200 ............................... 52
Eclipse ................................ 50
Galant ................................. 40
Montero ................................ 52
Pickup
2.4L ................................. 36
3.0L ................................. 52
Ram-50
2.4L ................................. 36
3.0L
Standard ........................... 52
Optional ........................... 55
Stealth & 3000GT ....................... 52
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FLUID CAPACITIES\
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Application Quantity
Automatic Transaxle (Dexron-II)
Colt, Colt 200, Colt Vista, Galant & Mirage ...... 6.4 Qts. (6.1L)\
Galant (AWD) ..................................... 6.8 Qts. (6.5L\
)
Eclipse
Except Turbo ................................... 6.4 Qts. (6.1L)\
Turbo .......................................... 7.4 Qts. (7.0L)\
Stealth & 3000GT ................................. 7.9 Qts. (7.5L)\
Summit ........................................... 6.1 Qts. (5.8L)\
Automatic Transmission (Dexron-II)
Montero .......................................... 7.6 Qts. (7.2L)\
Pickup & Ram-50 .................................. 7.4 Qts. (7.0L)\
Cooling System (Includes Heater & Reserve Tank)
Colt, Colt 200, Mirage & Summit .................. 5.3 Qts. (5.0L)\
Colt Vista ....................................... 7.4 Qts. (7.0L)\
Eclipse

Page 735 of 1333

$MITSUBISHI MONTERO 1991 Service Manual 1.8L ............................................ 6.6 Qts. (6.2L)\ 2.0L ............................................ 7.6 Qts. (7.2L)\ Galant ...........................................$

1.8L ............................................ 6.6 Qts. (6.2L)\
2.0L ............................................ 7.6 Qts. (7.2L)\
Galant ........................................... 7.6 Qts. (7.2L)\
Montero ......................................... 10.0 Qts. (9.5L)\
Pickup (2WD)
Automatic Transmission ......................... 6.4 Qts. (6.1L)\
Manual Transmission ............................ 6.3 Qts. (6.0L)\
Pickup (4WD) ..................................... 8.9 Qts. (8.4L\
)
Ram-50 (2WD)
Automatic Transmission ......................... 6.5 Qts. (6.1L)\
Manual Transmission ............................ 6.3 Qts. (6.0L)\
Ram-50 (4WD)
2.4L
Automatic Transmission ....................... 6.5 Qts. (6.1L)\
Manual Transmission .......................... 6.6 Qts. (6.2L)\
3.0L
Automatic Transmission ....................... 8.8 Qts. (8.3L)\
Manual Transmission .......................... 8.9 Qts. (8.4L)\
Stealth & 3000GT ................................. 8.8 Qts. (8.3L)\
Crankcase (Includes Filter)
Colt, Colt 200, Mirage & Summit .................. 4.2 Qts. (4.0L)\
Colt Vista ....................................... 4.0 Qts. (3.8L)\
Eclipse ...................................... (1) 4.5 Qts. (4.3L)
Galant
2.0L (SOHC) .................................... 4.0 Qts. (3.8L\
)
2.0L (DOHC) ................................ ( 1) 4.5 Qts. (4.3L)
Montero .......................................... 5.5 Qts. (5.3L)\
Pickup ........................................... 4.5 Qts. (4.3L)\
Ram-50 ........................................... 5.5 Qts. (5.3L)\
Stealth & 3000GT ............................. ( 1) 4.5 Qts. (4.3L)
Differential (SAE 80W-90/API GL-5)
Colt Vista (4WD), Eclipse ........................ 1.5 Pts. (.7L\
)
Galant, Stealth & 3000GT .......................... 1.5 Pts. (.7L)\
Montero
Front .......................................... 1.2 Qts. (1.1L)\
Rear ........................................... 2.7 Qts. (2.6L)\
Pickup & Ram-50
Front
2.4L ......................................... 1.6 Qts. (1.5L)\
3.0L ......................................... 2.7 Qts. (2.6L)\
Rear
2WD .......................................... 1.6 Qts. (1.5L)\
4WD
2.4L ....................................... 1.6 Qts. (1.5L)\
3.0L ....................................... 2.7 Qts. (2.6L)\
Manual Transaxle (SAE 75W-85/API GL-4)
Colt, Colt 200, Mirage & Summit
4-Speed ........................................ 3.6 Pts. (1.7L)\
5-Speed ........................................ 3.8 Pts. (1.8L)\
Colt Vista
2WD ............................................ 2.6 Qts. (2.5L)\
4WD ............................................ 2.2 Qts. (2.1L)\
Eclipse (FWD)
Except Turbo ................................... 1.9 Qts. (1.8L)\
Turbo .......................................... 2.3 Qts. (2.2L)\
Eclipse & Galant (AWD) ........................... 2.4 Qts. (2.3L\
)
Galant ........................................... 1.9 Qts. (1.8L)\
Stealth & 3000GT ................................. 2.4 Qts. (2.3L)\
Manual Transmission (SAE 75W-85/API GL-4)
Montero .......................................... 2.3 Qts. (2.2L)\
Pickup & Ram-50
2WD ............................................ 2.4 Qts. (2.3L)\
4WD ............................................ 2.3 Qts. (2.2L)\

Page 736 of 1333

$MITSUBISHI MONTERO 1991 Service Manual Power Steering (Dexron-II) Colt, Colt Vista, Colt 200, Mirage & Summit ...... 1.9 Qts. (.9L)\ Eclipse & Galant .................................. 1.9 Qts. (.9L)\ Montero ................$

Power Steering (Dexron-II)
Colt, Colt Vista, Colt 200, Mirage & Summit ...... 1.9 Qts. (.9L)\
Eclipse & Galant .................................. 1.9 Qts. (.9L)\
Montero .......................................... 2.2 Pts. (1.0L)\
Pickup & Ram-50 ................................... 1.9 Qts. (.9L)\
Stealth & 3000GT
2-Wheel Steering ................................ 1.9 Pts. (.9L)\
4-Wheel Steering ............................... 2.5 Pts. (1.2L)\
Transfer Case (SAE 75W-85/API GL-4)
Colt Vista ........................................ 1.5 Pts. (.7L)\
Eclipse & Galant .................................. 1.3 Pts. (.6L)\
Montero, Pickup & Ram-50 ......................... 4.7 Pts. (2.2L)\
Stealth ............................................. .3 Pt. (.2L)\
3000GT .............................................. .6 Pt. (.3L)\
(1) - Add 1.0 Pt. (.5L) with oil cooler.
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QUICK-SERVICE
SERVICE INTERVALS & SPECIFICATIONS
REPLACEMENT INTERVALS\
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Component Miles
Colt, Colt 200, Mirage & Summit
Air Filter ....................... 30,000
Automatic Transaxle Fluid ........ 30,000
Belts ............................ 30,000
Coolant .......................... 30,000
Fuel & Vapor Hoses ............... 50,000
Oil ................................ 7500
Oil Filter ....................... 15,000
Spark Plugs ...................... 30,000
Timing Belt ...................... 60,000
Colt Vista
Air Filter ....................... 30,000
Automatic Transaxle Fluid ........ 30,000
Belts ............................ 30,000
Coolant .......................... 30,000
EGR Valve ( 1) .................... 50,000
Fuel & Vapor Hoses ............... 50,000
Oil ................................ 7500
Oil Filter ....................... 15,000
O2 Sensor ( 1) .................... 80,000
Rear Axle Fluid .................. 30,000
Spark Plugs ...................... 30,000
Spark Plug Wires ( 1) ............. 60,000
Timing Belt ...................... 60,000
Vapor Canister ( 1) .............. 100,000
Mirage
Air Filter ....................... 30,000
Automatic Transaxle Fluid ........ 30,000
Belts ............................ 30,000
Coolant .......................... 30,000
Fuel & Vapor Hoses ............... 50,000
Oil ................................ 7500
Filter ........................... 15,000
Spark Plugs ...................... 30,000
Timing Belt ...................... 60,000
Eclipse

Page 737 of 1333

MITSUBISHI MONTERO 1991 Service Manual Air Filter ....................... 30,000
Automatic Transaxle Fluid ........ 30,000
Belts ............................ 30,000
Coolant .......................... 30,000
Fuel & Vapor H

Air Filter ....................... 30,000
Automatic Transaxle Fluid ........ 30,000
Belts ............................ 30,000
Coolant .......................... 30,000
Fuel & Vapor Hoses ............... 50,000
Oil
Non-Turbo ........................ 7500
Turbo ............................ 5000
Oil Filter
Non-Turbo ...................... 15,000
Turbo .......................... 10,000
Spark Plugs ...................... 30,000
Timing Belt ...................... 60,000
Galant
Air Filter ....................... 30,000
Automatic Transaxle Fluid ........ 30,000
Belts ............................ 30,000
Coolant .......................... 30,000
Fuel & Vapor Hoses ............... 50,000
Oil
Non-Turbo ........................ 7500
Turbo ............................ 5000
Oil Filter
Non-Turbo ...................... 15,000
Turbo .......................... 10,000
Rear Axle Fluid .................. 30,000
Spark Plugs ...................... 30,000
Timing & Balance Shaft Belts ..... 60,000
Montero
Air Filter ....................... 30,000
Automatic Transmission Fluid ..... 30,000
Belts ............................ 30,000
Coolant .......................... 30,000
Front & Rear Axle Fluid .......... 30,000
Fuel Filter ...................... 50,000
Fuel & Vapor Hoses ............... 50,000
Oil ................................ 7500
Oil Filter ....................... 15,000
O2 Sensor (2) .................... 80,000
Spark Plugs ...................... 30,000
Spark Plug Wires ( 2) ............. 60,000
Timing Belt ...................... 60,000
Transfer Case Fluid .............. 30,000
Vapor Canister ( 2) .............. 100,000
Pickup & Ram-50
Air Filter ....................... 30,000
Automatic Transmission Fluid ..... 30,000
Belts ............................ 30,000
Coolant .......................... 30,000
EGR Valve (2.4L) ( 2) ............. 50,000
Front & Rear Axle Fluid .......... 30,000
Fuel Filter ...................... 50,000
Fuel & Vapor Hoses ............... 50,000
Oil ................................ 7500
Oil Filter ....................... 15,000
O2 Sensor ( 2) .................... 80,000
Spark Plugs ...................... 30,000
Spark Plug Wires ( 2) ............. 60,000
Timing Belt ...................... 60,000
Transfer Case Fluid .............. 30,000
Vapor Canister ( 2) .............. 100,000
Stealth
Air Filter ....................... 30,000

Page 738 of 1333

MITSUBISHI MONTERO 1991 Service Manual Automatic Transaxle Fluid ........ 30,000
Belts ............................ 30,000
Coolant .......................... 30,000
Front & Rear Axle Fluid .......... 30,000
Fuel & Vapor H

Automatic Transaxle Fluid ........ 30,000
Belts ............................ 30,000
Coolant .......................... 30,000
Front & Rear Axle Fluid .......... 30,000
Fuel & Vapor Hoses ............... 50,000
Oil
Non-Turbo ........................ 7500
Turbo ............................ 5000
Oil Filter
Non-Turbo ...................... 15,000
Turbo .......................... 10,000
Spark Plugs ...................... 60,000
Timing Belt ...................... 60,000
3000GT
Air Filter ....................... 30,000
Belts ............................ 30,000
Coolant .......................... 30,000
Fuel & Vapor Hoses ............... 50,000
Front & Rear Axle Fluid .......... 30,000
Oil
Non-Turbo ........................ 7500
Turbo ............................ 5000
Oil Filter
Non-Turbo ...................... 15,000
Turbo .......................... 10,000
Spark Plugs ...................... 60,000
Timing Belt ...................... 60,000
(1) - Federal 4WD models only.
( 2) - Federal models only.
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BELT ADJUSTMENT\
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Deflection
Application ( 1) In. (mm)
Colt, Colt 200, Mirage & Summit
1.5L ...................................... .28-.35 (7.1-8.9)
1.6L ..................................... .35-.45 (8.9-11.4)
Colt Vista
2.0L ..................................... .28-.40 (7.1-10.2)
Eclipse
1.8L ..................................... .32-.43 (8.1-11.1)
2.0L ..................................... .35-.45 (8.9-11.4)
Galant
Alternator Belt .......................... .35-.45 (8.9-11.4)
A/C Belt .......................................... .32 (8.1)
Power Steering Belt ....................... .24-.35 (6.1-8.9)
Montero
3.0L ...................................... .20-.24 (5.1-6.1)
Pickup & Ram-50
2.4L ...................................... .27-.39 (6.8-9.9)
3.0L ...................................... .32-.39 (8.1-9.9)
Stealth & 3000GT
SOHC
Alternator & Power Steering Belt ........ .24-.35 (6.1-8.9)
A/C Belt ................................ .28-.37 (7.1-9.5)
DOHC
Alternator Belt (With or Without A/C) ... .16-.22 (4.1-5.6)
Power Steering Belt .................... .35-.43 (8.9-11.1)
( 1) - With 22 lbs. (10 kg) pressure applied midway on belt run.

Page 739 of 1333

$MITSUBISHI MONTERO 1991 Service Manual ��\ ��\ ��\ ��\ ��\ ��\ ��\ �� MECHANICAL CHECKS ENGINE COMPRESSION$

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MECHANICAL CHECKS
ENGINE COMPRESSION
Check engine compression with engine at normal operating
temperature at specified cranking speed, all spark plugs removed and
throttle wide open.
COMPRESSION SPECIFICATIONS
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Application (1) Specification
Compression Ratio
1.5L (VIN A) ...................... 9.4:1
1.6L (VIN Y) ...................... 9.2:1
1.8L (VIN T) ...................... 9.0:1
2.0L (VIN R) ...................... 9.0:1
2.0L (VIN U) ...................... 9.0:1
2.0L (VIN V) ...................... 8.5:1
2.4L (VIN W) ...................... 8.5:1
3.0L (VIN B) ..................... 10.0:1
3.0L (VIN C) ...................... 8.0:1
3.0L (VIN S) ...................... 8.9:1
Compression Pressure ( 2)
1.5L (VIN A) ....... 137 psi (9.6 kg/cm
)
1.6L (VIN Y) ...... 171 psi (12.0 kg/cm)
1.8L (VIN T) ....... 131 psi (9.2 kg/cm)
2.0L (VIN R) ....... 137 psi (9.6 kg/cm)
2.0L (VIN U) ....... 114 psi (8.0 kg/cm)
2.0L (VIN V) ....... 119 psi (8.4 kg/cm)
2.4L (VIN W) ....... 119 psi (8.4 kg/cm)
3.0L (VIN B) ....... 139 psi (9.8 kg/cm)
3.0L (VIN C) ....... 115 psi (8.1 kg/cm)
3.0L (VIN S) ....... 119 psi (8.4 kg/cm)
( 1) - See A - ENGINE/VIN ID article in the
ENGINE PERFORMANCE Section for VIN
information.
( 2) - Maximum variation between cylinders is
14 psi (1.0 kg/cm
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VALVE CLEARANCE
NOTE: Valve adjustment is required on 1.5L engines only. Check
adjustment at 15,000 mile intervals.
VALVE CLEARANCE SPECIFICATIONS - 1.5L
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Application ( 1) In. (mm)
Hot Engine
Intake ....................... .006 (.15)
Exhaust ...................... .010 (.25)
Cold Engine
Intake ....................... .003 (.07)
Exhaust ...................... .007 (.17)
( 1) - Adjust valves with engine hot.
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Page 740 of 1333

$MITSUBISHI MONTERO 1991 Service Manual IGNITION SYSTEM IGNITION COIL IGNITION COIL RESISTANCE - Ohms @ 68F (20C)��\ ��\ ��\ ��\ ��\ ��$

IGNITION SYSTEM
IGNITION COIL
IGNITION COIL RESISTANCE - Ohms @ 68F (20C)\
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Application Primary Secondary
1.5L (VIN A) ................ .9-1.2 ............... 20,000-29,000\
1.6L (VIN Y) ( 1) ............ .77-.95 .............. 10,300-13,900
1.8L (VIN T) ................ .9-1.1 ............... 19,000-27,000\
2.0L (VIN R & U) ( 1) ........ .77-.95 .............. 10,300-13,900
2.0L (VIN V) ................ .72-.88 .............. 10,800-13,200\
2.4L (VIN W) ................ .72-.88 .............. 10,300-13,900\
3.0L (VIN B & C) ( 1) ........ .67-.81 .............. 11,300-15,300
3.0L (VIN S) ................ .72-.88 .............. 10,300-13,900\
( 1) - Distributorless ignition.
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HIGH TENSION WIRE RESISTANCE
HIGH TENSION WIRE RESISTANCE\
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Application (1) Ohms
1.5L (VIN A)
Coil Wire ........................... ( 2)
No. 1 Wire ....................... 11,500
No. 2 Wire ......................... 9100
No. 3 Wire ......................... 9000
No. 4 Wire ......................... 6700
1.8L (VIN T)
Coil Wire ........................... ( 2)
No. 1 Wire ....................... 10,100
No. 2 Wire ....................... 11,500
No. 3 Wire ....................... 12,000
No. 4 Wire ....................... 13,000
2.0L (VIN R & U)
Coil Wire ...................... Not Used
No. 1 Wire ......................... 5800
No. 2 Wire ......................... 8400
No. 3 Wire ....................... 10,600
No. 4 Wire ......................... 9700
2.0L (VIN V)
Colt Vista
Coil Wire ........................ 2700
No. 1 Wire ..................... 10,100
No. 2 Wire ..................... 11,800
No. 3 Wire ..................... 13,100
No. 4 Wire ..................... 13,000
Galant
Coil Wire ........................ 2700
No. 1 Wire ..................... 10,100
No. 2 Wire ..................... 11,800
No. 3 Wire ..................... 11,800
No. 4 Wire ..................... 14,200
2.4L (VIN W)
Coil Wire .......................... 3000
No. 1 Wire ....................... 10,000
No. 2 Wire ....................... 12,000

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