gas type MITSUBISHI MONTERO 1991 Service 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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area. Always wear eye protection when working around air conditioning
systems and R-12. The system's high pressure can cause severe injury
to eyes and skin if a hose were to burst. R-12 evaporates quickly
when exposed to atmosphere, freezing anything it contacts.
2) Use care when handling refrigerant containers. DO NOT drop
or strike containers or expose refrigerant containers to excessive
heat. Containers must never be heated more than 125
F (52 C). Never
expose R-12 directly to open flame.
CAUTION: When R-12 is exposed to an open flame, drawn into a running
engine, or detected with a Halide (propane) leak tester,
poisonous phosgene gas is formed. Keep work areas ventilated
and avoid running engines near work area.
USING INDIVIDUAL R-12 CANS
Disposable refrigerant cans (referred to as one pound cans)
have a flat type seal or a screw type seal, and proper can tap must be
used for each type. Be sure sealing gasket on can tap is in good
condition. A proper safety can tap will prevent refrigerant from
flowing back into open can, as tap has a one-way flow control.
NOTE: Recent findings by the EPA indicate that refrigerant is
harmful to the Earth's protective Ozone layer. When
discharging refrigerant avoid allowing refrigerant to enter
the atmosphere. Refrigerant recovery system should be used
when discharging the system.
MULTI-CAN DISPENSING VALVES
A multi-can dispensing valve allows attachment of several
cans of refrigerant, and is a good substitute when a bulk container is
not available. Cans are installed onto each leg of multi-can
dispensing valve in the same manner as the individual cans, and each
leg has its own can tap.
CAN TAP INSTALLATION FLAT TYPE SEAL CANS
On cam-lock or one-piece can taps, first turn the handle
outward to the fully open position. Securely engage locking lugs over
the can flange, and lock them in place by turning cam lock or locking
nut. Screw tap assembly into adapter so sealing gasket is fully seated
against the can top. Turn tap inward to pierce the can and close the
tap. DO NOT open tap until ready to purge the service hose or dispense
refrigerant into the system.
On 2-piece can taps, be certain tap handle is turned fully
inward to the closed position. Check that locking base is turned to
its outer limit. Securely engage locking lugs over the can flange.
Turn entire tap assembly (without disturbing the closed setting)
downward into the locking base to pierce the can. DO NOT open tap
until ready to dispense into system.
SCREW TYPE SEAL CANS
Ensure can tap is fully closed. Screw refrigerant can into
can tap fitting until tight. This will pierce the can. Connect tap to
center hose on manifold gauge set. DO NOT open tap until ready to
dispense R-12 into system.
WARNING: DO NOT open high side hand valve while air conditioning
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system is in operation. This high pressure could rupture can
or fitting at safety can valve, resulting in damage and
personal injury.
CONNECTING LINES & FITTINGS
A new "O" ring should be used in all instances when
connecting lines and fittings (dip "O" ring in clean refrigeration oil
and make certain it is not twisted during installation). Always use
two wrenches to avoid twisting or distorting lines and fittings,
tighten coupling nuts securely.
PLACING SYSTEM IN OPERATION
After component replacement and/or system servicing has been
completed and all connections have been made, proceed as follows:
1) Evacuate the system using a vacuum pump.
2) Charge the system with new R-12 (refrigerant) according t\
o
each individual vehicle as outlined in the
GENERAL COOLING SYSTEM SERVICING article. Also see Refrigerant
Capacity in this Section.
3) Leak test the system, with particular attention to all new
connections and components.
4) Make a performance test of the system. Never assume that a
recharging has automatically corrected a problem.
COMPRESSOR REMOVAL INFORMATION - ISOLATION METHOD
On systems which have compressors equipped with stem-type
service valves (Tecumseh), it is possible to isolate the compressor
for removal.
Isolating
Turn both high and low pressure manual valves to extreme
clockwise (front seat) position. Loosen cap on high pressure manual
valve connection to compressor and allow gas to escape until
compressor is relieved of pressure.
COMPRESSOR REMOVAL INFORMATION - DISCHARGE METHOD
This procedure is to be used on vehicles which have
compressor equipped with Schrader service valves. In these cases, the
compressor cannot be isolated and the system must be discharged, using
approved refrigerant recovery/recycling equipment, prior to compressor
removal.
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NOTE: Electro-magnetic interference (EMI) may be caused by
incorrect installation of accessories or components. EMI can
result in improper system operation.
BACKING PLATES
BACKING PLATE INSPECTION \
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Condition Code Procedure
Anchor pin bent ......... B .. Require repair or replacement.
Anchor pin broken ....... A ............ Require replacement.
Anchor pin worn, affecting
structural integrity ... B ............ Require replacement.
Backing plate bent ...... B .. Require repair or replacement.
Backing plate broken .... A ............ Require replacement.
Backing plate cracked ... B .. Require repair or replacement.
Corroded, affecting
structural integrity .... A ............ Require replacement.
Loose ................... B .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Shoe lands worn ......... A .. Require repair or replacement.
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BRAKE FLUID
CAUTION: Most manufacturers prohibit the use of DOT 5 brake fluid
in a system equipped with ABS.
DOT 3, DOT 4, and DOT 5.1 brake fluids are clear or light
amber in color. DOT 5 brake fluid is violet in color. Correct fluid
required for the brake system is stamped on the master cylinder cover.
BRAKE FLUID INSPECTION
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Condition Code Procedure
Beyond service interval . 3 .. Suggest flushing and refilling
with correct fluid.
Brake fluid type
incorrect .............. B .. Require flushing and refilling
with correct fluid.
Contaminated, for example,
fluid other than brake
fluid present .......... A or B ....... ( 1) Require service.
Hydraulic component ..... 3 .. Suggest flushing and refilling
overhaul or replacement with correct fluid.
Rubber master cylinder
cover gasket distorted
and gummy .............. A .......... ( 2) Require replacement
of gasket.
( 1) - If a fluid other than brake fluid is present in the brake
system which DOES affect the rubber parts, the required
service is to:
* Remove all components having rubber parts from the
system.
* Flush lines with denatured alcohol or brake cleaner
* Repair or replace all components having rubber parts
* Flush and fill with correct brake fluid. (Code A)
If a fluid other than brake fluid is present in the brake
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inspection procedures.
A visual inspection is made to determine if any required
emission control devices are missing, modified or disconnected.
Missing, modified or disconnected systems must be made fully
operational before a vehicle can be certified.
POSITIVE CRANKCASE VENTILATION (PCV)
PCV controls the flow of crankcase fumes into the intake
manifold while preventing gases and flames from traveling in the
opposite direction. PCV is either an open or closed system. See Fig. 2
.
Ensure PCV system is installed as required. Verify valve,
required hoses, connections, flame arresters, etc., are present,
routed properly and in serviceable condition.
Fig. 2: Typical Open & Closed Type PCV System
THERMOSTATIC AIR CLEANER (TAC)
The TAC supplies warm air to air intake during cold engine
operation. This system is active during cold engine warm-up only.
Under all other operating conditions, air cleaner function is the same
as any non-thermostatic unit.
Ensure required exhaust shroud, hot air duct, vacuum hoses
and air cleaner components are present and installed properly. See
Fig. 3 . Ensure any required thermostatic vacuum switches are in place
and vacuum hoses are installed and in serviceable condition. Also
ensure air cleaner lid is installed right side up. Check for oversized
air filter elements and for additional holes in the air cleaner
housing.
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Single Diaphragm EGR Valve
This type uses a single diaphragm connected to the valve by a
shaft. Diaphragm is spring-loaded to keep valve closed in the absence
of vacuum. As throttle valves open and engine speed increases, vacuum
is applied to the EGR vacuum diaphragm, opening the EGR valve. This
vacuum signal comes from a ported vacuum source. Variations in the
vacuum signal control the amount of exhaust gas that is recirculated.
See Fig. 7 .
Verify EGR valve is present and not modified or purposely
damaged. Ensure thermal vacuum switches, pressure transducers, speed
switches, etc., (if applicable) are not by-passed or modified. Ensure
vacuum hose(s) to EGR valve is not plugged.
Fig. 7: Typical Single Diaphragm EGR Valve
Courtesy of General Motors Corp.
Dual Diaphragm EGR Valve
This type uses 2 diaphragms with different effective areas
and 2 vacuum sources. Although similar to the single diaphragm type,
the second diaphragm is added below the upper diaphragm and is rigidly
attached to the valve seat. See Fig. 8. These diaphragms form a vacuum
chamber which is connected to manifold vacuum.
During highway cruising when manifold vacuum is high in the
center chamber, manifold vacuum tends to pull the valve closed.
However, the vacuum signal applied to the top side of the upper
diaphragm overcomes the downward spring force and the manifold vacuum
pull, due to the diaphragm's larger piston. This regulates the amount
of EGR.
When manifold vacuum is low during acceleration, the higher
vacuum signal opens the valve, permitting more EGR. When manifold
vacuum is high during highway cruising, the valve is only partially
opened, reducing the amount of EGR.
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These 3 orifices are opened and closed by electric solenoids. The
solenoids are, in turn, controlled by the Electronic Control Module
(ECM). When a solenoid is energized, the armature with attached shaft
and swivel pintle is lifted, opening the orifice. See Fig. 11.
The ECM uses inputs from the Coolant Temperature Sensor
(CTS), Throttle Position Sensor (TPS) and Mass Airflow (MAF) senso\
rs
to control the EGR orifices to make 7 different combinations for
precise EGR flow control. At idle, the EGR valve allows a very small
amount of exhaust gas to enter the intake manifold. This EGR valve
normally operates above idle speed during warm engine operation.
Verify EGR valve is present and not modified or purposely
damaged. Ensure thermal vacuum switches, pressure transducers, speed
switches, etc., (if applicable) are not by-passed or modified. Ensure
vacuum hose(s) to EGR valve is not plugged. Ensure electrical
connector to EGR valve is not disconnected.
Fig. 11: Typical Digital EGR Valve
Courtesy of General Motors Corp.
Integrated Electronic EGR Valve
This type functions similar to a ported EGR valve with a
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Spark control systems are designed to ensure the air/fuel
mixture is ignited at the best possible moment to provide optimum
efficiency and power and cleaner emissions.
Ensure vacuum hoses to the distributor, carburetor, spark
delay valves, thermal vacuum switches, etc., are in place and routed
properly. On Computerized Engine Controls (CEC), check for presence of\
required sensors (O2, MAP, CTS, TPS, etc.). Ensure they have not been
tampered with or modified.
Check for visible modification or replacement of the feedback
carburetor, fuel injection unit or injector(s) with a non-feedback
carburetor or fuel injection system. Check for modified emission-
related components unacceptable for use on pollution-controlled
vehicles.
AIR INJECTION SYSTEM (AIS)
Air Pump Injection System (AP)
The air pump is a belt-driven vane type pump, mounted to
engine in combination with other accessories. The air pump itself
consists of the pump housing, an inner air cavity, a rotor and a vane
assembly. As the vanes turn in the housing, filtered air is drawn in
through the intake port and pushed out through the exhaust port. See
Fig. 13 .
Check for missing or disconnected belt, check valve(s),
diverter valve(s), air distribution manifolds, etc. Check air
injection system for proper hose routing.
Fig. 13: Typical Air Pump Injection System
Courtesy of General Motors Corp.
Pulsed Secondary Air Injection (PAIR) System
PAIR eliminates the need for an air pump and most of the
associated hardware. Most systems consists of air delivery pipe(s),
pulse valve(s) and check valve(s). The check valve prevents exhaust
gases from entering the air injection system. See Fig. 14.
Ensure required check valve(s), diverter valve(s), air
distribution manifolds, etc., are present. Check air injection system
for proper hose routing.
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EARLY FUEL EVAPORATION (EFE)
The EFE valve is actuated by either a vacuum actuator or a
bimetal spring (heat-riser type). The EFE valve is closed when engine
is cold. The closed valve restricts exhaust gas flow from the exhaust
manifold. This forces part of the exhaust gas to flow up through a
passage below the carburetor. As the exhaust gas quickly warms the
intake mixture, distribution is improved. This results in better cold
engine driveability, shorter choke periods and lower emissions.
Ensure EFE valve in exhaust manifold is not frozen or rusted
in a fixed position. On vacuum-actuated EFE system, check EFE thermal
vacuum valve and check valve(s). Also check for proper vacuum hose
routing. See Fig. 15.
Fig. 15: Typical Vacuum-Actuated EFE System
Courtesy of General Motors Corp.
EMISSION MAINTENANCE REMINDER LIGHT (EMR) (IF EQUIPPED)
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NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
REMOVAL
Remove intake and exhaust manifolds and valve cover. Cylinder
head and camshaft carrier bolts (if equipped), should be removed only
when the engine is cold. On many aluminum cylinder heads, removal
while hot will cause cylinder head warpage. Mark rocker arm or
overhead cam components for location.
Remove rocker arm components or overhead cam components.
Components must be installed in original location. Individual design
rocker arms may utilize shafts, ball-type pedestal mounts or no rocker
arms. For all design types, wire components together and identify
according to the corresponding valve. Remove cylinder head bolts.
Note length and location. Some applications require cylinder head
bolts be removed in proper sequence to prevent cylinder head damage.
See Fig. 1 . Remove cylinder head.
Fig. 1: Typical Cylinder Head Tightening or Loosening Sequence
This Graphic For General Information Only
INSTALLATION
Ensure all surfaces and head bolts are clean. Check that head
bolt holes of cylinder block are clean and dry to prevent block damage
when bolts are tightened. Clean threads with tap to ensure accurate
bolt torque.
Install head gasket on cylinder block. Some manufacturer's
may recommend sealant be applied to head gasket prior to installation.
Note that all holes are aligned. Some gasket applications may be
marked so certain area faces upward. Install cylinder head using care
not to damage head gasket. Ensure cylinder head is fully seated on
cylinder block.
Some applications require head bolts be coated with sealant
prior to installation. This is done if head bolts are exposed to water
passages. Some applications require head bolts be coated with light
coat of engine oil.
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Reasons to Suggest Repair or Replacement
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.
ENGINE ASSEMBLIES
SERVICE PROCEDURES REQUIRED AND SUGGESTED FOR PROPER VEHICLE
OPERATION
CYLINDER HEAD ASSEMBLIES
NOTE: A Cylinder Head Assembly is a cylinder head fitted with
valves, associated springs, retainers, and on overhead
camshaft cylinder heads (OHC), camshaft, camshaft
bearings, lash adjusters, tappets and rockers.
CYLINDER HEAD ASSEMBLY INSPECTION
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Condition Code Procedure
Adjustable valve lash is
out of specification ... B ................. Require repair.
Internal component failure
(any component) ........ A ........... ( 1) Require repair or
replacement of cylinder
head assembly.
( 1) - It is Required that all other failure related components
be inspected for cause and condition. Additional components
or assemblies may be Suggested for repair or replacement,
such as a water pump on a short block (reason code 4,
technician's recommendation based on substantial and
informed experience).
Example:
If there is a failed head gasket with an external coolant
leak, in addition to Requiring replacement of the head
gasket, inspection of the following for cause and condition
is Required: Block, Cooling System, Cylinder Head. It may
be Suggested that additional inspections be performed, such
as the other head gasket on a V-type engine.
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LONG BLOCK ASSEMBLIES
NOTE: A Long Block Assembly is a short block assembly together
with a cylinder head assembly and all those components
fitted within the rocker or cam cover, and timing cover