MAINTENANCE INFORMATION

1991 Mitsubishi Montero

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.






























































 
 (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































































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
 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
operating conditions.

Normal Service

* Driven More Than 10 Miles Daily

* No Operating Conditions From Severe Service Schedule

Severe Service (Unique Driving Conditions)

* Short Trips In Freezing Temperatures

* Towing Or Commercial Use
* Driving Off-Road Or In Salty Or Sandy Areas
* Severe Dust Conditions
* Hot Weather, Stop-And-Go Driving
* Extensive Idling

CAMSHAFT TIMING BELT

CAUTION: Failure to replace a faulty camshaft timing belt may result
in serious engine damage.

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 belt 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 in
this manual reflect these changes.
Belts or components should be inspected and replaced if any
of the following conditions exist:

* Cracks Or Tears In Belt Surface

* Missing, Damaged, Cracked Or Rounded Teeth
* Oil Contamination
* Damaged Or Faulty Tensioners
* Incorrect Tension Adjustment

Replace camshaft timing belt at 60,000 mile intervals.

SERVICE POINT LOCATIONS

Fig. 1: Service Point Locations (1983-86 2.6L 4-Cylinder Engine)

Courtesy of Mitsubishi Motor Sales of America.
Fig. 2: Service Point Locations (1987-91 2.6L 4-Cylinder Engine)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Service Point Locations (1987-91 3.0L V6 Engine)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 4: Service Point Locations (1992 3.0L V6 Engine)

Courtesy of Mitsubishi Motor Sales of America.

INFORMATION LABEL LOCATIONS

Fig. 5: Information Label Locations (1983-86 2-Door Models)
Courtesy of Mitsubishi Motor Sales of America.
Fig. 6: Information Label Locations (1987-90 2-Door Models)
Courtesy of Mitsubishi Motor Sales of America.
Fig. 7: Information Label Locations (1989-92 4-Door Models)
Courtesy of Mitsubishi Motor Sales of America.

SERVICE LABOR TIMES

SERVICE LABOR TIMES TABLE (HOURS)


































































30,000 (60,000) 50,000
Application Mile Service Mile Service

1983-86 2.6L 4-Cylinder

Automatic Transmission .... 7.9 (8.2) ................. 5.2
Manual Transmission ....... 6.9 (7.2) ................. 5.2
1987-90 2.6L 4-Cylinder
Automatic Transmission .... 7.9 (8.9) ................. 2.6
Manual Transmission ....... 6.9 (7.9) ................. 2.6
1989-96 3.0L V6
Automatic Transmission .... 6.1 (10.6) ................ 2.6
Manual Transmission ....... 5.1 (9.6) ................. 2.6


































































LUBRICATION SPECIFICATIONS
LUBRICATION SPECIFICATIONS TABLE


































































Application Fluid Specifications

Brake & Clutch Fluid ........................... DOT 3 Or DOT 4

Engine Coolant ............. Ethylene-Glycol Antifreeze Coolant
Engine Oil (1)
Minimum Temperature
Greater Than 32  F (0  C) ..... SAE 20W-40 Or 20W-50 API SG/CD
Greater Than -10  F (-23  C) .. SAE 10W-30 Or 10W-40 API SG/CD
Maximum Temperature
Less Than 60  F (16  C) ......... SAE 5W-30 Or 5W-40 API SG/CD
Front Axle & Conventional Rear Axle
Minimum Temperature
Greater Than -10  F (-23  C) ..... SAE 85W-90, 80W-90 API GL-5
Maximum Temperature
Less Than -30  F (-34  C) ................... SAE 75W API GL-5
Power Steering Fluid ........................... Dexron-IIE ATF
Rear Axle (With Limited
Slip Differential) ........... Hypoid Gear Oil (8149630EX) Or
Equivalent
Transmission
Automatic .................................... Dexron-IIE ATF
Manual Transaxle &
Transfer Case (4WD) ........... SAE 75W-85W, 75W-90 API GL-5

(1) - Since temperature ranges for different oil grades overlap,

brief fluctuations in outside temperatures are no cause for
concern.


































































FLUID CAPACITIES
FLUID CAPACITIES TABLE


































































Application Quantity

A/C System R-12 Refrigerant

1983-87 .......................................... 24-26 Ozs.
1988-91 ............................................. 32 Ozs.
1992-93 ............................................. 28 Ozs.
A/C System R-134a Refrigerant (1)
1994-96 .......................................... 21-23 Ozs.
Automatic Transmission
1984-86 ................................. ( 2) 7.2 Qts. (6.8L)
1987-93 ..................................... 7.6 Qts. (7.2L)
1994-96 (3.0L SOHC) ......................... 7.6 Qts. (7.2L)
 1994-96 (3.0L DOHC & 3.5L) .................. 9.0 Qts. (8.5L)
Cooling System
1983-88 ..................................... 8.5 Qts. (8.0L)
1989-96
2.6L ....................................... 9.7 Qts. (9.2L)
3.0L ...................................... 10.0 Qts. (9.5L)
3.5L ...................................... 10.0 Qts. (9.5L)
Differential
1983-88 ..................................... 1.9 Qts. (1.8L)
1989-93
2.6L ....................................... 1.9 Qts. (1.8L)
3.0L ....................................... 2.7 Qts. (2.6L)
1994-96
3.0L & 3.5L ................................ 2.7 Qts. (2.6L)
Engine Oil
1983-86 ..................................... 6.0 Qts. (5.8L)
1987 ........................................ 5.2 Qts. (5.0L)
1988 ........................................ 5.0 Qts. (4.8L)
1989-91 ..................................... 5.5 Qts. (5.3L)
1992-96 ..................................... 5.2 Qts. (4.9L)
Power Steering ................................ 1.1 Qts. (1.0L)
Fuel Tank
1983-88 .................................... 15.9 Gals. (60L)
1989-90
2.6L 2-Door ............................... 15.9 Gals. (60L)
3.0L 2-Door ............................... 19.9 Gals. (75L)
2.6L & 3.0L 4-Door .......................... 24 Gals. (92L)
1991-96 ...................................... 24 Gals. (92L)
Manual Transmission
1983-91 ..................................... 2.3 Qts. (2.2L)
1992 ........................................ 2.4 Qts. (2.3L)
1993-96 ..................................... 2.6 Qts. (2.5L)
Transfer Case
1983-91 ..................................... 2.3 Qts. (2.2L)
1992-96 ..................................... 2.4 Qts. (2.3L)

(1) - Use of R12 in a R134a system will result in SEVERE DAMAGE.

(2) - 1983 model equipped with manual transmission only.


































































WHEEL & TIRE SPECIFICATIONS

Tire specifications are imprinted on the tire side wall. The
recommended cold tire inflation pressures are listed on a label
attached to the rear face of the driver’s door. These pressures
provide the best combination of ride comfort, tire wear and stability
under normal conditions.

CAUTION: DO NOT mix tires of different design such as radial ply

with bias or bias-belted tires. Mixing tire types will
adversely affect road handling and may lead to loss of
vehicle control. When using snow tires, they must be used
in set of four for maneuverability and safety. DO NOT use
tire chains on front wheels.

TIRE & WHEEL SPECIFICATIONS TABLE





























































Wheel Size Tire Size

1983-86
15 x 6JJ (Steel) .............................. 215 SR15
1987-88
 15 x 6JJ (Steel) ........................... P225/75 R15
1989-1996
15 x 6JJ (Steel) ........................... P225/75 R15
15 x 6JJ (Steel or Aluminum) ............... P235/75 R15
15 X 7JJ (Aluminum) ........................ 31-10.50R15





























































TIRE INFLATION SPECIFICATIONS TABLE





























































Application Pressure
psi (kg/cm )

1983-88
Front (1) ..................................... 26 (1.8)
Rear .......................................... 34 (2.3)
Rear ...................................... ( 2) 26 (1.8)
1989-91
Front (1) ..................................... 26 (1.8)
Rear .......................................... 35 (2.4)
Rear ...................................... ( 2) 26 (1.8)
1992-96
P235/75R15
Front ........................................ 26 (1.8)
Rear ......................................... 35 (2.4)
31-10.50R15
Front ........................................ 29 (2.1)
Rear ......................................... 40 (2.8)

(1) - No chain clearance.

(2) - Inflation pressure for better ride comfort when
driving with no cargo.





























































WHEEL TIGHTENING
WHEEL TIGHTENING SPECIFICATIONS TABLE





























































Application Ft. Lbs. (N.m.)

1983 ....................................... 50-57 (70-80)

1984-96 .................................. 72-87 (100-120)





























































BATTERY SPECIFICATIONS
CAUTION: When battery is disconnected, vehicles equipped with
computers may lose memory data. When battery power is
restored, driveability problems may exist on some vehicles.
These vehicles may require a relearn procedure. See
COMPUTER RELEARN PROCEDURES article in the GENERAL
INFORMATION Section.

Battery is maintenance-free and does not normally require

additional water. However, under severe conditions it is advisable to
check battery fluid periodically. Use only distilled water to fill
battery cell should it become necessary to add water. Charge condition
can be checked by a visual test indicator on top of battery.

BATTERY REPLACEMENT SPECIFICATIONS TABLE





























































Application BCI Group Number
2.6L Engine ........................................... 45
2.6L Optional ......................................... 45
3.0L V6 ........................................... ( 1) 24
3.5L V6 ........................................... ( 1) 24

(1) - Check hood clearance on 1986 and newer models.





























































CAUTIONS & WARNINGS

SUPPLEMENTAL RESTRAINT SYSTEM (SRS) AIR BAG SYSTEM

NOTE: See the AIR BAG RESTRAINT SYSTEM article in the
ACCESSORIES/SAFETY EQUIPMENT Section.

The SRS has no user-servicable parts. Always have servicing

done by an authorized dealer.

When performing maintenance on air bag equipped vehicles

always observe proper safety precautions.

WARNING: To avoid injury from accidental air bag deployment, read and
carefully follow all warnings and service precautions. See
appropriate AIR BAG RESTRAINT SYSTEM article in the
ACCESSORIES/SAFETY EQUIPMENT section.

CAUTION: Disconnect negative battery cable before servicing any air

bag system, steering column or passenger side dash
component. After any repair, turn ignition key to the ON
position from passenger’s side of vehicle in case of
accidental air bag inflation

ANTI-LOCK BRAKE SYSTEM (ABS)

CAUTION: Never mix different diameter tires. On loose or uneven
surfaces, the ABS system may require longer stopping
distances than conventional brake systems. Exercise caution
when removing mud or snow from the wheels so as not to
damage the ABS wiring or speed sensors.

BATTERY WARNING
WARNING: When battery is disconnected, vehicles equipped with
computers may lose memory data. When battery power is
restored, driveability problems may exist on some vehicles.
These vehicles may require a relearn procedure. See
appropriate COMPUTER RELEARN PROCEDURES article in the
GENERAL INFORMATION section below.

REPLACING BLOWN FUSES

Before replacing a blown fuse, remove ignition key, turn off
all lights and accessories to avoid damaging the electrical system. Be
sure to use fuse with the correct indicated amperage rating. The use
of an incorrect amperage rating fuse may result in a dangerous
electrical system overload.

BRAKE PAD WEAR INDICATOR

Indicator will cause a squealing or scraping noise, warning
that brake pads need replacement.
 CATALYTIC CONVERTER
Continued operation of vehicle with a severe malfunction
could cause converter to overheat, resulting in possible damage to
converter and vehicle.

COOLANT (PROPYLENE-GLYCOL FORMULATIONS)

CAUTION: To avoid possible damage to vehicle use only ethylene-glycol
based coolants with a mixture ratio from 44-68% anti-freeze.
DO NOT use 100% anti-freeze as it will cause the formation
of cooling system deposits. This results in coolant
temperatures of over 300  F (149  C) which can melt plastics.
100% anti-freeze has a freeze point of only -8  F (-22  C).

CAUTION: Propylene-Glycol Mixtures has a smaller temperature range

than Ethylene-Glycol. The temperature range (freeze-boil)
of a 50/50 Anti-Freeze/Water Mix is as follows:
Propylene-Glycol -26  F (-32  C) - 257  F (125  C)
Ethylene-Glycol -35  F (-37  C) - 263  F (128  C)

CAUTION: Propylene-Glycol/Ethylene-Glycol Mixtures can cause the

destabilization of various corrosion inhibitors. Also
Propylene-Glycol/Ethylene-Glycol has a different specific
gravity than Ethylene-Glycol coolant, which will result in
inaccurate freeze point calculations.

ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS

WARNING: Many solid state electrical components can be damaged by
static electricity (ESD). Some will display a warning label,
but many will not. Discharge personal static electricity by
touching a metal ground point on the vehicle prior to
servicing any ESD sensitive component.

ENGINE OIL
CAUTION: Never use non-detergent or straight mineral oil.

FUEL SYSTEM SERVICE

WARNING: Relieve fuel system pressure prior to servicing any fuel
system component (fuel injection models).

HALOGEN BULBS
WARNING: Halogen bulbs contain pressurized gas which may explode if
overheated. DO NOT touch glass portion of bulb with bare
hands. Eye protection should be worn when handling or working
around halogen bulbs.

RADIATOR CAP
CAUTION: Always disconnect the fan motor when working near the
radiator fan. The fan is temperature controlled and could
start at any time even when the ignition key is in the OFF
position. DO NOT loosen or remove radiator cap when cooling
system is hot.

RADIATOR FAN
WARNING: Keep hands away from radiator fan. Fan is controlled by a
thermostatic switch which may come on or run for up to
15 minutes even after engine is turned off.

WARRANTY INFORMATION
CAUTION: Always refer to customer’s copy of warranty information for
specific model application and/or coverage limitations.

NEW VEHICLE LIMITED WARRANTY

Covers all manufacturer-installed parts and components for
any repairs, replacements or adjustments needed to correct defects in
materials or workmanship under normal use and maintenance for 36
months or 36,000 miles, whichever comes first, from date of delivery
to the first retail buyer or first date of use.

POWERTRAIN LIMITED WARRANTY

Upon expiration of New Vehicle Limited Warranty, this
warranty covers powertrain against defects in materials or workmanship
up to a maximum of 36 months or 50,000 miles, whichever occurs first.
On 1991-96 models, warranty period is extended to 5 years or 60,000
miles, whichever occurs first. See copy of warranty for specific
components covered.

BATTERY WARRANTY
Covers replacement of original battery for 12 months or 12,
000 miles, whichever occurs first.

AIR CONDITIONER WARRANTY

Covers manufacturer’s air conditioners for 36 months or 36,
000 miles, whichever occurs first. Air conditioner refrigerant charge
is covered for the first 12 months or 12,000 miles, whichever occurs
first. On 1992-96 models, refrigerant is covered only as part of a
warranty repair.

ANTI-CORROSION PERFORATION LIMITED WARRANTY

Covers any body sheet metal panel found to have developed
perforation (rust-through) due to corrosion for 5 years regardless of
mileage. Outer panel coverage extends to 7 years or 100,000 miles,
whichever occurs first, on 1992-96 models.

EMISSION SYSTEM DEFECT WARRANTY (EXCEPT CALIFORNIA)

Warrants that the vehicle was designed, built and equipped to
conform at the time of sale with all applicable U.S. emission
standards. Covers any repairs needed to correct defects in materials
or workmanship which would cause the vehicle not to meet these
standards for 5 years or 50,000 miles, whichever occurs first.

EMISSION SYSTEM PERFORMANCE WARRANTY (EXCEPT CALIFORNIA)

Covers all repairs, adjustments, or replacements if vehicle
has been maintained in accordance with the prescribed scheduled
maintenance instructions and fails to conform to applicable emission
standards and such failure results or will result in the vehicle owner
having to bear any penalty or other sanctions under local, state or
federal law. Warranty period is 5 years or 50,000 miles, whichever
occurs first. Covers remedy of non-conformity if vehicle fails to pass
an EPA approved emissions test during the first 24 months or 24,000
miles of this warranty. During the remainder of the warranty period,
covers remedy of non-conformity resulting from failure of certain
emission-related components. See copy of warranty for specific
components covered.

EMISSION SYSTEM WARRANTY (CALIFORNIA)

Warrants that the vehicle was designed, built and equipped to
conform at the time of sale with all applicable U.S. and California
emission standards, and that the emission control system is free from
defects in materials or workmanship which would cause the vehicle not
to meet these standards for 5 years or 50,000 miles, whichever occurs
first. On 1990 and later models, warranty coverage is 3 years or 50,
000 miles, whichever occurs first, with certain emission-related
components covered for 7 years or 70,000 miles, whichever occurs
first. See copy of warranty for specific components covered.

FUSES & CIRCUIT BREAKERS

FUSE PANEL LOCATION

The electrical system is protected against shorts by fuses
that are designed to fail, to prevent damage to the wire harness. The
fuse block is located under the instrument panel on the driver’s side.
If a fuse is blown, locate the cause before replacing the fuse. Spare
fuses are contained in the fuse block.

FUSE PANEL IDENTIFICATION (1983-91)

Fig. 8: Fuse Panel Identification (1983-91)

Courtesy of Mitsubishi Motor Sales of America, Inc.

Fuse & Circuit Breaker Identification

 1 - 20 Amp (Yellow)
Hazard Light, Dome Light, Clock
2 - 10 Amp (Red)
Taillights
3 - 10 Amp (Red)
Turn Signal Lights
4 - 10 Amp (Red)
Back-Up Lights, Gauges
5 - 15 Amp (Light Blue)
Defogger
6 - 20 Amp (Yellow)
Heater
7 - 15 Amp (Light Blue)
Stoplights
8 - 15 Amp (Light Blue)
Horn, Wiper, Washer
9 - 10 Amp (Red)
Rear Wiper, Rear Washer
10 - 15 Amp (Light Blue)
Cigarette Lighter, Radio

FUSE PANEL IDENTIFICATION (1992-96)

Fig. 9: Fuse Panel Identification (1992-96)

Courtesy of Mitsubishi Motor Sales of America, Inc.

Fuse & Circuit Breaker Identification

 1 - 20 Amp
Not Used
2 - Not Used
10 Amp (1994-96)
ELC-4 A/T Control Module, Cruise Control Unit
3 - 10 Amp
Blower Motor Relay, Headlight Washer Relay, Defogger Relay,
Car Telephone (1992-93)
4 - 10 Amp
Radio Clock, Accessory Socket Relay,
Cruise Control Unit (1994-96), Data Link Connector (1994-96)
5 - 15 Amp
Remote Controlled Mirror, Cigarette Lighter
Accessory Socket Relay (1992-93)
6 - 15 Amp
Door Lock Relay, Door Lock Control Unit (1994-96)
7 - 10 Amp
Overdrive Relay, Variable Shock Absorber Control Unit,
4WD Indicator Control Unit, ABS Power Relay (1992-93),
ABS Control Unit (1994-96), Combination Meter (1994-96)
8 - 10 Amp
Power Window Relay
9 - 15 Amp
Wiper, Washer, Sunroof
10 - 10 Amp
Horn, Cruise Control Unit (1992-93)
11 - 10 Amp
Combination Meter, Multi-meter, Motor Antenna Control Unit,
Buzzer Assembly
12 - 15 Amp
Turn Signal Light, Hazard Light, SRS Diagnosis Unit
13 - 10 Amp
Not Used
14 - 15 Amp
Accessory Socket
15 - Not Used
16 - 25 Amp
Blower Motor
17 - 15 Amp
Stoplight
18 - 10 Amp
Back-up Light, Rear Differential Lock Control Unit
19 - 10 Amp
Engine Control Module, Dome Light, Reading Light,
Cargo Light, Combination Meter, Clock, Door Lock Relay,
Cruise Control Unit, Car Telephone (1992-93)
ELC-4 A/T Control Module (1994-96), Ignition Key Illumination
Light Timer (1994-96)