Mitsubishi Montero 1993 User Manual

5 (1)

3.0L V6 - VIN [H]

1993 Mitsubishi Montero

1993 CHRYSLER CORP./MITSUBISHI ENGINES

3.0L V6

Dodge: Ram-50

Mitsubishi: Montero, Pickup

ENGINE IDENTIFICATION

NOTE: For engine repair procedures not covered in this article, see ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION article in the GENERAL INFORMATION section.

Engine may be identified by Vehicle Identification Number (VIN) stamped on a metal pad located near lower left corner of windshield. The eighth character identifies the engine model. Engine code number is stamped on front upper edge of cylinder block, below cylinder head, or on vehicle information plate on firewall. Engine serial number is stamped near the engine code number.

ENGINE IDENTIFICATION CODES TABLE

Application

Engine Code

VIN Code

Montero,

Pickup & Ram-50

 

 

3.0L V6

.......................

6G72 ...............

H

ADJUSTMENTS

VALVE CLEARANCE ADJUSTMENT

NOTE: All engines are equipped with hydraulic lash adjusters.

Adjustment is not required.

REMOVAL & INSTALLATION

* PLEASE READ FIRST *

CAUTION: When battery is disconnected, vehicle computer and memory systems may lose memory data. Driveability problems may exist until computer systems have completed a relearn cycle.

NOTE: For reassembly reference, label all electrical connectors, vacuum hoses, and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

FUEL PRESSURE RELEASE

Perform these steps to release fuel system pressure:

*Disconnect fuel pump harness connector at fuel tank.

*Start engine. After it stalls, turn ignition switch to OFF position.

*Disconnect battery (-) terminal. Reconnect fuel pump harness.

*Wrap shop towels around fuel return and high pressure hoses to prevent fuel splashing on engine. Disconnect fuel return hose

and high pressure fuel hose to drain any residual fuel.

ENGINE

Removal

1)Remove hood. Drain cooling system. Remove radiator. Remove skid plate and splash shields. Release fuel system pressure. See FUEL PRESSURE RELEASE. Disconnect negative battery cable.

2)Remove air cleaner ducts. Remove accessory drive belts. Remove and support A/C compressor and power steering pump, leaving hoses connected. Disconnect oil cooler hoses. Cover fuel hose with shop towel, and disconnect high pressure fuel hose and "O" ring.

Disconnect fuel return hose.

3)Label and disconnect all vacuum hoses. Disconnect cooling system hoses. Label and unplug all electrical connections from engine. Remove heat shield from motor mounts. Remove motor mount bolts. Ensure all hoses and wires are disconnected and set aside.

4)Disconnect exhaust pipe from exhaust manifolds. Remove starter. Attach engine hoist to engine. Support transmission. Disconnect engine from transmission. See appropriate information in CLUTCH article in the CLUTCHES section, or refer to procedures described in TRANSMISSION SERVICING - M/T article in the MANUAL TRANSMISSION SERVICING section. Remove engine.

Installation

To install, reverse removal procedure. Install new "O" rings onto fuel lines. Install new exhaust gaskets and nuts. See TORQUE SPECIFICATIONS TABLE at the end of this article. Replenish fluids.

CAUTION: DO NOT allow foreign material into turbocharger air intake hoses or pipes.

INTAKE MANIFOLD

CAUTION: Fuel system is under pressure. Fuel pressure must be released before disconnecting fuel lines. See FUEL PRESSURE RELEASE.

Removal

1)Release fuel pressure. Drain cooling system. Remove throttle body. Remove EGR valve and tube (if equipped). Remove front and rear manifold brackets. Remove upper intake manifold. See Fig. 1.

2)Remove spark plug cables, spark plugs, distributor, and coil. Remove fuel pressure regulator, fuel injectors, fuel rails, and grommets. Remove coolant and heater hoses. Remove temperature sensors and thermoswitch. Remove coolant outlet fitting and thermostat. Remove retaining nuts and intake manifold.

Fig. 1: View Of Typical Upper Intake Manifold Components Courtesy of Mitsubishi Motor Sales of America, Inc.

Installation

Clean all gasket mating surfaces. Inspect for damage and cracks on all mounting surfaces. To install, reverse removal procedure using, new gaskets and "O" rings. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS TABLE at the end of this article.

Fig. 2: Exploded View Of Typical Lower Intake Manifold Courtesy of Mitsubishi Motor Sales of America, Inc.

EXHAUST MANIFOLDS

Removal

1)Remove O2 sensor. Disconnect exhaust pipes from manifolds. Lower exhaust pipes. Remove heat shields. Before removing right manifold, remove decking hook and alternator brace.

2)Before removing left exhaust manifold, remove EGR tube (if equipped) and gasket. Remove front intake manifold plenum bracket. Remove exhaust manifolds and gaskets.

Installation

To install, reverse removal procedure. Install new gaskets. Lubricate new dipstick tube "O" ring with engine oil before installation. Install manifold nuts and washers in original locations. On all models, tighten nuts to specification. See TORQUE SPECIFICATIONS TABLE at the end of this article.

CYLINDER HEADS

Removal

1)Drain cooling system. Remove intake manifolds and brackets. See INTAKE MANIFOLD. Remove spark plug wires. Remove splash shields. Disconnect O2 sensor. Remove heat shields and exhaust manifolds. See EXHAUST MANIFOLDS.

2)Remove distributor. Remove timing belt outer covers, camshaft sprockets, timing belt, and timing belt inner covers. See TIMING BELT. Remove accessory bracket bolts from front of cylinder head. Remove rocker cover and gasket.

NOTE: To prevent cylinder head warpage and cracking, loosen cylinder head bolts in 2 or 3 stages in proper sequence.

3) Using Socket (MD998051), unscrew cylinder head bolts in 2 or 3 stages in proper sequence. See Fig. 3. Remove cylinder head and camshaft assemblies. Note orientation of washers under cylinder head bolts.

Fig. 3: Removing & Installing Cylinder Head Bolts

Courtesy of Mitsubishi Motor Sales of America, Inc.

Inspection

Measure cylinder head height. Measure warpage at gasket and

manifold surfaces. Resurface head if warpage exceeds specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Replace cylinder head if it is not within specification after resurfacing.

Installation

1)Ensure mating surfaces are clean and dry. Note identification mark located on front of head gasket. Identification mark is "R". Install head gasket with identification mark toward timing belt side of engine, facing upward.

2)Install cylinder head. Install washers cylinder head bolts with chamfered side toward bolt head. Using proper sequence, tighten bolts to specification in 2 or 3 stages in proper sequence. See

Fig. 3. See TORQUE SPECIFICATIONS TABLE at the end of this article.

3)Apply sealant to rocker cover sealing surfaces before installation. See Fig. 4. Align rocker cover gasket projections with notches in rocker cover. Lubricate all "O" rings with engine oil before installation. Install new "O" rings onto distributor adapter and oil dipstick tube.

4)Lubricate camshaft area with oil prior to installing distributor adapter. To complete installation, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS TABLE at the end of this article. After engine reaches normal operating temperature, allow engine to cool. Retighten cylinder head bolts to specification.

Fig. 4: Applying Sealant To Rocker Cover

Courtesy of Mitsubishi Motor Sales of America, Inc.

FRONT CRANKSHAFT OIL SEAL

Removal & Installation

Remove timing belt and crankshaft sprocket. See TIMING BELT. Pry oil seal from oil pump. Before installation, coat seal lip with grease. Using Seal Driver (MD998717), install seal in oil pump. Install remaining components. See TORQUE SPECIFICATIONS TABLE at the end of this article.

TIMING BELT

Removal

1)Drain cooling system. Disconnect upper radiator hose. Remove upper radiator shroud. Remove cooling fan and fan clutch assembly. Remove cooling fan pulley. Remove drive belts. Remove power steering pump, leaving hoses connected. Set power steering pump aside.

2)Remove power steering pump brackets. Remove A/C tensioner

pulley and mounting bracket. Remove A/C compressor with hoses connected, and remove mounting bracket. Remove cooling fan bracket assembly. Note location and length of bolts for reassembly reference.

NOTE: "V" belt will be damaged by tool. DO NOT use engine "V" belt to hold crankshaft pulley unless belt is to be replaced.

3)Remove upper timing belt covers and gaskets. See Fig. 6. Remove lower timing belt cover and gaskets. Using Holder (MB998747) and a used "V" belt, remove crankshaft pulley bolt. Remove crankshaft pulley.

4)Remove flange. See Fig. 6. Rotate crankshaft to align all timing marks. See Fig. 7. Loosen belt tensioner bolt, and rotate belt tensioner counterclockwise to relieve belt tension.

5)If reusing timing belt, place arrow on belt to indicate belt running direction. Remove timing belt and belt tensioner. If camshaft sprocket requires removal, install Holder (MB990775) onto camshaft sprocket. Remove retaining bolt and camshaft sprocket. Remove rear timing belt cover if necessary.

Fig. 5: Removing Engine Support Bracket

Courtesy of Mitsubishi Motor Sales of America, Inc.

Fig. 6: Exploded View Of Timing Belt Components Courtesy of Mitsubishi Motor Sales of America, Inc.

Fig. 7: Aligning Timing Marks

Courtesy of Mitsubishi Motor Sales of America, Inc.

Fig. 8: Identifying Timing Belt Cover Bolt Lengths Courtesy of Mitsubishi Motor Sales of America, Inc.

Installation

1) Install rear timing belt cover. Tighten bolts to

specification. See TORQUE SPECIFICATIONS TABLE at the end of this article. Install camshaft sprockets (if removed). Using holder, hold camshaft and tighten retaining bolt to specification.

2)Install belt tensioner and spring. Ensure spring is secured on pin of water pump and engaged in hole of belt tensioner, with hook of spring pointing away from cylinder block.

3)Rotate belt tensioner counterclockwise as far as possible, and temporarily tighten bolt. Align all timing marks with No. 1 cylinder at TDC of compression stroke. See Fig. 7.

4)Install timing belt onto crankshaft sprocket first, then onto left camshaft sprocket, with all slack removed from tension side of belt. Route timing belt onto water pump pulley, right camshaft sprocket, and tensioner. Remove any slack from belt by rotating left and then right camshaft sprockets counterclockwise.

5)Ensure belt is installed in original direction of rotation, and all timing marks are aligned. Install flange on crankshaft. Loosen belt tensioner bolts slightly, and allow tensioner to apply belt tension.

6)Using Crankshaft Socket (MD998716), rotate crankshaft 2 revolutions clockwise. DO NOT rotate counterclockwise. Realign all timing marks. Tighten belt tensioner bolts to specification. Using belt tension gauge, measure belt tension halfway between crankshaft sprocket and camshaft sprocket on side opposite belt tensioner.

7)Belt tension should be 57-84 lbs. (26-38 kg). To install remaining components, reverse removal procedure. Install bolts in proper holes. See Fig. 8. Tighten bolts to specification. See TORQUE SPECIFICATIONS TABLE at the end of this article.

CAMSHAFT & ROCKER ARMS

Removal

1)Remove PCV valve and breather hoses. Remove timing belt, camshaft sprocket, and rear timing belt cover. See TIMING BELT. Remove rocker covers and gaskets. Remove circular packing from rear of camshafts.

2)Remove camshaft oil seal from front of cylinder head or distributor adapter. Remove distributor adapter and "O" ring. Install Valve Lash Adjuster Holder (MD998443) onto rocker arm. See Fig. 9. Note arrow marks on bearing caps and cylinder head. See Fig. 10.

3)Bearing cap location number is stamped on front side of bearing cap. Remove bearing cap bolts. Keep components in order for reassembly reference. Remove rocker arm assembly. Remove camshaft from cylinder head.

Fig. 9: Installing Valve Lash Adjuster Holder Courtesy of Mitsubishi Motor Sales of America, Inc.

Mitsubishi Montero 1993 User Manual

Fig. 10: Identifying Bearing Cap & Sealant Locations Courtesy of Mitsubishi Motor Sales of America, Inc.

Inspection

1) Remove bearing caps, rocker arms, and springs from shafts. Mark component location for reassembly reference. Inspect rocker arm and shaft for damaged roller and flaking. Measure rocker arm I.D. and rocker arm shaft O.D. Determine oil clearance. Measure spring free length. Replace components if not within specification. See ROCKER ARM & SHAFT SPECIFICATIONS table.

2)Inspect camshaft and distributor gear for damage. Measure camshaft end play, journal diameter, and lobe height. Replace camshaft if it is not within specification. See CAMSHAFT table under ENGINE SPECIFICATIONS.

3)Lubricate components with engine oil. Reassemble rocker arms, springs, and bearing caps. Install bearing caps with identification number toward camshaft sprocket. Ensure oil holes and notch of shafts are properly positioned. See Fig. 11.

ROCKER ARM & SHAFT SPECIFICATIONS TABLE

Application

 

 

In. (mm)

Oil Clearance ................

(1) .0004-.0016 (.010-.041)

Rocker Arm I.D. ............................

.7444

(18.91)

Rocker

Arm Shaft O.D.

......................

.7440

(18.90)

Spring

Free Length .........................

 

2.173

(55.19)

(1) - Maximum clearance is .004" (.10 mm).

Fig. 11: Installing Rocker Arm Shafts

Courtesy of Mitsubishi Motor Sales of America, Inc.

Installation

1) Lubricate camshaft with engine oil, and install into

cylinder head. Install valve lash adjusters and valve lash adjuster holders (if removed). See Fig. 9.

2)Apply 3M Sealant (4171) to designated areas of cylinder head. See Fig. 10. Use care so sealant does not get onto camshaft or camshaft bearings. Install rocker arm assembly. Ensure arrow on bearing cap faces same direction as arrow on cylinder head. See

Fig. 10. Tighten bearing cap bolts to specification. See TORQUE SPECIFICATIONS TABLE at the end of this article. Remove valve lash adjuster holders.

3)Lubricate camshaft oil seal area with engine oil. Using Seal Driver (MD998713), install camshaft oil seal. Using Circular Packing Installer (MD998306), install circular packing to press-in depth of .02" (.5 mm).

4)Apply Three Bond (1212D) sealant to rocker cover sealing surfaces before installation. See Fig. 4. Lubricate new "O" ring with oil, and install onto distributor adapter (if removed).

5)Lubricate camshaft area with oil before installing distributor adapter. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS TABLE at the end of this article.

REAR CRANKSHAFT OIL SEAL

Removal

Remove transaxle/transmission. See appropriate article in TRANSMISSION SERVICING or CLUTCHES. Remove flywheel or drive plate. Remove rear oil seal housing. Pry seal from seal housing.

Installation

Lubricate seal lip with engine oil. Using Seal Driver (MD998718), install seal into seal housing. Apply sealant to sealing surface of seal case. Install seal case. Install flywheel or drive plate. Tighten bolts to specification. See TORQUE SPECIFICATIONS TABLE at the end of this article. To complete installation, reverse removal procedure.

WATER PUMP

Removal

Drain cooling system. Remove timing belt and crankshaft sprocket. See TIMING BELT. Remove coolant ducts to water pump if necessary. Remove water pump bolts, noting length and location for reassembly reference. Remove water pump.

Installation

To install, reverse removal procedure, using new gasket and "O" rings. Coat all "O" rings with water before installation. Install water pump and gasket. Tighten bolts to specification. See TORQUE SPECIFICATIONS TABLE at the end of this article.

OIL PAN

Removal (Montero)

1)Remove hood. Remove skid plate and lower covers. Raise and support vehicle. Disconnect and remove exhaust pipe from exhaust manifolds. Drain engine oil. Remove starter cover and starter. Unplug oil pressure sending unit connector. Remove front suspension crossmember.

2)Remove transmission braces. Remove ground cable. Remove engine mount heat shields. Attach engine hoist. Remove motor mount bolts. Raise engine and insert a 1" wood spacer between front insulator and mounts. Lower engine onto wood blocks.

3)Raise and support vehicle. Remove oil pan bolts. Using

Seal Cutter (MD998727), separate oil pan from cylinder block. Remove oil pan.

Removal (Pickup & Ram-50)

1)Remove skid plate and lower covers. Raise and support vehicle. Drain engine oil. Using Steering Linkage Puller (C-3894-A or MB990635), disconnect relay rod from idler arm and steering box.

2)Remove oil pan bolts. Using Seal Cutter (MD998727), separate oil pan from cylinder block. Remove pan from vehicle.

Inspection (All Models)

Clean sealant from mating surfaces on engine block and oil pan. Inspect oil pan for cracks and damage. Inspect sealing surface for damage and deformation. Inspect oil pick-up screen for damage.

Installation (All Models)

1)To install, reverse removal procedure. Apply sealant to oil pan flange in a continuous .16" (4 mm) diameter bead. See Fig. 12. Install oil pan within 15 minutes of applying sealant.

2)Tighten bolts to specification in proper sequence. See TORQUE SPECIFICATIONS TABLE at the end of this article. Wait at least 30 minutes before adding oil and starting engine. On AWD models, refill transfer assembly with GL-4 hypoid gear oil. On all models, complete installation by reversing removal procedure.

Fig. 12: Applying Sealant & Tightening Oil Pan Bolts Courtesy of Mitsubishi Motor Sales of America, Inc.

OVERHAUL

CYLINDER HEAD

Cylinder Head

Measure cylinder head height. Measure warpage at gasket and manifold surfaces. Resurface head if warpage exceeds specification. See appropriate CYLINDER HEAD table under ENGINE SPECIFICATIONS. Replace cylinder head if it is not within specification after resurfacing.

NOTE: Install valve springs with enamel-coated side toward valve spring retainer.

Valve Springs

Measure free length of valve springs. Measure spring pressure at specified height. Replace springs if not within specification. See appropriate VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS. Inspect valve spring for squareness. Replace spring if out-of-square exceeds 4 degrees.

Valve Stem Oil Seals

With valves removed, remove oil seals from cylinder head. Lubricate new seals with engine oil. Using Valve Stem Oil Seal Installer (MD998377 for Montero, MD998729 for Pickup, Ram-50), install valve stem oil seal.

Valve Guides

1)Measure valve stem oil clearance. Replace valve guide if not within specification. See appropriate VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.

2)Using rod of Valve Guide Remover/Installer (MD998115), drive out valve guide toward combustion chamber side of cylinder head. Note length of valve guides.

3)On all models, cylinder head must be bored to install oversized valve guide once guide is removed. DO NOT install valve guide of same O.D. as old guide. Bore cylinder head to specification for oversize valve guide. See appropriate OVERSIZE VALVE GUIDE SPECIFICATIONS table.

4)Install proper length valve guide. Intake guide is 1.73" (43.9 mm) long; exhaust guide is 1.89" (48.0 mm) long. On all models, position cylinder head with combustion chamber downward.

5)Using valve guide remover/installer, install valve guide. Remover/installer sets valve guide height. On all models, ensure valve slides smoothly in valve guide. Recondition valve seat.

OVERSIZE VALVE GUIDE SPECIFICATIONS TABLE

Oversize: In. (mm)

Size Mark

Bore Size: In. (mm)

.002

(.05) ...........

5 ...

.5138-.5147

(13.050-13.073)

.010

(.25) ..........

25 ...

.5217-.5224

(13.251-13.269)

.020

(.51) ..........

50 ...

.5315-.5323

(13.500-13.520)

Valve Seat

1)Measure valve spring installed height after valve and valve seat have been reconditioned and lightly lapped. With valve assembly installed, measure installed height of valve spring between spring seat and retainer. Valve seat must be replaced if measurement exceeds 1.63" (41.4 mm).

2)To replace seat, grind wall until seat can be removed. Machine cylinder head to accommodate an oversize valve seat. See OVERSIZE VALVE SEAT SPECIFICATIONS table. Heat cylinder head to

approximately 480 F (250 C), and install valve seat. Grind valve seat using 45-degree stone. Use 30-degree and 60-degree stones to set seat height.

OVERSIZE VALVE SEAT SPECIFICATIONS TABLE

Application

 

 

Specification

In. (mm)

 

 

 

 

In. (mm)

Intake

 

 

 

 

 

Bore Depth

 

 

 

 

.012

(.3)

Oversize ...............

.311-.319

(7.9-8.1)

.024

(.6)

Oversize ...............

.323-.331

(8.2-8.4)

Bore Diameter

 

 

 

.012

(.3)

Oversize .....

1.7441-1.7453

(44.300-44.330)

.024

(.6)

Oversize .....

1.7559-1.7571

(44.600-44.630)

Exhaust

 

 

 

 

 

Bore Depth

 

 

 

 

.012

(.3)

Oversize ...............

.311-.319

(7.9-8.1)

.024

(.6)

Oversize ...............

.323-.331

(8.2-8.4)

Bore Diameter

 

 

 

.012

(.3)

Oversize .....

1.5079-1.5091

(38.300-38.331)

.024

(.6)

Oversize .....

1.5197-1.5209

(38.600-38.630)

Valves

Disassemble cylinder head. Measure valve stem diameter, valve margin, and overall length. See appropriate VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS. Inspect valve for worn stem tip. Measure valve margin after grinding valves. Replace valves if not within specification.

Lash Adjusters

Before installation, submerge lash adjuster in diesel fuel. Using a small wire, hold down internal check valve. Pump plunger up and down 4 or 5 times to bleed air from lash adjuster.

CYLINDER BLOCK ASSEMBLY

Cylinder Block

1)Inspect cylinder block for cracks, warpage, cylinder bore taper, and out-of-round. Replace or repair cylinder block if it is not within specification. See CYLINDER BLOCK table under ENGINE SPECIFICATIONS.

2)Measure cylinder bore and piston skirt diameter. Piston skirt diameter should be measured at 90-degree angle to piston pin. Clearance between piston and cylinder bore must be within specification. See appropriate PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS.

Piston & Rod Assembly

1)Remove cylinder heads and oil pan. See CYLINDER HEADS and OIL PAN under REMOVAL & INSTALLATION. Remove cylinder ridge. Mark connecting rod and cap for cylinder identification.

2)Note front mark on piston and connecting rod. See Fig. 13. Mark is positioned toward timing belt side of engine. Remove rod cap and piston assembly.

3)Piston ring end gap and side clearance must be within specification. See appropriate PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. Install rings onto piston with ring code identification marks toward top of piston. Top ring is marked T1, and No. 2 ring is marked 2R. Lubricate piston, rings, and cylinder bore with engine oil.

NOTE: Front mark "R" on piston indicates installation in cylinders No. 1, 3, or 5; front mark "L" indicates installation in cylinders No. 2, 4, or 6. Ensure front mark on piston and connecting rod are toward timing belt side of engine. See Fig. 13.

4)Distribute ring end gaps properly around piston. See Fig. 13. Install piston and rod into cylinder bore, with front mark toward timing belt side of engine.

5)Measure bearing clearance using Plastigage. Tighten rod cap nuts to specification. See TORQUE SPECIFICATIONS TABLE at the end of this article. Connecting rod must move freely on crankshaft. Measure connecting rod side play. Repair or replace connecting rod if not within specification. See CONNECTING RODS table under ENGINE SPECIFICATIONS.

Fig. 13: Aligning Piston & Rings

Courtesy of Mitsubishi Motor Sales of America, Inc.

Fitting Pistons

Measure cylinder bore and piston skirt diameter. Piston skirt

diameter should be measured at 90-degree angle to piston pin. Clearance between piston and cylinder bore must be within specification. See appropriate PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS.

Piston Pin Replacement

1)Note reference mark on top of piston and connecting rod. See Fig. 13. Using press and Piston Pin Remover/Installer (MD998184), remove pin.

2)Inspect piston for cracks and damage. Measure ring side clearance. Replace piston if not within specification. See appropriate PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS.

3)Measure connecting rod for bend and twist. Replace connecting rod if twist exceeds .004" (.10 mm) or bend exceeds .002" (.05 mm).

NOTE: Install piston with reference mark aligned with connecting rod reference mark. See Fig. 13.

4) Position piston onto connecting rod. Align reference marks on top of piston and connecting rod. See Fig. 13. Lubricate all components with oil. Press piston pin into piston and connecting rod. To install, reverse removal procedure. Ensure piston pin is centered in piston.

Crankshaft & Main Bearings

1)Remove flywheel or drive plate. Remove transaxle/transmission mounting plate and rear seal case. Remove oil pump, oil pan, and oil pick-up tube. Mark connecting rod and main bearing caps for location.

2)Remove connecting rod caps and bearings. Note direction of arrow on main bearing cap. Remove main bearing cap. See Fig. 14. Remove crankshaft. Remove main bearings from cylinder block. Mark bearings for location.

3)Inspect crankshaft for cracks and damaged gear or threads. Measure crankshaft for taper and out-of-round. Replace or repair crankshaft if it is not within specification. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.

4)Install upper main bearings into cylinder block. Ensure oil holes are aligned, and bearings are properly seated. Lubricate bearings with engine oil. Install thrust bearing with oil grooves toward crankshaft thrust surface.

5)Install crankshaft into block. Install thrust bearing with oil grooves toward crankshaft thrust surface. Install main bearing caps with arrow toward front of engine.

6)Measure oil clearance using Plastigage. Tighten bolts to specification in proper sequence. See Fig. 14. See TORQUE SPECIFICATIONS TABLE at the end of this article. Clearance must be within specification. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table. If oil clearance is not within specification, replace bearings or crankshaft.

7)Ensure crankshaft rotates freely with main bearing cap installed. Measure crankshaft end play. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table.

8)Install connecting rod caps and bearings. Install components in original locations. Tighten rod nuts to specification. See TORQUE SPECIFICATIONS TABLE at the end of this article. To complete installation, reverse removal procedure. Tighten bolts to specification.

Fig. 14: Tightening Sequence For Main Bearing Cap Bolts Courtesy of Mitsubishi Motor Sales of America, Inc.

Connecting Rod Bearings

1)Mark bearing cap and connecting rod for location. Remove connecting rod cap and bearing. Install replacement bearing.

2)Align reference marks on rod cap and connecting rod. Measure bearing clearance with Plastigage. Connecting rods must move freely on crankshaft. Measure connecting rod side play. See CONNECTING RODS table under ENGINE SPECIFICATIONS.

Crankshaft End Play

If end play is not within specification, inspect thrust bearings and crankshaft. Replace thrust bearing or crankshaft to obtain correct end play. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.

ENGINE OILING

ENGINE LUBRICATION SYSTEM

Oil pressure is provided by a rotor-type pump driven by crankshaft. Pressure relief valve is located in oil pump body.

Crankcase Capacity

Montero, Pickup, and Ram-50 oil capacity is 5.0 qts. (4.7L). Add .5 qt. (.4L) when filter is replaced. Add .5 qt. (.4L) with oil cooler.

Oil Pressure

Oil pressure should be at least 11 psi (.8 kg/cm ) at idle and engine oil temperature of 167-194 F (75-90 C).

OIL PUMP

Removal

Remove timing belt and crankshaft sprocket. See TIMING BELT under REMOVAL & INSTALLATION. Remove oil pan. See OIL PAN under REMOVAL & INSTALLATION. Remove oil filter and mounting bracket. Remove oil pump and gasket from cylinder block. Note bolt length and location for installation reference.

Disassembly & Inspection

1)Disassemble pump. Inspect for scoring and cracks. Install rotors into pump body. Measure clearance between driven rotor and pump body. See OIL PUMP SPECIFICATIONS table.

2)Measure rotor side clearance. Replace rotor set or pump assembly if not within specification. Ensure relief valve slides freely in pump body bore. Inspect relief valve spring for damage.

OIL PUMP SPECIFICATIONS TABLE

Application

 

In. (mm)

Driven Rotor-To-Pump Body ........

.0039-.0071

(.099-.180)

Rotor Side Clearance .............

.0016-.0037

(.041-.094)

Reassembly & Installation

1)Reassemble pump. Tighten pump rear cover bolts to specification. See TORQUE SPECIFICATIONS TABLE at the end of this article. Install oil pump and gasket. Align splined teeth of oil pump with crankshaft. Install bolts, and tighten to specification.

2)If oil seal was removed, coat new seal with grease. Using Seal Driver (MD998717), install seal in oil pump until flush with case. Install remaining components.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS TABLE

Application

Ft. Lbs. (N.m)

Air Intake Plenum Stay Bolts ...............

11-14 (15-19)

Camshaft Bearing Cap Bolt ..................

14-15 (19-20)

Camshaft Sprocket Bolt .....................

58-72 (79-98)

Connecting Rod Nut .........................

37-38 (50-52)

Crankshaft Pulley Bolt

 

Montero ..............................

108-116 (146-157)

Pickup & Ram-50 ......................

130-137 (176-186)

Cylinder Head Bolt (1) (Cold Engine) .......

65-72 (88-98)

Drive Plate Bolt ...........................

53-55 (72-75)

Exhaust Manifold Nut .......................

11-16 (15-22)

Flywheel Bolt ..............................

53-55 (72-75)

Intake Manifold Bolts ......................

11-15 (15-20)

Left Engine Support Bracket Bolt ...........

15-21 (20-30)

Main Bearing Cap Bolt ......................

55-61 (75-83)

Oil Pick-Up Tube Bolt ......................

11-15 (15-20)

Rear Engine Support Bracket-To-Engine

 

Bolt ......................................

13-18 (18-25)

Relief Valve Plug ..........................

29-36 (39-49)

Right Engine Support Bracket Bolt

 

10 x 22-mm ...............................

25-36 (34-49)

12 x 22-mm & 12 x 32 mm ..................

47-61 (64-83)

Rocker Shaft ...............................

14-15 (19-20)

Timing Belt Tensioner Bolt .................

16-21 (22-29)

Water Pump Bolt ............................

14-20

(19-27)

 

INCH Lbs. (N.m)

Delivery Pipe Bolt .........................

84-108 (9-12)

Distributor Adapter Bolt .................

108-132

(12-15)

Oil Filter Bracket Bolt ..................

108-120

(12-14)

Oil Pan Bolt .................................

48-60 (5-7)

Oil Pump Cover Bolt ........................

72-108 (8-12)

Oil Pump Mounting Bolt ...................

108-120

(12-14)

Rear Seal Case Bolt ........................

84-108

(9-12)

Rocker Cover Bolt ............................

72-84 (8-9)

Throttle Body Bolt .........................

84-108

(9-12)

Timing Belt Cover Bolt .....................

84-108

(9-12)

Transmission Mounting Plate Bolt ...........

84-108

(9-12)

(1) - Tighten in 2 stages in proper sequence. See Fig. 3.

ENGINE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS

GENERAL ENGINE SPECIFICATIONS TABLE

Application

Specification

Displacement ........................

181.4 Cu. In.

(3.0L)

Bore ....................................

3.587" (91.1

mm)

Stroke ..................................

2.992" (76.0

mm)

Compression Ratio ..................................

 

8.9:1

Fuel System ..........................................

 

 

PFI

Horsepower @ RPM ..............................

143

@ 5000

Torque Ft. Lbs. @ RPM .........................

168

@ 2500

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS SPECS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS SPECS TABLE

Application

In. (mm)

Crankshaft

 

 

End Play

 

 

Standard .....................

.0020-.0098 (.050-.250)

Limit

.....................................

.012 (.30)

Main Bearings

 

Journal

Diameter ...........................

2.36 (59.9)

Journal

Out-Of-Round ......................

.0002 (.005)

Journal

Taper .............................

.0002 (.005)

Oil Clearance

 

Standard .....................

.0008-.0020 (.020-.051)

Limit

.....................................

.004 (.10)

Connecting Rod Bearings

 

Journal

Diameter .........................

1.965 (49.91)

Journal

Out-Of-Round ......................

.0002 (.005)

Journal

Taper .............................

.0002 (.005)

Oil Clearance

 

Standard .....................

.0008-.0020 (.020-.051)

Limit

.....................................

.004 (.10)

CONNECTING RODS SPECIFICATIONS

CONNECTING RODS SPECIFICATIONS TABLE

Application

In. (mm)

Maximum Bend ..................................

.002

(.05)

Maximum Twist (Total Rod Length) ..............

.004

(.10)

Side Play

 

 

Standard .......................

.0039-.0099 (.099-.251)

Limit .......................................

.016

(.41)

PISTONS, PINS & RINGS SPECIFICATIONS

PISTONS, PINS & RINGS SPECIFICATIONS TABLE

Application

In. (mm)

Pistons

 

Clearance ......................

.0008-.0016 (.020-.040)

Diameter .................................

3.587 (91.11)

Pins

 

 

Piston Fit ........................................

(1)

Rod Fit ...........................................

(2)

Rings

 

 

No.

1

 

End Gap

 

 

Standard ...................

.0118-.0177 (.300-.450)

 

Limit ...................................

.031 (.79)

Side Clearance

 

 

Standard ...................

.0020-.0035 (.051-.089)

 

Limit ...................................

.004 (.10)

No.

2

 

End Gap

 

 

Standard ...................

.0098-.0157 (.249-.399)

 

Limit ...................................

.031 (.79)

Side Clearance

 

 

Standard ...................

.0008-.0024 (.020-.060)

 

Limit ...................................

.004 (.10)

No.

3 (Oil)

 

End Gap

 

 

Standard .......................

.008-.024 (.20-.60)

 

Limit ...................................

.039 (.99)

(1)- Slip.

(2)- At press load of 1653-3858 lbs. (750-1750 kg).

CYLINDER BLOCK SPECIFICATIONS

CYLINDER BLOCK SPECIFICATIONS TABLE

Application

In. (mm)

Cylinder Bore

 

Standard Diameter ........................

3.590 (91.19)

Maximum Taper & Out-Of-Round ..............

.0008 (.020)

Maximum Deck Warpage

 

Standard ....................................

.002 (.05)

Limit .....................................

.0040 (.102)

VALVES & VALVE SPRINGS SPECIFICATIONS

VALVES & VALVE SPRINGS SPECIFICATIONS TABLE

Application

Specification

Intake Valves

 

Face Angle ....................................

45-45.5

Minimum Margin ..........................

.028" (.71 mm)

Standard Length .....................

4.055" (103.00 mm)

Stem Diameter ............

.3134-.3140" (7.960-7.976 mm)

Exhaust Valves

 

Face Angle ....................................

45-45.5

Minimum Margin .........................

.059" (1.50 mm)

Standard Length .....................

4.043" (102.70 mm)

Stem Diameter ............

.3122-.3130" (7.930-7.950 mm)

Valve Springs

 

Free Length

 

Standard ...........................

1.960" (49.78 mm)

Limit ..............................

1.920" (48.77 mm)

Installed Height .....................

1.591" (40.41 mm)

Out-Of-Square

 

Standard ..........................................

2

Limit .............................................

4

Pressure (Valve Closed) ..

(1) 74 @ 1.591 (33.6 @ 40.41)

(1) - Lbs. @ In. (kg @ mm).

CYLINDER HEAD SPECIFICATIONS

CYLINDER HEAD SPECIFICATIONS TABLE

Application

Specification

Cylinder Head Height ...................

3.310" (84.07 mm)

Maximum Warpage ...........................

.008" (.20 mm)

Valve Seats (Intake & Exhaust)

45 -45.5

Seat Angle ....................................

Seat Width ....................

.035-.051" (.90-1.30 mm)

Seat Bore Diameter .......

1.732-1.742" (44.00-44.25 mm)

Valve Guides

 

Intake Valve

 

Valve Guide Cylinder

 

Head Bore I.D. ........

.5118-.5189" (13.00-13.18 mm)

Valve Guide Length ....................

1.732" (44 mm)

Stem-To-Guide Clearance

 

Standard ...............

.0012-.0024" (.030-.060 mm)

Limit ...............................

.004" (.10 mm)

Exhaust Valve

 

Valve Guide Cylinder

 

Head Bore I.D. ........

.5118-.5189" (13.00-13.18 mm)

Valve Guide Length ....................

1.890" (48 mm)

Stem-To-Guide Clearance

 

Standard ...............

.0020-.0035" (.050-.090 mm)

Limit ...............................

.006" (.15 mm)

CAMSHAFT SPECIFICATIONS

CAMSHAFT SPECIFICATIONS TABLE

Application

In. (mm)

End Play

 

 

Standard ...........................

.004-.008 (0.1-0.2)

Limit .......................................

.015 (0.4)

Journal Diameter .............................

1.34 (34.0)

Lobe Height

 

 

Standard .................................

1.620

(41.15)

Limit ....................................

1.600

(40.64)

Oil Clearance ....................

.0020-.0035 (.050-.090)

ABBREVIATIONS

1993 Mitsubishi Montero

GENERAL INFORMATION

COMMONLY USED ABBREVIATION

"A" ABBREVIATION TABLE

"A" ABBREVIATION TABLE

ABBREVIATION DEFINITION

A Amperes

A/C

Air Conditioning

 

A/T

Automatic Transmission/Transaxle

 

AAP

Auxiliary Accelerator Pump

 

AB

Air Bleed

 

ABCV

Air Bleed Control Valve

 

ABDC

After Bottom Dead Center

 

ABRS

Air Bag Restraint System

 

ABS

Anti-Lock Brake System

 

AC

Alternating Current

 

ACC

A/C Clutch Compressor

 

ACCS

A/C Cycling Switch

 

ACCUM

Accumulator

 

ACCY

Accessory

 

ACT

Air Charge Temperature Sensor

 

ACV

Thermactor Air Control Valve

 

ADJ

Adjust or Adjustable

 

ADV

Advance

 

AFS

Airflow Sensor

 

AI

Air Injection

 

AIR or A.I.R.

Air Injection Reactor

 

AIS

Air Injection System

 

ALCL

Assembly Line Communications Link

 

ALDL

Assembly Line Diagnostic Link

 

ARC

Automatic Ride Control

 

ASCD

Automatic Speed Control Device

 

ASCS

Air Suction Control Solenoid

 

ASD

Auto Shutdown

 

ASDM

Air Bag System Diagnostic Module

 

ASV

Air Suction Valve

 

ATC

Automatic Temperature Control

 

ATDC

After Top Dead Center

 

ATF

Automatic Transmission Fluid

 

ATS

Air Temperature Sensor

 

AXOD

Automatic Transaxle Overdrive

 

Abs.

Absolute

 

Accy.

Accessory

 

Alt.

Alternator or Altitude

 

Amp.

Ampere

 

Assy.

Assembly

 

Auto.

Automatic

 

Aux.

Auxiliary

 

Avg.

Average

 

"B" ABBREVIATION TABLE

"B" ABBREVIATION TABLE

ABBREVIATION DEFINITION

B/P Backpressure

BAC

By-Pass Air Control

 

BAP

Barometric Absolute Pressure Sensor

 

BARO

Barometric

 

BBDC

Before Bottom Dead Center

 

BCM

Body Control Module

 

BDC

Bottom Dead Center

 

BHP

Brake Horsepower

 

BLK

Black

 

BLU

Blue

 

BMAP

Barometric & Manifold Absolute Pressure Sensor

 

BOO

Brake On-Off Switch

 

BP

Barometric Pressure sensor

 

BPS

Barometric Pressure Sensor

 

BPT

Backpressure Transducer

 

BRN

Brown

 

BTDC

Before Top Dead Center

 

BTU

British Thermal Unit

 

BVSV

Bimetallic Vacuum Switching Valve

 

Baro.

Barometric

 

Batt.

Battery

 

Bbl.

Barrel (Example: 4-Bbl.)

 

Blst.

Ballast

 

Blwr.

Blower

 

Brkr.

Breaker

 

"C" ABBREVIATION TABLE

"C" ABBREVIATION TABLE

ABBREVIATION DEFINITION

C Celsius (Degrees)

C(3) I

Computer Controlled Coil Ignition

 

C(4)

Computer Controlled Catalytic Converter

 

CANP

Canister Purge solenoid

 

CARB

California Air Resources Board

 

CAT

Catalytic Converter

 

CB

Circuit Breaker

 

CBD

Closed Bowl Distributor

 

CBVV

Carburetor Bowl Vent Valve

 

cc

Cubic Centimeter

 

CCC

Computer Command Control

 

CCD

Computer Controlled Dwell

 

CCM

Central Control Module

 

CCO

Converter Clutch Override

 

CCOT

Cycling Clutch Orifice Tube

 

CCW

Counterclockwise

 

CDI

Capacitor Discharge Ignition

 

CEC

Computerized Engine Control

 

CFI

Central Fuel Injection

 

CID

Cubic Inch Displacement

 

CID

Cylinder Identification sensor

 

CIS

Continuous Injection System

 

CIS-E

Continuous Injection System-Electronic

 

CKT

Circuit

 

CLR

Clear

 

CNG

Compressed Natural Gas

 

CO

Carbon Monoxide

 

CO2

Carbon Dioxide

 

CONV

Convertible

 

CP

Canister Purge

 

CPA

Connector Position Assurance

 

CPS

Crank Position Sensor

 

CTS

Coolant Temperature Sensor

 

CV

Check Valve or Constant Velocity

 

CVC

Constant Vacuum Control

 

CW

Clockwise

 

CYL or Cyl.

Cylinder

 

Calif.

California

 

Carb.

Carburetor

 

Chrg.

Charging

 

Circ.

Circuit

 

Cntrl.

Control

 

Comp.

Compressor or Compartment

 

Conn.

Connector

 

Cont.

Continued

 

Conv.

Convertible or Converter

 

Cu. In.

Cubic Inch

 

Cyl.

Cylinder

 

"D" ABBREVIATION TABLE

"D" ABBREVIATION TABLE

ABBREVIATION DEFINITION

"D" Drive

DBC

Dual Bed Catalyst

 

DC

Direct Current or Discharge

 

DDD

Dual Diaphragm Distributor

 

DERM

Diagnostic Energy Reserve Module

 

DFI

Digital Fuel Injection

 

DIC

Driver Information Center

 

DIS

Direct Ignition System

 

DIS

Distributorless Ignition System

 

DIST

Distribution

 

DISTR

Distributor

 

DK BLU

Dark Blue

 

DK GRN

Dark Green

 

DME

Digital Motor Electronics (Motronic System)

 

DOHC

Double Overhead Cam

 

DOT

Department of Transportation

 

DP

Dashpot

 

DRB-II

Diagnostic Readout Box

 

DVOM

Digital Volt/Ohm Meter (see VOM)

 

Def.

Defogger or Defroster

 

Def.

Defrost

 

Defog.

Defogger

 

Diag.

Diagnostic

 

Dist.

Distributor or Distribution

 

Dr.

Door

 

"E" ABBREVIATION TABLE

"E" ABBREVIATION TABLE

ABBREVIATION DEFINITION

EAC Electric Assist Choke

EACV

Electric Air Control Valve

 

EBCM

Electronic

Brake Control Module

 

ECA

Electronic

Control Assembly

 

ECAT

Electronically Controlled Automatic Transaxle

 

ECM

Electronic

Control Module

 

ECT

Engine Coolant Temperature Sensor

 

ECU

Electronic

Control Unit or Engine Control Unit

 

EDF

Electric Drive Fan relay assembly

 

EDIS

Electronic

Distributorless Ignition System

 

EEC

Electronic

Engine Control

 

EECS

Evaporative Emission Control System

 

EEPROM

Electronically Erasable PROM

 

EFE

Early Fuel

Evaporation

 

EFI

Electronic

Fuel Injection

 

EGO

Exhaust Gas Oxygen sensor (see HEGO)

 

EGR

Exhaust Gas Recirculation system

 

EGRC

EGR Control solenoid or system

 

EGRV

EGR Vent solenoid or system

 

EMR

Emission Maintenance Reminder Module

 

ESA

Electronic

Spark Advance

 

ESC

Electronic

Spark Control

 

EST

Electronic

Spark Timing

 

ETR

Emergency Tensioning Retractor

 

EVAP

Fuel Evaporative System

 

EVIC

Electronic

Vehicle Information Center

 

EVO

Electronic

Variable Orifice

 

EVP

EGR Valve Position Sensor

 

EVR

EGR Valve Regulator

 

EVRV

Electronic

Vacuum Regulator Valve

 

Elect.

Electronic

 

 

Eng.

Engine

 

 

Evap.

Evaporative

 

 

Exc.

Except

 

 

"F" ABBREVIATION TABLE

"F" ABBREVIATION TABLE

ABBREVIATION DEFINITION

F Fahrenheit (Degrees)

F/B

Fuse Block

 

FBC

Feedback Carburetor

 

FI

Fuel Injector or Fuel Injection

 

FICD

Fast Idle Control Device

 

FIPL

Fuel Injector Pump Lever

 

FP

Fuel Pump

 

FPM

Fuel Pump Monitor

 

FPR-VSV

Fuel Pressure Regulator Vacuum Switching Valve

 

FWD

Front Wheel Drive

 

Fed.

Federal

 

Ft. Lbs.

Foot Pounds

 

"G" ABBREVIATION TABLE

"G" ABBREVIATION TABLE

ABBREVIATION DEFINITION

g grams

GND or GRND

Ground

 

GRN

Green

 

GRY

Gray

 

Ga.

Gauge

 

Gals.

gallons

 

Gov.

Governor

 

"H" ABBREVIATION TABLE

"H" ABBREVIATION TABLE

ABBREVIATION DEFINITION

H/D Heavy Duty

HAC

High Altitude Compensation

 

HC

Hydrocarbons

 

HEDF

High Speed Electro Drive Fan relay or circuit

 

HEGO

Heated Exhaust Gas Oxygen Sensor

 

HEGOG

HEGO Ground circuit

 

HEI

High Energy Ignition

 

HLDT

Headlight

 

HO

High Output

 

HP

High Performance

 

HSC

High Swirl Combustion

 

HSO

High Specific Output

 

HTR

Heater

 

HVAC

Heating

 

Headlt.

Headlight

 

Hg

Mercury

 

Hgt.

Height

 

Htr.

Heater

 

Hz

Hertz (Cycles Per Second)

 

"I" ABBREVIATION TABLE

"I" ABBREVIATION TABLE

ABBREVIATION DEFINITION

I.D. Inside Diameter

IAC

Idle Air Control

 

IACV

Idle Air Control Valve

 

IC

Integrated Circuit

 

ID

Identification

 

IDM

Ignition Diagnostic Monitor

 

IGN

Ignition system or circuit

 

ILC

Idle Load Compensator

 

In. Hg

Inches of Mercury

 

INCH Lbs.

Inch Pounds

 

INFL REST

Inflatable Restraint

 

INJ

Injector or Injection

 

IP

Instrument Panel

 

IPC

Instrument Panel Cluster

 

ISA

Idle Speed Actuator

 

ISC

Idle Speed Control

 

ISS

Idle Stop Solenoid

 

ITS

Idle Tracking Switch

 

IVSV

Idle Vacuum Switching Valve

 

Ign.

Ignition

 

In.

Inches

 

Inj.

Injector

 

"J" ABBREVIATION TABLE

"J" ABBREVIATION TABLE

ABBREVIATION DEFINITION

J/B Junction Block

"K" ABBREVIATION TABLE

"K" ABBREVIATION TABLE

ABBREVIATION DEFINITION

k/ohms 1000 ohms (kilo as in k/ohms)

kg

 

Kilograms (weight)

 

kg/cm

 

Kilograms Per Square Centimeter

 

KAM

Keep Alive Memory

 

KAPWR

Keep Alive Power

 

KM/H

 

Kilometers Per Hour

 

KOEO

 

Key On Engine Off

 

KOER

 

Key On Engine Running

 

KS

 

Knock Sensor

 

"L" ABBREVIATION TABLE

"L" ABBREVIATION TABLE

ABBREVIATION DEFINITION

L Liter(s)

L/D

Light Duty

 

LCD

Liquid Crystal Display

 

LED

Light Emitting Diode

 

LH

Left Hand

 

LOS

Limited Operation Strategy

 

LT BLU

Light Blue

 

LT GRN

Light Green

 

LUS

Lock-Up Solenoid

 

Lbs.

Pounds

 

Lt(s).

Light(s)

 

Lugg.

Luggage

 

"M" ABBREVIATION TABLE

"M" ABBREVIATION TABLE

ABBREVIATION DEFINITION

mA Milliamps

mV

Millivolts

 

mfd.

Microfarads

 

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