GENERAL INFORMATION AND MAINTENANCE

HOW TO USE THIS BOOK

This repair manual for Mitsubishi Pick-up trucks and Montero is designed to help you understand the inner workings of your vehicle and save you money on its upkeep.

The first two sections will be the most used, since they contain information and procedures on both maintenance and tune-ups. Studies have shown that a properly tuned and maintained vehicle can get better gas mileage (which translates into lower operating costs) and periodic maintenance can catch minor problems before they turn into major repair bills. The other sections deal with the more complex systems of your vehicle. Operating systems from engine through brakes are covered to the extent that the average do-it-yourselfer becomes mechanically involved. It will give you the detailed instructions to help you change your own brake pads and shoes, tune-up the engine, replace spark plugs and filters, and do many more jobs that will save you money, give you personal satisfaction and help you avoid expensive problems.

A secondary purpose of this book is a reference guide for owners who want to understand their vehicle and/or their mechanics better. In this case, no tools at all are required. Knowing just what a particular repair job requires in parts and labor time will allow you to evaluate whether or not you're getting a fair price quote and help decipher itemized bills from a repair shop.

Before attempting any repairs or service on your vehicle, read through the entire procedure outlined in the appropriate section. This will give you the overall view of what tools and supplies will be required. There is nothing more frustrating than having to walk to the bus stop on Monday morning because you were short one gasket on Sunday afternoon. So read ahead and plan ahead. Each operation should be approached logically and all procedures thoroughly understood before attempting any work. Some special tools that may be required can often be rented from local automotive jobbers or places specializing in renting tools and equipment. Check the yellow pages of your phone book.

All sections contain adjustments, maintenance, removal and installation procedures, and some overhaul procedures. When overhaul is not considered practical, we tell you how to remove the failed part and then how to install the new or rebuilt replacement. In this way, you at least save the labor costs. Backyard overhaul of some components (such as the alternator or water pump) is just not practical, but the removal and installation procedure is often simple and well within the capabilities of the average vehicle owner.

Two basic mechanic's rules should be mentioned here. First, whenever the LEFT side of the vehicle or engine is referred to, it is meant to specify the DRIVER'S side of the vehicle. Conversely, the RIGHT side of the vehicle means the PASSENGER'S side. Second, all screws and bolts are removed by turning counterclockwise, and tightened by turning clockwise, unless otherwise noted.

Safety is always the most important rule. Constantly be aware of the dangers involved in working on or around an automobile and take proper precautions to avoid the risk of personal injury or damage to the vehicle. See the entry in this section, Servicing Your Vehicle Safely, and the SAFETY NOTICE on the acknowledgment page before attempting any service procedures and pay attention to the instructions provided. There are 3 common mistakes in mechanical work:

1. Incorrect order of assembly, disassembly or adjustment. When taking something apart or putting it together, performing steps in the wrong order usually just costs you extra time; however it CAN break something. Read the entire procedure before beginning disassembly. Do everything in the order in which the instructions say you should do it, even if you can't immediately see a reason for it. When you're taking apart something that is very intricate (for example a carburetor), you might want to draw a picture of how it looks when assembled at one point in order to make sure you get everything back in its proper position. We will supply exploded views whenever possible, but sometimes the job requires more attention to detail than an illustration provides. When making adjustments (especially tune-up adjustments), perform them in order. One adjustment often affects another and you cannot expect satisfactory results unless each adjustment is made only when it cannot be changed by any other.
2. Overtorquing (or undertorquing) nuts and bolts. While it is more common for overtorquing to cause damage, undertorquing can cause a fastener to vibrate loose and cause serious damage, especially when dealing with aluminum parts. Pay attention to torque specifications and utilize a torque wrench in assembly. If a torque figure is not available remember that if you are using the right tool for the job, you will probably not have to strain yourself to get a fastener tight enough. The pitch of most threads is so slight that the tension you put on the wrench will be multiplied many times in actual force on what you are tightening. A good example of how critical torque is can be seen in the case of spark plug installation, especially where you are putting the plug into an aluminum cylinder head. Too little torque can fail to crush the gasket, causing leakage of combustion gases and consequent overheating of the plug and engine parts. Too much torque can damage the threads or distort the plug, which changes the spark gap at the electrode. Since more and more manufacturers are using aluminum in their engine and chassis parts to save weight, a torque wrench should be in any serious do-it-yourselfer's tool box.

   There are many commercial chemical products available for ensuring that fasteners won't come loose, even if they are not torqued just right (one common brand is Loctite® ). If you're worried about getting something together tight enough to hold, but loose enough to avoid mechanical damage during assembly, one of these products might offer substantial insurance. Read the label on the package and make sure the product is compatible with the materials, fluids, etc. involved before choosing one.

3. Crossthreading. This occurs when a part such as a bolt is screwed into a nut or casting at the wrong angle and forced, causing the threads to become damaged. Crossthreading is more likely to occur if access is difficult. It helps to clean and lubricate fasteners, to start threading with the part to be installed going straight in, and to use your fingers. If you encounter resistance, unscrew the part and start over again at a different angle until it can be inserted and turned several times without much effort. Keep in mind that many parts, especially spark plugs, use tapered threads so that gentle turning will automatically bring the part you're threading to the proper angle if you don't force it or resist a change in angle. Don't put a wrench on the part until it's been turned in a couple of times by hand. If you suddenly encounter resistance and the part has not seated fully, don't force it. Pull it back out and make sure it's clean and threading properly.

   Always take your time and be patient; once you have some experience, working on your vehicle may become an enjoyable hobby.