light MITSUBISHI MONTERO 1991 Service Manual

system consists of PCV valve, oil separator, breather and ventilation
hoses.
PCV valve is a one-way check valve, located in valve cover.
When engine is running, manifold vacuum pulls PCV valve open, allowing
crankcase fumes to enter intake manifold. If engine backfires through
intake manifold, PCV valve closes to prevent crankcase combustion.
SELF-DIAGNOSTIC SYSTEM
Self-diagnostic system monitors input and output signals. On
all models, codes can be read using analog voltmeter. On some models,
scan tool can be used to read codes. For additional information, see G
- TESTS W/ CODES article.
CHECK ENGINE Light
Also called Malfunction Indicator Light by manufacturer,
comes on when ignition is turned on. Light remains on for several
seconds after engine has started. If an abnormal input signal occurs,
light comes on and code is stored in memory. If an abnormal input
signal returns to normal, ECU turns light off but code remains stored
in memory until cleared. If ignition is turned on again, light will
not come on until ECU detects malfunction during system operation.
NOTE: ECU diagnostic memory is retained by direct power supply
from the battery. Memory is not erased by turning off
ignition but is erased if battery or ECU is disconnected.

NOTE: With switch removed, check continuity between switch
connector terminal and switch body. With switch installed,
check continuity between switch connector terminal and
transfer case.
4WD Indicator Light Switch (RAM-50)
With switch removed, check continuity between connector
terminal and switch body. With switch end pressed, there should be no
continuity. With switch end released, there should be continuity.
Center Differential Lock Operation Detection Switch (Montero)
Check continuity between terminals at Brown wire connector
terminal on top of transfer case. With transfer control lever in "4H"
position, there should be no continuity. With transfer control lever
in "4HLc" position, there should be continuity. See Fig. 2.
4WD Operation Detection Switch (Montero)
Check continuity between terminals at Black wire connector
terminal on top of transfer case. With transfer control lever in "2H"
position, there should be no continuity. With transfer control lever
in "4H" position, there should be continuity. See Fig. 2.
Center Differential Lock Detection Switch (Montero)
Check continuity between terminals at Brown wire connector
terminal on side of transfer case. With transfer control lever in "4H"
position, there should be no continuity. With transfer control lever
in "4HLc" position, there should be continuity. See Fig. 2.
2WD-4WD Detection Switch (Montero)
Check continuity between terminals at Black wire connector
terminal on side of transfer case. With transfer control lever in "4H"
position, there should be no continuity. With transfer control lever
in "2H" position, there should be continuity. See Fig. 2.
HI/LO Detection Switch (Montero)
Check continuity between terminals at White wire connector
terminal on side of transfer case. With transfer control lever in "N"
(between "4HLc" and "4LLc") position, there should be no continuity.
With transfer control lever in "4HLc" position, there should be
continuity. With transfer control lever in "4LLc" position, there
should be continuity. See Fig. 2.

Fig. 2: Detection Switch Testing Locations (Montero)
Courtesy of Mitsubishi Motor Sales of America.
REMOVAL & INSTALLATION
Removal
1) Remove negative battery cable. Remove transfer case skid
plate (if equipped). Scribe alignment marks and remove both drive
shafts. Drain oil from transfer case. Disconnect wiring harness from
back-up light switch, all 4WD switches and any other electrical
connectors (if equipped).
2) Disconnect speedometer cable from drive. Unclip cable from
case. Place transfer case shifter in "2H" position and transmission in
Neutral. Remove 6 bolts holding control lever assembly. Remove control
lever assembly and gasket.
3) Remove select plunger bore plug at right side of case.
Remove select spring and plunger. Remove change shifter spring pin.
Remove change shifter. Remove transfer case mount. Remove 4 bolts and
2 nuts holding transfer case to adapter. Remove transfer case from
vehicle.

1) Install input gear and front output shaft oil seals into
transfer case housing. Pack grease between lips of seals and press
seal circumference uniformly.
2) Install input gear assembly in transfer case. See Figs. 3
and 6. Input gear assembly snap ring is available in selective
thicknesses. Use thickest snap ring that will fit into input shaft
groove. Allowed snap ring clearance is 0-.0024" (0-.060 mm).
3) Insert needle bearing onto rear output shaft assembly.
Install high-low synchronizer sleeve and shift fork. Install 2WD-4WD
shift fork. Engage chain securely on front and rear output shaft
sprockets. Assemble 2WD-4WD synchronizer sleeve with 2WD-4WD shift
fork. Install assembly over 2WD-4WD shift rail. Install front and rear
output shafts with chain as an assembly.
4) Install 2WD-4WD shift lug, distance piece, 2WD-4WD shift
rail and spring pin. Ensure slit in spring pin is in line with 2WD-4WD
shift rail. Install 2 spring retainers with spring on 2WD-4WD shift
rail. Install snap ring to end of 2WD-4WD shift rail. See Fig. 3.
5) Insert 2 needle bearings and spacer into countergear.
Install one thrust washer at each end of countergear. Ensure tab on
thrust washers fits into groove of transfer case. Install countergear
shaft assembly with "O" ring.
6) Install side cover and gasket. Install oil guide. Apply
sealant to both sides of gasket and install gasket and chain cover.
Ensure oil guide end fits into chain cover opening. Fit snap ring into
groove of rear bearing on rear output shaft. Tighten bolts to
specification. See TORQUE SPECIFICATIONS .
7) Install interlock plunger. Shift 2WD-4WD shift rail to 4WD
position. Install high-low shift rail through high-low shift fork in
case. Install 2 poppet balls and springs. Install seal plugs. When
installing poppet springs, smaller end must be toward ball.
8) On models with pulse generator, install pulse rotor, wave
spring and spacer. Measure protrusion "A" of front output shaft rear
bearing and recess "B" of cover and calculate clearance. See Fig. 9.
If clearance is greater than .079" (2.0 mm), select and install spacer\
to bring clearance within specification. If clearance is less than .
079" (2.0 mm), use wave spring alone. Apply sealant to both sides of
gasket and install gasket and cover. Install pulse generator (if
equipped).
9) On all models, align high-low shift fork and shift rail
spring holes and drive in roll pin with punch. Roll pin should be
installed with slit on center line of shift rail. Install wave spring
on rear of rear output shaft bearing. Apply sealant to both sides of
rear cover gasket. Install gasket and cover.
10) Check output shaft end play. Measure protrusion "A" of
rear output shaft rear bearing and recess "B" of cover and calculate
clearance. Ensure end play is 0-.004" (0-.10 mm). Apply sealant to
both sides of gasket and install gasket and cover. See Fig. 9.
11) Install speedometer sleeve assembly in rear cover. Align
match mark on speedometer sleeve assembly in rear cover. See Fig. 10.
Align match mark on speedometer sleeve with mark on case according to
number of teeth on speedometer driven gear. Install speedometer driven
gear sleeve clamp and tighten bolt to specification. Install both 4WD
indicator light switches with steel balls. See TORQUE SPECIFICATIONS.

TORQUE SPECIFICATIONS TABLE








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Application Ft. Lbs. (N.m)
Adapter-To-Transfer Bearing Retainer ......... (1) 14 (19)
Case Nuts & Bolts .......................... 22-31 (30-42)
Center Differential Case Bolts ................... 48 (65)
Chain Cover Bolt ........................... 22-31 (30-42)
Detection Switch ............................. ( 1) 27 (36)
Drain Plug ................................. 22-26 (30-35)
Dynamic Damper ................................... 52 (70)
High-Low Shift Rail Plug ..................... ( 1) 24 (33)
Interlock Plunger Plug ................. ( 1) 22-26 (30-35)
Lock Plate Bolts ........................... 11-16 (15-22)
Oil Dam Cover ................................ ( 1) 14 (19)
Oil Filler Plug ............................ 22-26 (30-35)
Output Shaft Cover Bolt .................... 11-16 (15-22)
Poppet Plug .................................. ( 1) 27 (36)
Pulse Rotor Bolt ....................... ( 2) 11-16 (15-22)
Rear Cover Bolt ............................ 11-16 (15-22)
Rear Output Shaft Lock Nut ............... 74-96 (100-130)
Seal Plug .............................. ( 2) 22-31 (30-42)
Speedometer Sleeve Clamp Bolt .............. 11-16 (15-22)
4WD Indicator Light Switch ................... ( 2) 22 (33)
INCH Lbs. (N.m)
Pulse Generator Bolt .................. ( 2) 89-106 (10-12)
Side Cover Bolt ............................. 71-89 (8-10)
( 1) - Montero.
( 2) - Ram-50.









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WIRING DIAGRAMS

REMOVAL
1) Disconnect negative battery cable. Remove front exhaust
pipe. On Montero, remove transfer case shift lever knob, dust boot and
retainer plate or console. Remove transfer case gearshift assembly.
2) On all models, raise and support vehicle. Remove
undercarriage cover and/or skid plate(s). Drain transmission and
transfer case (if applicable). Place reference mark on drive shaft(s)\
and remove. Disconnect all external solenoid and switch connections.
3) Disconnect speedometer cable and control cables at
transmission. Remove starter and bellhousing cover. Place reference
mark on torque converter and drive plate for reassembly reference.
Remove torque converter bolts.
4) Disconnect transmission cooler lines. Remove oil filler
tube. Secure transmission on a jack. Raise transmission slightly to
take weight off mount. Remove crossmember-to-mount bolts and
crossmember.
5) Remove transfer case mounting bracket and mount (if
equipped). Remove transmission-to-engine mounting bolts. Carefully
lower transmission from vehicle.
CAUTION: Ensure torque converter is fully seated in transmission
before installation.
INSTALLATION
1) To install, reverse removal procedure. Tighten
transmission-to-engine bolts and torque converter-to-drive plate bolts
to specification. See TORQUE SPECIFICATIONS table at end of article.
Tighten mount bolts with weight of engine and transmission on mounts.
Ensure reference marks on drive shaft(s) and torque converter-to-drive\
plate align.
2) Apply sealant to transfer case gearshift assembly gasket
before installation. Coat transmission oil filler tube "O" ring with
transmission fluid before installation. Refill transmission fluid to
specified level. Adjust all control cables.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Applications Ft. Lbs. (N.m)
FWD Models
Torque Converter-To-Drive Plate Bolt
Precis ....................................... 53-55 (72-76)
All Others ................................... 34-38 (46-52)
Transaxle-To-Engine Block Bolt
Mirage
8-mm Bolt ............................................ (1)
10-mm Bolt ................................. 22-25 (30-34)
12-mm Bolt ................................. 31-40 (42-54)
Eclipse & Galant
8-mm Bolt ............................................ (1)
10-mm Bolt ................................. 22-25 (30-34)
Precis
8-mm Bolt .................................. 22-25 (30-34)
10-mm Bolt ................................. 31-40 (42-54)
3000GT
Upper Coupling Bolts ............................. 54 (73)
Lower Coupling Bolts ............................. 65 (88)

PICKUP
1) Ensure engine idle is adjusted correctly. Ensure throttle
lever and throttle cable bracket are not bent. Pull lightly on inner
throttle cable.
2) While in closed throttle position, measure gap between
inner cable stopper and outer cable housing. Adjust cable as necessary
to obtain a gap of .031-.059" (.79-1.50 mm). See Fig. 4 (STEP 1).
Fig. 4: Adjusting Throttle Cable (Pickup)
Courtesy of Mitsubishi Motor Sales of America.
3) While holding throttle in wide open position, pull on
inner throttle cable. Adjust bell crank as necessary to obtain a gap
of 1.46-1.50" (37.08-38.10 mm) between inner cable stopper and outer
cable. See Fig. 4 (STEP 2).
4) With throttle fully closed, recheck gap between inner
cable stopper and outer cable housing. Gap should be .031-.059" (.79-
1.50 mm). See Fig. 4 (STEP 3). While holding throttle in wide open
position, pull on inner throttle cable. Check for a gap of 1.30-1.38"
(33.02-35.05 mm).
Montero Ensure throttle lever and throttle cable bracket
are not bent. Ensure distance between inner cable stopper end and dust
cover is 0-.04" (0-1.0 mm). See Fig. 5.
Fig. 5: Adjusting Throttle Cable (Montero)
Courtesy of Mitsubishi Motor Sales of America.
SHIFT LINKAGE

SHIFT LEVER SLEEVE
NOTE: Pickup does not have shift lever sleeve.
EXCEPT PICKUP
To adjust shift lever sleeve, remove shift handle on top of
shift lever. With lever in Neutral, turn sleeve so distance between
sleeve and lever end is .60-.63" (15.2-16.0 mm). See Fig. 8. Ensure
beveled side of sleeve faces toward push button (if equipped).
Fig. 8: Adjusting Shift Lever Sleeve (Except Pickup)
Courtesy of Mitsubishi Motor Sales of America.
NEUTRAL SAFETY SWITCH
EXCEPT MONTERO & PICKUP
1) Place shift and manual control levers in Neutral. For
adjustment, turn switch body in order to align small end of manual
control lever with corresponding flange on switch body. Tighten switch
mounting bolts to 84-108 INCH lbs. (10-12 N.m).
CAUTION: DO NOT drop switch body.
2) Loosen nut at end of transaxle control cable, and lightly
pull in direction of switch. Tighten nut to 84-120 INCH lbs. (10-14 N.
m). See Fig. 9.
3) Ensure selector lever is in Neutral. Ensure lever
functions correctly at transaxle, in range corresponding to that
indicated by selector lever.

1) Neutral safety switch is located under shift lever
console. Set shift lever so pin at end of rod is positioned correctly.
See Fig. 10 .
2) Using an ohmmeter, check continuity between Black/Yellow
wires when neutral safety switch is moved back and forth. Mark
bracket.
3) Tighten neutral safety switch mounting screws so clearance
between switch and selector lever is .1" (2.5 mm).
Fig. 10: Adjusting Neutral Safety Switch (Montero)
Courtesy of Mitsubishi Motor Sales of America.
PICKUP
Neutral safety switch is part of transmission-mounted neutral
safety/back-up light switch assembly, and is non-adjustable.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)
Drain Plug
Transaxle/Transmission
Montero ................................. 13-17 (18-23)
All Other Models ........................ 22-25 (30-35)
Transfer Case ............................ 22-25 (30-35)
INCH Lbs. (N.m)
Oil Filter/Screen Bolt
Except Montero & Pickup ................ 48-60 (5.4-6.8)
Montero ................................ 43-52 (4.9-5.9)
Pickup ........................................ 35 (4.0)
Oil Pan Bolt
Eclipse & Montero ...................... 36-42 (4.0-4.8)
Pickup ........................................ 156 (18)
All Other Models ..................... 84-108 (9.5-12.2)









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TR O UBLE S H O OTIN G - B ASIC P R O CED URES

1991 M it s u bis h i M onte ro
GENERAL TROUBLE SHOOTING
* PLEASE READ THIS FIRST *
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
ACCESSORIES & ELECTRICAL
CHARGING SYSTEM TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
BASIC CHARGING SYSTEM TROUBLE SHOOTING CHART









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CONDITION POSSIBLE CAUSE CORRECTION








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Vehicle Will Not Dead battery Check battery cells,
Start alternator belt
tension and alternator
output
Loose or corroded battery Check all charging
connections system connections
Ignition circuit or switch Check and replace as
malfunction necessary









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Alternator Light Loose or worn alternator Check alternator drive
Stays On With drive belt tension and
Engine Running condition, See Belt
Adjustment in TUNE-UP
article in the
TUNE-UP section
Loose alternator wiring Check all charging
connections system connections
Short in alternator light See Indicator Warning
wiring Lights in STANDARD
INSTRUMENTS in the
ACCESSORIES &
EQUIPMENT section
Defective alternator stator See Bench Tests in
or diodes ALTERNATOR article
Defective regulator See Regulator Check in