sensor MITSUBISHI MONTERO 1991 Service Manual

* Check airflow sensor.
* Check coolant temperature sensor.
* Check idle position switch.
* Check power supply to ECU ground.
* Check fuel pressure.
* Check for disconnected or damaged vacuum hoses.
* Check for control relay malfunction.
* Check for PFI system malfunction.
* Check for fuel pump drive control system malfunction.
* Check for ignition coil malfunction.
* Check for ignition timing malfunction.
* Check for power transistor malfunction.
* Check for fuel injector malfunction.
* Check for ECU malfunction.
* Ensure electrical harness, connectors and wires are not
broken or loose.
ROUGH OR UNSTABLE IDLE
* Check intake air temperature sensor.
* Check purge control solenoid valve (if applicable).
* Check vehicle speed sensor.
* Check engine coolant temperature sensor.
* Check barometric pressure sensor.
* Check ignition switch.
* Check idle position switch.
* Check throttle position sensor.
* Check TDC sensor.
* Check crank angle sensor.
* Check power steering oil pressure switch.
* Check A/C switch and power relay (if applicable).
* Check inhibitor switch.
* Check oxygen sensor.
* Check airflow sensor.
* Check motor position sensor (if equipped).
* Check fuel pressure.
* Check for disconnected or damaged vacuum hoses.
* Check PFI system malfunction.
* Check for stepper motor malfunction (if applicable).
* Check for fuel injector malfunction.
* Check for power transistor malfunction.
* Check for vehicle speed switch malfunction.
* Check for ECU malfunction.
* Ensure electrical harness, connectors and wires are not
broken or loose.
ENGINE HESITATES OR POOR ACCELERATION
* Check intake air temperature sensor.
* Check engine coolant temperature sensor.
* Check barometric pressure sensor.
* Check ignition switch.
* Check ignition coil.
* Check EGR control solenoid valve (if applicable).
* Check idle position switch.
* Check throttle position sensor.
* Check TDC sensor.
* Check crank angle sensor.
* Check power steering oil pressure switch.
* Check A/C switch (if applicable).
* Check inhibitor switch (A/T).
* Check oxygen sensor.
* Check airflow sensor.

* Check motor position sensor (if applicable).
* Check fuel pressure.
* Check for disconnected or damaged vacuum hoses.
* Check for PFI system malfunction.
* Check for stepper motor malfunction (if applicable).
* Check for fuel injector malfunction.
* Check for power transistor malfunction.
* Check for A/C power relay control system malfunction (if
applicable).
* Check for ECU malfunction.
* Ensure electrical harness, connectors and wires are not
broken or loose.
ENGINE SURGES
* Check coolant temperature sensor.
* Check idle position switch.
* Check EGR control solenoid valve (if applicable).
* Check fuel pressure.
* Check for fuel injector malfunction.
DETONATION OR KNOCKING
* Check airflow sensor.
* Check for cooling system problems.
* Check fuel quality.
* Check intake air temperature sensor.
* Check barometric pressure sensor.
* Check ignition coil.
* Check power transistor.
* Check for EGR system malfunction.
POOR FUEL MILEAGE
* Check intake air temperature sensor.
* Check engine coolant temperature sensor.
* Check barometric pressure sensor.
* Check ignition switch.
* Check idle position switch.
* Check throttle position sensor.
* Check TDC sensor.
* Check crank angle sensor.
* Check power steering oil pressure switch.
* Check A/C switch (if applicable).
* Check inhibitor switch (A/T).
* Check oxygen sensor.
* Check airflow sensor.
* Check motor position sensor (if applicable).
* Check fuel pressure.
* Check for PFI system malfunction.
* Check for stepper motor malfunction.
* Check for fuel injector malfunction.
* Check for power transistor malfunction.
INTERMITTENTS
INTERMITTENT PROBLEM DIAGNOSIS
Intermittent fault testing requires duplicating circuit or
component failure to identify problem. These procedures may lead to
computer setting a fault code which may help in diagnosis.
If problem vehicle does not produce fault codes, monitor

\003
E - T H EO RY/O PER ATIO N - E FI

1 991 M it s u bis h i M onte ro
1990-91 ENGINE PERFORMANCE
Chrysler/Mitsubishi Theory & Operation - Fuel Injection
All Models
INTRODUCTION
This article covers basic description and operation of engine
performance-related systems and components. Read this article before
diagnosing vehicles or systems with which you are not completely
familiar.
AIR INDUCTION SYSTEM
NON-TURBOCHARGED ENGINES
All Chrysler/Mitsubishi engines with Port Fuel Injection
(PFI), called Multi-Point Injection (MPI) by the manufacturer, use t\
he
same basic air induction system. Remote air filter (with airflow
sensor) is ducted to a plenum-mounted throttle body.
TURBOCHARGED ENGINES
In addition to basic air induction system used on all other
models, turbocharging system components include turbocharger, air-to-
air intercooler, air by-pass valve, wastegate actuator, wastegate
control solenoid valve and intake ducting.
Wastegate Control Solenoid Valve
Engine Control Unit (ECU) energizes solenoid valve,
controlling leakage rate of turbocharger pressure to wastegate
actuator.
COMPUTERIZED ENGINE CONTROLS
Multi-Point Injection (MPI) is a computerized engine control
system which controls fuel injection, ignition timing, idle speed and
emission control systems.
ELECTRONIC CONTROL UNIT (ECU)
NOTE: Components are grouped into 2 categories. The first category
covers INPUT DEVICES, which control or produce voltage
signals monitored by the Engine Control Unit (ECU). The
second category covers OUTPUT SIGNALS, which are components
controlled by the ECU.
ECU receives and processes signals from input devices. Such
operating conditions as cold starting, altitude, acceleration and
deceleration affect input device signals. Based upon signals received,
ECU sends signals to various components which control fuel injection,
ignition timing, idle speed and emission control systems.
INPUT DEVICES
Vehicles are equipped with different combinations of input
devices. Not all input devices are used on all models. To determine

input device usage on specific models, see appropriate wiring diagram
in M - WIRING DIAGRAMS.
Air Conditioner Switch
When A/C is turned on, signal is sent to ECU. With engine at
idle, ECU increases idle speed through Idle Speed Control (ISC) motor.\
Airflow Sensor
Incorporated in airflow sensor assembly, airflow sensor is a
Karmen Vortex-type sensor which measures intake airflow rate.
Intake air flows through tunnel in airflow sensor assembly.
Airflow sensor transmits radio frequency signals across direction of
incoming airflow, downstream of vortex. Intake air encounters vortex,
causing turbulence in tunnel.
Turbulence disrupts radio frequency, causing variations in
transmission. Airflow sensor converts frequency transmitted into a
proportionate electrical signal which is sent to ECU.
Airflow Sensor Assembly
Mounted inside air cleaner, incorporates airflow sensor,
atmospheric pressure sensor and intake air temperature sensor.
Atmospheric (Barometric) Pressure Sensor
Incorporated in the airflow sensor assembly, converts
atmospheric pressure to electrical signal which is sent to ECU. ECU
adjusts air/fuel ratio and ignition timing according to altitude.
Coolant Temperature Sensor
Converts coolant temperature to electrical signal for use by
ECU. ECU uses coolant temperature information for controlling fuel
enrichment when engine is cold.
Crankshaft Angle & TDC Sensor Assembly
Assembly is located in distributor on SOHC engines. On DOHC
engines, which use Direct (or Distributorless) Ignition System (DIS)\
,
assembly is separate unit mounted in place of distributor. Assembly
consists of triggering disc (mounted on shaft) and stationary optical
sensing unit. Camshaft drives shaft, triggering optical sensing unit.
ECU determines crank angle and TDC based on signals received from
optical sensing unit.
Detonation Sensor (Turbo Only)
Located in cylinder block, senses engine vibration during
detonation (knock). Sensor converts vibration into electrical signal.
ECU retards ignition timing based on this signal.
Engine Speed (Tach Signal)
ECU uses ignition coil tach signal to determine engine speed.
Idle Position Switch
On all DOHC engines and Sigma 3.0L, idle position switch is
separate switch mounted on throttle body. On all other models, idle
position switch is incorporated in ISC motor or throttle position
sensor, depending on vehicle application. When throttle valve is
closed, switch is activated. When throttle valve is at any other
position, switch is deactivated. This input from idle position switch
is used by ECU for controlling fuel delivery time during deceleration.
Ignition Timing Adjustment Terminal
Used for adjusting base ignition timing. When terminal is
grounded, ECU timing control function is by-passed, allowing base
timing to be adjusted.

Inhibitor Switch (Automatic Transmission Only)
Inhibitor switch senses position of transmission select
lever, indicating engine load due to automatic transmission
engagement. Based on this signal, ECU commands ISC motor to increase
throttle angle, maintaining optimum idle speed.
Intake Air Temperature Sensor
Incorporated in airflow sensor assembly, this resistor-based
sensor measures temperature of incoming air and supplies air density
information to ECU.
Motor Position Sensor (MPS)
Incorporated in ISC motor (or separate unit on some models),
senses ISC motor plunger position and sends electrical signal to ECU.
Oxygen (O2) Sensor
Located in exhaust system, generates an output voltage.
Output voltage varies with oxygen content of exhaust gas stream. ECU
adjusts air/fuel mixture based on signals from oxygen sensor.
Power Steering Oil Pressure Switch
Detects increase in power steering oil pressure. When power
steering oil pressure increases, switch contacts close, signalling
ECU. ECU commands ISC motor, raising idle speed to compensate for drop
in engine RPM due to power steering load.
TDC Sensor
See CRANKSHAFT ANGLE & TDC SENSOR ASSEMBLY.
Throttle Position Sensor (TPS)
A variable resistor mounted on throttle body. ECU uses
voltage signal received from TPS to determine throttle plate angle.
Vehicle Speed Sensor
Located in speedometer in instrument cluster, uses a reed
switch to sense speedometer gear revolutions. ECU uses gear
revolutions to determine vehicle speed.
OUTPUT SIGNALS
NOTE: Vehicles are equipped with different combinations of
computer-controlled components. Not all components listed
below are used on every vehicle. For theory and operation on
each output component, refer to the system indicated in
brackets after component.
CHECK ENGINE Light
See SELF DIAGNOSTIC SYSTEM.
EGR Control Solenoid Valve
See EXHAUST GAS RECIRCULATION (EGR) CONTROL under EMISSION
SYSTEMS.
Fuel Injectors
See FUEL CONTROL under FUEL SYSTEM.
Fuel Pressure Control Solenoid Valve (Turbo Only)
See FUEL DELIVERY under FUEL SYSTEM.
Fuel Pressure Regulator
See FUEL DELIVERY under FUEL SYSTEM.
Fuel Pump Relay (MPI Control Relay)

See FUEL DELIVERY under FUEL SYSTEM.
Idle Speed Control Servo
See IDLE SPEED under FUEL SYSTEM.
Power Transistor(s) & Ignition Coils
See IGNITION SYSTEMS.
Purge Control Solenoid Valve
See EVAPORATIVE CONTROL under EMISSION SYSTEMS.
Self-Diagnostic Connector
See SELF-DIAGNOSTIC SYSTEM.
Wastegate Control Solenoid Valve
See TURBOCHARGED ENGINES under AIR INDUCTION SYSTEM.
FUEL SYSTEM
FUEL DELIVERY
Electric fuel pump (located in gas tank) feeds fuel through
in-tank fuel filter, external fuel filter (located in engine
compartment) and fuel injector rail.
Fuel Pump
Consists of an impeller driven by a motor. Pump has an
internal check valve to maintain system pressure and a relief valve to
protect the fuel pressure circuit. Pump receives voltage supply from
Multi-Point Injection (MPI) control relay.
Fuel Pressure Control Solenoid Valve (Turbo Only)
Prevents rough idle due to fuel percolation. On engine
restart, if engine coolant or intake air temperatures reach a preset
value, ECU applies voltage to fuel pressure control solenoid valve for
2 minutes after engine re-start. Valve opens, allowing atmospheric
pressure to be applied to fuel pressure regulator diaphragm. This
allows maximum available fuel pressure at injectors, enriching fuel
mixture and maintaining stable idle at high engine temperatures.
Fuel Pressure Regulator
Located on fuel injector rail, this diaphragm-operated relief
valve adjusts fuel pressure according to engine manifold vacuum.
As engine manifold vacuum increases (closed throttle), fuel
pressure regulator diaphragm opens relief valve, allowing pressure to
bleed off through fuel return line, reducing fuel pressure.
As engine manifold vacuum decreases (open throttle), fuel
pressure regulator diaphragm closes valve, preventing pressure from
bleeding off through fuel return line, increasing fuel pressure.
FUEL CONTROL
Fuel Injectors
Fuel is supplied to engine through electronically pulsed
(timed) injector valves located on fuel rail(s). ECU controls amount\
of fuel metered through injectors based upon information received from
sensors.
IDLE SPEED
Air Conditioner Relay
When A/C is turned on with engine at idle, ECU signals ISC

motor to increase idle speed. To prevent A/C compressor from switching
on before idle speed has increased, ECU momentarily opens A/C relay
circuit.
Idle Speed Control (ISC) Motor
Controls pintle-type air valve (DOHC engines) or throttle
plate angle (SOHC engines) to regulate volume of intake air at idle.
During start mode, ECU controls idle intake air volume
according to coolant temperature input. After starting, with idle
position switch activated (throttle closed), fast idle speed is
controlled by ISC motor and fast idle air control valve (if equipped).\
When idle switch is deactivated (throttle open), ISC motor
moves to a preset position in accordance with coolant temperature
input.
When automatic transmission (if equipped) is shifted from
Neutral to Drive, A/C is turned on or power steering pressure reaches
a preset value, ECU signals ISC motor to increase engine RPM.
Fast Idle Air Control Valve
Some models use a coolant temperature-sensitive fast idle air
control valve, located on throttle body, to admit additional intake
air volume during engine warm-up. Control valve closes as temperature
increases, restricting by-pass airflow rate. At engine warm-up, valve
closes completely.
IGNITION SYSTEMS
DIRECT IGNITION SYSTEM (DIS) - DOHC ENGINES
Ignition system is a 2-coil, distributorless ignition system.
Crankshaft angle and TDC sensor assembly, mounted in place of
distributor, are optically controlled.
Power Transistors & Ignition Coils
Based on crankshaft angle and TDC sensor inputs, ECU controls
timing and directly activates each power transistor to fire coils.
Power transistor "A" controls primary current of ignition coil "A" to
fire spark plugs on cylinders No. 1 and 4 at the same time. Power
transistor "B" controls primary current of ignition coil "B" to fire
spark plugs on cylinders No. 2 and 3 at the same time.
Although each coil fires 2 plugs at the same time, ignition
takes place in only one cylinder since the other cylinder is on its
exhaust stroke when plug fires.
ELECTRONIC IGNITION SYSTEM - SOHC ENGINES
Mitsubishi breakerless electronic ignition system uses a disc
and optical sensing unit to trigger power transistor.
Power Transistor & Ignition Coil
Power transistor is mounted inside distributor with disc and
optical sensing unit. When ignition is on, ignition coil primary
circuit is energized. As distributor shaft rotates, disc rotates,
triggering optical sensing unit. ECU receives signals from optical
sensing unit. Signals are converted and sent to power transistor,
interrupting primary current flow and inducing secondary voltage.
IGNITION TIMING CONTROL SYSTEM
Ignition timing is controlled by ECU. ECU adjusts timing
based upon various conditions, such as engine temperature, altitude
and detonation (turbo vehicles only).

EMISSION SYSTEMS
EXHAUST GAS RECIRCULATION (EGR) CONTROL
Federal (Non-Turbocharged)
To lower oxides of nitrogen (NOx) exhaust emissions, a non-
computer controlled exhaust gas recirculation system is used. EGR
operation is controlled by throttle body ported vacuum. Vacuum is
routed through thermovalve to prevent EGR operation at low engine
temperatures.
Spring pressure holds EGR valve closed during low vacuum
conditions (engine idling or wide open throttle). When vacuum pressure\
increases and overcomes EGR spring pressure, EGR valve is lifted and
allows exhaust gases to flow into intake manifold for combustion.
California & Turbocharged
ECU controls EGR operation by activating EGR control solenoid
valve according to engine load. When engine is cold, ECU signals EGR
control solenoid valve to deactivate EGR.
California models are equipped with an EGR temperature
sensor. When EGR malfunction occurs, EGR temperature decreases and ECU
illuminates CHECK ENGINE (malfunction indicator) light.
EGR Control Solenoid Valve
Denies or allows vacuum supply to EGR valve, based upon ECU
commands.
Thermovalve
Denies or allows vacuum supply to EGR valve based on coolant
temperature.
EVAPORATIVE CONTROL
Fuel evaporation system prevents fuel vapor from entering
atmosphere. System consists of a special fuel tank with vapor
separator tanks (if equipped), vacuum relief filler cap, overfill
limiter (2-way valve), fuel check valve, thermovalve (if equipped),
charcoal canister, purge control valve, purge control solenoid valve
and connecting lines and hoses.
Purge Control Solenoid Valve
When engine is off, fuel vapors are vented into charcoal
canister. When engine is warmed to normal operating temperature and
running above idle, ECU energizes purge control solenoid valve,
allowing vacuum to purge valve.
Canister vapors are then drawn through purge valve into
intake manifold for burning. Purge control solenoid valve remains
closed during idle and engine warm-up to reduce HC and CO emissions.
HIGH ALTITUDE CONTROL (HAC)
This system compensates for variations in altitude. When
atmospheric (barometric) pressure sensor determines vehicle is above
preset altitude, ECU compensates by adjusting air/fuel mixture and
ignition timing. If HAC system is inoperative, there will be an
increase in emissions.
PCV VALVE
Positive Crankcase Ventilation (PCV) valve operates in the
closed crankcase ventilation system. Closed crankcase ventilation

\003
TR AN SM IS SIO N R EM OVA L & IN STA LLA TIO N - A /T
1991 M it s u bis h i M onte ro
199192 TRANSMISSION SERVICING
Transmission Removal & Installation
Mitsubishi: Eclipse, Galant, Mirage, Montero,
Pickup, Precis, 3000GT
MANUAL
NOTE: For manual transmission/transaxle replacement procedures,
see appropriate article in CLUTCHES.
AUTOMATIC FWD MODELS
REMOVAL
1) Remove battery and battery tray. On 3000GT, remove
undercover(s). On Eclipse turbo, drain and remove intercooler. On all
models, remove air cleaner and case. Raise and support vehicle. Remove
wheels. Disconnect control cables at transaxle. Drain transaxle fluid.
2) On Mirage 1.6L, disconnect tension rod. On all models,
disconnect neutral safety switch connector, oil cooler hoses and
electrical connectors from transaxle. Disconnect speedometer cable and
throttle control cable (if equipped). Remove starter motor.
3) On Galant models with electronically controlled
suspension, remove air compressor and bracket. Disconnect front height
sensor rod at lower control arm.
4) On all models, remove upper transaxle-to-engine bolts.
Remove engine undercover (if equipped). On all models, remove drive
axle shafts. See FWD AXLE SHAFTS article in DRIVE AXLES. Separate
lower control arms from struts for access to axle shafts (if
necessary).
5) Remove front exhaust pipe (if necessary). On Eclipse 4WD,\
Galant 4WD and 3000GT, remove right member and gusset. On 4WD models,
separate transfer assembly from transaxle. Reference mark transfer
assembly-to-drive shaft and remove transfer assembly.
6) On all models, remove transmission inspection (dust)
cover. Place index mark on torque converter and drive plate for
reassembly reference. Remove torque converter-to-drive plate bolts.
Push torque converter away from engine into transaxle.
7) Support transaxle with jack. Remove transaxle mounts
bolts, mounting brackets and remaining transaxle-to-engine bolts.
Slide transaxle assembly to right and lower to remove.
CAUTION: Ensure torque converter is fully seated in transaxle before
installation. Always install new snap rings on inner
constant velocity joints.
INSTALLATION
1) To install, reverse removal procedure. Tighten transaxle-
to-engine bolts and torque converter-to-drive plate bolts to
specification. See TORQUE SPECIFICATIONS table at end of article.
2) Ensure reference marks on torque converter-to-drive plate
and transfer assembly-to-drive shaft align. Tighten mounting bolts
with weight of engine and transaxle on mounts. Refill transaxle fluid
to specified level. Adjust all control cables.
RWD MODELS

fluid to bring level to lower mark of dipstick if necessary. Recheck
fluid level after transmission is at normal operating temperature.
TRANSFER CASE
Drain plug is located on bottom of transfer case. Change
drain plug gasket whenever fluid is changed. On 3000GT, lubricant
level should be approximately .5" (13 mm) below fill hole on side of
transfer case. On all others models, lubricant level should be to
bottom of fill hole on side of transfer case.
HYDRAULIC CONTROL PRESSURE ADJUSTMENTS
LINE PRESSURE CHECK (EXCEPT MONTERO & PICKUP)
1) Set parking brake. Place shift lever in Neutral position.
Attach engine tachometer. Remove line pressure port plug located above
front transaxle shaft, forward of governor pressure port plug. On
Precis, line pressure port is located below bell housing, at front of
transaxle oil pan. Using appropriate adapter, attach pressure gauge.
2) Start engine, and bring to operating temperature. With
gear selector in Drive position, bring engine speed to 2500 RPM. Pull
throttle control cable (if equipped) wide open at transaxle side.
3) Line pressure should be 98-100 psi (6.9-7.0 kg/cm
) on
Mirage, or 124-127 psi (8.7-8.9 kg/cm) on all others. If line
pressure is not to specification, proceed to LINE PRESSURE ADJUSTMENT.
LINE PRESSURE ADJUSTMENT (EXCEPT MONTERO & PICKUP)
1) Drain transaxle fluid. Remove oil pan. Disconnect throttle
control cable from throttle cam. Remove oil temperature sensor (if
equipped). Disconnect solenoid connector. On some models, it may be
necessary to push solenoid wire harness connector and grommet into
transaxle case.
2) Remove oil filter screen and plate. Noting location and
length of bolts, remove valve body. DO NOT drop internal parts. Adjust
line pressure by turning regulator valve adjusting screw.
3) Turn adjusting screw counterclockwise to increase pressure
or clockwise to decrease pressure. One complete turn of adjusting
screw changes line pressure as follows.
* 3.7 psi (.26 kg/cm
) on Mirage with F3A21 Transaxle
* 5.4 psi (.39 kg/cm) on Precis
* 54 psi (3.8 kg/cm) on all others
4) After adjustment, reverse removal procedure to install.
Refill transaxle.
LINE PRESSURE (MONTERO)
1) Remove plug from line pressure take-off port located
behind transmission shift control lever. Install Hydraulic Pressure
Meter (MD998330) with Adapter (MD998206).
2) Place vehicle on dynamometer. Apply parking brake and
start engine. With brake applied, place transmission in Drive. Note
pressure at idle. Pressure should be 74-85 psi (5.2-6.0 kg/cm
).
3) Raise engine RPM to stall speed (2100-2400 RPM). Note lin\
e
pressure. Pressure should be 156-185 psi (11.0-13.0 kg/cm
).
4) Shift transmission into Reverse with brake applied. At
idle, pressure should be 112-130 psi (7.9-9.1 kg/cm
). Raise engine
RPM to stall speed (2100-2400 RPM). Note line pressure. Pressure
should be 227-285 psi (16.0-20.0 kg/cm
). If readings are not to