clock MITSUBISHI MONTERO 1991 Owner's Manual

NOTE: Fixed Speed Adjusting Screw (SAS) is preset by manufacturer
and usually does not require adjustment. Only adjust fixed
SAS if other adjustment procedures require it, or if
manufacturer's original setting has been changed.
3.0L Montero, Pickup, Ram-50, Stealth & 3000GT
1) Loosen throttle cable. Loosen fixed SAS lock nut. See
Fig. 4. Turn fixed SAS counterclockwise until throttle valve is fully
closed. Turn fixed SAS clockwise until throttle valve begins to open.
Turn fixed SAS clockwise 1 1/4 turns after throttle valve begins to
open.
2) Tighten lock nut while holding fixed SAS in position.
Adjust throttle cable. Adjust basic idle speed. See BASIC IDLE SPEED
under IDLE SPEED & MIXTURE. Adjust throttle position sensor. See
THROTTLE POSITION SENSOR (TPS).
All Other Models
To adjust fixed SAS, adjust basic idle speed. See BASIC IDLE
SPEED under IDLE SPEED & MIXTURE.
Fig. 4: Fixed Speed Adj. Screw & Feeler Gauge Pos. (3.0L)
Courtesy of Mitsubishi Motor Sales of America.
IDLE MIXTURE

NOTE: Idle mixture is computer controlled on fuel injected engines
and is nonadjustable. CO level specifications are not
available from manufacturer.
THROTTLE POSITION SENSOR (TPS)
TPS ADJUSTMENT
NOTE: Ensure basic idle speed is set to specification before
adjusting TPS. See BASIC IDLE SPEED under IDLE SPEED &
MIXTURE. Perform all adjustments with engine at normal
operating temperature, front wheels in straight-ahead
position, cooling fan and all accessories off, and
transmission in Park or Neutral.
TPS TEST APPLICATION









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Application Test
1.5L
Colt, Colt 200,
Mirage & Summit ............. TEST NO. 1
1.6L
Mirage ....................... TEST NO. 2
1.8L
Eclipse ...................... TEST NO. 3
2.0L (VIN V)
Colt Vista & Galant .......... TEST NO. 1
2.0L (VIN R & U)
Galant ....................... TEST NO. 1
Eclipse ...................... TEST NO. 3
2.4L
Pickup & Ram-50 .............. TEST NO. 1
3.0L
Montero, Pickup & Ram-50 ..... TEST NO. 4
Stealth & 3000GT ............. TEST NO. 5









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Test No. 1
1) Turn ignition on for more than 15 seconds. DO NOT start
engine. Turn ignition off. ISC plunger should be retracted fully.
2) Ensure ISC plunger is in fully retracted position.
Disconnect harness connector(s) from ISC motor. Turn ignition on. DO
NOT start engine.
3) Using digital voltmeter, backprobe terminal No. 19
(Green/White wire) and terminal No. 24 (Black or Green/Black wire) a\
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Engine Control Unit (ECU) wiring harness connector. Note TPS output
voltage.
4) If output voltage is .48-.52 volt, go to step 6). If
output voltage is not .48-.52 volt, loosen TPS mounting screw(s) and
rotate TPS clockwise, or counterclockwise, until output voltage is
within specification. Tighten TPS mounting screws.
5) Turn ignition off. Reconnect harness connector(s) at ISC
motor. Start engine. Ensure engine idles within curb idle speed
specification.
6) Turn ignition off. Disconnect negative battery cable for
at least 15 seconds to clear diagnostic trouble code. Reconnect
negative battery cable. Operate engine at idle for about 5 minutes to
ensure engine idles smoothly.
Test No. 2
1) Turn ignition on. DO NOT start engine. Loosen throttle

cable. Using digital voltmeter, backprobe terminal No. 19 (Green/White
wire) and terminal No. 24 (Black or Green/Black wire) at Engine
Control Unit (ECU) wiring harness connector. Check TPS output voltage.\
2) If output voltage is .48-.52 volt, go to step 3). If
output voltage is not .48-.52 volt, remove throttle body. Loosen TPS
mounting screws and rotate TPS clockwise, or counterclockwise, until
output voltage is within specification. Tighten TPS mounting screws.
3) Turn ignition off. Disconnect voltmeter from ECU harness
connector. Adjust throttle cable. Disconnect negative battery cable
for at least 10 seconds to clear diagnostic code. Reconnect negative
battery cable. Operate engine at idle for about 5 minutes to ensure
engine idles smoothly.
Test No. 3
1) Turn ignition on for more than 15 seconds. DO NOT start
engine. Turn ignition off. This should fully retract ISC plunger.
2) Ensure ISC plunger is fully retracted. Disconnect TPS
harness connectors. Connect Test Harness (MD998474) between
connectors. Connect digital voltmeter between Red and Blue wires of
test harness.
3) Turn ignition on. DO NOT start engine. TPS voltage should
be .48-.52 volt. If TPS voltage is .48-.52 volt, go to step 4). If TPS
voltage is not .48-.52 volt, loosen TPS mounting screws and rotate TPS
clockwise, or counterclockwise, until correct voltage is obtained.
Tighten TPS mounting screws.
4) Turn ignition off. Disconnect voltmeter and remove test
harness. Reconnect TPS harness connectors. Adjust throttle cable.
Start engine and check idle speed.
5) Turn ignition off. Disconnect negative battery cable for
at least 10 seconds to clear diagnostic trouble code. Reconnect
negative battery cable. Operate engine at idle for about 5 minutes to
ensure engine idles smoothly.
Test No. 4
1) Loosen throttle cable. Disconnect electrical connector
from TPS. Connect digital ohmmeter between Green/White and
Green/Yellow wire terminals of TPS electrical connector (on TPS side
of harness).
2) Insert .026" (.66 mm) feeler gauge between fixed Speed
Adjusting Screw (SAS) and throttle lever. See Fig. 4. Loosen TPS
mounting screws. Rotate TPS fully clockwise. Check for continuity
between Green/White wire and Green/Yellow wire terminals of TPS
electrical connector.
3) Rotate TPS counterclockwise until ohmmeter registers no
continuity. Tighten TPS mounting screws and reconnect TPS electrical
connector.
4) Using digital voltmeter, backprobe terminal No. 19
(Green/White wire) and terminal No. 24 (Black or Green/Black wire) a\
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Engine Control Unit (ECU) wiring harness connector. Turn ignition on.
DO NOT start engine. Check TPS output voltage.
5) If TPS output voltage is 0.4-1.0 volt, go to step 6). If
TPS output voltage is not 0.4-1.0 volt, check TPS and wiring harness
for damage or malfunction. Replace TPS or repair wiring harness if
necessary and go to next step.
6) Remove feeler gauge. Turn ignition off. Disconnect
voltmeter from ECU connector. Adjust throttle cable. Operate engine at
idle for about 5 minutes to ensure engine idles smoothly and within
specification.
Test No. 5
1) Disconnect electrical connector from TPS. Connect digital
ohmmeter between Yellow/Red wire and Black wire terminals of TPS.
2) Insert .026" (.66 mm) feeler gauge between fixed Speed

Adjusting Screw (SAS) and throttle lever. See Fig. 4. Loosen TPS
mounting screws. Rotate TPS fully counterclockwise. Check for
continuity between Yellow/Red wire and Black wire terminals of TPS.
3) Rotate TPS clockwise until ohmmeter registers no
continuity. Tighten TPS mounting screws. Reconnect TPS electrical
connector.
4) Use a digital voltmeter to backprobe terminal No. 19
(Brown/Red wire) and terminal No. 24 (Brown wire) at Engine Control
Unit (ECU) wiring harness on SOHC vehicles, or terminal No. 64
(Brown/Red wire) and terminal No. 72 (Black wire) on DOHC vehicles.
Turn ignition on. DO NOT start engine. Check TPS output voltage.
5) If TPS output voltage is 0.4-1.0 volt, go to step 6). If
TPS output voltage is not 0.4-1.0 volt, check TPS and wiring harness
for damage or malfunction. Replace TPS or repair wiring harness if
necessary and go to step 6).
6) Remove feeler gauge. Turn ignition off. Disconnect
voltmeter from ECU connector. Operate engine at idle for about 5
minutes to ensure engine idles smoothly and within specification.
IDLE POSITION SWITCH
NOTE: Idle position switch is preset by manufacturer. Adjustment
is usually not necessary. If other procedures in this
article require adjustment of idle position switch or if
switch setting has been changed, adjust switch as follows.
1.6L Mirage, 2.0L Eclipse & 2.0L Galant (DOHC)
1) Loosen throttle cable. Disconnect electrical connector
from idle position switch. See Fig. 5. Loosen lock nut at base of
switch. Turn switch counterclockwise until throttle valve is fully
closed.
2) Connect ohmmeter between switch terminal and switch body
(ground). Turn idle position switch clockwise until ohmmeter registers\
continuity. At this point, throttle valve should begin to open.
3) Turn switch 15/16 of a turn beyond contact point. Tighten
lock nut at base of idle position switch, holding switch to prevent it
from turning while tightening.
4) Adjust throttle cable. Adjust basic idle speed. See BASIC
IDLE SPEED. Adjust TPS. See TPS ADJUSTMENT.
All Other Models
Idle position switch is incorporated in ISC motor and is
automatically adjusted when TPS is adjusted. See TPS ADJUSTMENT.
Fig. 5: Idle Position Switch Location (1.6L & 2.0L (VIN R &U))
Courtesy of Mitsubishi Motor Sales of America.

Replace cruise control switch if it does not test correctly.
Main Switch (1992)
1) In each switch position, continuity should be present
between terminals No. 2 and 7 for switch illumination. See Figs. 22-
29. When switch is moved to Neutral position, continuity should be
present between terminals No. 1 and 4.
2) When switch is moved to ON position, continuity should be
present between terminals No. 1, 4 and 5. Connect battery voltage to
terminal No. 5 and ground terminal No. 4.
3) Battery voltage should then be present on terminal No. 1
when main switch is moved to On position. Replace switch if it does
not test correctly.
BRAKELIGHT/STOPLIGHT SWITCH TEST
Disconnect switch connector. When brake pedal is pressed,
continuity should be present between terminals No. 2 and 3. See
Figs. 22 -29. When brake pedal is released, continuity should be
present between terminals No. 1 and 4. Replace switch if it does not
test correctly.
IDLE SWITCH & THROTTLE POSITION SENSOR TESTS
Throttle Position Sensor (1992)
1) Disconnect sensor connector. Resistance between terminals
No. 1 and 4 should be 3500-6500 ohms. Use an analog ohmmeter to
measure resistance between terminals No. 1 and 3. See Figs. 22-29.
2) Slowly open throttle valve to wide open throttle.
Resistance should change smoothly as throttle is opened. Replace
throttle position sensor if it does not test correctly.
Idle Switch (1992)
1) Disconnect throttle position sensor connector. Continuity
should be present between terminals No. 1 and 2 with accelerator pedal
released. See Figs. 22-29. Continuity should not be present with
accelerator pedal pressed.
2) If continuity is not present with accelerator released,
loosen throttle position sensor mounting screw. Turn throttle position
sensor completely clockwise. Recheck continuity. Replace throttle
position sensor if idle switch does not test correctly.
INHIBITOR SWITCH TEST
Disconnect switch connector. Shift transaxle into Neutral and
Park positions. On 1991 models, continuity should be present between
Black/Yellow wire terminals No. 3 and 4. On 1992 models, continuity
should be present between terminals No. 7 and 12. See Figs. 22-29. On
all models, if continuity is not present, adjust inhibitor switch. If
switch is adjusted properly, replace switch.
VACUUM PUMP TEST
1992
1) Remove vacuum pump connector. Resistance should be 50-60
ohms between terminal No. 1 and terminals No. 2 and 3. See Figs. 22-
29. Ensure solenoid valve makes operating noise when battery voltage
is applied between terminal No. 1 and terminals No. 2 and 3.
2) If solenoid valve does not make noise, replace vacuum pump
assembly. Apply battery voltage to terminals No. 1 and 4, motor should
operate. Replace vacuum pump if motor does not operate.

PROBLEM
Possible Cause Action









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GREASE LEAKING
Ripped CV Boot ................................... Replace Boot
CLICKING NOISE WHILE CORNERING
Dry/Worn CV Joints .................... Replace Outer CV Joints
CLUNK ON ACCELERATION
Dry/Worn CV Joints .................... Replace Inner CV Joints
Worn Trans. Gears/Bearings ..................... Inspect Trans.
VIBRATION/SHUDDER ON ACCELERATION
Dry/Worn CV Joints .......................... Replace CV Joints
Alignment Out ................................. Check Alignment
Incorrect Spring Height ................... Check Spring Height
SQUEALING OR HUMMING
Dry/Worn CV Joints ..................... Lube/Replace CV Joints
Faulty Wheel Bearing .................... Replace Wheel Bearing









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TESTING & INSPECTION
AXLE SHAFT END PLAY
Using dial indicator, check axle shaft end play. End play
must be .0020-.0079" (.05-.20 mm). If end play is not within
specification, change shims to obtain correct end play. See AXLE
SHAFTS under REMOVAL & INSTALLATION.
AXLE TOTAL BACKLASH
1) Raise and support rear axle. Place transmission in
Neutral. Apply parking brake. Rotate drive shaft clockwise. Place
reference marks on pinion dust cover and differential housing.
2) Rotate drive shaft counterclockwise and measure distance
between reference marks. Differential must be removed and backlash
adjusted if distance exceeds 0.2" (5.0 mm).
LIMITED SLIP DIFFERENTIAL PRELOAD
1) Place transmission in Neutral. Block front wheels. Raise
one rear wheel free of ground and remove wheel. Use Axle Puller
Adapter (MB990241) for Montero and Pickup models. Install adapter on
wheel studs. Release parking brake.
2) Using torque wrench, measure starting torque on Pickup
models while rotating wheel in forward direction. On Montero models,
measure rotating torque. This measurement is read once axle is
turning. Differential must be repaired if torque is less than
specification. See TESTING SPECIFICATIONS table.

1 - 20 Amp (Yellow)
Hazard Light, Dome Light, Clock
2 - 10 Amp (Red)
Taillights
3 - 10 Amp (Red)
Turn Signal Lights
4 - 10 Amp (Red)
Back-Up Lights, Gauges
5 - 15 Amp (Light Blue)
Defogger
6 - 20 Amp (Yellow)
Heater
7 - 15 Amp (Light Blue)
Stoplights
8 - 15 Amp (Light Blue)
Horn, Wiper, Washer
9 - 10 Amp (Red)
Rear Wiper, Rear Washer
10 - 15 Amp (Light Blue)
Cigarette Lighter, Radio
CAUTIONS & WARNINGS
RADIATOR FAN & CAP
DO NOT loosen or remove radiator cap when cooling system is
hot. The system is under high pressure, and hot steam or boiling
liquid could gush out if cap is loosened or removed while system is
hot.
BRAKE FLUID
Be careful when handling brake fluid as it is harmful to eyes
and may damage painted surfaces.
REPLACING BLOWN FUSE
Before replacing a blown fuse, remove ignition key, turn off
all lights and accessories to avoid damaging the electrical system. Be
sure to use fuse with the correct indicated amperage rating. The use
of an incorrect amperage rating fuse may result in a dangerous
electrical system overload.

Removal (Montero)
1) Move temperature control lever to WARM position. Drain
coolant from vehicle. Disconnect heater hoses from heater unit. See
Fig. 1.
2) Remove lap heater ducts. Remove hood release bracket.
Using screwdriver, release tabs and remove left and right demister
grilles. Remove glove box frame attaching screws, and remove glove
box. Remove passenger lap heater duct.
3) Using screwdriver and shop towel, carefully pry at top
center of instrument cluster cover, and remove cover. Remove 2 screws
at bottom of instrument panel and one bolt at top of instrument panel.
Gently pull instrument cluster out, and disconnect speedometer cable
and electrical connections. Remove instrument cluster.
4) Remove 4 screws, and disconnect electrical connections on
back of instrument cluster. Remove instrument cluster. Handle
instrument cluster carefully. Instrument cluster can be damaged if
dropped.
5) Remove center console knobs and side screw plugs. Remove
screws, disconnect electrical connections and remove console. Remove 6
bolts and console bracket (center dash reinforcement). Disconnect
radio connections while removing console bracket.
6) Remove horn pad and steering wheel retaining nut. Mark
steering wheel and steering shaft for reassembly reference. Using
steering wheel puller, remove steering wheel.
7) Using screwdriver, carefully pry out dash plug at upper
center of dash panel. Remove 3 upper dash mounting nuts, one upper
screw above steering column, and 2 lower mounting screws. Remove dash
panel.
8) Remove control cables at heater unit. Remove heater unit
attaching screws. Remove heater ducts. Remove heater unit. Remove
heater control lever arm.
9) Remove heater control valve cover. Remove heater pipe and
heater control valve. Disconnect control arm linkage. Remove control
arm. Remove heater core by moving it sideways.
Installation
1) To install, reverse removal procedure. Insert heater hoses
fully into pipes, and clamp securely to prevent leaks. Connect heater
hoses with 1-1.2" (25-30 mm) overlap on outlet.
2) When filling radiator with coolant, first open heater
control valve fully and run engine to circulate coolant and discharge
air from inside heater and engine cooling system. Stop engine, and add
coolant.
3) Adjust all control cables. When installing heater hose
grommets, apply sealer. After installing heater control assembly,
ensure each lever operates smoothly.
Removal (Pickup & Ram-50)
1) Disconnect battery ground cable. Place heater control
lever to far right. Drain coolant. Using trim stick, pry out hazard
switch and remove electrical connection. Remove 4 instrument cluster
cover screws, and remove cover. Remove 4 instrument cluster screws.
Tilt instrument cluster out, and disconnect speedometer cable and
electrical connections. Remove cluster.
2) Remove fuse box cover and fuse box assembly. Remove glove
box. Remove defroster air ducts. Disconnect heater control cables.
Using trim stick, pry under and remove speaker grilles. Remove clock
or coin box in center of dash. Remove center dash hole cover (located
above clock).
3) Remove 2 center support cover screws, and remove cover.
Remove shift knob and 6 console attaching screws. Remove console.
Ensure all electrical connections are free of dash panel. Remove 3 top
nuts, one bolt above steering column, and side and lower attaching

Brake On/Off (BOO) Switch ................... Cruise Control Systems\
Engine Performance
Shift Interlock Systems
Buzzer Module ...................................... Warning Systems
Camshaft Position (CMP) Sensor .................. Engine Performance\
Central Control Module ........................... Anti-Theft System
Clockspring ............................... Air Bag Restraint System
Cruise Control Systems
Steering Column Switches
Clutch Pedal Position Switch .............................. Starters
Clutch Start Switch ....................................... Starters
Combination Meter ......................... Analog Instrument Panels
Constant Control Relay Module (CCRM) ............ Engine Performance\
Electric Cooling Fans
Convenience Center .............................. Power Distribution
Illumination/Interior Lights
Convertible Top Motor ........................ Power Convertible Top
Convertible Top Switch ....................... Power Convertible Top
Crankshaft Position (CKP) Sensor ................ Engine Performance\
Cruise Control Module ....................... Cruise Control Systems
Cruise Control Switch ....................... Cruise Control Systems
Condenser Fan Relay(s) ....................... Electric Cooling Fans\
Data Link Connector (DLC) ....................... Engine Performance\
Daytime Running Lights Module ............... Daytime Running Lights
Exterior Lights
Defogger Relay ................................ Rear Window Defogger
Diagnostic Energy Reserve Module (DERM) ... Air Bag Restraint System\
Discriminating Sensor (Air Bag) ........... Air Bag Restraint System\
Distributor ..................................... Engine Performance
Door Lock Actuators ............................... Power Door Locks
Remote Keyless Entry
Door Lock Relay(s) ................................ Power Door Locks\
Electrochromic Mirror ................................ Power Mirrors
Electronic Level Control (ELC)
Height Sensor .............................. Electronic Suspension
Electronic Level Control (ELC) Module ........ Electronic Suspension\
Engine Coolant Temperature (ECT)
Sending Unit ............................ Analog Instrument Panels
Engine Coolant Temperature (ECT) Sensor ......... Engine Performance\
Engine Control Module ........................... Engine Performance
Generators & Regulators
Starters
ETACS ECU .......................................... Warning Systems
Power Windows
Remote Keyless Entry
Evaporative (EVAP) Emissions Canister ........... Engine Performance\
EVAP Canister Purge Solenoid .................... Engine Performance
EVAP Canister Vent Solenoid ..................... Engine Performance
Exhaust Gas Recirculation (EGR) Valve ........... Engine Performance\
Fuel Tank Vacuum Sensor ......................... Engine Performance
Fog Lights ....................................... Headlight Systems
Daytime Running Lights
Fog Light Relay .................................. Headlight Systems
Daytime Running Lights
Fuel Door Release Solenoid ................. Power Fuel Door Release
Fuel Gauge Sending Unit ................... Analog Instrument Panels
Fuel Injectors .................................. Engine Performance
Fuel Pump ....................................... Engine Performance
Fuel Pump Relay ................................. Engine Performance
Power Distribution
Fuse/Relay Block ................................ Power Distribution
Fusible Links ................................... Power Distribution
Generators & Regulators

Parking Brake Switch ...................... Analog Instrument Panels
Park Lights ........................................ Exterior Lights
Park/Neutral Position Switch .............................. Starters
Engine Performance
Anti-Theft System
Body Control Module
Perimeter Lighting Control Relay ................... Exterior Lights
Power Amplifier ..................................... Power Antennas
Power Antenna Module ................................ Power Antennas
Power Antenna Motor ................................. Power Antennas
Power Distribution Center ....................... Power Distribution
Generators & Regulators
Starters
Power Door Lock Motors ............................ Power Door Locks
Power Mirror Motors .................................. Power Mirrors
Memory Systems
Power Sliding Door Controller .............. Power Sliding Side Door
Power Seat Motors ...................................... Power Seats
Memory Systems
Power Steering Pressure Switch .................. Engine Performance
Power Top Motor .............................. Power Convertible Top
Power Top Relay(s) ........................... Power Convertible Top\
Powertrain Control Module ....................... Engine Performance
Analog Instrument Panels
Cruise Control Systems
Data Link Connectors
Generators & Regulators
Starters
Power Window Motors .................................. Power Windows
Power Window Relay(s) ................................ Power Windows\
Radiator Fan Motor(s) ........................ Electric Cooling Fans\
Radiator Fan Relay(s) ........................... Engine Performance\
Electric Cooling Fans
Rainsense Module .............................. Wiper/Washer Systems
Raise Relay .................................. Power Convertible Top
Remote Anti-Theft Personality (RAP) Module ....... Anti-Theft System\
Starters
Warning Systems
Seat Belt Pretensioners ................... Air Bag Restraint System
Seat Belt Retractor Solenoid .................... Passive Restraints
Seat Belt Switch .......................... Air Bag Restraint System
Passive Restraints
Shift Interlock Solenoid ................... Shift Interlock Systems
Shift Lock Actuator ........................ Shift Interlock Systems
Side Marker Lights ................................. Exterior Lights
SIR Coil Assembly (Clockspring) ........... Air Bag Restraint System\
Slip Ring (Clockspring) ................... Air Bag Restraint System\
Steering Column Switches
SRS Control Module ........................ Air Bag Restraint System
Starter Motor ............................................. Starters
Starter Interrupt Relay ................................... Starters
Starter Solenoid .......................................... Starters
Starter Relay ............................................. Starters
Steering Wheel Position Sensor .................... Anti-Lock Brakes
Stoplights ......................................... Exterior Lights
Stoplight Switch ................................ Engine Performance
Cruise Control Systems
Anti-Lock Brakes
Sun Roof ECU ........................................ Power Sun Roof
Sun Roof Motor ...................................... Power Sun Roof
Sun Roof Position Sensor ............................ Power Sun Roof
Taillights ......................................... Exterior Lights
Throttle Position (TP) Sensor ................... Engine Performance\