engine MITSUBISHI MONTERO 1991 Service Manual
Page 1180 of 1333
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
Page 1190 of 1333
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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
Page 1193 of 1333
widening the gap to 1/4-3/8".
Disconnect spark plug wire
and insert test plug. Ground
plug, crank engine, and
check for spark.
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GOOD SPARK NO SPARK
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* If plug sparks, driveability * Remove coil wire from the
problem is most likely NOT distributor and attach the
in the ignition system. modified spark plug. Ground
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the plug and crank engine
while checking for spark.
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GOOD SPARK NO SPARK
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* If plug has a good spark, * Proceed to the IGNITION
the problem is in the plug PRIMARY TROUBLE SHOOTING
wires, distributor cap, or CHECK CHART below in this
rotor. Replace components article.
as necessary.
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Ignition Primary Trouble Shooting Chart
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START: Visually inspect primary ignition wires for
broken, frayed, split, or cut wires. Also check
for loose, corroded, or disconnected connectors.
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OK NOT OK
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* Check that battery voltage * Repair or replace damaged
is at least 11.5 volts. components as necessary.
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* Replace or recharge the * Check for battery voltage
battery. at the positive terminal of
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the coil.
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OK NOT OK
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* Check air Gap of the Pick-Up * Check resistance of ballast
coil in the distributor. resistor (if used) for the
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correct resistance value.
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Page 1194 of 1333
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OK NOT OK
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* Check Pick-Up coil for * Adjust or replace as
correct resistance value. necessary.
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NOT OK OK
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* Replace Pick-Up coil if * Check control module for
not to specification. good ground connections.
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OK
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* If vehicle fails to run at this point, go to
the appropriate article in the ENGINE
PERFORMANCE section.
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OK NOT OK
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* Check wires from the battery/ * Replace ballast resistor
ignition switch to the coil. if the measured resistance
Also check the coil primary value is not within
and secondary resistance. specification.
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STARTER 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 STARTER TROUBLE SHOOTING CHART
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CONDITION POSSIBLE CAUSE CORRECTION \
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Starter Fails Dead battery or bad Check battery charge
to Operate connections between and all wires and
starter and battery connections to starter
Ignition switch faulty Adjust or replace
or misadjusted ignition switch
Open circuit between Check and repair wires
starter switch ignition and connections as
terminal on starter relay necessary
Starter relay or starter See Testing in STARTER
defective article
Page 1195 of 1333
Open solenoid pull-in See Testing in STARTER
wire article
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Starter Does Not Weak battery or dead Charge or replace
Operate and cell battery as necessary
Headlights Dim
Loose or corroded battery Check that battery
connections connections are clean
and tight
Internal ground in See Testing in STARTER
starter windings article
Grounded starter fields See Testing in STARTERS
Armature rubbing on pole See STARTER article
shoes
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Starter Turns Starter clutch slipping See STARTER article
but Engine
Does Not Rotate
Broken clutch housing See STARTER article
Pinion shaft rusted or See STARTER article
dry
Engine basic timing See Ignition Timing in
incorrect TUNE-UP article
Broken teeth on engine Replace flywheel and
flywheel check for starter pinion
gear damage
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Starter Will Not Faulty overrunning See STARTER article
Crank Engine clutch
Broken clutch housing See STARTER article
Broken flywheel teeth Replace flywheel and
check for starter pinion
gear damage
Armature shaft sheared See STARTER article
or reduction gear teeth
stripped
Weak battery Charge or replace
battery as necessary
Faulty solenoid See On-Vehicle Tests in
STARTER article
Poor grounds Check all ground
connections for
tight and clean
connections
Ignition switch faulty Adjust or replace
or misadjusted ignition switch as
necessary
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Starter Cranks Battery weak or Charge or replace
Engine Slowly defective battery as necessary
Page 1196 of 1333
Engine overheated See ENGINE COOLING
SYSTEM article
Engine oil too heavy Check that proper
viscosity oil
is used
Poor battery-to-starter Check that all
connections between
battery and starter are
clean and tight
Current draw too low or See Bench Tests in
too high STARTER article
Bent armature, loose pole See STARTER article
shoes screws or worn
bearings
Burned solenoid contacts Replace solenoid
Faulty starter Replace starter
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Starter Engages Engine timing too far See Ignition Timing in
Engine Only advanced TUNE-UP article
Momentarily
Overrunning clutch not Replace overrunning
engaging properly clutch. See STARTER
article
Broken starter clutch See STARTER article
Broken teeth on engine Replace flywheel and
flywheel check starter pinion
gear for damage
Weak drive assembly See STARTER article
thrust spring
Weak hold-in coil See Bench Tests in
STARTER article
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Starter Drive Defective point assembly See Testing in STARTER
Will Not Engage article
Poor point assembly ground See Testing in STARTER
article
Defective pull-in coil Replace starter
solenoid
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Starter Relay Dead battery Charge or replace
Does Not Close battery as necessary
Faulty wiring Check all wiring and
connections leading to
relay
Neutral safety switch Replace neutral safety
faulty switch
Starter relay faulty Replace starter relay
Page 1197 of 1333
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Starter Drive Starter motor loose on Tighten starter
Will Not mountings attach bolts
Disengage
Worn drive end bushing See STARTER article
Damaged engine flywheel Replace flywheel and
teeth starter pinion gear for
damage
Drive yolk return spring Replace return spring
broken or missing
Faulty ignition switch Replace ignition switch
Insufficient clearance Replace starter
between winding leads to solenoid
solenoid terminal and main
contact in solenoid
Starter clutch not Replace starter clutch
disengaging
Ignition starter switch Replace ignition switch
contacts sticking
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Starter Relay Faulty solenoid switch, Check all wiring
Operates but switch connections or between relay and
Solenoid Does Not solenoid or replace
relay or solenoid as
necessary
Broken lead or loose Repair wire or wire
soldered connections connections as
necessary
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Solenoid Plunger Weak battery Charge or replace
Vibrates When battery as necessary
Switch is Engaged
Solenoid contacts Clean contacts or
corroded replace solenoid
Faulty wiring Check all wiring
leading to solenoid
Broken connections inside Repair connections or
switch cover replace solenoid
Open hold-in wire Replace solenoid
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Low Current Draw Worn brushes or weak Replace brushes or
brush springs as
necessary
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High Pitched Whine Distance too great Align starter or check
During Cranking between starter that correct starter
Before Engine pinion and flywheel and flywheel are being
Fires but Engine used
Fires and Cranks
Normally
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High Pitched Distance too small between
Whine After Engine starter pinion and flywheel
Page 1198 of 1333
Fires With Key Flywheel runout contributes
released. Engine to the intermittent nature
Fires and Cranks
Normally
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AIR CONDITIONING & HEAT
AIR CONDITIONING TROUBLE SHOOTING
WARNING: 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 AIR CONDITIONING TROUBLE SHOOTING CHART
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CONDITION POSSIBLE CAUSE \
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Compressor Not Working
Compressor clutch circuit open.
Compressor clutch coil inoperative.
Poor clutch ground connection.
Fan belts loose.
Thermostatic switch inoperative.
Thermostatic switch not adjusted.
Ambient temperature switch open.
Superheat fuse blown. \
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Excessive Noise or Vibration
Missing or loose mounting bolts.
Bad idler pulley bearings.
Fan belts not tightened correctly.
Compressor clutch contacting body.
Excessive system pressure.
Compressor oil level low.
Damaged clutch bearings.
Damaged reed valves.
Damaged compressor. \
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Insufficient or No Cooling;
Compressor Working
Expansion valve inoperative.
Heater control valve stuck open.
Low system pressure.
Blocked condenser fins.
Blocked evaporator fins.
Vacuum system leak.
Vacuum motors inoperative.
Control cables improperly adjusted.
Restricted air inlet.
Mode doors binding.
Blower motor inoperative.
Temperature above system capacity. \
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HEATER 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
Page 1202 of 1333
Parking Brake cables frozen See DRUM BRAKES
BRAKE SYSTEM
Incorrect installation of
inboard disc pad Remove and replace
correctly
Power booster output
rod too long See POWER BRAKE UNITS
BRAKE SYSTEM
Brake pedal not returning See DISC, DRUM BRAKES
freely BRAKE SYSTEM
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Brakes Grab or
Uneven Braking
Action Malfunction of combination See CONTROL VALVE or
valve BRAKE SYSTEM
Malfunction of power brake See POWER BRAKE UNITS
unit or BRAKE SYSTEM
Binding brake pedal See DISC, DRUM BRAKES
or BRAKE SYSTEM
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Pulsation or
Roughness Uneven pad wear caused by See DISC BRAKES or
caliper BRAKE SYSTEM
Uneven rotor wear See DISC BRAKES or
BRAKE SYSTEM
Drums out-of-round Reface or replace drums
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ENGINE MECHANICAL
COOLING 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.
COOLING SYSTEM TROUBLE SHOOTING
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CONDITION POSSIBLE CAUSE CORRECTION \
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Overheating Coolant Leak Fill/Pressure Test
System
A/C Condenser Fins Clogged Remove/Clean Condenser
Radiator Fins Clogged Remove/Clean Radiator
Thermostat Stuck Closed Replace Thermostat
Clogged Cooling System
Passages Clean/Flush Cooling
System
Page 1203 of 1333
Water Pump Malfunction Replace Water Pump
Fan Clutch Malfunction Replace Fan Clutch
Retarded Ignition Timing Reset Ignition Timing
Cooling Fan Malfunction Test Cooling Fan/
Circuit
Cooling Fan Motor
Malfunction Test Fan Motor
Cooling Fan Relay
Malfunction Test Fan Relay
Faulty Radiator Cap Replace Radiator Cap
Broken/Slipping Fan Belt Replace Fan Belt
Restricted Exhaust Repair Exhaust System
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Corrosion Impurities In Coolant Clean/Flush System \
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Coolant Leakage Damaged hose Replace Hose
Leaky Water Pump Replace Water Pump
Damaged Radiator Seam Replace/Repair Radiator
Leaky Thermostat Cover Replace Thermostat
Cover
Cylinder Head Problem Check Head/Head Gasket
Leaky Freeze Plugs Replace Freeze Plugs
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Recovery System Inoperative
Loose and/or Defective
Radiator Cap Replace Radiator Cap
Overflow Tube Clogged
and/or Leaking Repair Tube
Recovery Bottle Vent
Restricted Clean Vent
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No Heater Core Flow
Collapsed Heater Hose Replace Heater Hose
Plugged Heater Core Clean/Replace Heater
Core
Faulty Heater Valve Replace Heater Valve
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GASOLINE ENGINE - MECHANICAL 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