MITSUBISHI MONTERO 1991 Service Manual

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

screws. Remove dash panel.
4) Remove blower duct, center duct and defroster ducts. See
Fig. 2. Disconnect heater wiring harness from heater unit. Remove
heater center support brackets. Remove heater unit. Remove heater core
cover plate and joint hose. Remove heater core from heater unit.
Installation
1) To install, reverse removal procedure. Insert heater hoses
fully into pipes, and clamp securely to prevent leaks.
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.
HEATER CONTROL PANEL
Removal (Montero)
1) Remove heater control knob and heater fan switch knob.
Remove center console. Remove defroster nozzle at temperature control
cable side.
2) Remove lap heater duct and glove box stopper, and push
glove box forward and down. Disconnect inside/outside control cable
from blower assembly.
3) Disconnect control cables from heater unit. Remove heater
control panel mounting screws, and pull out panel slightly. Disconnect
heater fan switch harness connectors. Remove heater control panel.
Remove heater fan switch from heater control panel.
Installation
1) Place air outlet change-over lever at closed position.
With heater side air outlet change-over damper lever in position,
connect inner cable to lever, and secure cable casing using clips.
2) Place heater control lever at OFF position. With heater
control lever in position, connect inner cable to lever, and secure
cable casing using clips.
3) Place inside/outside air change-over lever at INSIDE
position. With heater side inside/outside air change-over damper lever
in position, connect inner cable to lever, and secure cable casing
using clips.
4) Set control lever to each position to check for correct
operation. If lever does not operate correctly, adjust by moving outer
wire at clipped point. Ensure each control lever moves smoothly. If
any noise or stiff movement exists, apply multipurpose grease to all
moving parts.
NOTE: When mounting heater control panel to instrument panel,
tighten upper bolts to instrument panel so they also secure
center panel.
Removal & Installation (Pickup & Ram-50)
Remove cluster panel. Remove all control cables at heater.
Remove heater control panel. To install, reverse removal procedure.
Adjust cables as necessary.
WIRING DIAGRAMS

Fig. 9: Heater System Wiring Diagram (Montero)

Fig. 10: Heater System Wiring Diagram (1992 Montero)

Fig. 11: Heater System Wiring Diagram (Pickup & Ram-50)

Fig. 12: Heater System Wiring Diagram (1992 Pickup & Ram-50)

HO W T O U SE S YSTE M W IR IN G D IA G RAM S
1991 M it s u bis h i M onte ro
GENERAL INFORMATION
Using Wiring Diagrams
All Models
INTRODUCTION
This CD obtains wiring diagrams and technical service
bulletins, containing wiring diagram changes from the domestic and
import manufacturers. These are checked for accuracy and are all
redrawn into a consistent format for easy use.
In the past, when cars were simpler, diagrams were simpler.
All components were connected by wires and diagrams seldom exceeded 4
pages in length. Today, some wiring diagrams require more than 16
pages. It would be impractical to expect a service technician to trace
a wire from page 1 across every page to page 16.
Removing some of the wiring maze reduces eyestrain and time
wasted searching across several pages. Today the majority of
these

diagrams follow a much improved format, which permits space for
internal switch details.
Wiring diagrams are drawn in a "top-down" format. The
diagrams are drawn with the power source at the top of the diagram and
the ground point at the bottom of the diagram. Components locations
are identified on the wiring diagrams. Any wires that don't connect
directly to a component are identified on the diagram to indicate
where they go.
COLOR ABBREVIATIONS
COLOR ABBREVIATIONS TABLE








\









\









\









\









\









\






Color Normal Optional
Black ................ BLK .......................... BK
Blue ................. BLU .......................... BU
Brown ................ BRN .......................... BN
Clear ................ CLR .......................... CR
Dark Blue .......... DK BLU ...................... DK BU
Dark Green ......... DK GRN ...................... DK GN
Green ................ GRN .......................... GN
Gray ................. GRY .......................... GY
Light Blue ......... LT BLU ...................... LT BU
Light Green ........ LT GRN ...................... LT GN
Orange ............... ORG .......................... OG
Pink ................. PNK .......................... PK
Purple ............... PPL .......................... PL
Red .................. RED .......................... RD
Tan .................. TAN .......................... TN
Violet ............... VIO .......................... VI
White ................ WHT .......................... WT
Yellow ............... YEL .......................... YL









\









\









\









\









\









\






IDENTIFYING WIRING DIAGRAM ABBREVIATIONS
NOTE: Abbreviations used on these diagrams are normally
self-explanatory. If necessary see ABBREVIATIONS

article in GENERAL INFORMATION.
IDENTIFYING WIRING DIAGRAM SYMBOLS
NOTE: Standard wiring symbol are used in these diagrams. The
illustration below will help clarify any symbols that are
not easily understood at a glance. Most components are
labeled "Motor", "Switch" or "Relay" in addition to being
drawn with the standard symbol.
Fig. 1: Identifying Wiring Diagram Symbols

WIRING DIAGRAM COMPONENT LOCATIONS
When trying to locate a component in a wiring diagram and you
don't know the specific system where it is located, use this handy
component locator to find the system wiring diagram in which the
component is located. Then, go to that system and locate the component
within the wiring diagram.
For example, if you don't know the specific system in which
the ignition switch is located, look up ignition switch in the wiring
diagram component location tables and go to the appropriate wiring
diagram(s) which contain either full or partial views of the ignition
switch. The full view of the ignition switch is located in Power
Distribution.
The first listing for the component will be the full or most
complete view of the component. Additional listings will be partial
views of the component. Not all components are used on all models.
All components will have a partial view in Ground
Distribution and Power Distribution. Data Link Connectors show
connecting circuits between modules. Alternate names for components
may be listed in wiring diagram component locations tables.
WIRING DIAGRAM COMPONENT LOCATIONS TABLE









\









\









\









\









\









\









\







Component Wiring Diagram
ABS Electronic Control Unit ....................... Anti-Lock Brakes
Data Link Connectors
ABS Hydraulic Unit ................................ Anti-Lock Brakes
Acceleration Sensor ............................... Anti-Lock Brakes
Accessory Delay Relay ................................ Power Windows
A/C Compressor Clutch Relay ..................... Engine Performance
A/C Sensor ...................................... Engine Performance
A/C Pressure Switch ............................. Engine Performance
Adaptive Lamp Control Module ....................... Exterior Lights
Air Bag(s) ................................ Air Bag Restraint System\
Air Bag Module ............................ Air Bag Restraint System
Air Bag Sensor(s) ......................... Air Bag Restraint System\
Air Injection Pump Relay ........................ Engine Performance
Air Temperature Sensor ............................ Overhead Console
Alternator (Generator) ..................... Generators & Regulators\
Anti-Theft Control Module ........................ Anti-Theft System
Starters
Autolamp Control Relay ........................... Headlight Systems
Daytime Running Lights
Automatic Shutdown (ASD) Relay .................. Engine Performance\
Generators & Regulators
Autostick Switch ................................ Engine Performance
Auxiliary Battery Relay .................... Generators & Regulators
Back-Up Lights ...................................... Back-Up Lights
Exterior Lights
Barometric (BARO) Pressure Sensor ............... Engine Performance\
Battery ......................................... Power Distribution
Battery Temperature Sensor ...................... Engine Performance
Body Control Module .......................... Body Control Computer
Anti-Theft System
Daytime Running Lights
Engine Performance
Headlight Systems
Warning Systems
Boost Control Solenoid .......................... Engine Performance
Boost Sensor .................................... Engine Performance
Brake Fluid Level Switch .................. Analog Instrument Panels

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