MITSUBISHI MONTERO 1991 Service Manual
Page 621 of 1333
Starters
Generator .................................. Generators & Regulators
Engine Performance
Power Distribution
Generic Electronic Module (GEM) ............... Body Control Modules\
Electronic Suspension
Glow Plug Relay ................................. Engine Performance
Glow Plugs ...................................... Engine Performance
Grounds ........................................ Ground Distribution
Headlight Door Module .............................. Headlight Doors
Headlight Relay .................................. Headlight Systems
Daytime Running Lights
Headlights ....................................... Headlight Systems
Daytime Running Lights
Heated Oxygen Sensor(s) (HO2S) .................. Engine Performan\
ce
Heated Windshield Control Module ................ Heated Windshields
Height Sensor ................................ Electronic Suspension
Horns ..................................... Steering Column Switches
Horn Relay ................................ Steering Column Switches
Idle Air Control (IAC) Motor/Valve .............. Engine Performance\
Ignition Coil(s) ................................ Engine Performance\
Ignition Key Lock Cylinder ....................... Anti-Theft System
Ignition Module ................................. Engine Performance
Ignition Switch ................................. Power Distribution
Engine Performance
Generators & Regulators
Starters
Illuminated Entry Module .............. Illumination/Interior Lights
Illumination Lights ................... Illumination/Interior Lights
Impact Sensor ............................. Air Bag Restraint System
Inertia Fuel Shutoff Switch ..................... Engine Performance
Inhibit Relay ............................................. Starters
Instrument Cluster ........................ Analog Instrument Panels
Intake Air Temperature (IAT) Sensor ............. Engine Performance\
Interior Lights ....................... Illumination/Interior Lights
Interlock Switch .......................................... Starters
Junction Block .................................. Power Distribution
Keyless Entry Receiver ........................ Remote Keyless Entry
Key Reminder Switch ....................................... Starters
Knock Sensor .................................... Engine Performance
Lamp Control Module ................................ Exterior Lights
License Plate Lamp ................................. Exterior Lights
Lighting Control Module ................... Lighting Control Modules
Anti-Theft System
Daytime Running Lights
Headlight Systems
Lower Relay .................................. Power Convertible Top
Malfunction Indicator Light (MIL) ............... Engine Performance\
Instrument Panels
Manifold Absolute Pressure (MAP) Sensor ......... Engine Performance\
Mass Airflow (MAF) Sensor ....................... Engine Performance\
Mega Fuse .................................. Generators & Regulators
Memory Seat/Mirror Module ........................... Memory Systems
Mirror Defogger ............................... Rear Window Defogger
Moon Roof Motor .................................... Power Moon Roof
Moon Roof Relay .................................... Power Moon Roof
Multi-Function Control Module ...................... Warning Systems
Neutral Safety Switch ..................................... Starters
Oil Level Switch ................................ Engine Performance
Oil Pressure Switch/Sending Unit .......... Analog Instrument Panels
Engine Performance
Overhead Console .................................. Overhead Console
Oxygen Sensor(s) (O2S) .......................... Engine Performan\
ce
Page 622 of 1333
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\
Page 623 of 1333
Torque Converter Clutch Solenoid/Switch ......... Engine Performance
Traction Control Switch ........................... Anti-Lock Brakes
Trailer Tow Connector .............................. Exterior Lights
Trailer Tow Relay .................................. Exterior Lights
Transmission/Transaxle .......................... Engine Performance
Transmission Control Module (TCM) ............... Engine Performance\
Starters
Transmission Range Sensor ................................. Starters
Back-Up Lights
Engine Performance
Transmission Range Switch ........................... Back-Up Lights
Engine Performance
Anti-Theft System
Turn Signal Flasher ................................ Exterior Lights
Turn Signal Lights ................................. Exterior Lights
Twilight Sentinel Switch ......................... Headlight Systems
Daytime Running Lights
Vapor Canister Leak Detection Pump .............. Engine Performance
Vehicle Control Module (VCM) .................... Engine Performance\
Vehicle Dynamic Module ....................... Electronic Suspension
Vehicle Speed Control Servo ................. Cruise Control Systems
Vehicle Speed Sensor .......................... Data Link Connectors
Analog Instrument Panels
Cruise Control Systems
Electronic Suspension
Voltage Regulator .......................... Generators & Regulators
Water-In-Fuel Sensor ............................ Engine Performance
Analog Instrument Panels
Wheel Speed Sensors ............................... Anti-Lock Brakes
Window Timer Module .......................... Power Convertible Top
Windshield Intermittent Wiper Relay ........... Wiper/Washer Systems
Windshield Washer Motor ....................... Wiper/Washer Systems
Wiper Motor ................................... Wiper/Washer Systems
\
\
\
\
\
\
\
Page 624 of 1333
IN STR UM EN T P A N EL
1991 M it s u bis h i M onte ro
1991 ACCESSORIES & SAFETY EQUIPMENT
Chrysler Motors/Mitsubishi Switches & Instrument Panels
Dodge; Ram-50
Mitsubishi: Montero, Pickup
DESCRIPTION & OPERATION
Instrument cluster includes speedometer, fuel gauge and
temperature gauge. Fuel gauge has a built-in voltage limiter to keep
voltage supply to gauges at 7 volts. Some models may also have a
shunt-type ammeter, oil pressure gauge, tachometer, voltmeter and/or
turbo boost pressure gauge. Oil pressure gauge uses full battery
voltage. The tachometer operates by pulse feed.
TROUBLE SHOOTING
FUEL/TEMPERATURE GAUGE NOT WORKING
Check for blown fuse, faulty voltage limiter or faulty relay.
Ensure sending unit connections are clean and tight. Test sending unit
for correct operation. Tighten connections in instrument cluster.
SPEEDOMETER NOT WORKING
Ensure speedometer cable is properly connected and correctly
routed. If speedometer pointer and/or odometer still do not work,
replace speedometer as an assembly.
TACHOMETER NOT WORKING
Tachometer is serviced as an assembly. If wiring harness is
okay, replace tachometer assembly.
WARNING LIGHTS NOT WORKING
Test for defective sending unit, burned out bulb, or broken
printed circuit. Ensure all wire connections are clean and tight.
TESTING
FUEL TANK SENDING UNIT
Resistance Test
Remove fuel tank sending unit from fuel tank. Measure
resistance between appropriate terminals with fuel float in Full and
Empty positions. See Fig. 1. Compare resistance reading to
FUEL TANK SENDING UNIT RESISTANCE SPECIFICATIONS table. If resistance
is not to specifications, replace fuel tank sending unit.
FUEL TANK SENDING UNIT RESISTANCE SPECIFICATIONS TABLE
\
\
\
\
\
\
Application Empty Full
All Models ........... 103-117 ................ 1-5
\
\
\
\
\
\
Page 625 of 1333
FUEL GAUGE
Simple Test
Disconnect fuel sending unit connector wire in luggage
compartment, cargo space, or at tank unit. Connect a 12-volt, 3.4-watt
bulb to harness side of connector, between power terminal and ground
(Yellow and Black wires on Montero). On Pickup and Ram-50 see Fig. 1.
Turn ignition switch to ON position. Ensure test bulb flashes, or
stays on, and fuel gauge needle moves. If bulb or gauge needle does
not function as described, check and repair fuel gauge circuit.
CAUTION: Gauge coils can be damaged if wire is grounded too long.
Perform test as quickly as possible.
Fig. 1: Identifying Fuel Gauge Test Connection (Pickup & Ram-50)
Courtesy of Chrysler Motors.
NOTE: The following test must be completed with instrument panel
cluster removed. Use ohmmeter for all measurements. If
resistance is extremely low, there may be a short in the
coil. If resistance is extremely high, there may be a broken
wire or similar problem in the gauge.
Resistance Test
Remove instrument cluster. See INSTRUMENT CLUSTER under
REMOVAL & INSTALLATION. Measure resistance between appropriate
terminals of instrument cluster or combination gauges. See Fig. 2 or
Page 626 of 1333
Fig. 3. See FUEL GAUGE RESISTANCE SPECIFICATIONS table. If resistance
readings are not to specifications, replace fuel gauge.
FUEL GAUGE RESISTANCE SPECIFICATIONS TABLE
\
\
\
\
\
\
\
Application Terminals Ohms
Montero .................... No. 1 & 2 ........................ 55
" .......................... No. 2 & 3 ....................... 165
" .......................... No. 1 & 3 ....................... 110
Pickup & Ram-50 .......... IGN & ground. ................... 62-78
" ........................... 7V & FU ...................... 49-61
\
\
\
\
\
\
\
Fig. 2: Fuel Gauge Resistance Check Terminal ID (Montero)
Courtesy of Mitsubishi Motor Sales of America.
Fig. 3: Fuel Gauge Resistance Check Terminal ID (Pickup & Ram-50)
Courtesy of Mitsubishi Motor Sales of America.
Page 627 of 1333
OIL PRESSURE GAUGE
Circuit Test
Disconnect oil pressure gauge wiring connector from sending
unit inside the engine compartment. Connect a 12-volt test light
between harness connector terminal and ground. Turn ignition on, but
DO NOT start engine. If test light comes on and gauge needle moves, go
to GAUGE RESISTANCE TEST. If test light does not come on and gauge
needle does not move, repair wiring to sending unit.
Gauge Resistance Test
Remove instrument cluster from instrument panel. See
INSTRUMENT CLUSTER under REMOVAL & INSTALLATION. Check continuity
between oil pressure gauge terminals. See Fig. 4 or Fig. 5. See
OIL PRESSURE GAUGE RESISTANCE SPECIFICATIONS table. If resistance is
not within specification, replace oil pressure gauge.
OIL PRESSURE GAUGE RESISTANCE SPECIFICATIONS TABLE
\
\
\
\
\
Application Ohms
Montero ...................................... 50
Pickup & Ram-50 ........................... 37-47
\
\
\
\
\
Fig. 4: Oil Pressure Gauge Test Terminal ID (Pickup & Ram-50)
Courtesy of Chrysler Motors
Page 628 of 1333
Fig. 5: Oil Pressure Gauge Test Terminal ID (Montero)
Courtesy of Chrysler Motors
REED SWITCH
Continuity Check (Except Pickup & Ram-50)
Remove instrument cluster. See INSTRUMENT CLUSTER under
REMOVAL & INSTALLATION. Check continuity between reed switch terminals
No. 1 and 2. See Fig. 6. Ensure continuity pulses on and off 4 times
per revolution of speedometer shaft connection. If continuity is not
as specified, replace reed switch.
Fig. 6: Identifying Reed Switch Test Terminals (Montero)
Courtesy of Mitsubishi Motor Sales of America.
SPEEDOMETER
Page 629 of 1333
Calibration Test
Adjust tire pressure to standard value. Using a calibrated,
reliable speedometer tester, compare reading of vehicle speedometer to
speedometer tester. See SPEEDOMETER ALLOWABLE VARIATION table. Replace
speedometer if necessary.
SPEEDOMETER ALLOWABLE VARIATION TABLE
\
\
\
\
\
MPH (km/h) Allowable Variation MPH (km/h)
20 (32) .......................... 19-22 (31-35)
40 (64) .......................... 38-44 (61-71)
60 (97) ......................... 57-66 (92-106)
80 (129) ....................... 76-88 (122-142)
100 (161) ..................... 94-110 (151-177)
\
\
\
\
\
TACHOMETER
NOTE: DO NOT reverse polarity when installing tachometer, as diode
and transistor may be damaged.
Calibration Test
Connect a calibrated, reliable tach-dwell meter to vehicle
ignition system. Operate engine at various speeds (RPM). See
TACHOMETER ALLOWABLE VARIATION table. If comparison between tach-dwell
meter and vehicle tachometer readings do not fall in the standard
range of permissible variation, replace vehicle tachometer.
TACHOMETER ALLOWABLE VARIATION TABLE
\
\
\
\
\
Engine Speed (RPM) Allowable Variation (RPM)
1000 .................................. 900-1100
3000 ................................. 2850-3150
5000 ................................. 4750-5250
6000 ................................. 5700-6300
\
\
\
\
\
TEMPERATURE GAUGE
CAUTION: DO NOT connect sender wire directly to ground during test.
Circuit Test
Disconnect temperature sender wire from sending unit. Connect
a 12-volt, 3.4-watt test bulb between connector terminal and ground.
Turn ignition switch to ON position. If test bulb flashes and
temperature gauge needle moves, go to SENSOR RESISTANCE TEST. If test
light does not flash and gauge needle does not move, repair wiring to
sending unit.
Sensor Resistance Test
Remove thermosensor (sending unit) from engine block. Place
sending unit in hot water of 158
F (70C) temperature. Check sensor
resistance with an ohmmeter. Thermosensor resistance should be 90-117
ohms at 158
F (70C). If thermosensor resistance in okay, go to GAUGE
RESISTANCE TEST. Replace thermosensor if resistance is not as
specified.
Gauge Resistance Test
Remove instrument cluster from instrument panel. See
INSTRUMENT CLUSTER under REMOVAL & INSTALLATION. Measure resistance
between temperature gauge terminals at rear of cluster or combination
Page 630 of 1333
gauges. See TEMPERATURE GAUGE RESISTANCE SPECIFICATIONS table. See
Fig. 7 or Fig. 8.
Fig. 7: Temperature Gauge Test Terminals (Montero)
Courtesy of Mitsubishi Motor Sales of America.
Fig. 8: Temperature Gauge Test Terminal ID (Pickup & Ram-50)
Courtesy of Mitsubishi Motor Sales of America.
TEMPERATURE GAUGE RESISTANCE SPECIFICATIONS TABLE
\
\
\
\
\