actuator MITSUBISHI MONTERO 1991 Service Manual

Fig. 10: Engine Support Bracket Bolt Removal Sequence (3000GT)
Courtesy of Mitsubishi Motor Sales of America, Inc.
NOTE: Apply spray lubricant on reamer bolt during removal as bolt
is sometimes seized in engine support bracket.
Removal (3000GT)
1) Remove lower splash shields. Remove cruise control
actuator (if equipped). Remove all drive belts. Disconnect electrical
connector at power steering pump. Remove A/C tensioner pulley and
mounting bracket.
2) Remove power steering pump with hoses connected, and wire
aside. Support engine. Remove front engine mount through bolt and
front engine mount. Remove timing belt No. 1 upper outer cover and
gaskets. See Fig. 7.
3) Remove engine support bracket bolts in proper sequence.
See Fig. 10 . Remove engine support bracket. Remove cover cap and
timing belt No. 2 upper outer cover and gaskets. Using Holder
(MB990767) and Adapter Bolts (MD998719), remove crankshaft pulley.
4) Remove lower outer cover, gaskets and flange. See Fig. 7.
Rotate crankshaft and align all timing marks. See Fig. 8. Loosen belt
tensioner bolt, and rotate belt tensioner counterclockwise to release
belt tension.
5) If reusing timing belt, place arrow on belt to indicate
direction of belt rotation. Remove timing belt and belt tensioner.
6) If camshaft sprocket requires removal, install Holder
(MB990767) with Adapter Bolts (MD998719) on camshaft sprocket. Remov\
e
camshaft sprocket bolt and camshaft sprocket. Remove rear timing belt
cover (if required).
Inspection (3000GT)
Inspect timing belt for wear on edges of drive teeth. Inspect
belt for oil contamination. Replace belt if damaged or contaminated.

actuator (if equipped). Remove all drive belts. Remove alternator.
Remove drive belt tensioner assembly.
2) Using Holder (MB990767) and Adapter Bolts (MD998754),
remove crankshaft pulley. See Fig. 12. Disconnect brake fluid level
sensor. Remove upper timing belt covers. Support engine. Remove front
engine mount through bolt and front engine mount.
NOTE: Apply spray lubricant on reamer bolt during removal as bolt
is sometimes seized in engine support bracket.
Fig. 12: Exploded View of Timing Belt Components (DOHC)
Courtesy of Mitsubishi Motor Sales of America, Inc.
3) Remove drive belt idler pulley. Remove engine support
bracket bolts in proper sequence. See Fig. 10. Remove engine support

\003
* A /C -H EA TE R S YSTE M U NIF O RM IN SPEC TIO N G UID ELIN ES *

1 991 M it s u bis h i M onte ro
GENERAL INFORMATION
A/C-Heater System Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
Motorist Assurance Program (MAP)
OVERVIEW
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Heating, Ventilation and Air Conditioning
ACCUMULATORS
ACTUATORS (ELECTRICAL)
ACTUATORS (VACUUM)
AIR CONDITIONING FITTINGS
AIR CONDITIONING HOSES
AIR CONDITIONING METAL LINES, HOSES AND FITTING ASSEMBLIES
AIR CONTROL DOORS
AIR DAMS (EXTERNAL)
AIR DISTRIBUTION SYSTEM
BELTS
BLEND DOORS
BLOWER FANS (BLOWER WHEEL OR SQUIRREL CAGE)
BLOWER MOTORS
BLOWER RESISTORS
BLOWER SWITCHES
CABIN AIR FILTERS
CIRCUIT BREAKERS
COMPRESSOR CLUTCH ASSEMBLIES
COMPRESSORS
CONDENSER AIR SEALS
CONDENSER FAN MOTORS
CONDENSERS
CONNECTORS
CONTROL CABLES
CONTROL HEADS (FUNCTION SELECTORS)
CONTROL LINKAGES
CONTROL MODULES
COOLANT
COOLING FAN BLADES
COOLING FAN CLUTCHES
COOLING FAN MOTORS
EVAPORATOR DRAIN TUBES
EVAPORATOR PRESSURE REGULATORS (EPRS)
EVAPORATORS
EXPANSION VALVES
FUNCTION SELECTORS
FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS
FUSIBLE LINKS
GASKETS
HEATER CASES
HEATER CONTROL VALVES
HEATER CORES

(1) - Inspect system to determine effects of dessicant bag
deterioration.









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ACTUATORS (ELECTRICAL)
ACTUATOR (ELECTRICAL) INSPECTION








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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted,
affecting performance .. A ........... ( 1) Require repair or
replacement.
Connector melted, not
affecting performance .. 2 ........... ( 1) Suggest repair or
replacement.
Connector missing ....... C ............ Require replacement.
Inoperative ............. A ........ ( 2) Require replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .. Suggest repair or replacement.
Out of adjustment ....... B .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 1 ........... ( 1) Suggest repair or
replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 1 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.









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ACTUATORS (VACUUM)
ACTUATOR (VACUUM) INSPECTION








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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of

pump. If fuel pressure drops slowly, fuel injector is leaking or fuel
pressure regulator valve seat is leaking. Check for faulty fuel
injector or fuel pressure regulator. Repair as required.
11) When fuel pressure test is complete, repeat fuel pressure
release procedure in steps 1) and 2) before disconnecting fuel
pressure gauge. Install new "O" ring at end of high pressure hose.
Check for fuel leaks.
FUEL PUMP TEST TERMINAL LOCATION TABLE









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Application Wire Color Location
Colt, Colt 200 ......... BLK/WHT .............. Center Of Firewall
Colt Vista ............. BLK/WHT ........ Right Center Of Firewall
Eclipse ................ BLK/WHT .......... Rear Of Battery Compt.
Galant ................. YEL/GRN ........... Left Rear Eng. Compt.
Mirage 1.5L ............ BLK/WHT .............. Center Of Firewall
Mirage 1.6L ............ BLK/BLU .............. Center Of Firewall
Montero .................. WHT .......... Right Center Of Firewall
Pickup ................. BLK/BLU ....... Right Side Of Eng. Compt.
Precis ................... YEL ............. Left Rear Eng. Compt.
Summit ................. BLK/WHT .............. Center Of Firewall
Ram-50 ................. BLK/BLU ....... Right Side Of Eng. Compt.
Stealth, 3000GT ........ BLK/BLU .......... Rear Of Battery Compt.









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REGULATED FUEL PRESSURE TABLE








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At Idle At Idle
w/Vacuum w/o Vacuum
Application psi (kg/cm
) psi (kg/cm)
Non-Turbo .................. 38 (2.7) ....... 47-50 (3.3-3.5)
Turbo
Except Eclipse A/T ....... 27 (1.9) ....... 36-38 (2.5-2.7)
Eclipse A/T .............. 33 (2.3) ....... 36-38 (2.9-3.2)









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Control Relay
Multipurpose relay switches power to vehicle sensors and
actuators including airflow sensor, crank angle sensor, idle speed
control, injectors and fuel pump. When ignition switch is turned to ON
position, ECU energizes coils controlling injectors, airflow sensor
and idle speed control. When ignition switch is turned to START
position, ECU energizes coils (through inhibitor switch on A/T models)\
to supply power to fuel pump. Relay failure will cause a no-start
condition. For testing procedure, see SYSTEM & COMPONENT TESTING
article.
IGNITION CHECKS
SPARK
Check for spark at coil wire (if applicable) and at each
spark plug wire using a high output spark tester. Check spark plug
wire resistance on suspect wires. For wire resistance specification,
see C - SPECIFICATIONS article in the ENGINE PERFORMANCE Section.
CRANK ANGLE SENSOR
For crank angle sensor testing procedure on all models except
Ram-50, Stealth, Eclipse, Laser, Pickup and 3000GT, see TEST NS-5:

CRUIS E C O NTR O L S YSTE M

1991 M it s u bis h i M onte ro
1991-92 SAFETY EQUIPMENT
Mitsubishi Cruise Control Systems
Montero
DESCRIPTION & OPERATION
The cruise control system is electronically and vacuum
controlled. System components include a control unit, actuator, vacuum
pump, cruise control switch, clutch pedal switch, cruise indicator
light, diode, inhibitor switch (A/T), stoplight switch, vehicle speed
sensor and A/T control unit.
The system has self-diagnostic capability. When
self-diagnostic mode is activated, each switch and sensor is checked
for defects. When cruise control system has been cancelled without
using a normal cancel method, a code will be set and stored in control
unit. Codes can be retrieved to help determine which circuit is
malfunctioning.
PRELIMINARY INSPECTION
Before performing TROUBLE SHOOTING steps, inspect linkage
assembly, actuator, cables and vacuum hoses. Ensure linkage and cables
move smoothly. Ensure cables do not have excessive slack or tension.
TROUBLE SHOOTING
NOTE: For further trouble shooting information, see CHECK RESULTS
& SYMPTOM CHARTS. See Figs. 11-16.
SYSTEM CANCELS OR WILL NOT RESET AFTER CANCELLATION
1) Check trouble codes, see SELF-DIAGNOSTICS under DIAGNOSIS
& TESTING. If no trouble codes are stored, ensure cruise control can
be set.
2) If cruise control can be set, system may have cancelled
because of driving on steep hills or loose wiring connection. If
cruise control still cannot be set, perform SYSTEM INPUT TESTS under
DIAGNOSIS & TESTING.
3) On 1991 models, if SYSTEM INPUT TESTS check okay, check
actuator circuit. See TEST NO. 5 under CIRCUIT TESTS (1991). On 1992
models, if SYSTEM INPUT TESTS check okay, check vacuum pump circuit.
See TEST NO. 6 under CIRCUIT TESTS (1992). On all models, if SYSTEM
INPUT TESTS do not check okay, see INPUT CODE CHART. See Fig. 9 or 10.
ADJUSTMENTS
CRUISE CONTROL CABLE
1991
1) Ensure cruise control and accelerator cables are free of
bends and folds. Remove actuator cover. Loosen lock nuts and adjusting
nuts to free cables. Adjust accelerator cable "A" to correct
dimension. See Fig. 1 or 2.
2) Tighten lock nuts. Loosen adjustment bolts on intake air
plenum. Adjust plate so that inner cable free play is .04-.08" (1-2

mm). Tighten adjustment plate bolts.
3) Ensure throttle link is touching fixed Speed Adjusting
Screw (SAS). With intermediate link "A" in contact with stopper,
tighten adjusting nut "A" in direction that reduces inner cable free
play. See Fig. 3.
4) Stop turning adjusting nut "A" just before intermediate
link "A" begins to move. Back off adjusting nut "A" 1/2 turn. Inner
cable free play should be 0-.04" (0-1 mm). Tighten lock nut. Ensure
the distance intermediate link "B" begins to move when selector of
actuator turns is 04-.08" (1-2 mm). See Fig. 4.
5) Press accelerator pedal to ensure intermediate links "A"
and "B" operate smoothly. Install actuator cover.
Fig. 1: Adjusting Cruise Control & Accelerator Cables (1991 - 1 Of 4)\
Courtesy of Mitsubishi Motor Co.

Test No. 1 (Power & Ground Circuit)
1) Turn ignition on. When cruise control main switch is
turned to ON position, battery voltage should be present on terminal
No. 7 of cruise control unit connector.
2) If voltage is not present, check fuse No. 3 and replace as
necessary. If fuse is okay, check and repair harness as necessary.
Terminal No. 10 should be grounded at all times. If terminal No. 10 is
not grounded, repair harness.
Test No. 2 (Set Switch Circuits)
When set switch is turned to ON position, voltage should not
be present on terminal No. 5 of cruise control unit. When set switch
is turned to OFF position, battery voltage should be present on
terminal No. 5 of cruise control unit. If circuit does not test
correctly, replace switch as necessary or repair harness.
Test No. 3 (Resume Switch Circuit)
When resume switch is turned to ON position, voltage should
not be present on terminal No. 4 of cruise control unit. When resume
switch is turned to OFF position, battery voltage should be present on
terminal No. 4 of cruise control unit. If circuit does not test
correctly, replace switch as necessary or repair harness.
Test No. 4 (Vehicle Speed Sensor Circuit)
When vehicle moves slowly, voltage should alternate from zero
volts to 3-5 volts at terminal No. 15 of cruise control unit. If
circuit does not test correctly, replace sensor as necessary or repair
harness.
Test No. 5 (Actuator Circuit)
1) When cruise control main switch is in On position, voltage
should not be present on terminal No. 8 of cruise control unit.
2) When vehicle is accelerated using resume switch, voltage
should not be present on terminal No. 9 of cruise control unit. When
vehicle is coasting by using set switch, battery voltage should be
present on terminal No. 9.
3) When vehicle is accelerated using resume switch, battery
voltage should be present on terminal No. 20 of cruise control unit.
When vehicle is coasting by using set switch, voltage should not be
present on terminal No. 20 of cruise control unit. If circuit does not
test correctly, replace actuator as necessary or repair harness.
Test No. 6 (Stoplight Switch Circuit)
1) When brake pedal is pressed, battery voltage should be
present on terminal No. 3 of cruise control unit. If voltage is not
present, adjust or replace brake switch.
2) Battery voltage should be present at all times on terminal
No. 11 of cruise control unit. If voltage is not present, check fuse
no. 7. If fuse is okay, repair harness.
Test No. 7 (Inhibitor Switch Circuit)
1) When gear shift lever is moved to Neutral or Park
position, voltage should not be present on terminal No. 2 of cruise
control unit.
2) When gear shift lever is moved to any other position,
battery voltage should be present on terminal No. 2 of cruise control
unit. If circuit does not test correctly, replace switch as necessary
or repair harness.
Test No. 8 (Clutch Switch Circuit)
When clutch pedal is pressed, battery voltage should be
present at terminal No. 1 of cruise control unit. If circuit does not

ACTUATOR TESTS
Resistance Test (1991)
Disconnect actuator connector. Resistance between terminals
No. 1 and 2 should be 20 ohms. See Figs. 17-21. If resistance is not
correct, replace actuator assembly.
Operational Test (1991)
1) With connector disconnected, connect battery voltage to
terminal No. 1. See Figs. 17-21. Ground terminal No. 2. Connect
ammeter between positive side of battery and terminal No. 1 of
actuator connector.
2) Solenoid should make a click sound. Ammeter should read .
5-.7 amps. Connect positive side of battery to terminal No. 4 and
ground terminal No. 3. Actuator should pull in and stop.
3) While actuator is moving in, ammeter should read less than
.5 amps. When actuator travel reaches midpoint, disconnect terminal
No. 1 from positive side of battery. Actuator should return to
original position. If actuator does not test correctly, replace
actuator.
4) Reverse connections of terminals No. 4 and 3 in step 2).
Connect battery voltage to terminal No. 3 and ground terminal No. 4.
Actuator should move out then stop. While actuator is moving, ammeter
should read less than .5 amps.
1992
Remove actuator. Apply vacuum to actuator. Actuator linkage
holder should move more than 1.38" (35 mm). Actuator diaphragm should
hold vacuum. Replace actuator if actuator does not test correctly.
VEHICLE SPEED SENSOR TEST
1) Remove instrument cluster. See INSTRUMENT CLUSTER under
REMOVAL & INSTALLATION. Check continuity between vehicle speed sensor
terminals at instrument cluster. See Fig. 30 or 31.
2) Ensure continuity pulses on and off 4 times per revolution
of speedometer shaft connection. If continuity is not as specified,
replace vehicle speed sensor.
Fig. 30: 1991 Checking Speed Sensor Circuit
Courtesy of Mitsubishi Motor Co.

Fig. 31: 1992 Checking Speed Sensor Circuit
Courtesy of Mitsubishi Motor Co.
REMOVAL & INSTALLATION
ACTUATOR
Removal & Installation (1991)
Remove linkage protector. Loosen adjusting nuts for
accelerator cables "A" and "B". See Fig. 1 or 2. Disconnect actuator
side inner cable. Disconnect actuator electrical connector. Remove
actuator. To install, reverse removal procedure.
Removal & Installation (1992)
Disconnect cruise control cable from link. Disconnect
actuator wiring connector. Remove vacuum pump and vacuum pump bracket.
Remove actuator and actuator bracket. To install, reverse removal
procedure.
CRUISE CONTROL SWITCH
Removal & Installation (1991)
See STEERING COLUMN SWITCH in this article.
Removal & Installation (1992)