instrument panel MITSUBISHI MONTERO 1991 Service Manual

Eclipse & Galant ............. TEST NO. 2
2.4L
Pickup & Ram-50 .............. TEST NO. 1
3.0L
Montero, Pickup, Ram-50,
Stealth & 3000GT ............ TEST NO. 2









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Test No. 1
1) Loosen throttle cable. Turn ignition on for more than 15
seconds. DO NOT start engine. Turn ignition off. This should fully
retract ISC motor plunger.
2) On 2.0L Galant (VIN V), connect jumper wire between
ignition timing adjustment connector and ground. See IGNITION TIMING
ADJUSTMENT CONNECTOR LOCATION table under IGNITION TIMING.
3) On all models, disconnect harness connector(s) from Idle
Speed Control (ISC) motor. Ensure ISC plunger is in fully retracted
position. Unscrew fixed Speed Adjusting Screw (SAS) until throttle
valve is fully closed. See Fig. 1.
CAUTION: When cleaning throttle body, plug air by-pass hole in
throttle body to prevent solvent from entering passage.
4) Start engine. Check basic idle speed. See IDLE SPEED
SPECIFICATIONS table. If basic idle speed is within specification, go
to step 7). If basic idle speed is not within specification, remove
air intake hose and clean throttle body. Reconnect air intake hose.
Recheck basic idle speed.
5) If basic idle speed is still not within specification
after cleaning throttle body, adjust basic idle speed by turning idle
speed adjusting screw. See Fig. 1. After adjusting basic idle speed,
turn fixed SAS screw clockwise until engine speed begins to increase.
6) Turn fixed SAS screw counterclockwise until engine speed
decreases. Turn fixed SAS screw counterclockwise an additional 1/2
turn from point at which engine speed no longer decreases. Turn off
engine.
7) Adjust throttle cable. Reconnect harness connector(s) at
ISC motor. Start engine. Operate engine for about 5 minutes. Ensure
engine idles within curb idle speed specification. See IDLE SPEED
SPECIFICATIONS table.
8) 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. 2
1) Locate ignition timing adjustment connector. See IGNITION
TIMING ADJUSTMENT CONNECTOR LOCATION table under IGNITION TIMING.
Connect jumper wire between ignition timing adjustment connector and
ground.
2) Locate diagnostic connector under instrument panel.
Connect jumper wire between diagnostic connector terminal No. 10
(White wire) and ground. See Fig. 3. Start engine. Check basic idle
speed. See IDLE SPEED SPECIFICATIONS table. If basic idle speed is
within specification, go to step 9). If basic idle speed is not within
specification, go to step 3).
3) Remove air intake hose. Check throttle body. If throttle
body contains deposits, go to next step. If throttle body is clean,
disconnect jumper wires connected in steps 1) and 2). On all models
except Eclipse, Galant and Mirage, go to step 6). On Eclipse, Galant
and Mirage, go to step 5).
CAUTION: When cleaning throttle body, plug air by-pass hole in

Remove lower steering column cover. Disconnect electrical
connectors. Remove screws attaching cruise control switch to steering
column. Remove switch. To install, reverse removal procedure.
STEERING COLUMN SWITCH
WARNING: DO NOT hammer steering wheel. Collapsible steering column
mechanism may be damaged.
Removal & Installation (1991)
Remove horn pad and steering wheel. Remove upper and lower
column covers. Remove column switch. To install, reverse removal
procedure.
VEHICLE SPEED SENSOR
Removal & Installation
Remove instrument cluster. See INSTRUMENT CLUSTER in this
article. Speed sensor is a part of speedometer.
INSTRUMENT CLUSTER
Removal & Installation
Disconnect negative battery cable. Remove cluster cover.
Disconnect speedometer cable. Remove instrument cluster. To install,
reverse removal procedure.
CONTROL UNIT
Removal & Installation (1991)
Cruise control unit is located behind left front kick panel.
Remove left front kick panel. Remove control unit. To install, reverse
removal procedure.
Removal & Installation (1992)
Cruise control unit is located behind center of dash panel.
Remove center trim panel and radio or radio plug bezel. Remove control
unit. To install, reverse removal procedure.
WIRING DIAGRAMS
For 1992 wiring diagram, See appropriate chassis wiring
diagram in the WIRING DIAGRAMS Section.

\003
DEFO GGER - R EA R W IN DO W

1991 M it s u bis h i M onte ro
1991 ACCESSORIES & SAFETY EQUIPMENT
Chrysler Corp./Eagle/Mitsubishi Defoggers - Rear Window
Dodge; Colt, Colt Vista, Colt 200, Stealth
Eagle; Summit
Mitsubishi: Eclipse, Galant, Mirage, Montero, 3000GT
Plymouth; Colt, Colt Vista, Colt 200
DESCRIPTION & OPERATION
The rear window defogger is a heating wire grid bonded to the
inside of the window. Heat is regulated by a control switch located on
the instrument panel.
TROUBLE SHOOTING
DEFOGGER DOES NOT WORK
Check for blown fuse, poor contact, defective defogger
switch, poor connection or open wire.
INDICATOR LIGHT DOES NOT WORK
Check for burned out bulb, open wire or poor connection.
TESTING
NOTE: Testing information for all components on all vehicles is
not available from manufacturer.
DEFOGGER SWITCH TEST
NOTE: Remove window defogger switch and disconnect switch
connector for the following test.
Colt, Colt 200, Mirage & Summit
Turn defogger switch to OFF position. Check switch continuity
using ohmmeter. Continuity should be present between terminals No. 3
and 6. See Fig. 1. Turn defogger switch to ON position. Continuity
should be present between terminals No. 1 and 5, 2 and 4, and 3 and 6.
Colt Vista
Turn defogger switch to OFF position. Check switch continuity
using ohmmeter. Continuity should be present between terminals No. 3
and 6, and terminals No. 4 and 1. See Fig. 1. Turn defogger switch to
ON position. Continuity should exist between terminals No. 5 and 2, 3
and 6, and 4 and 1.
Eclipse
Turn defogger switch to OFF position. Check switch continuity
using ohmmeter. Continuity should be present between terminals No. 1
and 5, and terminals No. 2 and 6. Turn defogger switch to ON position.
Continuity should be present between terminals No. 3 and 4, 1 and 5,
and 2 and 6. See Fig. 1.
Galant
Turn defogger switch to OFF position. Check switch continuity

Colt, Colt 200, Mirage & Summit
Remove defogger timer from junction block under left side of
instrument panel. Connect a battery and test light to defogger timer
terminals. See Fig. 3. Apply battery voltage to terminal No. 7 for 5-7
seconds. Ensure test light illuminates for approximately 10 seconds.
Reapply battery voltage to terminal No. 7. Test light should go off
when voltage is applied again.
Colt Vista
With ignition switch in ON position, apply battery voltage to
terminal No. 2 of defogger timer. Timer should operate for
approximately 11 seconds then stop. See Fig. 3.
Eclipse & Galant
Remove defogger timer from interior relay block. Connect
battery voltage and test light to timer. See Fig. 3. Ensure test light
illuminates for approximately 11 seconds when battery voltage is
applied to terminal No. 4. Reapply battery voltage to terminal No. 4
and observe test light. Test light should go off.
Fig. 3: Identifying Defogger Timer Terminals
Courtesy of Chrysler Motors.
GRID TEST
1) Start engine and operate at 2000 RPM. Ensure battery is
fully charged. Turn defogger switch to ON position. Using a voltmeter,
check voltage at center section of each grid wire. If voltage is
approximately 6 volts, grid wire is okay. If voltage is approximately
12 volts, an open is present in the negative circuit. Move probe
slowly toward the negative terminal to determine location of open
circuit.
2) If voltage is zero volt, an open is present in the
positive circuit. Move probe slowly toward the positive terminal to

Self-Diagnosis Behind glove compartment.
Ignition Coil Power Transistor At rear of coil.
Maintenance Reminder Light Reset Behind instrument panel.









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A - E N G IN E/V IN ID

1991 M it s u bis h i M onte ro
1991 ENGINE PERFORMANCE
Chrysler Motors/Mitsubishi Introduction
MODEL COVERAGE
MODEL COVERAGE TABLE (MITSUBISHI)







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 Body  Engine Fuel  Ignition 

Model Code (
1) Engine ( 2) ID ( 3)System System ( 4) 










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  1.8L SOHC (
5)  T  PFI  Optical 

 









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\b
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Eclipse  S,T  2.0L DOHC (
6)  R  PFI  DIS 

 









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\b
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 2.0L DOHC Turbo (
6) U  PFI  DIS 










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  2.0L SOHC (
6)  V  PFI  Optical 

 









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\b
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Galant  R,X  2.0L DOHC (
6)  R  PFI  DIS 

 









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 2.0L DOHC Turbo (
6) U  PFI  DIS 










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  1.5L SOHC (
7)  A  PFI  Optical 

Mirage  U 









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  1.6L DOHC (
8)  Y  PFI  DIS 










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Montero  J  3.0L V6 SOHC (
9)  S  PFI  Optical 










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  2.4L SOHC (
10)  W  PFI  Optical 

Pickup  L,M 









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  3.0L V6 SOHC (
9)  S  PFI  Optical 










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Precis  A,F,D  1.5L SOHC (
11)  J  PFI  Optical 










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  3.0L V6 DOHC (
9)  B  PFI  DIS 

3000GT  D,E 









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  3.0L V6 DOHC  C  PFI  DIS 

  Turbo (
9)    










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(
1) - Body Code is 5th digit of VIN. VIN is located on upper left 

corner of instrument panel. 

(
2) - See ENGINE CODE LOCATION. 

(
3) - Engine ID is 8th digit of VIN. 

(
4) - Ignition timing is computer controlled. On all models with 

Distributorless Ignition System (DIS), crank angle sensor is 

mounted where distributor is normally mounted. 

(
5) - 4G37 engine. 

(
6) - 4G63 engine. 

(
7) - 4G15 engine. 

(
8) - 4G61 engine. 

(
9) - 6G72 engine. 

(
10 ) - 4G64 engine. 

(
11 ) - G4AJK engine. 










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VIN DEFINITION
Numbers preceding the explanations in the legend below refer
to the sequence of characters as listed on VIN identification label.

FU SES & C IR CUIT B REA K ER S

1991 M it s u bis h i M onte ro
Fuses & Circuit Breakers
1983-91 Mitsubishi
Montero
FUSES & CIRCUIT BREAKERS
FUSE PANEL LOCATION
The electrical system is protected against shorts by fuses
that are designed to fail, to prevent damage to the wire harness. The
fuse block is located under the instrument panel on the driver's side.
If a fuse is blown, locate the cause before replacing the fuse. Spare
fuses are contained in the fuse block.
FUSE PANEL IDENTIFICATION (1983-91)
Fig. 1: Fuse Panel Identification (1983-91)
Courtesy of Mitsubishi Motor Sales of America, Inc.
Fuse & Circuit Breaker Identification

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

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









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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