bench test MITSUBISHI MONTERO 1998 Service Manual

component. Failure to do this may result in accidental air
bag deployment and possible personal injury. Refer to
DISABLING & ACTIVATING AIR BAG SYSTEM .
* For about 60 seconds after air bag system is disabled, it
retains enough voltage to deploy air bags. After disabling
system, wait at least 60 seconds before servicing.
* After servicing, always turn ignition on from passenger-side
of vehicle in case of accidental air bag deployment.
* After servicing, check SRS warning light to verify system
operation. See SYSTEM OPERATION CHECK.
* Always wear safety glasses when servicing or handling an
air bag.
* The SRS-ECU must be stored in its original special container
until used for service. It must be stored in a clean, dry
place, away from sources of extreme heat, sparks and high
electrical energy.
* DO NOT expose air bag module and clockspring to temperatures
greater than 200
F (93C).
* When placing a live air bag module on a bench or other
surface, always face air bag module and trim cover up, away
from surface. This will reduce motion of module if air bag
accidentally deploys.
* After air bag deploys, air bag surface may contain deposits
of sodium hydroxide, which irritates skin. Always wear
safety glasses, rubber gloves and long-sleeved shirt during
clean-up. Wash hands using mild soap and water. Follow
correct clean-up and disposal procedures. Refer to
DISPOSAL PROCEDURES .
* Because of critical system operating requirements, DO NOT
service any SRS components. Repairs are only made by
replacing defective part(s).
* DO NOT allow any electrical source near inflator on the back
of air bag module.
* When carrying a live (undeployed) air bag module, trim cover
must be pointed away from body to minimize injury in case of
accidental air bag deployment.
* DO NOT probe wire harness connector terminals. Instead, use
SRS Check Harness (MB991530).
* DO NOT probe a wire through insulator, as this will damage
it and eventually cause failure due to corrosion.
* When performing electrical tests, prevent accidental
shorting of terminals. Such shorts can damage fuses or
components and may cause a second fault code to set, making
diagnosis of original problem more difficult.
* Never use an analog volt/ohm meter or test light in place of
a Digital Volt/Ohm Meter (DVOM). Use only a DVOM with a
maximum test current of 2 mA (milliamps) at minimum range of
resistance measurement. Also see SPECIAL TOOLS.
* If SRS is not fully functional for any reason, DO NOT drive
vehicle until system is repaired and is fully functional. DO
NOT remove bulbs, modules, sensors or other components, or
in any way disable system from operating normally. If SRS is
not functional, park vehicle until repairs are made.
SPECIAL TOOLS
To avoid air bag deployment when working on SRS, DO NOT use
electrical test equipment such as test lights, battery or A/C-powered
volt/ohmmeter, or any type of electrical equipment other than those
specified by manufacturer. See SRS RECOMMENDED TOOLS table.
SRS RECOMMENDED TOOLS TABLE









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See Fig. 1 . Connect negative voltmeter lead to ground.
2) Disconnect generator output wire from terminal "B".
Install a 100-amp ammeter in series with terminal "B" and disconnected
output lead. Connect positive lead of ammeter to terminal "B" and
negative lead to disconnected output wire. Install a tachometer, and
reconnect negative battery cable.
3) Turn ignition switch on and ensure voltmeter indicates
battery voltage. If voltage is not present, check for open in wire
between generator terminal "S" and positive battery terminal. Check
for blown fusible link.
4) Start engine. Ensure all lights and accessories are off.
Operate engine at 2500 RPM and read voltmeter when generator output
current drops to 10 amps or less. Voltage regulator is okay if voltage
output is within specification. See REGULATOR VOLTAGE SPECIFICATIONS
table.
REGULATOR VOLTAGE SPECIFICATIONS TABLE









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Ambient Temperature Voltage
-4
F (-20C) ................................... 14.2-15.4
68F (20C) .................................... 13.9-14.9
140F (60C) ................................... 13.4-14.6
176F (80C) ................................... 13.1-14.5








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GENERATOR RELAY TEST
NOTE: Information for all other models is not available from
manufacturer at time of publication.
Diamante & Mirage
Remove generator relay. On Diamante, relay is located in
relay box in engine compartment near battery. On Mirage, relay is
located in relay box in engine compartment between battery and strut
tower. On both models, connect positive lead of ohmmeter to relay
terminal No. 4. See WIRING DIAGRAMS. Connect negative lead of ohmmeter
to relay terminal No. 2. Continuity should be present. Switch ohmmeter
lead locations. Continuity should not be present. Replace generator
relay if continuity is not as specified.
BENCH TESTING
RECTIFIER ASSEMBLY
1) Using ohmmeter, check for continuity between diodes and
stator coil lead connection. See Fig. 2. Reverse leads. If continuity
is present in both directions, diode is shorted. Replace rectifier
assembly.
2) To check entire diode assembly, use an ohmmeter to check
for continuity between both ends of each diode. See Fig. 2. Switch
ohmmeter leads. Continuity should be present in one direction only. If
continuity is not as specified, diode is defective. Replace rectifier
assembly.

Eclipse
Without Theft Alarm ........................ Behind Center Of Dash
With Theft Alarm .... Under Left Of Instrument Panel, On Relay Box
Galant ................................... Inside Right Front Fender
Mirage .......................... In Left Underhood Fuse/Relay Block
Montero ...................................... Behind Center Of Dash
Montero Sport ................... In Left Underhood Fuse/Relay Block
3000GT ......................... In Right Underhood Fuse/Relay Block









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Fig. 1: Identifying Starter Relay Connector Terminals (3000GT)
Courtesy of Chrysler Corp.
BENCH TESTING
* PLEASE READ THIS FIRST *
CAUTION: Perform tests in less than 10 seconds to prevent damage to
coil.
NO-LOAD TEST
1) Install starter in soft-jawed vise. Connect starter in
series with a fully-charged 12-volt battery. Connect a 100-amp ammeter
and carbon pile rheostat in series with positive battery post and
starter motor terminal. See Fig. 2.
2) Install voltmeter across starter motor. Adjust carbon pile
rheostat to full resistance. Connect cable from starter motor body to
negative battery terminal. Adjust carbon pile rheostat to proper test
voltage. Ensure maximum amperage is as specified and starter rotates

ARMATURE TEST
Ensure armature is not grounded. Place armature in growler.
Hold a thin steel blade parallel and just above armature while slowly
rotating armature in growler. A shorted armature will cause blade to
vibrate and be attracted to core. Using an ohmmeter, check continuity
between armature coil cores and commutator segments (small diameter
end of armature). Continuity should not exist. Check for continuity
between segments. Continuity should exist. Replace armature as
necessary.
BRUSH HOLDER TEST
Using an ohmmeter, check continuity between brush holder
plate and brush holder. Continuity should not exist. Replace brush
holder as necessary.
REMOVAL & INSTALLATION
NOTE: On Montero with A/T, it may be necessary to disconnect
transmission oil cooler line for starter removal.
Removal & Installation
Disconnect negative battery cable. If necessary, raise
vehicle on hoist. Remove starter mounting bolts and starter. To
install, reverse removal procedure.
OVERHAUL
Check commutator for out-of-round and proper amount of
undercut. Replace or repair armature if not within specification. See
STARTER SPECIFICATIONS table. Ensure brushes are not worn beyond wear
line (outer line closest to commutator contact surface). Check pinion
gap. See PINION GAP MEASUREMENT under BENCH TESTING. See Figs. 5 and
6.
Fig. 5: Exploded View Of Direct Drive Starter (Typical)
Courtesy of Mitsubishi Motor Sales of America

STEERING COLUMN
1998 Mitsubishi Montero
1997-98 STEERING
Mitsubishi - Steering Columns - RWD & 4WD
Mitsubishi: Montero, Montero Sport
DESCRIPTION & OPERATION
WARNING: Vehicle is equipped with a Supplemental Restraint System
(SRS) that includes an air bag located in steering wheel.
Use caution when working around steering column. Ensure
battery is disconnected before attempting any repair. DO NOT
apply electrical power to any component on steering column
without disconnecting air bag module (air bag could deploy).
Steering column consists of a collapsible steering shaft with
lower joint assembly. Vehicle is equipped with a Supplemental
Restraint System (SRS) that includes an air bag and clockspring
located in steering column wheel.
NOTE: For information not covered in this article, air bag
DIAGNOSIS & TESTING or DISPOSAL PROCEDURES, see AIR BAG
RESTRAINT SYSTEM article.
DISABLING & ACTIVATING AIR BAG SYSTEM
WARNING: Wait at least 60 seconds after disconnecting negative
battery cable before servicing SRS. System reserve capacitor
maintains SRS voltage for about 60 seconds after battery is
disconnected. Servicing SRS before 60-second period may
cause accidental air bag deployment and possible personal
injury.
To disable system, turn ignition switch to OFF position.
Disconnect and isolate negative battery cable end. Wait at least 60
seconds. To activate system, reconnect negative battery cable.
AIR BAG SERVICE PRECAUTIONS
The following precautions should be observed when working
with SRS:
* Disable SRS before servicing any SRS or steering column
component. Failure to do this may result in accidental air
bag deployment and possible personal injury. See DISABLING &
ACTIVATING AIR BAG SYSTEM.
* Wait at least 60 SECONDS after disabling air bag system. SRS
system retains enough voltage, for a short time after system
is disabled, to deploy air bag.
* After repairs, always turn ignition on to ensure SRS warning
light is working properly and no system faults are indicated.
* Always wear safety glasses when servicing or handling an air
bag.
* DO NOT expose air bag module and clockspring to temperatures
more than 200
F (93C).
* When placing a live air bag on a bench or other surface,
always face air bag and trim cover up, away from surface.
This will reduce motion of module if air bag accidentally

TROUBLE SHOOTING - BASIC PROCEDURES
1998 Mitsubishi Montero
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

ALTERNATOR article








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Alternator Blown fuse See WIRING DIAGRAMS
Light Stays Off
With Ignition
Switch ON
Defective alternator See Testing in
ALTERNATOR article
Defective indicator light See Indicator Warning
bulb or socket Lights in STANDARD
INSTRUMENTS in the
ACCESSORIES &
EQUIPMENT section









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Alternator Short in alternator wiring See On-Vehicle Tests
Light Stays OFF in ALTERNATOR article
With Ignition
Switch ON
Defective rectifier bridge See Bench Tests in
ALTERNATOR article









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Lights or Fuses Defective alternator wiring See On-Vehicle Tests
Burn Out in ALTERNATOR article
Frequently
Defective regulator See Regulator Check in
ALTERNATOR article
Defective battery Check and replace as
necessary









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Ammeter Gauge Loose or worn drive belt Check alternator drive
Shows Discharge belt tension and
condition. See Belt
Adjustment in TUNE-UP
article in the
TUNE-UP section
Defective wiring Check all wires and
wire connections
Defective alternator or See Bench Tests and
regulator On-Vehicle Tests in
ALTERNATOR article
Defective ammeter, or See Testing in
improper ammeter wiring STANDARD INSTRUMENTS
connection in the ACCESSORIES &
EQUIPMENT section









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Noisy Loose drive pulley Tighten drive pulley
Alternator attaching nut
Loose mounting bolts Tighten all alternator
mounting bolts
Worn or dirty bearings See Bearing
Replacement
ALTERNATOR article

Defective diodes or stator See Bench Test in
ALTERNATOR article









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Battery Does Loose or worn drive belt Check alternator drive
Stay Charged belt tension and
condition. See
Belt Adjustment in
appropriate TUNE-UP
article in the
TUNE-UP section
Loose or corroded battery Check all charging
connections system connections
Loose alternator connections Check all charging
system connections
Defective alternator or See On-Vehicle Tests
battery and Bench Tests in
ALTERNATOR article
Add-on electrical accessories Install larger
exceeding alternator capacity alternator









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Battery Defective battery Check alternator
Overcharged- output and repair as
Uses Too Much necessary
Water
Defective alternator See On-Vehicle Test and
Bench Tests in
ALTERNATOR article
Excessive alternator voltage Check alternator output
and repair as necessary









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IGNITION 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.
Ignition Secondary Trouble Shooting Chart








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START: Visually inspect Spark Plug Wires, Coil Wires, 

Plug Wire Boots, Rotor, and Distributor Cap for 

signs of damage. 










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OK   NOT OK 




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* To test secondary ignition   * Repair or replace 

system, modify a Spark Plug   damaged components 

by attaching a ground wire   as necessary 

to the body of the plug and  









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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

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
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