belt MITSUBISHI MONTERO 1987 1.G Workshop Manual

8-2 ELECTRICAL SYSTEM PARTS LOCATION - Relay and Control Unit
ELECTRICAL SYSTEM IPARTS LOCATION NOIBAB-A
RELAY AND CONTROL UNIT
16W722
n 17
hub indicator control unit A A Automatic free-wheeling 2
Blower
assembiy& x v/i 16W152B Items Symbol
--
Air conditioner relay D
--
Auto choke relay G
--
Automatic free-wheeling hub indicator control
A
unit
Condenser blower motor relay H
Feed back carburetor control unit C
Hazard warning flasher unit F
Headlight washer relay F
Heater relay E
Intermittent wiper relay F
~___
Light control relay I
~___
Over drive relay F
Power window relay F
Seat belt warning timer B
Turn-signal flasher unit F
carburetor
control unit
Air conditioner relay
d--- I- Jr Evaporator E
1 .STB Re\iision

WIRING HARNESS - Troubleshooting
1660236
Power
supply
h
Fuse
ON
/----
/
/
Motor
1660239
CHECKING CABLES AND WIRES
1. Check connections for looseness, rust and stains.
2. Check terminals and wires for corrosion by battery electrolyte,
$tc.
3. Check terminals and wires for open circuit or impending open
circuit.
4. Check wire insulation and coating for damage, cracks and de-
grading.
5. Check conductive parts of terminals for contact with other
metallic parts (vehicle body and other parts).
6. Check grounding parts to verify that there is complete conti-
nuity between attaching bolt(s) and vehicle body.
7. Check for incorrect wiring.
8. Check that wirings are so clamped as to ‘prevent contact with
sharp corners of the vehicle body, etc. or hot parts (exhaust
manifold, pipe, etc.).
9. Check that wirings are clamped firmly to secure enough clear-
ance from the fan pulley, fan belt and other rotating or moving
parts.
10. Check that the wirings between the fixed parts such as the
vehicle body and the vibrating parts such as the engine are
made with adequate allowance for vibrations.
HANDLING ON-VEHICLE BAlTERY
When checking or servicing does not require power from the on-
vehicle battery, be sure to disconnect the cable from the battery
(-)terminal. This is to prevent problems that could be caused by
shorting of the circuit. Disconnect the (-) terminal first and recon-
nect it last.
TROUBLESHOOTING
A circuit consists of the power supply, switch, relay, load, ground,
etc. There are various methods to check a circuit including an
overall check, voltage check, shortcircuit check and continuity
check. Each of these methods is briefly described in the following.
1. Voltage check
(1) Ground one lead wire of the test light. If a voltmeter is
used instead of the test light, ground the grounding
side lead wire.
(2) Connect the other lead wire of the test light to the
power side terminal of the connector 0. The test light
should come on or the voltmeter should indicate a
voltage.
(3) Then, connect the test light or voltmeter to the
connector (3,. The test light should not come on, or the
voltmeter should indicate no voltage. When the switch
is turned on in this state, the test light should come on,
or the voltmeter should indicate a voltage, with the
motor starting to run.
(4) The circuit illustrated here is normal but if there is any
problem such as the motor failing to run, check
voltages beginning at the connector nearest to the
motor unit the faulty part is identified. 1 ST6 Revision

8-32 WIRING HARNESS - Instrument Panel
3 INSTRUMENT PANEL
Connector symbol
C
C-65 c-04
C-06
C-64
C-63
C-61
CL57 C-b6 C!55 d54 c!5
Remarks
For information concerning the ground points (example:
q ),
refer to P.8-7.
C-01 Back door lock switch
C-02 Defogger switch
C-03 Kev reminder and seat belt
warning buzzer
c-04
pi;’ Combination meter
C-08 Diode
C-09 Rear wiper and washer switch
r&~}Oil pressure gauge
C-12 f;hybination gauge illumination
C-l 3 Blower switch
C-14 Combination gauge wiring
harness and front wiring harness
combination
C-15 F;hybination gauge illumination
C,::F}Voltage meter C-l 8 Heater relay
C-l 9 Air conditioner wiring harness
and front wiring harness
combination
E:$)}Air conditioner relay C-31 Blower motor resistor
C-32 Dedicated fuse (Air conditioner
circuit)
C-33 Air conditioner switch
C-34 yl;Jer control lonob illumination
$:;;I Thermostat
$:;;I Feed back carburetor control unit
C-26 Front speaker (R.H.)
C-27 Front wiring harness and roof
wiring harness combination
C-28 Automatic free-wheeling hub
indicator control unit
C-29 Seat belt warning timer
C-30 Front wiring harness and door
wiring harness (R.H.)
combination c-35
C-36
c-37
C-38
c-39
c40
“3’ ‘. Blower switch
Clock
Heater control panel illumination
light
Ashtray illumination light
Air conditioner switch
illumination light
Front wiring harness and center
panel wiring harness
combination
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WIRING HARNESS - Instrument Panel 8-33
cy50 C149 Cl48 c-47
El$,}Cigarette lightet
C-43 Cigarette lighter illumination light
E::$ Radio
C-46 Shift position illumination light
C-47 Inhibitor switch
C-48 OD-OFF switch
C-49 Parking brake switch
C-50 Seat belt switch
C-51 Hazard switch
E3 Column switch
C-54 Key reminder switch
C-55 Ignition switch
C-56 Stop light switch C-57 Dimmer control switch
C-58 Front wiring harness and door
wiring harness (L.H.) combination
C-59 Turn-signal flasher unit
C-60 Power window relay
C-61 Intermittent wiper relay
C-62 Hazard flasher unit
C-63 OD-OFF relay
C-64 Headlight washer motor relay
C-65 Front speaker (L.H.)
Ision

WIRING HARNESS - Meter Circuit
12 METER CIRCUIT
m 1 A-02
Sub fusible link
15-w Ignition switch
Main fusible -
--
link
A-22
‘1
m -ffiFirmer control BY
4
[Refer to P.8-511
I I 0 column :
[Refer to P.E
@/ Multi-purpose fuse
(bYI
To turn,signal switchfd,,, ,
[Refer to P.8-491 1
To seat belt timer
[Refer to P.8-661
To seat belt warning
buzzer [Refer to P.8-661 M
G 1
I
To alternator
fRefer to P.8-371
0.85tW
41D 1 I 4
‘o dimmer, passir-
witc , “,, ,
:h and light control Ir r n ! , I I I
clay [Refer to P.8461 ~ -_
To dome light Kb
[Refer to P.8-471 4
To door yi~“,h,,_(RG)
ID,.&-* +,.
1
I YBdD t
m ”
q
3
-ly-J
_-- -_ I- r
Combination meter
1 STB Revision

8-66 WIRING HARNESS - Buzzer Circuit
21 BUZZER CIRCUIT
OR
A 0 Key reminder
switch
nil 1
link Battery A-02
-1.25-B -
0
-
Main fusible Sub fusible link
IT8 ‘I 01
Ignition switch
dhm b- Multi-purpose
[Refer to P.8-491
0 1
C P-P
a 3
-CCl P mm-l
z- z-CY m aa-cd
c-03 r c-50 -J -.A
I.5 ‘bb’ IC ski&t
switch
Key reminder
Combination
meter and seat belt
warning buzzer
Remark
For information concerning the ground points (example:
q ),
refer to P.8-7. Seat belt
warning timer
37W607
Wiring color code
B: Black Br: Brown
G: Green Gr: Gray L: Blue Lg: Light green
LI: Light blue
0.: Orange P: Pink R: Red Y: Yellow W: White 1 ST9 Revision

WIRING HARNESS - Centralized Junction
Multi-purpose Fuse
Power supply circuit Fuse No. Rated
capacity A Applicable circuits
Battery 1 20
Clock, Dome light, Hazard warning flashers
Headlight relay 2 10 Tail lights, License plate lights, Illumination lights, Headlight
washer relay, Position lights
__-
Ignition switch (IG) 3 10 Heater relay, Seat belt warning timer, Turn-signal lights,
Alternator, Seat belt switches, Power window relay, Fuel and
water temperature gauges, Oil pressure gauge, Voltage meter,
Indicator and warning lights, Inhibitor switch, Automatic
free-wheeling hub indicator control unit
4
IO Back-up lights, Auto choke relay, OD-OFF relay
__-
5 15 Rear window defogger
Battery 6 20 Heater, Back door lock
7 15 Key-reminder switch, Stop lights, Buzzer
Ignition switch (ACC) 8 15 Windshield wipers and washer, Headlight washer relay,
Intermittent wiper relay, Horn
9 10 Rear window wiper and washer
10 15 Cigarette lighter, Radio, Tape player, Clock (ACC), Spare terminal,
Air conditioner relay

CHARGING SYSTEM - General Information 8-71
CHARGING SYSTEM
GENERAL INFORMATION
NOBEMD
The charging system comprises battery, alternator with regulator, charging indicator light and wire.
The alternator has 6 built in rectifiers (3 positive and 3 negative), which rectify alternating current to direct current.
Accordingly, the alternator terminal B is D/C. Furthermore the alternator regulates the charge voltage through the
use of battery voltage detection system.
The main parts of the alternator are: rotor, stator, rectifier, condenser, brush, bearing, drive belt pulley and a
brush holder with built in electronic voltage regulator.
:--\;-----------I ;
I.C. regulator
I
-A I.C. alternator -y
Brush
heat -sink assembly Drive
-belt
pulley
Rotor light
6EL239
Stator 6EN246 6EN211
1 STB Revision

CHARGING SYSTEM -Troubleshooting 8-75
TROUBLESHOOTING
NOBEH-
Symptom Probable cause
Remedy Reference
we
Charging warning in- Fuse blown
dicator does not light
with ignition switch Light burned out
“ON” and engine off. 1
1 Wiring connection loose Check fuses
Replace light
Tighten loose connections 8-70
-
-
Charging warning in-
dicator does not go
out with engine
running
(Battery requires fre-
quent recharging)
L
t
Run-down battery
c
Electronic voltage regulator faulty
Drive belt loose or worn
Battery cables loose, corroded or worn
Fuse blown
Fusible link blown
Electronic voltage regulator or alternator
faulty
Wiring faulty
Drive belt loose or worn
Wiring connection loose or open circuit
Fusible link blown Replace voltage regulator
Adjust tension or replace drive
belt
Repair or replace cables
Check fuses
Replace fusible link
Test alternator
Repair wiring
Adjust tension or replace drive
belt
Tighten loose connection or
repair wiring
Replace fusible link 8-79
Refer to
GROUPS.
8-8 1
8-70
8-69
8-77
8-79
-
Refer to
GROUP 9.
-
8-69
Poor grounding 1 Repair
I-
I I I Electronic voltage regulator or alternator
faulty Test alternator 8-77
8-79
Overcharge Decrease in life of battery
Replace battery
8-81 I
Electronic voltage regulator faulty Replace voltage regulator 8-79
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8-78 CHARGING SYSTEM - Service Adiustment Procedures
80A
n
Relay with diode
Voltmeter
Ammeter Iad
176
OUTPUT CURRENT TEST
This test judges whether or not the alternator gives an output
current that is equivalent to the nominal output.
Preparation
(1) Prior to the test, check the following items and correct as
necessary.
(a) Check the battery installed in the vehicle to ensure that it
is in sound state*. The battery checking method is de-
scribed in “BATTERY”.
NOTE
*The battery that is used to test the output current should
be one that has been rather discharged. With a fully
charged battery, the test may not be conducted correctly
due to an insufficient load.
(b) Check tension of the alternator drive belt. The belt tension
check method is described in “GROUP 7 COOLING -
Service Adjustment Procedures”.
(2) Turn off the ignition switch.
(3) Disconnect the battery ground cable.
(4) Disconnect the alternator output wire from the alternator “B”
terminal.
(5) Connect a DC ammeter (0 to 100 A) in series between the “B”
terminal and the disconnected output wire. Connect the (+)
lead of the ammeter to the “B” terminal and connect the (-)
lead wire to the disconnected output wire.
NOTE
Tighten each connection by bolt and nut securely as a heavy
current will flow. Do not relay on clips.
(6) Connect a voltmeter (0 to 20 V) between the “B” terminal and
ground. Connect the (+) lead wire to the alternator “B” ter-
minal and (-) lead wire to a sound ground.
(7) Set the engine tachometer and connect the battery ground
cable.
(8) Leave the engine hood open.
Test
(1) Check to see that the voltmeter reads the same value as the
battery voltage.
If the voltmeter reads 0 V, an open circuit in the wire between
the alternator “B” terminal and battery (-) terminal, a blown
fusible link or poor grounding is suspected.
(2) Turn on the headlight switch and start the engine.
(3) Set the headlight at high beam and the heater blower switch
at HIGH, quickly increase the engine speed to 2500 rpm and
read the maximum output current value indicated by the am-
meter.
NOTE
After the engine start up, the charging current quickly drops.
therefore, above operation must be done quickly to read max-
imum current value correctly.
[ STB Revision
--I