oil MITSUBISHI MONTERO 1987 1.G Workshop Manual

8 INTRODUCTION - Precautions Before Service
r oorn,
FOOOl;
FOOOl8
PRECAUTIONS BEFORE SERVICE
PROTECTIN” THE VEHICLE NOODAAC
If theIre is a likelihood of damaging painted or interior parts
during service operations, protect them with suitable covers
(such as seat covers. fender covers, etc.).
REMOVAL AND DISASSEMBLY
When checking a malfunction, find the cause of the problem.
If it is determined that removal and/or disassembly is neces-
sary, perform the work by following the procedures contained
in this, Workshop Manual.
If punch marks or mating marks are made to avoid error in
assembly and facilitate the assembly work, be sure to make
them in locations which will have no detrimental effect on
performance and/or appearances.
If an area having many parts, similar parts, and/or parts which
are’ symmetrical right and left is disassembled, be sure to
arrange the parts so that they do not become mixed during the
assembly process.
1. Arrange the parts removed in the proper order.
2. Determine which parts are to be reused and which are to
be replaced.
3. If bolts, nuts, etc., are to be replaced, be sure to use only
the exact size specified.,
SPECIAL TOOLS
If other tools are substituted for the special tools to do service
or repair work, there is the danger that vehicle parts might be
damaged, or the mechanic might be injured; therefore, be
sure to use the special tool whenever doing any work for
which the use of one is specified.
PARTS TO IBE REPLACED
If any of the following parts are removed, they must be
replaced with new parts.
1. Oil seals
2. Gaskets (except rocker cover gasket)
3. Packings
4. O-rings
5. Lock washers
6. Cotter pins
7. Self-locking nuts
DO05111
STB Revision ,j .’

12 INTRODUCTION - Precautions Before Service
(3) If an ammeter or similar instrument is to be connected
to a live-wire circuit, use tape to protect the wire, use a
i clamp to secure the wire, and make sure that there is
, no contact with any other parts.
(4’) Be sure to provide a fuse for the load circuit of the
optional equipment.
FooO281
TUBES AND OTHER RUBBER PARTS
Be careful to avoid spilling any gasoline, oil, etc.. because if it
adheres to any tubes or other rubber parts, they might be
adversely affected.
LUBRICANTS
In accordance with the instructions in this Workshop Manual,
apply the specified lubricants in the specified locations during
assembly and installation.
BRAKE FLUID
Be careful to avoid spilling any brake fluid, because if it
adheres to the vehicle body, the paint coat might be discol-
ored.
DOING SERVICE WORK IN GROUPS OF TWO OR
MORE TECHNICIANS
If the service work is to be done by two or more technicians
extra caution must be taken.
-FOOO3OI
1 STB Revision ’
:

8-1
ELECTRICAL
CONTENTS
NOBAA-
ACCESSORY ......................................................
188
Cigarette Lighter ............................................
,190
Clock ...............................................................
,191
AUDIO SYSTEM ................................................
.192
AUTOMATIC FREE-WHEELING HUB
INDICATOR SYSTEM ........................................
208
Automatic Free-wheeling Hub
Indicator Control Unit
..................................... ,216
Pulse Generator ..............................................
215
BACK DOOR WINDOW DEFOGGER
................ .203
Defogger switch ............................................
,206
Printed Heater Lines
...................................... ,207
CHARGING SYSTEM .........................................
71
Alternator ........................................................
83
Service Adjustment Procedures
..................... 77
Battery Charging ........................................
82
Inspection of Battery ..................................
81
Output Current Test ...................................
78
Regulated Voltage Test ..............................
79
Voltage Drop Test of Alternator Output
Wire ............................................................
77
ELECTRICAL SYSTEM PARTS LOCATION
...... 2
Diode ...............................................................
5
Fusible Link and Fuse
..................................... 6
Grounding .......................................................
7
Relay and Control Unit ....................................
2
Sensor .............................................................
4
HORN ..................................................................
184
Horn Switch
.................................................... 187
IGNITION SYSTEM ............................................
105
Ignition Switch
................................................ 122
Ignition System ...............................................
1 14
Service Adjustment Procedures
.................... .l 1 1
Checking Ignition System
..........................
11 1
Checking Ignition Timing
...........................
11 1
Spark Plug Cable Test
................................
1 12
Spark Plug Test
.......................................... 1 12 INSPECTION OF HARNESS CONNECTOR ...... 9
Check for Improper Engagement of
Terminal .......................................................... 9
Continuity and Voltage Test for Connector .... 9
Engaging and Disengaging of Connector
Terminal ..........................................................
9
LIGHTING SYSTEM ........................................... 143
Column Switch
................................ .
.............. .I59
Dimmer Control Switch
................................. .I62
Hazard Warning Switch
................................. .I61
Headlight ........................................................ ,158
Service Adjustment Procedures
.................... .I57
Headlight Aiming .......................................
157
METERS AND GAUGES .................................... 123
Service Adjustment Procedures
.................... .I30
Fuel Gauge Simple Test ................................. .I31
Fuel Gauge Unit Inspection ........................... .I31
Oil Pressure Gauge Simple Test
.................... .I32
Oil Pressure Gauge Unit Simple Test
............ ,132
Speedometer Inspection
............................... .I30
Tachometer Inspection .................................. ,130
Voltage Meter Simple Test
............................ .I33
Water Temperature Gauge Simple Test
....... ..I3 1
Water Temperature Gauge Unit Inspection
. ..I3 2
STARTING SYSTEM .......................................... 91
Starter Motor ............ ....................................... 97
WIPER AND WASHER SYSTEM
....................... .163
WIRING HARNESS ............................................ 13
Centralized Junction ....................................... 69
Circuit Diagram ............................................... 34
Configuration Diagram .................................... 27
How to Read Wiring Diagrams ....................... 20
Troubleshooting .............................................. 13

DIODE
ELECTRICAL SYSTEM PARTS LOCATION - Diode 8-5
Diode (for automatic transmission oil
Diode (for EGR warning light)
1 @NJ22
STB Revision

WIRING HARNESS - Troubleshooting 8-15
1660227
Black lead wire
Ground y
1680228
Normal open (NO) type
OFF
ax
Current does not flow ON
Current flows
Normal close (NC) type
OFF
l-2
Current flows ON
-op--
IX
Current does not flow
1680229
pm I 3. Jumper wire
A jumper wire is used to close an open circuit. Never use one
to connect a power supply directly to a load.
4. Voltmeter
A voltmeter is used to measure the circuit voltage. Normally,
the positive (red lead) probe is applied to the point of voltage
measurement and the negative (black lead) probe to the body
ground.
5. Ohmmeter
An ohmmeter is used to.check continuity or measure resis-
tance of a switch or coil. If the measuring range has been
changed, the zero point must be adjusted before measure-
ment.
CHECKING SWITCHES In a circuit diagram, a switch is represented by a symbol and in the
idle state.
1. Normal open or normal close switch
Switches are classified into those which make the circuit open
and those which make the circuit closed when off.
#vision
I

8-16 WIRING HARNESS - Troubleshooting
OFF
1st stage
2nd stage
3rd stage
1
--_
4th stage
1660230
16W896
Cover
Coil
Iron
piece Spring
Iron
core
Contact
1660231
I
l-
Battery:
I
-
d
T Relav
T I
I 1660232 1
Normal ooen (NO) tvoe
Deenergized state Energized state
I
1
2
ED
3
4
1 2
BP
3
4
1 YZZZw;6B0233 CurreZ! not flow
2. SWITCH CONNECTION
This figure illustrates a complex switch. The switch plates
indicated by solid lines move in the direction of the arrow
when
operated. The continuity between terminals at each po-
sition is as indicated in the table below.
NOTE
M denotes continuity between terminals.
CHECKING RELAYS
1. When current flows through the coil of a relay, its core is
magnetized to attract the iron piece, closing (ON) the contact
at the tip of the iron piece. When the coil current is turned off,
the iron piece is made to return to its original position by a
spring, opening the contact (OFF).
2. By using a relay, a heavy current can be turned on and off
by a switch of small capacity. For example, in the circuit
shown here, when the switch is turned on (closed), current
flows to the coil of the relay. Then, its contact is turned on
(closed) and the light comes on. The current flowing at this
time to the switch is the relay coil current only and is very
small.
3. The relays may be classified into the normal open type and the
normal close type by their contact construction.
NOTE
The deenergized state means that no kurrent is flowing
through the coil and the energized state means that current is
flowing through the coil.
J . . . I 1 STB Revmon

8-20 WIRING HARNESS - How to Read Wiring Diagrams
HOW TO READ WIRING DIAGRAM NOEDBAE
HOW TO READ CONFIGURATION DIAGRAMS
(1) Connector symbols
A wiring diagram shows the installed condition of each connector in a schematic style. The connectors are
shown and classified as follows, depending on their locations and are marked by connector symbols.
In case connectors of the same shape (same number of wires) are centralized, their colors are indicated for
identification.
Examp’e : p.!- f.~~~~ ~;~~o,
Connector’s unique number (serial number)
A : Engine compartment
B : Interior and frame
C : Instrument panel
Main fusible link
A-03
A-o4
> 4WD indicator switch
A-05 Automatic transmission oil
I temperature switch indicates that the connector is located in the
Same connector No. is used in the wiring diagram and the circuit diagram.
I Indicates color of the
A-58 connector. I
1 ST6 Revision

8-26 WIRING HARNESS - HOW to Read Wiring Diagrams
SYMBOLIC MARKS
Various equipment is indicated symbolically in circuit idiagrams as shown below.
Battery Body ground Single bulb Resistor Diode Capacitor
Fuse Equipment ground
Fusible link
Motor
Speaker Coil ~
4 Transistor Crossing of lines
4 -1~ with conron
WIRE COLOR CODES Wire colors are identified by the following color codes.
Example: 1.25 - GB Code Wire color Code Wire color
B
Br Black
Brown LI
0 Light blue
Oranqe
I P
i 1 Gr 1 Grav 1 R 1 Red I
I L I Blue
I Y I Yellow I
L 1.25: Wire size (mm2)
F: Flexible wire
T: Twisted wire
(1) No code indicates 0.5 mm2(.0008 in.*).
(2) Cable color-code in parantheses indicates
0.3 mm* (.0005 in.‘).
Lg Light green W White
NOTE
If a cable has two colors, the first of the two color code characters
indicates the basic color (color of the cable coating) and the sec-
ond indicates the marking color.
STB Revision

8-28 WIRING HARNESS - Engine Compartment
1 ENGINE COMPARTMENT
Connector symbol
A
;:::I Main fusible link
;:::I 4WD indicator switch
A-05 Automatic transmission oil
temperature switch
A-06 Back-u light and 4WD indicator
A-07)wiring f!arness and cord
assembly combination
;:g> Back-up light switch
A-l 0 OD-OFF solenoid
A-l 1 Pulse generator
A-l 2 Front wiring harness and
transmission wiring harness
combination
A-13 Air conditioner solenoid valve
A-l 4 Front wiper motor A-
A156
A-55
A-l 7 Checker
A-18 Diode
A-19 Brake fluid level sensor
A-20 Front harness and back-up light
A-21 land 4WD indicator wiring
harness combination
it;;> Sub fusible link
A-24 Carburetor assembly
A-25 Control wiring harness and air
conditioner wiring harness
combination
A-26 Front wiring harness and control
wiring harness combination
A-27 Device box A-53 A-52
A-54
A-28 Auto choke relay
A-29 Front wiring harness and air
conditioner wiring harness
combination
A-30 Headlight washer motor
A-31 Front combination light (L.H.)
A-32 Light control relay
A-33 Dedicated fuse (Upper beam
indicator circuit)
A-34 Headlight (L.H.)
A-35 Condenser fan motor
A-40 Condenser fan motor relay
1 STB Revision

WIRING- HARNESS - Engine Compartment 8-29
; A-06 A-08 A-1 0 A-12 A-14
,.
1 A-15 8
I I
,I I I, I /
A-48
WI
&-ii& ’
A-35 Ai34 A!33 J-3:
A-39 A-37
36W618
A41
i-$ Ignition coil
A-44
A-45 Magnetic clutch
A-46 Water temperature sensor (FBC circuit)
;rii}Alternator
A-49 Water temperature switch (Air conditioner circuit)
A-50 Water temperature gauge unit
A-51 Water temperature switch (OD control circuit)
A-52 Oil pressure gauge or oil pressure switch
$3 Low pressure switch A-55 Headlight (R.H.)
A-56 Front harness and air conditioner wiring harness
combination
A-57 Front combination light (R.H.)
A-58 Front washer motor
A-59 Oxygen sensor
Remarks
(1) The mark * shows the reference mounting position of
wiring harness.
(2) For information concerning the ground points (exam-
ple:
q ), refer to P.8-7.
1 STB Revision