TPS MITSUBISHI MONTERO 1991 User Guide

Installation
1) To install, reverse removal procedure. Injectors may be
removed after fuel rail is removed from intake manifold. Use new
insulators and "O" rings when installing injectors.
2) Use spindle oil or gasoline on "O" ring. Install injectors
into fuel rail with a twisting motion. Adjust throttle and kickdown
cable (if applicable). Do not drop injectors while removing or
installing fuel rail.
OXYGEN (O2) SENSOR
Removal & Installation
1) O2 Sensor is mounted in exhaust pipe below exhaust header.
It is equipped with a permanent pigtail which must be protected from
damage when sensor is removed. Ensure sensor is free of contaminants,
avoid using cleaning solvents of any type. Sensor may be difficult to
remove when engine temperature is less than 120
F (48 C).
2) Always use anti-seize compound on threads before
installation. On non-turbo models, remove sensor using Remover
(MD998703). On turbo models, use Remover (MD998748) on Eclipse and
Galant, or Remover (MD998770) on Stealth and 3000GT. Tighten oxygen
sensor to specification. See TORQUE SPECIFICATIONS table.
THROTTLE BODY
Removal
Disconnect air intake hose. Remove accelerator and automatic
speed control cables (if equipped). Disconnect fuel vapor hose,
electrical harness connector, vacuum hose and coolant hoses. Remove
throttle body retaining bolts.
Disassembly
Remove throttle position sensor. Remove idle speed control
motor. Remove throttle bracket and connector bracket (if equipped).
Remove idle position switch and adjusting nut.
NOTE: DO NOT remove throttle valve. DO NOT use cleaning solvents
on throttle position sensor, idle speed control motor or
idle position switch.
Cleaning
Clean all parts except those noted in solvent. Check vacuum
port and passage for clogging. Clean vacuum, vapor and fuel passages
with compressed air.
Reassembly
To reassemble, reverse disassembly procedure.
Installation
To install, reverse removal procedure.
THROTTLE POSITION SENSOR/SWITCH
Removal & Installation
Throttle position sensor/switch is located on throttle body.
Disconnect TPS electrical connector. Remove bolts holding TPS and
remove TPS. To install, reverse removal procedure. Tighten throttle
position sensor/switch to specification. See TORQUE SPECIFICATIONS
table. For adjustment procedure, see ON-VEHICLE ADJUSTMENTS article.
TURBOCHARGERS

Fuel Tank Drain Plug ....................... 11-18 (15-24)
Exhaust Manifold-To-Engine Nuts ............ 18-22 (24-30)
Exhaust Manifold-To-Turbocharger Bolts ..... 40-47 (54-64)
Exhaust Pipe Bolts ......................... 22-29 (30-39)
Oil Pipe-To-Engine ......................... 10-14 (14-19)
Oxygen (O2) Sensor ......................... 29-36 (39-49)
Plenum-To-Intake Manifold Bolts ............ 11-15 (15-20)
Water Pipe-To-Turbocharger
Except Stealth & 3000GT .................. 25-36 (34-49)
Stealth & 3000GT ............................... 22 (30)
INCH Lbs. (N.m)
Fuel Rail Bolts .......................... 84-108 (10-12)
Heat Protector Bolts ..................... 108-132 (12-15)
ISC Switch Screws ........................ 20-54 (2.5-4.5)
TPS Switch Screws ........................ 13-20 (1.5-2.5)
Wastegate Actuator Bolts ................... 84-108 (9-12)









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THROTTLE POSITION SENSOR (TPS) RESISTANCE TABLE








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Application ( 1) Terminal (Ground-Output) Ohms
Colt Vista
Closed ...................... 2-1 .......... 3500-6500
Open ...................... ( 2) 2-3 ........ 3500-6500
Eclipse 2.0L (VIN R&U)
Closed ...................... 2-3 .......... 3500-6500
Open ...................... ( 2) 3-4 ........ 3500-6500
Pickup & Ram-50 3.0L
Closed ...................... 1-4 .......... 3500-6500
Open ...................... ( 2) 2-3 ........ 3500-6500
Stealth & 3000GT
Closed ...................... 4-1 .......... 3500-6500
Open ...................... ( 2) 4-2 ........ 3500-6500
All Others
Closed ...................... 1-4 .......... 3500-6500
Open ...................... ( 2) 2-4 ........ 3500-6500
( 1) - Measure across TPS terminals with connector disconnected.
( 2) - Resistance should increase smoothly.









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VEHICLE SPEED SENSOR CONTINUITY TEST TABLE ( 1)








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Application ( 2) Continuity
All Models ............ 4 Changes Per Revolution
( 1) - Measure continuity at back of speedometer.
See L - WIRING DIAGRAMS article in the
ENGINE PERFORMANCE Section.
( 2) - With ECU connector disconnected. Turn speedometer
cable to cycle reed switch on and off.









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VEHICLE SPEED SENSOR VOLTAGE TEST TABLE ( 1)








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Application ( 2) Volts
All Models
Ignition switch OFF ................ 1 Or Less
Ignition switch ON ................... 4.5-4.9
( 1) - Measure voltage at back of speedometer. See
L - WIRING DIAGRAMS article in the ENGINE
PERFORMANCE Section.
( 2) - With ECU connector disconnected. Turn speedometer
cable to cycle reed switch on and off.









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Application ( 1) Basic ( 2) ( 3) Actual
1.5L
Colt & Colt 200 ................ 5 @ 650-850 ...... 10 @ 650-850
Mirage & Summit ................ 5 @ 650-850 ...... 10 @ 650-850
1.6L
Mirage ......................... 5 @ 650-850 ....... 8 @ 650-850
1.8L
Eclipse ........................ 5 @ 600-800 ...... 10 @ 600-800
2.0L
Colt Vista & Galant (VIN V) .... 5 @ 600-800 ...... 10 @ 600-800\
Eclipse ........................ 5 @ 650-850 ....... 8 @ 650-850
Galant
(VIN R) ...................... 5 @ 650-850 ....... 8 @ 650-850\
(VIN U) ...................... 5 @ 650-850 ...... 12 @ 650-850\
2.4L
Pickup & Ram-50 ................ 5 @ 650-850 ....... 8 @ 650-850
3.0L
Montero, Pickup & Ram-50 ....... 5 @ 600-800 ...... 15 @ 600-800
Stealth & 3000GT ............... 5 @ 600-800 ...... 15 @ 600-800
( 1) - With ignition timing adjustment connector grounded or vacuum
hose (farthest from distributor) disconnected.
( 2) - With ignition timing adjustment connector ungrounded or vacuum
hose (farthest from distributor) connected. Ignition timing may
fluctuate.
( 3) - If vehicle altitude is more than 2300 ft. above sea level,
actual timing may be advanced.









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FUEL SYSTEM
FUEL PUMP
REGULATED FUEL PRESSURE








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At Idle w/Vacuum At Idle w/o Vacuum
Application psi (kg/cm) psi (kg/cm)
Eclipse 2.0L (VIN U)
With Man. Trans. ................. 33 (2.3) .... 36-38 (2.5-2.7\
)
With Auto. Trans. ................ 33 (2.3) .... 41-46 (2.9-3.2\
)
Galant 2.0L (VIN V), Montero (3.0L),
Pickup (3.0L) & Ram-50 (3.0L) ..... 38 (2.7) .... 47-50 (3.3\
-3.5)
Stealth & 3000GT (VIN B & S) ....... 38 (2.7) .... 47-50 (3.3-3\
.5)
Stealth & 3000GT (VIN C) ........... 34 (2.8) .... 43-45 (3.0-3\
.2)
All Others ......................... 38 (2.7) .... 47-50 (3.3-3.5\
)









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INJECTOR RESISTANCE
INJECTOR RESISTANCE








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Application Ohms
Non-Turbo ........................... 13-16
Turbo ................................. 2-3









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THROTTLE POSITION SENSOR (TPS)

TPS SPECIFICATIONS








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Application ( 1) Volts
Montero 3.0L ....................... .4-1.0
Except Montero .................... .48-.52
( 1) - At idle.









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connector portion of sensor slightly above water.
2) Gradually heat water and read resistance values across
terminal connectors. See COOLANT TEMPERATURE SENSOR RESISTANCE table.
If resistance is not within specification, replace sensor.
COOLANT TEMPERATURE SENSOR RESISTANCE TABLE









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TemperatureF (C) Ohms
Montero & Pickup 3.0L
32 (0) ............................. 5900
68 (20) ............................ 2500
104 (40) ........................... 2700
176 (80) ............................ 300
All Others
32 (0) ............................. 5900
68 (20) ............................ 2500
104 (40) ........................... 1100
176 (80) ............................ 300









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CRANK ANGLE SENSOR
See IGNITION SYSTEM.
DETONATION SENSOR
See IGNITION SYSTEM.
EGR TEMPERATURE SENSOR
California
See EXHAUST GAS RECIRCULATION (EGR) under EMISSION SYSTEMS &
SUB-SYSTEMS.
IDLE POSITION SWITCH
NOTE: Idle position switch is incorporated in idle speed control
motor assembly, motor position sensor or throttle position
sensor, depending upon vehicle application.
Pickup 2.4L & Ram-50 2.4L
1) Disconnect motor position sensor (MPS) connector. Connect\
ohmmeter lead between ground and MPS connector terminal No. 4. See
Fig. 2 .
2) With accelerator pedal pressed, no continuity should be
present. With accelerator pedal released, continuity should be
present. If switch continuity is not as specified, replace MPS.
Montero, Pickup 3.0L & Ram-50 3.0L
1) Disconnect throttle position sensor (TPS) connector.
Connect ohmmeter between TPS connector terminals No. 1 and 2. See
Fig. 6 .
2) With accelerator pedal pressed, no continuity should be
present. With accelerator pedal released, continuity should be
present. If idle switch continuity is not as specified, replace TPS.
INHIBITOR SWITCH
Automatic Transmission
Switch is mounted to automatic transaxle, near shift lever

Circuit Circuit
Application Terminals Terminals
Montero, Pickup 3.0L & Ram-50 3.0L ..... 2 & 4 ............. 1 & 3









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POWER STEERING OIL PRESSURE SWITCH
1) Power steering oil pressure switch is mounted on power
steering pump. Disconnect single wire connector at switch. Start
engine.
2) Connect ohmmeter between switch terminal and ground. If
continuity is present with steering wheel in straight-ahead position,
replace switch. If continuity is not present while turning steering
wheel, perform POWER STEERING IDLE-UP SYSTEM TEST. See IDLE-UP SYSTEMS
under IDLE CONTROL SYSTEM.
THROTTLE POSITION SENSOR
1) TPS is mounted to throttle body, at end of throttle shaft.
Disconnect TPS connector. See Fig. 6. Using ohmmeter, measure total
resistance between TPS connector terminals as specified in TPS
CONNECTOR TERMINAL IDENTIFICATION table. If resistance is not 3500-
6500 ohms, replace TPS.
2) Using an analog (needle-type) ohmmeter, measure variable
resistance between TPS connector terminals as specified in TPS
CONNECTOR TERMINAL IDENTIFICATION table.
3) Operate throttle valve from closed to wide open throttle.
If rate of resistance does not change smoothly within 3500-6500 ohms
throughout range of throttle valve movement, replace TPS.
Fig. 6: TPS Sensor Connector Terminal ID
Courtesy of Mitsubishi Motor Sales of America.
TPS CONNECTOR TERMINAL IDENTIFICATION TABLE









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Fig. 4: 18-Way ECU Connector
Courtesy of Chrysler Motors.
Fig. 5: 24-Way ECU Connector
Courtesy of Chrysler Motors.
Fig. 6: Self-Diagnostic Connector Terminal Identification
Courtesy of Mitsubishi Motor Sales of America.
FAULT CODES
FAULT CODES TABLE








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Fault Code System Fault Description
11 .................... Open or short in O2 sensor circuit
12 ............... Open or short in airflow sensor circuit
13 ...... Open or short in intake air temp. sensor circuit
14 .......................... Open or short in TPS circuit
15 (1) .... Open or short in motor position sensor circuit
21 ......... Open or short in coolant temp. sensor circuit
22 ........ No voltage change in crank angle sensor signal
23 ............... No voltage change in TDC sensor circuit
24 ( 2) .. No voltage change in vehicle speed sensor signal
25 ........... Open or short in barometric pressure sensor
31 ( 3) ........ Open or short in detonation sensor circuit
41 ..................... Open or short in injector circuit
42 .............. Open or short in fuel pump drive circuit
43 ( 4) ......... Open or short in EGR temp. sensor circuit

Fig. 260: DR-6 Flow Chart & Circuit Diagram (2.0L Non-Turbo)
DR-7: CHECKING THROTTLE POSITION SENSOR (TPS) - 2.0L

Inhibitor Switch (Automatic Transmission Only)
Inhibitor switch senses position of transmission select
lever, indicating engine load due to automatic transmission
engagement. Based on this signal, ECU commands ISC motor to increase
throttle angle, maintaining optimum idle speed.
Intake Air Temperature Sensor
Incorporated in airflow sensor assembly, this resistor-based
sensor measures temperature of incoming air and supplies air density
information to ECU.
Motor Position Sensor (MPS)
Incorporated in ISC motor (or separate unit on some models),
senses ISC motor plunger position and sends electrical signal to ECU.
Oxygen (O2) Sensor
Located in exhaust system, generates an output voltage.
Output voltage varies with oxygen content of exhaust gas stream. ECU
adjusts air/fuel mixture based on signals from oxygen sensor.
Power Steering Oil Pressure Switch
Detects increase in power steering oil pressure. When power
steering oil pressure increases, switch contacts close, signalling
ECU. ECU commands ISC motor, raising idle speed to compensate for drop
in engine RPM due to power steering load.
TDC Sensor
See CRANKSHAFT ANGLE & TDC SENSOR ASSEMBLY.
Throttle Position Sensor (TPS)
A variable resistor mounted on throttle body. ECU uses
voltage signal received from TPS to determine throttle plate angle.
Vehicle Speed Sensor
Located in speedometer in instrument cluster, uses a reed
switch to sense speedometer gear revolutions. ECU uses gear
revolutions to determine vehicle speed.
OUTPUT SIGNALS
NOTE: Vehicles are equipped with different combinations of
computer-controlled components. Not all components listed
below are used on every vehicle. For theory and operation on
each output component, refer to the system indicated in
brackets after component.
CHECK ENGINE Light
See SELF DIAGNOSTIC SYSTEM.
EGR Control Solenoid Valve
See EXHAUST GAS RECIRCULATION (EGR) CONTROL under EMISSION
SYSTEMS.
Fuel Injectors
See FUEL CONTROL under FUEL SYSTEM.
Fuel Pressure Control Solenoid Valve (Turbo Only)
See FUEL DELIVERY under FUEL SYSTEM.
Fuel Pressure Regulator
See FUEL DELIVERY under FUEL SYSTEM.
Fuel Pump Relay (MPI Control Relay)