alternator MITSUBISHI MONTERO 1991 User Guide
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 1991, Model line: MONTERO, Model: MITSUBISHI MONTERO 1991Pages: 1333, PDF Size: 24.61 MB
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* E LE C TR IC AL S YSTE M U NIF O RM IN SPEC TIO N G UID ELIN ES *
1 991 M it s u bis h i M onte ro
GENERAL INFORMATION
Electrical System Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
ACTUATOR MOTORS (SOLENOIDS) (ELECTRIC)
ACTUATOR MOTORS (VACUUM)
AIR BAGS
ALTERNATORS AND GENERATORS
AMPLIFIERS
ANTENNAS
BATTERIES
BATTERY CABLES
BATTERY CABLES
BATTERY HOLD DOWN HARDWARE
BATTERY TRAYS AND HOLD DOWN HARDWARE
BATTERY WIRES
BELTS
BULB SOCKETS
BULBS, SEALED BEAMS AND LEDS
CD PLAYERS
CIGARETTE LIGHTER ASSEMBLIES
CIRCUIT BREAKERS
CLUTCH SWITCHES
CONNECTORS
CONTROL MODULES
CRUISE CONTROL BRAKE SWITCHES
CRUISE CONTROL CABLES
CRUISE CONTROL CLUTCH SWITCHES
CRUISE CONTROL LINKAGES AND CABLES
CRUISE CONTROL RESERVOIRS
CRUISE CONTROL TUBES
CRUISE CONTROL VACUUM DUMP RELEASE VALVES
CRUISE CONTROL VACUUM HOSES, TUBES AND RESERVOIRS
CRUISE CONTROL VEHICLE SPEED SENSORS
DEFOGGERS
DEFROSTERS
DELAYS
DIMMERS
ELECTRIC HEATERS
EQUALIZERS
FUSE BLOCKS
FUSE BOXES AND BLOCKS
FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS
FUSIBLE LINKS
GAUGES
GENERATORS
GROUND CABLES AND STRAPS
GROUND STRAPS
HEADLIGHT ADJUSTERS
HEATING ELEMENTS (DEFROSTERS, DEFOGGERS, ELECTRIC HEATERS AND SEATS)
HORNS AND SIRENS
Page 359 of 1333
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... (1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Inoperative ............. A ........ ( 2) Require replacement.
Leaking (vacuum) ........ A .. Require repair or replacement.
Linkage bent,
affecting performance .. A ... Require repair or replacement
of linkage.
Linkage bent, not
affecting performance .. 2 ... Suggest repair or replacement
of linkage.
Linkage binding,
affecting performance .. A ... Require repair or replacement
of linkage.
Linkage binding, not
affecting performance .. 1 .. Suggest repair or replacement
of linkage.
Linkage broken .......... A ... Require repair or replacement
of linkage.
Linkage loose, affecting
performance ............ A ... Require repair or replacement
of linkage.
Linkage loose, not
affecting performance .. 1 ... Suggest repair or replacement
of linkage.
Linkage missing ......... C ............ Require replacement.
Linkage noisy ........... 2 .. Suggest repair or replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .. Suggest repair or replacement.
Out of adjustment ....... A .. Require repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Inoperative includes intermittent operation or out of
OEM specification.
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AIR BAGS
For all air bag components and conditions, refer to vehicle
manufacturer's specifications for diagnosis and parts replacement.
ALTERNATORS AND GENERATORS
NOTE: If components have been added that increase vehicle
electrical load requirement (for example, sound systems,
air conditioning, alarm systems, etc.), charging system
output must meet the increased demand.
ALTERNATOR AND GENERATOR INSPECTION
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Condition Code Procedure
Alternator output meets
OEM specification but is
insufficient for add-on
Page 360 of 1333
electrical load ........ 2 ... Suggest upgrade of alternator
or removal of excess electrical
load.
Alternator's rated output
is below OEM
specification .......... B ............ Require replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware non-
functioning ............ A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... (1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Diode inoperative ....... A ........... ( 2) Require repair or
replacement.
Housing broken, affecting
performance ............ A .. Require repair or replacement.
Housing broken, not
affecting performance .. .. ........ No service suggested or
required.
Housing cracked, affecting
performance ............ A .. Require repair or replacement.
Housing cracked, not
affecting performance .. 1 .. Suggest repair or replacement.
Inoperative ............. A ........... ( 2) Require repair or
replacement.
Noisy ................... 2 .. Suggest repair or replacement.
Pulley incorrect ........ B ............ Require replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Terminal resistance
(voltage drop) out of
specification .......... A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Voltage drop out of
specification .......... A .. Require repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Inoperative includes intermittent operation or out of OEM
specification.
Page 378 of 1333
![MITSUBISHI MONTERO 1991 User Guide GENERATORS
See ALTERNATORS AND GENERATORS .
GROUND CABLES AND STRAPS
GROUND CABLE AND STRAP INSPECTION \
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See ALTERNATORS AND GENERATORS .
GROUND CABLES AND STRAPS
GROUND CABLE AND STRAP INSPECTION \
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GENERATORS
See ALTERNATORS AND GENERATORS .
GROUND CABLES AND STRAPS
GROUND CABLE AND STRAP INSPECTION \
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Corroded, affecting
performance ............ A .. Require repair or replacement.
Corroded, not affecting
performance ............ 2 .. Suggest repair or replacement.
Insulation damaged,
exposing conductors .... 2 ............ Suggest replacement.
Loose ................... A ................. Require repair.
Missing ................. C ............ Require replacement.
Open .................... A .. Require repair or replacement.
Resistance high ......... A .. Require repair or replacement.
Terminal resistance
(voltage drop) is out of
specification .......... B .. Require repair or replacement.
Voltage drop out of
specification .......... B .. Require repair or replacement.
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GROUND STRAPS
See GROUND CABLES AND STRAPS .
HEADLIGHT ADJUSTERS
HEADLIGHT ADJUSTER INSPECTION \
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Bent, preventing
adjustment ............. A .. Require repair or replacement.
Broken .................. A .. Require repair or replacement.
Indicator broken ........ A ............ Require replacement.
Indicator missing ....... C ............ Require replacement.
Missing ................. C .......... Require replacement of
Page 619 of 1333
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
Page 692 of 1333
Courtesy of Mitsubishi Motor Sales of America.
2) Disconnect air intake hose and vacuum hoses. Remove air
hose and air outlet housing. Remove heat protectors. Disconnect
exhaust pipe. Remove power steering oil pump and bracket. Remove
engine hanger bracket. Disconnect oil inlet pipe.
3) Disconnect coolant hose and tubes. Remove nuts and bolts
securing exhaust manifold. Remove exhaust manifold and gaskets.
Disconnect oil return pipe. Remove turbocharger assembly.
Removal (Stealth & 3000GT Front)
1) Disconnect negative battery cable. Drain engine oil and
coolant. Remove radiator. Disconnect exhaust pipe. Remove air intake
hose, air hoses and air pipe. Remove alternator and belt. Remove oil
dipstick guide.
2) Remove heat protector. Disconnect oxygen sensor electrical
connector. Remove oil return pipe. Remove turbocharger support bracket
and remove turbocharger from exhaust manifold. See Fig. 10.
Fig. 10: Removing Front Turbocharger (Stealth & 3000GT)
Courtesy of Mitsubishi Motor Sales of America.
Removal (Stealth & 3000GT Rear)
1) Disconnect battery cables and remove battery. Drain engine
oil and coolant. Remove accelerator cable. Remove air hose, air pipe
and heat protectors. Disconnect clutch booster vacuum hose. Remove air
Page 698 of 1333
touching a metal ground point on the vehicle prior to
servicing any ESD sensitive component.
ENGINE OIL
CAUTION: Never use non-detergent or straight mineral oil.
FUEL SYSTEM SERVICE
WARNING: Relieve fuel system pressure prior to servicing any fuel
system component (fuel injection models).
HALOGEN BULBS
Halogen bulbs contain pressurized gas which may explode if
overheated. DO NOT touch glass portion of bulb with bare hands. Eye
protection should be worn when handling or working around halogen
bulbs.
POWER STEERING FLUID
When adding power steering fluid, avoid spilling. Damage to
alternator, located beneath power steering reservoir, could result.
RADIATOR CAP
CAUTION: Always disconnect the fan motor when working near the
radiator fan. The fan is temperature controlled and could
start at any time even when the ignition key is in the OFF
position. DO NOT loosen or remove radiator cap when cooling
system is hot.
RADIATOR FAN
WARNING: Keep hands away from radiator fan. Fan is controlled by a
thermostatic switch which may come on or run for up to 15
minutes even after engine is turned off.
SERVICE POINT LOCATIONS
Fig. 1: Service Point Locations (1987-91 2.6L 4-Cylinder Engine)
Courtesy of Mitsubishi Motor Sales of America.
Page 707 of 1333
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Service Or Inspect
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Valve Clearance (Jet Valve Only)
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Manual Transmission Oil & Transfer Case
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Carburetor Choke Mechanism & Linkage (If Equipped)
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Disc Brake Pads
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Drum Brake Linings & Rear Wheel Cylinders
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Brake Hoses
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Fuel & Vapor Hoses
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Steering Linkage Seals & Drive Shaft Boots
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Lubricate Ball Joint
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Power Steering Fluid (If Equipped)
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Exhaust System
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Drive Belt (Water Pump & Alternator)
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Engine Coolant
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Lubrication Specifications
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Application Specification
Brake & Clutch Fluid ............................ DOT 3 Or DOT 4
Engine Coolant .............. Ethylene-Glycol Antifreeze Coolant
Engine Oil (
1)
Minimum Temperature
Greater Than 32
F (0
C) ...... SAE 20W-40 Or 20W-50 API SG/CD
Greater Than -10
F (-23
C) ..... SAE 10W-30, 10W-40 API SG/CD
Maximum Temperature
Page 712 of 1333
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concern.
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Fluid Capacities
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Application Quantity
Engine Oil
1987 ......................................... 5.2 Qts. (5.0L)
1988 ......................................... 5.0 Qts. (4.8L)
1989-92 ...................................... 5.5 Qts. (5.3L)
1993-94 ...................................... 5.2 Qts. (4.9L)
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60,000 MILE (96,000 KM) SERVICE
60,000 MILE (96,000 KM) SERVICE \
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Valve Clearance (Jet Valve Only)
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Distributor Cap, Rotor & Spark Advanced System
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Intake Temperature Control System
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Rear Drum Brake Linings & Wheel & Cylinders
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Exhaust System
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Vacuum, Water, Crankcase Ventilation & Secondary Air Hoses
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Air Filter
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Greater Than 32
F (0
C) ...... SAE 20W-40 Or 20W-50 API SG/CD
Greater Than -10
F (-23
C) ..... SAE 10W-30, 10W-40 API SG/CD
Maximum Temperature
Less Than 60
F (16
C) .......... SAE 5W-30 Or 5W-40 API SG/CD
(
1) - Since temperature ranges for different oil grades overlap,
brief fluctuations in outside temperatures are no cause for
concern.
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Fluid Capacities
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Application Quantity
Engine Oil
1987 ......................................... 5.2 Qts. (5.0L)
1988 ......................................... 5.0 Qts. (4.8L)
1989-92 ...................................... 5.5 Qts. (5.3L)
1993-95 ...................................... 5.2 Qts. (4.9L)
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90,000 MILE (144,000 KM) SERVICE
90,000 MILE (144,000 KM) SERVICE \
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Manual Transmission Oil & Transfer Case
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Disc Brake Pads
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Drum Brake Linings & Rear Wheel Cylinders
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Brake Hoses
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Fuel & Vapor Hoses
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Exhaust System
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Drive Belt (Water Pump & Alternator)
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