MITSUBISHI MONTERO 1991 Service Manual

Remove lower steering column cover. Disconnect electrical
connectors. Remove screws attaching cruise control switch to steering
column. Remove switch. To install, reverse removal procedure.
STEERING COLUMN SWITCH
WARNING: DO NOT hammer steering wheel. Collapsible steering column
mechanism may be damaged.
Removal & Installation (1991)
Remove horn pad and steering wheel. Remove upper and lower
column covers. Remove column switch. To install, reverse removal
procedure.
VEHICLE SPEED SENSOR
Removal & Installation
Remove instrument cluster. See INSTRUMENT CLUSTER in this
article. Speed sensor is a part of speedometer.
INSTRUMENT CLUSTER
Removal & Installation
Disconnect negative battery cable. Remove cluster cover.
Disconnect speedometer cable. Remove instrument cluster. To install,
reverse removal procedure.
CONTROL UNIT
Removal & Installation (1991)
Cruise control unit is located behind left front kick panel.
Remove left front kick panel. Remove control unit. To install, reverse
removal procedure.
Removal & Installation (1992)
Cruise control unit is located behind center of dash panel.
Remove center trim panel and radio or radio plug bezel. Remove control
unit. To install, reverse removal procedure.
WIRING DIAGRAMS
For 1992 wiring diagram, See appropriate chassis wiring
diagram in the WIRING DIAGRAMS Section.

Fig. 32: 1991 Cruise Control System Wiring Diagram
Courtesy of Mitsubishi Motor Co.

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DEFO GGER - R EA R W IN DO W

1991 M it s u bis h i M onte ro
1991 ACCESSORIES & SAFETY EQUIPMENT
Chrysler Corp./Eagle/Mitsubishi Defoggers - Rear Window
Dodge; Colt, Colt Vista, Colt 200, Stealth
Eagle; Summit
Mitsubishi: Eclipse, Galant, Mirage, Montero, 3000GT
Plymouth; Colt, Colt Vista, Colt 200
DESCRIPTION & OPERATION
The rear window defogger is a heating wire grid bonded to the
inside of the window. Heat is regulated by a control switch located on
the instrument panel.
TROUBLE SHOOTING
DEFOGGER DOES NOT WORK
Check for blown fuse, poor contact, defective defogger
switch, poor connection or open wire.
INDICATOR LIGHT DOES NOT WORK
Check for burned out bulb, open wire or poor connection.
TESTING
NOTE: Testing information for all components on all vehicles is
not available from manufacturer.
DEFOGGER SWITCH TEST
NOTE: Remove window defogger switch and disconnect switch
connector for the following test.
Colt, Colt 200, Mirage & Summit
Turn defogger switch to OFF position. Check switch continuity
using ohmmeter. Continuity should be present between terminals No. 3
and 6. See Fig. 1. Turn defogger switch to ON position. Continuity
should be present between terminals No. 1 and 5, 2 and 4, and 3 and 6.
Colt Vista
Turn defogger switch to OFF position. Check switch continuity
using ohmmeter. Continuity should be present between terminals No. 3
and 6, and terminals No. 4 and 1. See Fig. 1. Turn defogger switch to
ON position. Continuity should exist between terminals No. 5 and 2, 3
and 6, and 4 and 1.
Eclipse
Turn defogger switch to OFF position. Check switch continuity
using ohmmeter. Continuity should be present between terminals No. 1
and 5, and terminals No. 2 and 6. Turn defogger switch to ON position.
Continuity should be present between terminals No. 3 and 4, 1 and 5,
and 2 and 6. See Fig. 1.
Galant
Turn defogger switch to OFF position. Check switch continuity

using ohmmeter. Continuity should be present between terminals No. 1
and 4, and terminals No. 5 and 6. Turn defogger switch to ON position.
Continuity should exist between terminals No. 3 and 2, 5 and 6, and 1
and 4. See Fig. 1.
Montero
Turn defogger switch to OFF position. Check switch continuity
using ohmmeter. Continuity should be present between terminals No. 5
and 6, and terminals No. 1 and 2. Turn defogger switch to ON position.
Continuity should exist between terminals No. 3 and 4, 5 and 6, and 1
and 2. See Fig. 1.
Stealth & 3000GT
Remove defogger switch assembly from instrument cluster
bezel. With defogger switch in OFF position, check switch continuity
using ohmmeter. Continuity should exist between terminals No. 3 and 4.
With defogger switch in ON position, continuity should exist between
terminals No. 1 and 2, 1 and 6, and 3 and 4. See Fig. 1.
Fig. 1: Identifying Defogger Switch Terminals
Courtesy of Chrysler Motors.
DEFOGGER RELAY TEST

Colt, Colt 200, Mirage & Summit
Remove defogger relay located to the right of fuse block.
Ground relay terminal No. 4, and apply battery voltage to terminal No.
2. Check relay continuity using ohmmeter. Continuity should exist
between terminals No. 1 and 3. With voltage disconnected, continuity
should not be present between terminals No. 1 and 3. Ensure continuity
is present between terminals No. 2 and 4. See Fig. 2.
Colt Vista, Eclipse, Stealth & 3000GT
Remove defogger relay located on left center of firewall.
Ground relay terminal No. 4, and apply battery voltage to relay
terminal No. 3. Check relay continuity using ohmmeter. Ensure
continuity exists between terminals No. 1 and 2. With voltage
disconnected, continuity should not exist between terminals No. 1 and
2. Continuity should exist between terminals No. 3 and 4. See Fig. 2.
Galant
Remove defogger relay located in right front corner of engine
compartment. Ground relay terminal No. 1, and apply battery voltage to
terminal No. 3. Check relay continuity using ohmmeter. Continuity
should exist between terminals No. 4 and 5. See Fig. 2. With voltage
disconnected, continuity should not exist between terminals No. 4 and
5. Ensure continuity exists between terminals No. 1 and 3. See Fig. 2.
Fig. 2: Identifying Defogger Relay Terminals
Courtesy of Chrysler Motors.
DEFOGGER TIMER TEST

Colt, Colt 200, Mirage & Summit
Remove defogger timer from junction block under left side of
instrument panel. Connect a battery and test light to defogger timer
terminals. See Fig. 3. Apply battery voltage to terminal No. 7 for 5-7
seconds. Ensure test light illuminates for approximately 10 seconds.
Reapply battery voltage to terminal No. 7. Test light should go off
when voltage is applied again.
Colt Vista
With ignition switch in ON position, apply battery voltage to
terminal No. 2 of defogger timer. Timer should operate for
approximately 11 seconds then stop. See Fig. 3.
Eclipse & Galant
Remove defogger timer from interior relay block. Connect
battery voltage and test light to timer. See Fig. 3. Ensure test light
illuminates for approximately 11 seconds when battery voltage is
applied to terminal No. 4. Reapply battery voltage to terminal No. 4
and observe test light. Test light should go off.
Fig. 3: Identifying Defogger Timer Terminals
Courtesy of Chrysler Motors.
GRID TEST
1) Start engine and operate at 2000 RPM. Ensure battery is
fully charged. Turn defogger switch to ON position. Using a voltmeter,
check voltage at center section of each grid wire. If voltage is
approximately 6 volts, grid wire is okay. If voltage is approximately
12 volts, an open is present in the negative circuit. Move probe
slowly toward the negative terminal to determine location of open
circuit.
2) If voltage is zero volt, an open is present in the
positive circuit. Move probe slowly toward the positive terminal to

determine location of open circuit.
WIRING DIAGRAMS
See appropriate chassis wiring diagram in the WIRING DIAGRAMS
Section.

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DRIV E A XLE - F R O NT

1991 M it s u bis h i M onte ro
1990-92 DRIVE AXLES
Differentials & Axle Shafts - Front
Montero, Pickup 4WD
DESCRIPTION
Front axle assembly consists of differential carrier, housing
tube, inner shaft and drive axles. A full-floating axle design is
used. Drive axles are flexible assemblies made up of inner and outer
CV joints. Birfield Joints (BJ) and Double Offset Joints (DOJ) are
used at opposite ends of each drive axle.
AXLE RATIO & IDENTIFICATION
Ratio is determined by dividing number of ring gear teeth by
number of drive pinion teeth.
AXLE RATIO SPECIFICATIONS









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Application Ratio
Montero ............................ 4.63:1
Pickup ............................. 4.22:1









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NOTE: References to BJ refer to Birfield Joint and DOJ to Double
Offset Joint.
TESTING
TOTAL ASSEMBLY BACKLASH
Place transfer case in "4H" position. Raise and support
vehicle. Check total backlash at flange. If backlash at flange exceeds
.55" (14.0 mm), check assembly for wear and proper adjustment.
DRIVE AXLES R & I
REMOVAL
1) Remove undercover on Montero. Place hub in free-wheeling
position. Place transfer case in 2H position. Remove drive hub cover,
snap ring and shim from drive axle. Remove brake calipers and wire out
of way.
2) Using dial indicator, check drive axle end play. Rotate
drive axle forward and rearward until maximum end play is obtained.
End play must be adjusted during reassembly if not within .008-.020"
(.20-.50 mm). Disconnect tie rod assembly. Support lower control arm
with jack.
3) Separate ball joints from knuckle. Remove knuckle and
front hub assembly. Remove left drive axle from differential carrier.
Use care not to damage oil seal. On right drive axle, remove drive
axle-to-inner shaft retaining bolts. Remove right drive axle.
CAUTION: Support lower control arm during drive axle removal and
installation.

CAUTION: Always replace circlips on BJ splines of left drive axle
and splines of inner shaft.
INSTALLATION
1) Install right drive axle on inner shaft. Install new
circlip on BJ side of left drive axle. Drive left drive axle into
differential. Use care not to damage oil seal.
2) Reinstall knuckle with front hub assembly. If drive axle
end play requires adjustment, select proper shim to obtain proper end
play. Shim is located behind snap ring on end of drive axle. Install
shim and recheck axle end play. Install remaining components in
reverse of removal procedure.
DIFFERENTIAL CARRIER R & I
REMOVAL
1) Raise and support vehicle. Drain gear oil. Support
differential carrier. Remove drive axles and inner shaft. See DRIVE
AXLES R & I and INNER SHAFT & BEARING R & I in this article. Place
alignment mark on drive shaft and pinion flange for reassembly
reference.
2) Remove drive shaft. Remove differential mounting brackets
at differential and frame. See Fig. 1. Disconnect front crossmember
from frame. Remove differential carrier assembly and front
crossmember. Remove differential carrier from front crossmember.
INSTALLATION
To install, reverse removal procedure. Align marks on drive
shaft and pinion flange.

Fig. 1: Front Drive Axle & Suspension
Courtesy of Chrysler Motors.
INNER SHAFT & BEARING R & I
REMOVAL
1) Remove right drive axle. See DRIVE AXLES R & I in this
article. Remove inner shaft from differential carrier. Pry dust seal
from housing tube assembly using a screwdriver if replacement is
required. See Fig. 1.
2) If oil seal replacement is required, remove housing tube.
Using slide hammer, remove oil seals. Bend outer area of dust cover
inward on inner shaft. Press bearing from shaft. Remove dust cover
from shaft.
INSPECTION
Inspect inner shaft for damaged splines or threads. Inspect
bearing for roughness or damage. Measure shaft O.D. Replace shaft if
not within specification. See INNER SHAFT SPECIFICATIONS table.