ignition MITSUBISHI MONTERO 1991 Workshop Manual
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 1991, Model line: MONTERO, Model: MITSUBISHI MONTERO 1991Pages: 1333, PDF Size: 24.61 MB
Page 537 of 1333
Connector missing ....... A ................. Require repair.
Contaminated ............ A ........... (3) Require repair or
replacement.
Leaking ................. A .. Require repair or replacement.
Malfunctioning .......... A ........... ( 4) Require repair or
replacement.
Missing ................. C ............ Require replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 2) 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.
Threads damaged ......... A .. Require repair or replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
( 1) - Refer to manufacturer's diagnostic trouble code
procedure and require repair or replacement of affected
component(s).
( 2) - Determine cause and correct prior to repair or
replacement of part.
( 3) - Determine source of contamination, such as engine
coolant, fuel, metal particles, or water. Require
repair or replacement.
( 4) - Includes inoperative, intermittent operation, or failure to
perform all functions.
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IGNITION SWITCHES
See SWITCHES.
IGNITION TERMINALS
See
IGNITION WIRES, BOOTS, COIL TOWERS AND TERMINALS (SECONDARY) .
IGNITION WIRES, BOOTS, COIL TOWERS AND TERMINALS (SECONDARY)
NOTE: You are not required to replace ignition wires in sets.
However, you may suggest replacement of the entire
secondary wire set for preventive maintenance.
IGNITION WIRE, BOOT, COIL TOWER AND TERMINAL (SECONDARY) INSPECTION
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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Page 538 of 1333
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Carbon-tracked .......... A ............ Require replacement.
Corroded ................ 1 .. Suggest repair or replacement.
Insulation leaking
(shorted) .............. A .. Require repair or replacement.
Metal heat shield bent .. 2 .. Suggest repair or replacement.
Missing ................. C ............ Require replacement.
Oil-soaked (spongy) ..... 1 ............ Suggest replacement.
Resistance incorrect .... B ............ Require replacement.
Routed incorrectly ...... 2 ............. (1) Suggest repair.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 2) 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.
( 1) - If improper routing affects the performance of other
systems, require repair. Proper routing, hardware,
heatshields, etc., are intended to prevent premature
failure of secondary ignition components.
( 2) - Determine cause and correct prior to repair or
replacement of part.
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IN-TANK FUEL STRAINERS
IN-TANK FUEL STRAINER INSPECTION \
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Condition Code Procedure
Missing ................. C ............ Require replacement.
Restricted .............. A .. Require repair or replacement.
Torn .................... A ............ Require replacement.
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INERTIA FUEL SHUT-OFF SWITCHES
INERTIA FUEL SHUT-OFF SWITCH 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
Page 578 of 1333
\003
A - E N G IN E/V IN ID
1991 M it s u bis h i M onte ro
1991 ENGINE PERFORMANCE
Chrysler Motors/Mitsubishi Introduction
MODEL COVERAGE
MODEL COVERAGE TABLE (MITSUBISHI) \
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Body Engine Fuel Ignition
Model Code (
1) Engine ( 2) ID ( 3)System System ( 4)
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\b\
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1.8L SOHC (
5) T PFI Optical
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\b\b\
\b\
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Eclipse S,T 2.0L DOHC (
6) R PFI DIS
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\b\b\
\b\
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2.0L DOHC Turbo (
6) U PFI DIS
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\b\
\b\
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\b\
\b\b\
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2.0L SOHC (
6) V PFI Optical
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\b\b\
\b\
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Galant R,X 2.0L DOHC (
6) R PFI DIS
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\b\
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2.0L DOHC Turbo (
6) U PFI DIS
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\b\
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\b\b\
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1.5L SOHC (
7) A PFI Optical
Mirage U
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\b\
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1.6L DOHC (
8) Y PFI DIS
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Montero J 3.0L V6 SOHC (
9) S PFI Optical
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2.4L SOHC (
10) W PFI Optical
Pickup L,M
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\b\
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3.0L V6 SOHC (
9) S PFI Optical
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Precis A,F,D 1.5L SOHC (
11) J PFI Optical
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\b\
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3.0L V6 DOHC (
9) B PFI DIS
3000GT D,E
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3.0L V6 DOHC C PFI DIS
Turbo (
9)
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(
1) - Body Code is 5th digit of VIN. VIN is located on upper left
corner of instrument panel.
(
2) - See ENGINE CODE LOCATION.
(
3) - Engine ID is 8th digit of VIN.
(
4) - Ignition timing is computer controlled. On all models with
Distributorless Ignition System (DIS), crank angle sensor is
mounted where distributor is normally mounted.
(
5) - 4G37 engine.
(
6) - 4G63 engine.
(
7) - 4G15 engine.
(
8) - 4G61 engine.
(
9) - 6G72 engine.
(
10 ) - 4G64 engine.
(
11 ) - G4AJK engine.
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VIN DEFINITION
Numbers preceding the explanations in the legend below refer
to the sequence of characters as listed on VIN identification label.
Page 596 of 1333
1 - 20 Amp (Yellow)
Hazard Light, Dome Light, Clock
2 - 10 Amp (Red)
Taillights
3 - 10 Amp (Red)
Turn Signal Lights
4 - 10 Amp (Red)
Back-Up Lights, Gauges
5 - 15 Amp (Light Blue)
Defogger
6 - 20 Amp (Yellow)
Heater
7 - 15 Amp (Light Blue)
Stoplights
8 - 15 Amp (Light Blue)
Horn, Wiper, Washer
9 - 10 Amp (Red)
Rear Wiper, Rear Washer
10 - 15 Amp (Light Blue)
Cigarette Lighter, Radio
CAUTIONS & WARNINGS
RADIATOR FAN & CAP
DO NOT loosen or remove radiator cap when cooling system is
hot. The system is under high pressure, and hot steam or boiling
liquid could gush out if cap is loosened or removed while system is
hot.
BRAKE FLUID
Be careful when handling brake fluid as it is harmful to eyes
and may damage painted surfaces.
REPLACING BLOWN FUSE
Before replacing a blown fuse, remove ignition key, turn off
all lights and accessories to avoid damaging the electrical system. Be
sure to use fuse with the correct indicated amperage rating. The use
of an incorrect amperage rating fuse may result in a dangerous
electrical system overload.
Page 608 of 1333
Fig. 6: Blower Motor Switch Connector Terminal ID (Montero)
Courtesy of Mitsubishi Motor Sales of America.
BLOWER MOTOR TEST
1) Turn ignition on. Check fuses. If fuses are bad, check
wiring harness for short circuits. If fuses are okay, check voltage
between heater relay and ground circuit. If voltage does not exist at
heater relay, check for broken wire between fuse block and heater
relay.
2) If voltage exists at heater relay, check relay, and
replace if necessary. See BLOWER MOTOR RELAY TEST under TESTING. If
relay is okay, disconnect blower motor connector. Set heater switch to
either LO, MED or HI setting.
3) Check voltage between harness side of connector and
vehicle ground. Battery voltage should be present. If battery voltage
is present, go to next step. If battery voltage is not present, check
continuity between resistor terminals. See BLOWER MOTOR RESISTOR TEST
under TESTING. If continuity is not present, replace resistor.
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 621 of 1333
Starters
Generator .................................. Generators & Regulators
Engine Performance
Power Distribution
Generic Electronic Module (GEM) ............... Body Control Modules\
Electronic Suspension
Glow Plug Relay ................................. Engine Performance
Glow Plugs ...................................... Engine Performance
Grounds ........................................ Ground Distribution
Headlight Door Module .............................. Headlight Doors
Headlight Relay .................................. Headlight Systems
Daytime Running Lights
Headlights ....................................... Headlight Systems
Daytime Running Lights
Heated Oxygen Sensor(s) (HO2S) .................. Engine Performan\
ce
Heated Windshield Control Module ................ Heated Windshields
Height Sensor ................................ Electronic Suspension
Horns ..................................... Steering Column Switches
Horn Relay ................................ Steering Column Switches
Idle Air Control (IAC) Motor/Valve .............. Engine Performance\
Ignition Coil(s) ................................ Engine Performance\
Ignition Key Lock Cylinder ....................... Anti-Theft System
Ignition Module ................................. Engine Performance
Ignition Switch ................................. Power Distribution
Engine Performance
Generators & Regulators
Starters
Illuminated Entry Module .............. Illumination/Interior Lights
Illumination Lights ................... Illumination/Interior Lights
Impact Sensor ............................. Air Bag Restraint System
Inertia Fuel Shutoff Switch ..................... Engine Performance
Inhibit Relay ............................................. Starters
Instrument Cluster ........................ Analog Instrument Panels
Intake Air Temperature (IAT) Sensor ............. Engine Performance\
Interior Lights ....................... Illumination/Interior Lights
Interlock Switch .......................................... Starters
Junction Block .................................. Power Distribution
Keyless Entry Receiver ........................ Remote Keyless Entry
Key Reminder Switch ....................................... Starters
Knock Sensor .................................... Engine Performance
Lamp Control Module ................................ Exterior Lights
License Plate Lamp ................................. Exterior Lights
Lighting Control Module ................... Lighting Control Modules
Anti-Theft System
Daytime Running Lights
Headlight Systems
Lower Relay .................................. Power Convertible Top
Malfunction Indicator Light (MIL) ............... Engine Performance\
Instrument Panels
Manifold Absolute Pressure (MAP) Sensor ......... Engine Performance\
Mass Airflow (MAF) Sensor ....................... Engine Performance\
Mega Fuse .................................. Generators & Regulators
Memory Seat/Mirror Module ........................... Memory Systems
Mirror Defogger ............................... Rear Window Defogger
Moon Roof Motor .................................... Power Moon Roof
Moon Roof Relay .................................... Power Moon Roof
Multi-Function Control Module ...................... Warning Systems
Neutral Safety Switch ..................................... Starters
Oil Level Switch ................................ Engine Performance
Oil Pressure Switch/Sending Unit .......... Analog Instrument Panels
Engine Performance
Overhead Console .................................. Overhead Console
Oxygen Sensor(s) (O2S) .......................... Engine Performan\
ce
Page 625 of 1333
FUEL GAUGE
Simple Test
Disconnect fuel sending unit connector wire in luggage
compartment, cargo space, or at tank unit. Connect a 12-volt, 3.4-watt
bulb to harness side of connector, between power terminal and ground
(Yellow and Black wires on Montero). On Pickup and Ram-50 see Fig. 1.
Turn ignition switch to ON position. Ensure test bulb flashes, or
stays on, and fuel gauge needle moves. If bulb or gauge needle does
not function as described, check and repair fuel gauge circuit.
CAUTION: Gauge coils can be damaged if wire is grounded too long.
Perform test as quickly as possible.
Fig. 1: Identifying Fuel Gauge Test Connection (Pickup & Ram-50)
Courtesy of Chrysler Motors.
NOTE: The following test must be completed with instrument panel
cluster removed. Use ohmmeter for all measurements. If
resistance is extremely low, there may be a short in the
coil. If resistance is extremely high, there may be a broken
wire or similar problem in the gauge.
Resistance Test
Remove instrument cluster. See INSTRUMENT CLUSTER under
REMOVAL & INSTALLATION. Measure resistance between appropriate
terminals of instrument cluster or combination gauges. See Fig. 2 or
Page 627 of 1333
OIL PRESSURE GAUGE
Circuit Test
Disconnect oil pressure gauge wiring connector from sending
unit inside the engine compartment. Connect a 12-volt test light
between harness connector terminal and ground. Turn ignition on, but
DO NOT start engine. If test light comes on and gauge needle moves, go
to GAUGE RESISTANCE TEST. If test light does not come on and gauge
needle does not move, repair wiring to sending unit.
Gauge Resistance Test
Remove instrument cluster from instrument panel. See
INSTRUMENT CLUSTER under REMOVAL & INSTALLATION. Check continuity
between oil pressure gauge terminals. See Fig. 4 or Fig. 5. See
OIL PRESSURE GAUGE RESISTANCE SPECIFICATIONS table. If resistance is
not within specification, replace oil pressure gauge.
OIL PRESSURE GAUGE RESISTANCE SPECIFICATIONS TABLE
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Application Ohms
Montero ...................................... 50
Pickup & Ram-50 ........................... 37-47
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Fig. 4: Oil Pressure Gauge Test Terminal ID (Pickup & Ram-50)
Courtesy of Chrysler Motors
Page 629 of 1333
Calibration Test
Adjust tire pressure to standard value. Using a calibrated,
reliable speedometer tester, compare reading of vehicle speedometer to
speedometer tester. See SPEEDOMETER ALLOWABLE VARIATION table. Replace
speedometer if necessary.
SPEEDOMETER ALLOWABLE VARIATION TABLE
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MPH (km/h) Allowable Variation MPH (km/h)
20 (32) .......................... 19-22 (31-35)
40 (64) .......................... 38-44 (61-71)
60 (97) ......................... 57-66 (92-106)
80 (129) ....................... 76-88 (122-142)
100 (161) ..................... 94-110 (151-177)
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TACHOMETER
NOTE: DO NOT reverse polarity when installing tachometer, as diode
and transistor may be damaged.
Calibration Test
Connect a calibrated, reliable tach-dwell meter to vehicle
ignition system. Operate engine at various speeds (RPM). See
TACHOMETER ALLOWABLE VARIATION table. If comparison between tach-dwell
meter and vehicle tachometer readings do not fall in the standard
range of permissible variation, replace vehicle tachometer.
TACHOMETER ALLOWABLE VARIATION TABLE
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Engine Speed (RPM) Allowable Variation (RPM)
1000 .................................. 900-1100
3000 ................................. 2850-3150
5000 ................................. 4750-5250
6000 ................................. 5700-6300
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TEMPERATURE GAUGE
CAUTION: DO NOT connect sender wire directly to ground during test.
Circuit Test
Disconnect temperature sender wire from sending unit. Connect
a 12-volt, 3.4-watt test bulb between connector terminal and ground.
Turn ignition switch to ON position. If test bulb flashes and
temperature gauge needle moves, go to SENSOR RESISTANCE TEST. If test
light does not flash and gauge needle does not move, repair wiring to
sending unit.
Sensor Resistance Test
Remove thermosensor (sending unit) from engine block. Place
sending unit in hot water of 158
F (70C) temperature. Check sensor
resistance with an ohmmeter. Thermosensor resistance should be 90-117
ohms at 158
F (70C). If thermosensor resistance in okay, go to GAUGE
RESISTANCE TEST. Replace thermosensor if resistance is not as
specified.
Gauge Resistance Test
Remove instrument cluster from instrument panel. See
INSTRUMENT CLUSTER under REMOVAL & INSTALLATION. Measure resistance
between temperature gauge terminals at rear of cluster or combination