battery MITSUBISHI MONTERO 1991 Repair Manual

STARTER NO LOAD SPECIFICATIONS








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Starter Test Maximum Amps @
Application Type (1) Voltage Minimum RPM
Diamante ............ GR .......... 11 .......... 90 @ 3000
Expo/Expo LRV
1.8L ............. DD ......... 11.5 ......... 53 @ 6000
1.8L ............. GR .......... 11 .......... 90 @ 3000
2.4L ............. DD ......... 11.5 ......... 60 @ 6600
2.4L ............. GR .......... 11 .......... 90 @ 3000
Eclipse
1.8L .............. DD ......... 11.5 ......... 60 @ 6600
2.0L .............. GR .......... 11 .......... 90 @ 3000
Galant
A/T & M/T DOHC .... GR .......... 11 .......... 90 @ 3000
M/T SOHC .......... DD ......... 11.5 ......... 60 @ 6600
Mirage
1.5L
A/T ............. DD ......... 11.5 ......... 60 @ 6600
M/T ............. DD ......... 11.5 ......... 60 @ 6500
1.6L .............. GR .......... 11 .......... 90 @ 3000
Montero ............. GR .......... 11 .......... 90 @ 3000
Pickup
2.4L A/T & 3.0L ... GR .......... 11 .......... 90 @ 3000
2.4L M/T .......... DD ......... 11.5 ......... 60 @ 6600
Precis
A/T ............... DD ......... 11.5 ......... 60 @ 6600
M/T ............... DD ......... 11.5 ......... 60 @ 6500
3000GT .............. GR .......... 11 .......... 90 @ 3000
( 1) - The letters DD indicates direct drive and GR indicates gear
reduction.









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PULL-IN COIL TEST
CAUTION: Perform tests in less than 10 seconds to prevent coil
damage.
1) Disconnect field coil wire from terminal "M" at starter
solenoid. See Fig. 2. Connect jumper wire between positive battery
terminal of 12-volt battery and terminal "S" of solenoid.
2) Connect a second jumper wire from negative battery
terminal and touch terminal "M" of starter solenoid. See Fig. 2. If
solenoid plunger moves inward, solenoid is good. If not, replace
solenoid.
Fig. 2: Starter Solenoid Terminal Identification
Courtesy of Chrysler Motors.
HOLD-IN COIL TEST

CAUTION: Perform tests in less than 10 seconds to prevent coil
damage.
1) Disconnect field coil wire from terminal "M" at starter
solenoid. See Fig. 2. Connect jumper wire between positive battery
terminal of 12-volt battery and terminal "S" of starter solenoid.
2) Connect a second jumper wire from negative battery
terminal and touch starter case. If solenoid plunger is pulled-in,
hold-in coil is good. If not, replace solenoid.
RETURN TEST
CAUTION: Perform tests in less than 10 seconds to prevent coil
damage.
1) Disconnect field coil wire from terminal "M" at starter
solenoid. See Fig. 2. Connect jumper wire between positive battery
terminal of 12-volt battery and terminal "M" of starter solenoid.
2) Connect a second jumper wire from negative battery
terminal and touch starter case. Pull pinion outward and release it.
Replace solenoid if pinion remains outward.
PINION GAP CHECK
1) Disconnect field coil wire from terminal "M" at starter
solenoid. See Fig. 2. Connect jumper wire between positive battery
terminal of 12-volt battery and terminal "S" of starter solenoid.
2) Connect a second jumper wire from negative battery
terminal and touch terminal "M" of starter solenoid. See Fig. 2.
Measure clearance between pinion and stopper. See Fig. 3.
3) Clearance should be within specification. See STARTER
SPECIFICATIONS table. Adjust clearance by adding or removing gaskets
between solenoid and front housing.
Fig. 3: Measuring Pinion Gap
Courtesy of Mitsubishi Motor Sales of America.
REMOVAL & INSTALLATION

Remove negative battery cable. If necessary, raise vehicle on
hoist. Remove starter mounting bolts and starter. To install, reverse
removal procedure.
NOTE: On Raider models with A/T, it may be necessary to disconnect
transmission oil cooler line for starter removal.
OVERHAUL
Check commutator for out-of-round and proper amount of
undercut. Replace or repair armature if not within specification. See
STARTER SPECIFICATIONS table. Ensure brushes are not worn beyond wear
line (outer line closest to commutator contact surface). Check pinion
gap. See PINION GAP CHECK in this article.
DISASSEMBLY
NOTE: Procedures may vary slightly between conventional and
reduction gear starters.
1) Loosen nut securing connecting plate-to-magnetic switch
"M" terminal. Remove screws securing magnetic switch and remove switch
(solenoid) assembly. Remove through bolts and brush cover assembly.
Tap yoke assembly loose with wooden mallet. Remove yoke, armature
assembly and pinion shift lever.
2) Remove pinion stop ring from end of armature shaft by
pushing stop ring to clutch side. Remove snap ring and overrunning
clutch assembly from armature shaft.
Fig. 4: Disassembled View of Typical Mitsubishi Starter
CLEANING & INSPECTION
Clean all parts. Do not use grease dissolving solvent on

Remove horn pad and steering wheel. See Figs. 1-6. See
STEERING COLUMN TESTING/REMOVAL & INSTALLATION table for figure
directory on specific model. Remove knee protector and upper and lower
column covers (if necessary). On Eclipse, remove hood lock release
handle and air ducts. On all models, remove any necessary cable bands,
and remove steering column switch. To install, reverse removal
procedure.
Removal (Stealth & 3000GT)
1) Disconnect negative battery cable. Wait 30 seconds, and
then remove air bag module mounting nut from back side of module. To
remove clockspring connector from air bag module, force lock outward
and pry it using a flat screwdriver. Ensure no undue force is exerted
on connector when it is removed. Remove air bag module, and store it
face up. See Fig. 7.
CAUTION: Wait at least 30 seconds after disconnecting battery cable
before continuing servicing.
2) Remove steering wheel and knee protector. Remove upper and
lower column covers. Remove air ducts. Remove right and left steering
column switches.
WARNING: DO NOT hammer on steering wheel. Collapsible steering column
mechanism may be damaged.
Installation
1) To install, reverse removal procedure. Before installing
steering wheel, center clockspring by lining up NEUTRAL mark of
clockspring with mark on steering column. To complete installation,
reverse removal procedure. DO NOT reconnect negative battery cable
until air bag module is installed.
2) After installation is complete, turn ignition on from
passenger side of vehicle. Supplemental Restraint System (SRS) light
on dash should come on for approximately 7 seconds. If SRS light does
not come on, stays on or flashes, repair air bag system.

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I - S YSTE M /C O M PO NEN T T E STS

1991 M it s u bis h i M onte ro
1991 ENGINE PERFORMANCE
System & Component Testing
Chrysler Motors: Ram-50
Mitsubishi: Montero, Pickup
INTRODUCTION
Before testing separate components or systems, perform
procedures in F - BASIC TESTING article in the ENGINE PERFORMANCE
Section. Since many computer controlled and monitored components set a
trouble code if they malfunction, also perform procedures in G - TESTS
W/CODES article in the ENGINE PERFORMANCE Section.
NOTE: Testing individual components does not isolate shorts or
opens. Perform all voltage tests with a Digital
Volt-Ohmmeter (DVOM) with a minimum 10-megohm input
impedance, unless stated otherwise in test procedure. Use
ohmmeter to isolate wiring harness shorts or opens.
COMPUTERIZED ENGINE CONTROLS
CONTROL UNIT
NOTE: To identify ECU power and ground circuits, see appropriate
L - WIRING DIAGRAMS article in the ENGINE PERFORMANCE
Section.
Ground Circuits
1) ECU is located near right kick panel. Turn ignition off.
Using an ohmmeter, check for continuity between ground and ECU
terminals No. 101 and 106. Resistance should be zero ohms. If
resistance is not zero ohms, repair open circuit between ECU connector
and ground.
2) Connect voltmeter negative lead to ground. Connect
positive lead to ECU ground terminals as in step 1). With vehicle
running, voltmeter should indicate less than one volt. If voltmeter
reading is greater than one volt, check for open, corrosion or loose
connection in ground circuit.
Power Circuits
ECU is located near right kick panel. Turn ignition on. Check
for battery voltage on ECU terminals No. 102 and 107. If battery
voltage is not present, check operation of MPI control relay. See
RELAYS under MOTORS, RELAYS & SOLENOIDS.
ENGINE SENSORS & SWITCHES
BAROMETRIC PRESSURE SENSOR
Sensor is a component part of airflow sensor assembly. See G
- TESTS W/CODES article in the ENGINE PERFORMANCE Section.
COOLANT TEMPERATURE SENSOR
1) Remove coolant temperature sensor located near thermostat
housing (2-wire connector). Place end of sensor in water with terminal\

95C). Disconnect oxygen sensor connector. See Fig. 5. Connect
ohmmeter between heater terminals of oxygen sensor connector as
specified in OXYGEN SENSOR 4-WIRE CONNECTOR TERMINAL IDENTIFICATION
table. This test checks resistance of oxygen sensor heater element.
Fig. 5: O2 Sensor Connector Term. ID
Courtesy of Mitsubishi Motor Sales of America.
2) When oxygen sensor is at 68
F (20C), resistance should be
approximately 12 ohms (20 ohms on 3.0L models). If resistance is not
within specification, replace oxygen sensor.
CAUTION: DO NOT apply battery voltage to oxygen sensor output
terminals. Damage to oxygen sensor could result.
3) Apply battery voltage to oxygen sensor heater terminals as
specified in OXYGEN SENSOR 4-WIRE CONNECTOR TERMINAL IDENTIFICATION
table. This heats oxygen sensor heater element.
4) Connect digital voltmeter between output terminals
specified in OXYGEN SENSOR 4-WIRE CONNECTOR TERMINAL IDENTIFICATION
table. Repeatedly race engine and observe oxygen sensor output
voltage. If oxygen sensor output voltage is not within 0.6-1.0 volt,
replace oxygen sensor.
OXYGEN SENSOR 4-WIRE CONNECTOR TERMINAL ID TABLE









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Heater Output

MOTORS
ISC Motor
See IDLE CONTROL SYSTEM.
RELAYS
NOTE: For internal wiring diagram of MPI control relay, see
appropriate L - WIRING DIAGRAMS article in the ENGINE
PERFORMANCE Section.
MPI Control Relay (Montero, Pickup 3.0L & Ram-50 3.0L)
1) MPI control relay is located near right kick panel. Check
for battery voltage at terminal No. 10 of relay connector. See Fig. 9.
If battery voltage is present, go to step 3). If battery voltage is
not present, check circuit between relay and battery, including
fusible link No. 1.
Fig. 9: MPI Control Relay Connector Term. ID (10 Pin)
Courtesy of Mitsubishi Motor Sales of America.
2) Apply battery voltage to terminal No. 10. Battery voltage
should not be present at terminals No. 4 and 5. Apply battery voltage
to terminal No. 10, and ground terminal No. 8. Battery voltage should
now be present at terminals No. 4 and 5.
3) Apply battery voltage to terminal No. 3. Battery voltage
should not be present at terminal No. 2. Apply battery voltage to
terminal No. 3, and ground terminal No. 7. Battery voltage should now
be present at terminal No. 2.
4) Apply battery voltage to terminal No. 9. Battery voltage
should not be present at terminal No. 2. Apply battery voltage to
terminal No. 9, and ground terminal No. 6. Battery voltage should now
be present at terminal No. 2. Replace relay if it does not test as
specified.
MPI Control Relay (Pickup 2.4L & Ram-50)
1) MPI control relay is located near right kick panel. Check
for battery voltage at terminal No. 4 of relay connector. See Fig. 10.
If battery voltage is present, go to step 3). If battery voltage is

not present, check circuit between relay and battery, including
fusible link No. 1.
Fig. 10: MPI Control Relay Connector Term. ID (8 Pin)
Courtesy of Mitsubishi Motor Sales of America.
2) Disconnect wiring harness connector at relay. Remove
relay. Check continuity between terminals No. 1 and 4, terminals No. 2
and 4 and terminals No. 3 and 4. If there is no continuity, go to next

right several times. Start engine, and turn steering wheel back and
forth to raise fluid temperature to approximately 122-140F (50-60C).
3) With engine idling, gradually close shutoff valve of
pressure gauge to increase hydraulic pressure. If idle speed does not
increase 200-250 RPM when fluid pressure reaches 213-284 psi (15-20
kg/cm
), replace power steering idle-up switch.
4) Gradually open shutoff valve. If engine speed does not
return to curb idle speed between 100-142 psi (7-10 kg/cm
), replace
power steering idle-up switch. Remove testing equipment. Bleed air
from system as in step 2).
IGNITION SYSTEM
NOTE: For basic ignition checks, see F - BASIC TESTING article in
ENGINE PERFORMANCE Section.
TIMING CONTROL SYSTEMS
Crank Angle Sensor
Crank angle sensor is located inside distributor on SOHC
engines and is attached to cylinder head on DOHC engines. If
malfunction occurs, Code 22 will set. For testing procedure, see
appropriate G - TESTS W/CODES article in the ENGINE PERFORMANCE
Section.
EMISSION SYSTEMS & SUB-SYSTEMS
EXHAUST GAS RECIRCULATION (EGR)
System Testing (Federal)
1) Disconnect Green-striped hose from throttle body, and
connect vacuum pump to hose end. Plug nipple where hose was connected
to throttle body. When engine is cold, 122
F (50C) or less, and at
idle, apply vacuum to disconnected hose. If idle does not change and
vacuum bleeds down, system is okay.
2) When engine is hot, 205
F (95C), and at idle, apply 1.8
in. Hg. If idle does not change and vacuum holds, system is okay.
Using a vacuum pump, apply 7.7 in. Hg. If idle becomes unstable or
engine stalls (and vacuum holds), system is okay.
System Testing (California)
1) Connect vacuum "T" fitting into Green-striped hose from
EGR valve, and connect vacuum gauge to vacuum tee. When engine coolant
temperature is 68
F (20C) or less and engine is idling, snap throttle
open to race engine. If no change in vacuum reading is detected on
gauge, system is okay.
2) When engine coolant temperature is 158
F (70C) or more
and engine is idling, snap throttle open to race engine. If vacuum
increases to 3.9 in. Hg or higher, system is okay.
3) Using vacuum pump, apply specified vacuum to open EGR
valve. See EGR VALVE SPECIFICATIONS table. If idle becomes unstable or
engine stalls, system is okay.
EGR Control Solenoid Valve (Pickup & Ram-50, California)
1) EGR control solenoid valve is located near left shock
tower. Label and disconnect vacuum hoses and wiring harness from
solenoid valve.
2) Connect hand vacuum pump to vacuum nipple where Green-
striped vacuum hose was connected. Apply vacuum and ensure vacuum does
not hold. Apply battery voltage to one terminal of solenoid, and
ground other. Ensure vacuum holds.

valve nipple where Red-striped hose was connected. Apply vacuum to
solenoid valve. Vacuum should hold.
2) Apply battery voltage to terminals of solenoid valve.
Vacuum should bleed down when voltage is applied to terminals. Using
an ohmmeter, check resistance across solenoid valve terminals. Reading
should be 36-44 ohms at 68
F (20C). If reading is not within
specification, replace valve.
POSITIVE CRANKCASE VENTILATION (PCV)
PCV Valve
Remove PCV valve, and insert thin screwdriver into threaded
end of valve to ensure plunger moves.