MITSUBISHI MONTERO 1991 Service Manual

overrunning clutch, armature assembly, solenoid assembly or field
coils due to possible damage. Inspect all parts for damage or wear and
replace as required.
BENCH TESTS
Brushes & Springs
Check brush spring tension using a spring scale. Check brush
contact surface condition and brush length. Check lead clip and wire
connections and condition of brush holders. Replace as required. See
Brush Spring Tension and Minimum Brush Length Charts.
BRUSH & SPRING SPECIFICATIONS
BRUSH SPRING TENSION








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Application Ozs. (g)
Chrysler Corp. Imports ............ 46-59 (1302-1670)









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MINIMUM BRUSH LENGTH ( 1)








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Application In. (mm)
Chrysler Corp. Imports ................... .45 (11.5)
(1) - Minimum brush length should coincide with the
brush wear mark.









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Armature
Check external condition of armature for scoring or other
damage. Measure shaft distortion with dial indicator. Replace armature
if shaft distortion exceeds .004" (.10 mm).
Commutator
1) Inspect commutator for roughness, grooves, burns or
pitting. Sand lightly with 500 grit sandpaper if necessary. Check
commutator for out-of-round and mica insulators undercut to a depth of
.020-.031" (.5-.8 mm).
2) If necessary, commutator may be turned less than .04" (1
mm) from original size and mica undercut. Replace if excessively worn.
Field Coil
1) Check field coil continuity by connecting test probe of
circuit tester or an ohmmeter to the field coil positive terminal and
brush holder. If circuit is open, replace field coil.
2) Check for grounding of field coils by placing one probe of
circuit tester on starter housing and other probe to field coil
positive terminal. If little or no resistance, field coil is grounded
and must be replaced.
Overrunning Clutch Assembly
1) Inspect pinion assembly and sleeve. Sleeve should slide
freely on armature shaft and spline. If damage or resistance is noted,
replace assembly.
2) Check pinion and flywheel teeth for excessive rubbing or
damaged teeth. Replace as required.
Pinion Gear Clearance
The clearance between the pinion gear and pinion stopper

collar should be .02-.08" (.51-2.03 mm) on Mitsubishi starters, when
solenoid is engaged. Adjust as necessary by changing shims between
solenoid and starter yoke.
Fig. 5: Measuring Pinion Gear-to-Pinion Stopper Clearance
Pinion Case Bearing
Inspect bearing for wear and check side play. If clearance
exceeds .008" (.2 mm), replace bearing. New bearing clearance should
be .002-.004" (.05-.10 mm) for Mitsubishi starters.
NOTE: Ensure that bearing is installed so that end of bearing is
flush with gear case end.
REASSEMBLY
To reassemble, reverse disassembly procedure. Fill gear case
on reduction gear models with grease. Lightly oil pinion and all
bearing surfaces.

Fig. 6: Exploded View of Direct Drive Starter
Courtesy of Mitsubishi Motor Sales of America.

Fig. 7: Exploded View of Gear Reduction Starter
Courtesy of Chrysler Motors.
STARTER SPECIFICATIONS

STARTER SPECIFICATIONS








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Application In. (mm)
Commutator Maximum Runout (1) ............ .004 (.10)
Commutator Minimum Diameter ( 1)
Diamante ............................ 1.118 (28.40)
Eclipse & Expo/Expo LRV
1.8L ............................... 1.220 (30.99)
2.0L ............................... 1.118 (28.40)
Galant
DOHC & SOHC A/T .................... 1.118 (28.40)
SOHC M/T ........................... 1.220 (30.99)
Mirage
1.5L ............................... 1.220 (30.99)
1.6L ............................... 1.118 (28.40)
Montero ............................. 1.134 (28.80)
Pickup
2.4L A/T & 3.0L .................... 1.134 (28.80)
2.4L M/T ........................... 1.236 (31.39)
3000GT .............................. 1.118 (28.40)
Commutator Undercut Depth ( 1) ............ .020 (.51)
Pinion Gap ...................... 020-.079 (.51-2.01)
( 1) - Information not available on Precis models.









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STE ER IN G C O LU M N S W IT C HES

1991 M it s u bis h i M onte ro
1991 ACCESSORIES & SAFETY EQUIPMENT
Chrysler Motors/Eagle/Mitsubishi Steering Column Switches
Dodge; Colt, Colt Vista, Colt 200, Ram-50, Stealth
Eagle; Summit
Mitsubishi: Eclipse, Galant, Mirage, Montero, Pickup, 3000Gt
Plymouth; Colt, Colt Vista, Colt 200
TESTING
For steering column switch testing, see STEERING COLUMN
SWITCH TESTING/REMOVAL & INSTALLATION table for figure reference.
STEERING COLUMN SWITCH TESTING/REMOVAL & INSTALLATION TABLE









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Model Figure Number
Colt, Colt 200, Mirage & Summit ............... See Fig. 1
Colt Vista .................................... See Fig. 2
Eclipse ....................................... See Fig. 3
Galant ........................................ See Fig. 4
Montero ....................................... See Fig. 5
Pickup & Ram-50 ............................... See Fig. 6
Stealth & 3000GT .............................. See Fig. 7









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REMOVAL & INSTALLATION
IGNITION SWITCH
Removal (Colt, Colt 200, Eclipse, Mirage & Summit)
1) Remove steering column switch. See STEERING COLUMN SWITCH
under REMOVAL & INSTALLATION. On automatic transaxle vehicles,
disconnect key interlock cable, and remove spring and slide lever.
2) On all vehicles, insert key and turn ignition switch to
ACC position. Push steering lock cylinder lock pin inward and pull
steering lock cylinder away from dash. Remove ignition switch and key
reminder switch.
Installation
1) Place ignition switch in LOCK position. Install slide
lever to steering lock cylinder. Install spring to inner cable of key
interlock cable (if used).
2) Connect key interlock cable to slide lever and steering
lock cylinder. Lightly grease around slide lever. To complete
installation, reverse removal procedure. Ensure key interlock system
functions properly.
Removal & Installation (Colt Vista, Galant, Montero, Pickup,
Ram-50, Stealth & 3000GT)
Remove knee protector (if necessary). Remove upper and lower
column covers. Remove air ducts and cable bands as necessary. Remove
ignition switch and key reminder switch. To install, reverse removal
procedure.
STEERING COLUMN SWITCH
Removal & Installation (Except Stealth & 3000GT)

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.

Fig. 1: Switch Testing and R & I (Colt, Mirage & Summit)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 2: Switch Testing and R & I (Colt Vista)
Courtesy of Chrysler Motors.

Fig. 3: Switch Testing and R & I (Eclipse)
Courtesy of Mitsubishi Motor Sales of America.