battery MITSUBISHI MONTERO 1991 Manual PDF
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 1991, Model line: MONTERO, Model: MITSUBISHI MONTERO 1991Pages: 1333, PDF Size: 24.61 MB
Page 871 of 1333
remains on (light may flash) during vehicle operation, cause of
malfunction must be determined by using DIAGNOSTIC FAULT CHARTS (if
testing with voltmeter) or diagnostic CODE CHARTS (if testing with
DRB-II). If a sensor fails, ECU will use a substitute value in its
calculations to continue engine operation. In this condition, vehicle
is functional, but loss of good driveability may result.
INTERMITTENT FAILURES
Intermittent failures may cause CHECK ENGINE light to flicker
or illuminate and go out after the intermittent fault goes away.
However, the corresponding trouble code will be retained in ECU
memory. If related fault does not reoccur within a certain time frame,
related trouble code will be erased from ECU memory. Intermittent
failures may be caused by a sensor, connector or wiring related
problems. See INTERMITTENTS in H - TESTS W/O CODES article.
PRETEST INSPECTION
Before proceeding with diagnosis, the following precautions
must be followed:
* Vehicle must have a fully charged battery and functional
charging system.
* Visually inspect connectors and circuit wiring being worked
on.
* DO NOT disconnect battery or ECU. This will erase any fault
codes stored in ECU.
* DO NOT cause short circuits when performing electrical tests.
This will set additional fault codes, making diagnosis of original
problem more difficult.
* DO NOT use a test light in place of a voltmeter.
* When checking for spark, ensure coil wire is NO more than
1/4" from ground. If coil wire is more than 1/4" from ground,
damage to vehicle electronics and/or ECU may result.
* DO NOT prolong testing of fuel injectors. Engine may
hydrostatically (liquid) lock.
* When a vehicle has multiple fault codes, always repair lowest
number fault code first.
* If DRB-II is being used to diagnose system, always perform
verification test after repairs are made.
ENTERING ON-BOARD DIAGNOSTICS (USING VOLTMETER)
1) Before entering on-board diagnostics, refer to PRETEST
INSPECTION in this article. Turn ignition switch to OFF position.
Locate self-diagnostic connector. See SELF-DIAGNOSTIC TEST CONNECTOR
LOCATION table. Using an analog voltmeter, connect voltmeter positive
lead to self-diagnostic connector terminal No. 1 and negative lead to
terminal No. 12 (ground). See Fig. 6.
2) Turn ignition switch to ON position and disclosure of ECU
memory will begin. If 2 or more systems are non-functional, they are
indicated by order of increasing code number. Indication is made by
12-volt pulses of voltmeter pointer. A constant repetition of short
12-volt pulses indicates system is normal. If system is abnormal,
voltmeter will pulse between zero and 12 volts.
3) Signals will appear on voltmeter as long and short 12-volt
pulses. Long pulses represent tens; short pulses represent ones. For
example 4 long pulses and 3 short pulses indicates Code 43. See
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Figs. 1 and 2. After recording abnormal code(s), perform necessary
repair.
4) After repair, turn ignition off and disconnect negative
battery cable for 10 seconds to erase ECU memory. Reconnect power
supply and repeat self-diagnostics to confirm repair.
SELF-DIAGNOSTIC TEST CONNECTOR LOCATION TABLE
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Application Location
Colt, Colt 200, Colt Wagon & Summit
1.5L ................................ Next to fuse block
1.6L .................................. Right kick panel
Colt Wagon & Colt Vista
1.8L & 2.0L SOHC .................... Next to fuse block
Eclipse ............................... Next to fuse block
Galant ................................... Left kick panel
Mirage ................................... Left kick panel
Montero .......................... Inside top of glove box
Precis ................................... Left kick panel
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Fig. 1: Diagnostic Fault Chart (1 of 2)
Courtesy of Mitsubishi Motor Sales of America.
Page 876 of 1333
sensor is shorted or disconnected. Watch minimum and maximum
values to help diagnose intermittent problems.
* Monitors - This screen shows technician sensors and system
controllers which affect fuel control, spark advance, RPM and
A/C relay. There are 4 different screens available. As an
example, screen No. 1 will show: airflow sensor, O2 sensor,
battery and fuel injector. All of these inputs affect fuel
control.
Actuator Tests
This mode allows technician to actuate injectors, fuel pump,
purge control, EGR solenoid, fuel pressure solenoid and wastegate.
Adjustments
This option provides a means for erasing fault code
information stored in ECU. Follow DRB-II instructions to accomplish
this task.
DRB-II ERROR SCREENS
ERROR SCREENS
SYSTEM FAULT ROM CHECK SUM XXXX Message
Cartridge or DRB-II failure.
SYSTEM FAULT KEYBOARD FAILURE Message
Restart DRB-II. Ensure DRB-II keys are not pressed during
power up. Another possibility is DRB-II failure.
SYSTEM FAULT ROM FAILURE XXXX
DRB-II failure.
SYSTEM FAULT EEPROM FAILURE
DRB-II failure.
SYSTEM FAILURE, COMMUNICATION FAILURE, REFER TO DIAGNOSTIC
PROCEDURES Message
Perform diagnostic connector test. See DRIVEABILITY TEST No.
8 (DR-8). Failure of Mitsubishi Motor Corporation (MMC) adapter is
another possibility.
SYSTEM FAILURE NO RESPONSE FROM ADAPTER or SYSTEM FAILURE
ADAPTER REQUIRED TO DIAGNOSE WITH THIS CARTRIDGE Message
Ensure you are using a correct Mitsubishi Motor Corporation
cartridge. Failure of MMC adapter is another possibility.
Fig. 3: 10-Way ECU Connector
Courtesy of Chrysler Motors.
Page 878 of 1333
44 (5) ..... Open or short in either ignition coil circuit
( 1) - Except Montero & Sigma.
( 2) - Will not turn on CHECK ENGINE light.
( 3) - 2.0L turbo only.
( 4) - California only. Except Sigma.
( 5) - Chrysler Motors models only.
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CLEARING CODES
Using DRB-II, from main menu select ADJUSTMENTS. Enter ERASE
FAULTS. Follow DRB-II instructions to accomplish this task. If DRB-II
is not available, fault codes may be cleared by disconnecting negative
battery cable for at least 10 seconds, allowing ECU to clear fault
codes.
TEST CHARTS
* PLEASE READ THIS FIRST *
NOTE: The following charts are supplied for Chrysler Motors
vehicles.
NS-1: TESTING IGNITION CIRCUIT - 1.5L
Fig. 7: Circuit Diagram NS-1 (1.5L) (1 of 2)
Fig. 8: Circuit Diagram NS-1 (1.5L) (2 of 2)
Page 1141 of 1333
voltage or resistance values using a DVOM while attempting to
reproduce conditions which may cause intermittent fault. A status
change on DVOM indicates a fault has been located.
When using a DVOM to pinpoint faults, monitor voltage reading
with ignition on, or vehicle running. Ensure ignition is in OFF
position or negative battery cable is disconnected when monitoring
circuit resistance. Change in ohmmeter reading during test procedures
indicates area of fault.
TEST PROCEDURES
Intermittent Simulation
To reproduce conditions which cause intermittent fault, use
the following methods:
* Lightly vibrate component.
* Heat component.
* Wiggle or bend wiring harness.
* Spray component with water.
* Remove/apply vacuum source.
Monitor circuit/component voltage or resistance while
simulating intermittent fault conditions. If vehicle is running,
monitor for self-diagnostic codes. Use test results to identify a
faulty component or circuit.
Page 1148 of 1333
system consists of PCV valve, oil separator, breather and ventilation
hoses.
PCV valve is a one-way check valve, located in valve cover.
When engine is running, manifold vacuum pulls PCV valve open, allowing
crankcase fumes to enter intake manifold. If engine backfires through
intake manifold, PCV valve closes to prevent crankcase combustion.
SELF-DIAGNOSTIC SYSTEM
Self-diagnostic system monitors input and output signals. On
all models, codes can be read using analog voltmeter. On some models,
scan tool can be used to read codes. For additional information, see G
- TESTS W/ CODES article.
CHECK ENGINE Light
Also called Malfunction Indicator Light by manufacturer,
comes on when ignition is turned on. Light remains on for several
seconds after engine has started. If an abnormal input signal occurs,
light comes on and code is stored in memory. If an abnormal input
signal returns to normal, ECU turns light off but code remains stored
in memory until cleared. If ignition is turned on again, light will
not come on until ECU detects malfunction during system operation.
NOTE: ECU diagnostic memory is retained by direct power supply
from the battery. Memory is not erased by turning off
ignition but is erased if battery or ECU is disconnected.
Page 1151 of 1333
TR AN SFE R C ASE
1991 M it s u bis h i M onte ro
1991-94 TRANSFER CASES
Mitsubishi
Dodge; Ram-50
Mitsubishi; Pickup, Montero
APPLICATION
TRANSFER CASE APPLICATIONS TABLE \
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Application ( 1) Transmission Model
Dodge
1991-93 Ram-50 (2.4L) .......................... V5M21-1
1991-93 Ram-50 (3.0L M/T) ...................... V5MT1-2
1991-93 Ram-50 (3.0L A/T) ...................... V4AC1-2
Mitsubishi
1991-92 Pickup ................................. V5MT1-2
1991 Montero (M/T) ............................. V5MT1-2
1991 Montero (A/T) ............................. V4AW2-2
1992 Montero (M/T) ......................... ( 2) V5MT1-3
1992 Montero (A/T) ......................... ( 2) V4AW2-3
1993-94 Montero (M/T) ...................... ( 2) V5MT1-2
1993-94 Montero (A/T) ........................ ( 2) R4AC1
( 1) - Transfer case is indicated by a -2 or -3 following the
transmission model number.
( 2) - Transfer cases for Montero are identical for automatic and
manual transmission models.
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DESCRIPTION
Transfer case is a part-time, 2-speed unit with a 3-piece
aluminum case. Transfer case has a floor-mounted shifter and integral
speedometer gear. In Montero a Viscous Coupling Unit (VCU) and center
differential allows 2WD-to-4WD shifting at speeds under 62 MPH and
full-time 4WD operation.
WARNING: When battery is disconnected, vehicles equipped with
computers may lose memory data. When battery power is
restored, driveability problems may exist on some vehicles.
These vehicles may require a relearn procedure. See the
COMPUTER RELEARN PROCEDURES article in the GENERAL
INFORMATION section.
TESTING
4WD INDICATOR CONTROL UNIT (MONTERO)
The 4WD indicator control unit is located behind radio or CD
player. Remove 4WD indicator control unit and disconnect harness.
Backprobe harness connector and measure voltage between terminal No. 8
(ground) and each respective terminal. Compare test results with
chart. See Fig. 1.
DETECTION SWITCH
Page 1154 of 1333
Fig. 2: Detection Switch Testing Locations (Montero)
Courtesy of Mitsubishi Motor Sales of America.
REMOVAL & INSTALLATION
Removal
1) Remove negative battery cable. Remove transfer case skid
plate (if equipped). Scribe alignment marks and remove both drive
shafts. Drain oil from transfer case. Disconnect wiring harness from
back-up light switch, all 4WD switches and any other electrical
connectors (if equipped).
2) Disconnect speedometer cable from drive. Unclip cable from
case. Place transfer case shifter in "2H" position and transmission in
Neutral. Remove 6 bolts holding control lever assembly. Remove control
lever assembly and gasket.
3) Remove select plunger bore plug at right side of case.
Remove select spring and plunger. Remove change shifter spring pin.
Remove change shifter. Remove transfer case mount. Remove 4 bolts and
2 nuts holding transfer case to adapter. Remove transfer case from
vehicle.
Page 1170 of 1333
\003
TR AN SM IS SIO N R EM OVA L & IN STA LLA TIO N - A /T
1991 M it s u bis h i M onte ro
1991 92 TRANSMISSION SERVICING
Transmission Removal & Installation
Mitsubishi: Eclipse, Galant, Mirage, Montero,
Pickup, Precis, 3000GT
MANUAL
NOTE: For manual transmission/transaxle replacement procedures,
see appropriate article in CLUTCHES.
AUTOMATIC FWD MODELS
REMOVAL
1) Remove battery and battery tray. On 3000GT, remove
undercover(s). On Eclipse turbo, drain and remove intercooler. On all
models, remove air cleaner and case. Raise and support vehicle. Remove
wheels. Disconnect control cables at transaxle. Drain transaxle fluid.
2) On Mirage 1.6L, disconnect tension rod. On all models,
disconnect neutral safety switch connector, oil cooler hoses and
electrical connectors from transaxle. Disconnect speedometer cable and
throttle control cable (if equipped). Remove starter motor.
3) On Galant models with electronically controlled
suspension, remove air compressor and bracket. Disconnect front height
sensor rod at lower control arm.
4) On all models, remove upper transaxle-to-engine bolts.
Remove engine undercover (if equipped). On all models, remove drive
axle shafts. See FWD AXLE SHAFTS article in DRIVE AXLES. Separate
lower control arms from struts for access to axle shafts (if
necessary).
5) Remove front exhaust pipe (if necessary). On Eclipse 4WD,\
Galant 4WD and 3000GT, remove right member and gusset. On 4WD models,
separate transfer assembly from transaxle. Reference mark transfer
assembly-to-drive shaft and remove transfer assembly.
6) On all models, remove transmission inspection (dust)
cover. Place index mark on torque converter and drive plate for
reassembly reference. Remove torque converter-to-drive plate bolts.
Push torque converter away from engine into transaxle.
7) Support transaxle with jack. Remove transaxle mounts
bolts, mounting brackets and remaining transaxle-to-engine bolts.
Slide transaxle assembly to right and lower to remove.
CAUTION: Ensure torque converter is fully seated in transaxle before
installation. Always install new snap rings on inner
constant velocity joints.
INSTALLATION
1) To install, reverse removal procedure. Tighten transaxle-
to-engine bolts and torque converter-to-drive plate bolts to
specification. See TORQUE SPECIFICATIONS table at end of article.
2) Ensure reference marks on torque converter-to-drive plate
and transfer assembly-to-drive shaft align. Tighten mounting bolts
with weight of engine and transaxle on mounts. Refill transaxle fluid
to specified level. Adjust all control cables.
RWD MODELS
Page 1171 of 1333
REMOVAL
1) Disconnect negative battery cable. Remove front exhaust
pipe. On Montero, remove transfer case shift lever knob, dust boot and
retainer plate or console. Remove transfer case gearshift assembly.
2) On all models, raise and support vehicle. Remove
undercarriage cover and/or skid plate(s). Drain transmission and
transfer case (if applicable). Place reference mark on drive shaft(s)\
and remove. Disconnect all external solenoid and switch connections.
3) Disconnect speedometer cable and control cables at
transmission. Remove starter and bellhousing cover. Place reference
mark on torque converter and drive plate for reassembly reference.
Remove torque converter bolts.
4) Disconnect transmission cooler lines. Remove oil filler
tube. Secure transmission on a jack. Raise transmission slightly to
take weight off mount. Remove crossmember-to-mount bolts and
crossmember.
5) Remove transfer case mounting bracket and mount (if
equipped). Remove transmission-to-engine mounting bolts. Carefully
lower transmission from vehicle.
CAUTION: Ensure torque converter is fully seated in transmission
before installation.
INSTALLATION
1) To install, reverse removal procedure. Tighten
transmission-to-engine bolts and torque converter-to-drive plate bolts
to specification. See TORQUE SPECIFICATIONS table at end of article.
Tighten mount bolts with weight of engine and transmission on mounts.
Ensure reference marks on drive shaft(s) and torque converter-to-drive\
plate align.
2) Apply sealant to transfer case gearshift assembly gasket
before installation. Coat transmission oil filler tube "O" ring with
transmission fluid before installation. Refill transmission fluid to
specified level. Adjust all control cables.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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Applications Ft. Lbs. (N.m)
FWD Models
Torque Converter-To-Drive Plate Bolt
Precis ....................................... 53-55 (72-76)
All Others ................................... 34-38 (46-52)
Transaxle-To-Engine Block Bolt
Mirage
8-mm Bolt ............................................ (1)
10-mm Bolt ................................. 22-25 (30-34)
12-mm Bolt ................................. 31-40 (42-54)
Eclipse & Galant
8-mm Bolt ............................................ (1)
10-mm Bolt ................................. 22-25 (30-34)
Precis
8-mm Bolt .................................. 22-25 (30-34)
10-mm Bolt ................................. 31-40 (42-54)
3000GT
Upper Coupling Bolts ............................. 54 (73)
Lower Coupling Bolts ............................. 65 (88)