battery MITSUBISHI MONTERO 1991 Manual Online
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 1991, Model line: MONTERO, Model: MITSUBISHI MONTERO 1991Pages: 1333, PDF Size: 24.61 MB
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TR O UBLE S H O OTIN G - B ASIC P R O CED URES
1991 M it s u bis h i M onte ro
GENERAL TROUBLE SHOOTING
* PLEASE READ THIS FIRST *
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
ACCESSORIES & ELECTRICAL
CHARGING SYSTEM TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
BASIC CHARGING SYSTEM TROUBLE SHOOTING CHART
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CONDITION POSSIBLE CAUSE CORRECTION \
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Vehicle Will Not Dead battery Check battery cells,
Start alternator belt
tension and alternator
output
Loose or corroded battery Check all charging
connections system connections
Ignition circuit or switch Check and replace as
malfunction necessary
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Alternator Light Loose or worn alternator Check alternator drive
Stays On With drive belt tension and
Engine Running condition, See Belt
Adjustment in TUNE-UP
article in the
TUNE-UP section
Loose alternator wiring Check all charging
connections system connections
Short in alternator light See Indicator Warning
wiring Lights in STANDARD
INSTRUMENTS in the
ACCESSORIES &
EQUIPMENT section
Defective alternator stator See Bench Tests in
or diodes ALTERNATOR article
Defective regulator See Regulator Check in
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![MITSUBISHI MONTERO 1991 Manual Online ALTERNATOR article \
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ALTERNATOR article \
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Alternator Blown fuse See WIRING DIAGRAMS
Light Stays Off
With Ignition
Switch ON
Defective alternator See Testing in
ALTERNATOR article
Defective indicator light See Indicator Warning
bulb or socket Lights in STANDARD
INSTRUMENTS in the
ACCESSORIES &
EQUIPMENT section
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Alternator Short in alternator wiring See On-Vehicle Tests
Light Stays OFF in ALTERNATOR article
With Ignition
Switch ON
Defective rectifier bridge See Bench Tests in
ALTERNATOR article
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Lights or Fuses Defective alternator wiring See On-Vehicle Tests
Burn Out in ALTERNATOR article
Frequently
Defective regulator See Regulator Check in
ALTERNATOR article
Defective battery Check and replace as
necessary
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Ammeter Gauge Loose or worn drive belt Check alternator drive
Shows Discharge belt tension and
condition. See Belt
Adjustment in TUNE-UP
article in the
TUNE-UP section
Defective wiring Check all wires and
wire connections
Defective alternator or See Bench Tests and
regulator On-Vehicle Tests in
ALTERNATOR article
Defective ammeter, or See Testing in
improper ammeter wiring STANDARD INSTRUMENTS
connection in the ACCESSORIES &
EQUIPMENT section
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Noisy Loose drive pulley Tighten drive pulley
Alternator attaching nut
Loose mounting bolts Tighten all alternator
mounting bolts
Worn or dirty bearings See Bearing
Replacement
ALTERNATOR article
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![MITSUBISHI MONTERO 1991 Manual Online Defective diodes or stator See Bench Test in
ALTERNATOR article
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ALTERNATOR article
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Defective diodes or stator See Bench Test in
ALTERNATOR article
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Battery Does Loose or worn drive belt Check alternator drive
Stay Charged belt tension and
condition. See
Belt Adjustment in
appropriate TUNE-UP
article in the
TUNE-UP section
Loose or corroded battery Check all charging
connections system connections
Loose alternator connections Check all charging
system connections
Defective alternator or See On-Vehicle Tests
battery and Bench Tests in
ALTERNATOR article
Add-on electrical accessories Install larger
exceeding alternator capacity alternator
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Battery Defective battery Check alternator
Overcharged- output and repair as
Uses Too Much necessary
Water
Defective alternator See On-Vehicle Test and
Bench Tests in
ALTERNATOR article
Excessive alternator voltage Check alternator output
and repair as necessary
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IGNITION SYSTEM TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
Ignition Secondary Trouble Shooting Chart
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START: Visually inspect Spark Plug Wires, Coil Wires,
Plug Wire Boots, Rotor, and Distributor Cap for
signs of damage.
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OK NOT OK
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* To test secondary ignition * Repair or replace
system, modify a Spark Plug damaged components
by attaching a ground wire as necessary
to the body of the plug and
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widening the gap to 1/4-3/8".
Disconnect spark plug wire
and insert test plug. Ground
plug, crank engine, and
check for spark.
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GOOD SPARK NO SPARK
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* If plug sparks, driveability * Remove coil wire from the
problem is most likely NOT distributor and attach the
in the ignition system. modified spark plug. Ground
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the plug and crank engine
while checking for spark.
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GOOD SPARK NO SPARK
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* If plug has a good spark, * Proceed to the IGNITION
the problem is in the plug PRIMARY TROUBLE SHOOTING
wires, distributor cap, or CHECK CHART below in this
rotor. Replace components article.
as necessary.
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Ignition Primary Trouble Shooting Chart
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START: Visually inspect primary ignition wires for
broken, frayed, split, or cut wires. Also check
for loose, corroded, or disconnected connectors.
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OK NOT OK
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* Check that battery voltage * Repair or replace damaged
is at least 11.5 volts. components as necessary.
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NOT OK OK
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* Replace or recharge the * Check for battery voltage
battery. at the positive terminal of
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the coil.
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OK NOT OK
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* Check air Gap of the Pick-Up * Check resistance of ballast
coil in the distributor. resistor (if used) for the
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correct resistance value.
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* Check Pick-Up coil for * Adjust or replace as
correct resistance value. necessary.
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NOT OK OK
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* Replace Pick-Up coil if * Check control module for
not to specification. good ground connections.
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OK
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* If vehicle fails to run at this point, go to
the appropriate article in the ENGINE
PERFORMANCE section.
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OK NOT OK
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* Check wires from the battery/ * Replace ballast resistor
ignition switch to the coil. if the measured resistance
Also check the coil primary value is not within
and secondary resistance. specification.
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STARTER TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
BASIC STARTER TROUBLE SHOOTING CHART
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CONDITION POSSIBLE CAUSE CORRECTION \
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Starter Fails Dead battery or bad Check battery charge
to Operate connections between and all wires and
starter and battery connections to starter
Ignition switch faulty Adjust or replace
or misadjusted ignition switch
Open circuit between Check and repair wires
starter switch ignition and connections as
terminal on starter relay necessary
Starter relay or starter See Testing in STARTER
defective article
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![MITSUBISHI MONTERO 1991 Manual Online Open solenoid pull-in See Testing in STARTER
wire article
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Open solenoid pull-in See Testing in STARTER
wire article
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Starter Does Not Weak battery or dead Charge or replace
Operate and cell battery as necessary
Headlights Dim
Loose or corroded battery Check that battery
connections connections are clean
and tight
Internal ground in See Testing in STARTER
starter windings article
Grounded starter fields See Testing in STARTERS
Armature rubbing on pole See STARTER article
shoes
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Starter Turns Starter clutch slipping See STARTER article
but Engine
Does Not Rotate
Broken clutch housing See STARTER article
Pinion shaft rusted or See STARTER article
dry
Engine basic timing See Ignition Timing in
incorrect TUNE-UP article
Broken teeth on engine Replace flywheel and
flywheel check for starter pinion
gear damage
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Starter Will Not Faulty overrunning See STARTER article
Crank Engine clutch
Broken clutch housing See STARTER article
Broken flywheel teeth Replace flywheel and
check for starter pinion
gear damage
Armature shaft sheared See STARTER article
or reduction gear teeth
stripped
Weak battery Charge or replace
battery as necessary
Faulty solenoid See On-Vehicle Tests in
STARTER article
Poor grounds Check all ground
connections for
tight and clean
connections
Ignition switch faulty Adjust or replace
or misadjusted ignition switch as
necessary
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Starter Cranks Battery weak or Charge or replace
Engine Slowly defective battery as necessary
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Engine overheated See ENGINE COOLING
SYSTEM article
Engine oil too heavy Check that proper
viscosity oil
is used
Poor battery-to-starter Check that all
connections between
battery and starter are
clean and tight
Current draw too low or See Bench Tests in
too high STARTER article
Bent armature, loose pole See STARTER article
shoes screws or worn
bearings
Burned solenoid contacts Replace solenoid
Faulty starter Replace starter
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Starter Engages Engine timing too far See Ignition Timing in
Engine Only advanced TUNE-UP article
Momentarily
Overrunning clutch not Replace overrunning
engaging properly clutch. See STARTER
article
Broken starter clutch See STARTER article
Broken teeth on engine Replace flywheel and
flywheel check starter pinion
gear for damage
Weak drive assembly See STARTER article
thrust spring
Weak hold-in coil See Bench Tests in
STARTER article
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Starter Drive Defective point assembly See Testing in STARTER
Will Not Engage article
Poor point assembly ground See Testing in STARTER
article
Defective pull-in coil Replace starter
solenoid
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Starter Relay Dead battery Charge or replace
Does Not Close battery as necessary
Faulty wiring Check all wiring and
connections leading to
relay
Neutral safety switch Replace neutral safety
faulty switch
Starter relay faulty Replace starter relay
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![MITSUBISHI MONTERO 1991 Manual Online \
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Starter Drive Starter motor loose on")
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Starter Drive Starter motor loose on Tighten starter
Will Not mountings attach bolts
Disengage
Worn drive end bushing See STARTER article
Damaged engine flywheel Replace flywheel and
teeth starter pinion gear for
damage
Drive yolk return spring Replace return spring
broken or missing
Faulty ignition switch Replace ignition switch
Insufficient clearance Replace starter
between winding leads to solenoid
solenoid terminal and main
contact in solenoid
Starter clutch not Replace starter clutch
disengaging
Ignition starter switch Replace ignition switch
contacts sticking
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Starter Relay Faulty solenoid switch, Check all wiring
Operates but switch connections or between relay and
Solenoid Does Not solenoid or replace
relay or solenoid as
necessary
Broken lead or loose Repair wire or wire
soldered connections connections as
necessary
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Solenoid Plunger Weak battery Charge or replace
Vibrates When battery as necessary
Switch is Engaged
Solenoid contacts Clean contacts or
corroded replace solenoid
Faulty wiring Check all wiring
leading to solenoid
Broken connections inside Repair connections or
switch cover replace solenoid
Open hold-in wire Replace solenoid
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Low Current Draw Worn brushes or weak Replace brushes or
brush springs as
necessary
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High Pitched Whine Distance too great Align starter or check
During Cranking between starter that correct starter
Before Engine pinion and flywheel and flywheel are being
Fires but Engine used
Fires and Cranks
Normally
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High Pitched Distance too small between
Whine After Engine starter pinion and flywheel
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CONDITION POSSIBLE CAUSE CORRECTION \
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Hesitation With Vacuum leak Inspect vacuum lines
Small Amount of
Gas Pedal Movement
Accelerator pump weak or Replace pump, see
inoperable FUEL SYSTEMS
Float level setting too low Reset float level,
see,FUEL SYSTEMS
Metering rods sticking or Inspect and/or
binding replace rods, see
FUEL SYSTEMS
Carburetor idle or transfer Inspect system and
system plugged remove restriction
Frozen or binding heated air Inspect heated air
inlet door for binding
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Hesitation With Defective accelerator pump Replace pump, see
Heavy Gas Pedal FUEL SYSTEMS
Movement
Metering rod carrier Remove restriction
sticking or binding
Large vacuum leak Inspect vacuum
system and repair
leak
Float level setting too Reset float level,
low see FUEL SYSTEMS
Defective fuel pump, lines Inspect pump, lines
or filter and filter
Air door setting incorrect Adjust air door
setting, see FUEL
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DIESEL ENGINE TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
NOTE: Diesel engines mechanical diagnosis is the same as gasoline
engines for items such as noisy valves, bearings, pistons,
etc. The following trouble shooting covers only items
pertaining to diesel engines.
BASIC DIESEL ENGINE TROUBLE SHOOTING CHART
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Engine Won't Bad battery connections Check connections
Crank or dead batteries and/or replace
Page 1212 of 1333
batteries
Bad starter connections Check connections
or bad starter and/or replace
batteries
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Engine Cranks Bad battery connections Check connections
Slowly, Won't or dead batteries and/or replace
Start batteries
Engine oil too heavy Replace engine oil
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Engine Cranks Glow plugs not functioning Check glow plug system,
Normally, But see FUEL SYSTEMS
Will Not Start Glow plug control not Check controller, see
functioning FUEL SYSTEMS
Fuel not injected into Check fuel injectors,
cylinders see FUEL SYSTEMS
No fuel to injection pump Check fuel delivery
system
Fuel filter blocked Replace fuel filter
Fuel tank filter blocked Replace fuel tank
filter
Fuel pump not operating Check pump operation
and/or replace pump
Fuel return system blocked Inspect system and
remove restriction
No voltage to fuel solenoid Check solenoid and
connections
Incorrect or contaminated Replace fuel
fuel
Incorrect injection pump Re-adjust pump timing,
timing see FUEL SYSTEMS
Low compression Check valves, pistons,
rings, see ENGINES
Injection pump malfunction Inspect and/or replace
injection pump
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Engine Starts, Incorrect slow idle Reset idle adjustment,
Won't Idle adjustment see TUNE-UP
Fast idle solenoid Check solenoid and
malfunctioning connections
Fuel return system blocked Check system and remove
restrictions
Glow plugs go off too soon See glow plug diagnosis
in FUEL SYSTEMS
Injection pump timing Reset pump timing, see
incorrect FUEL SYSTEMS
No fuel to injection pump Check fuel delivery
system
Incorrect or contaminated Replace fuel
fuel
Low compression Check valves, piston,
rings, see ENGINES
Injection pump malfunction Replace injection pump,
see FUEL SYSTEMS
Fuel solenoid closes in RUN Check solenoid and
position connections
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Engines Starts/ Incorrect slow idle Reset slow idle, see
Idles Rough W/out adjustment TUNE-UP
Smoke or Noise Injection line fuel leaks Check lines and
connections
Fuel return system blocked Check lines and
connections