instrument cluster MITSUBISHI MONTERO 1991 Service Manual

CRUISE CONTROL SWITCH FUNCTION TEST
NOTE: If vehicle speed decreases approximately 9 MPH below set
speed, set speed will be cancelled.
1) Cruise control switch is part of multifunction switch
mounted on steering column. To operate cruise control system, turn
ignition on. Turn cruise control switch to ON position. Ensure switch
indicator light comes on.
NOTE: Speed will not set beyond system limit of 90 MPH.
2) With cruise control switch in ON position, drive vehicle
between 25 and 90 MPH. Press and release SET button. Vehicle speed
should stay at set speed. Instrument cluster cruise indicator light
should come on. To increase set speed, turn control switch to RESUME
position and hold until new set speed is reached.
3) To lower set speed, press SET button and hold until new
set speed is reached. To return to set speed after cancellation, move
resume switch from ON to OFF position. Vehicle speed should return to
previous setting before cancellation. Set speed should cancel when any
of the following occurs:
* Brake pedal is pressed.
* Clutch pedal is pressed.
* Transmission is shifted to Neutral or Park.
* Cruise control main switch is turned off.
* Ignition switch is turned off.
SELF-DIAGNOSTICS
1) Self-diagnostics should be performed when cruise control
cancels without the driver using normal cancel modes. Diagnosis
connector is located on right side of fuse box. Use analog voltmeter
or Multi-Use Tester (MB991341) for code retrieval.
2) Use multi-use tester according to operating instructions
provided with tester. Connect leads of analog voltmeter between cruise
control terminal and ground terminal of self-diagnostic connector. See
Fig. 6 . Read voltmeter needle sweeps to determine trouble code.
NOTE: On 1991 models, codes No. 13, 14, 15, 16 and 17 will be
displayed whether malfunction is present or not.
3) Once trouble codes have been displayed, see SELF-
DIAGNOSTIC CODE CHART to determine appropriate CIRCUIT TEST. See
Fig. 7 or 8.
4) To clear trouble codes, either disconnect battery cable or
turn ignition on. Turn main cruise control switch and set switch to ON
position. Within one second turn resume switch to ON position.
5) Hold stoplight switch and cruise control switch in ON
position for more than 5 seconds. Verify codes are cleared.
Fig. 6: Identifying Self-Diagnostic Connector Terminals
Courtesy of Mitsubishi Motor Co.

test correctly, replace switch as necessary or repair harness.
Test No. 9 (Overdrive Switch Circuit)
When overdrive switch is pushed to ON position, battery
voltage should be present on terminals No. 13 and 14 of cruise control
unit. If circuit does not test correctly, replace switch as necessary
or repair harness.
Fig. 17: 1991 Cruise Control Unit Connector
Courtesy of Mitsubishi Motor Co.
Fig. 18: 1991 Instrument Cluster Connector
Courtesy of Mitsubishi Motor Co.

Fig. 26: 1992 Instrument Cluster Connector
Courtesy of Mitsubishi Motor Co.
Fig. 27: 1992 Overdrive Switch Connector
Courtesy of Mitsubishi Motor Co.
Fig. 28: 1992 Inhibitor Switch Connector
Courtesy of Mitsubishi Motor Co.

ACTUATOR TESTS
Resistance Test (1991)
Disconnect actuator connector. Resistance between terminals
No. 1 and 2 should be 20 ohms. See Figs. 17-21. If resistance is not
correct, replace actuator assembly.
Operational Test (1991)
1) With connector disconnected, connect battery voltage to
terminal No. 1. See Figs. 17-21. Ground terminal No. 2. Connect
ammeter between positive side of battery and terminal No. 1 of
actuator connector.
2) Solenoid should make a click sound. Ammeter should read .
5-.7 amps. Connect positive side of battery to terminal No. 4 and
ground terminal No. 3. Actuator should pull in and stop.
3) While actuator is moving in, ammeter should read less than
.5 amps. When actuator travel reaches midpoint, disconnect terminal
No. 1 from positive side of battery. Actuator should return to
original position. If actuator does not test correctly, replace
actuator.
4) Reverse connections of terminals No. 4 and 3 in step 2).
Connect battery voltage to terminal No. 3 and ground terminal No. 4.
Actuator should move out then stop. While actuator is moving, ammeter
should read less than .5 amps.
1992
Remove actuator. Apply vacuum to actuator. Actuator linkage
holder should move more than 1.38" (35 mm). Actuator diaphragm should
hold vacuum. Replace actuator if actuator does not test correctly.
VEHICLE SPEED SENSOR TEST
1) Remove instrument cluster. See INSTRUMENT CLUSTER under
REMOVAL & INSTALLATION. Check continuity between vehicle speed sensor
terminals at instrument cluster. See Fig. 30 or 31.
2) Ensure continuity pulses on and off 4 times per revolution
of speedometer shaft connection. If continuity is not as specified,
replace vehicle speed sensor.
Fig. 30: 1991 Checking Speed Sensor Circuit
Courtesy of Mitsubishi Motor Co.

Remove lower steering column cover. Disconnect electrical
connectors. Remove screws attaching cruise control switch to steering
column. Remove switch. To install, reverse removal procedure.
STEERING COLUMN SWITCH
WARNING: DO NOT hammer steering wheel. Collapsible steering column
mechanism may be damaged.
Removal & Installation (1991)
Remove horn pad and steering wheel. Remove upper and lower
column covers. Remove column switch. To install, reverse removal
procedure.
VEHICLE SPEED SENSOR
Removal & Installation
Remove instrument cluster. See INSTRUMENT CLUSTER in this
article. Speed sensor is a part of speedometer.
INSTRUMENT CLUSTER
Removal & Installation
Disconnect negative battery cable. Remove cluster cover.
Disconnect speedometer cable. Remove instrument cluster. To install,
reverse removal procedure.
CONTROL UNIT
Removal & Installation (1991)
Cruise control unit is located behind left front kick panel.
Remove left front kick panel. Remove control unit. To install, reverse
removal procedure.
Removal & Installation (1992)
Cruise control unit is located behind center of dash panel.
Remove center trim panel and radio or radio plug bezel. Remove control
unit. To install, reverse removal procedure.
WIRING DIAGRAMS
For 1992 wiring diagram, See appropriate chassis wiring
diagram in the WIRING DIAGRAMS Section.

using ohmmeter. Continuity should be present between terminals No. 1
and 4, and terminals No. 5 and 6. Turn defogger switch to ON position.
Continuity should exist between terminals No. 3 and 2, 5 and 6, and 1
and 4. See Fig. 1.
Montero
Turn defogger switch to OFF position. Check switch continuity
using ohmmeter. Continuity should be present between terminals No. 5
and 6, and terminals No. 1 and 2. Turn defogger switch to ON position.
Continuity should exist between terminals No. 3 and 4, 5 and 6, and 1
and 2. See Fig. 1.
Stealth & 3000GT
Remove defogger switch assembly from instrument cluster
bezel. With defogger switch in OFF position, check switch continuity
using ohmmeter. Continuity should exist between terminals No. 3 and 4.
With defogger switch in ON position, continuity should exist between
terminals No. 1 and 2, 1 and 6, and 3 and 4. See Fig. 1.
Fig. 1: Identifying Defogger Switch Terminals
Courtesy of Chrysler Motors.
DEFOGGER RELAY TEST

With lever set at OUTSIDE position, outside air is allowed to enter
and/or pass through heater. With lever set at INSIDE position, air is
recirculated inside passenger compartment.
BLOWER SWITCH
The blower can be operated at different fan speeds to
regulate amount of air forced through vehicle. Fan speed will increase
as switch is turned or moved right.
AIR CONTROL INDICATION SYSTEM
This system consists of indication lights built into
instrument cluster and 4 switches connected to various control levers.
An indication light glows when heater blower is on. Lights also
indicate choice of outlets and whether air source is inside or outside
vehicle. In addition, temperature of air directed from outlets is
indicated for each air outlet by light colors of green (cool air) and
orange (warm air).
ADJUSTMENTS
HEATER (TEMPERATURE) CONTROL VALVE
Place control lever to indicated position. See TEMPERATURE
CONTROL CABLE ADJUSTMENT table. See Fig. 3. Connect cable to heater
control valve and/or air damper lever according to table. Secure cable
sleeve using clips. With engine running, check for coolant leaks and
check operation of heater control valve. If heater control valve does
not operate properly, adjust by moving cable sleeve forward or
backward at retaining clip.
TEMPERATURE CONTROL CABLE ADJUSTMENT TABLE









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Application Control Lever Water Valve
Position Lever Position
Montero .................... Far Left ............... Toward cable
Pickup & Ram-50 ............ Far Left ........ (2) Away from cable
(2) - Disconnect link between air damper lever and water valve
lever. Close water valve. Close air damper. Reconnect link.
Attach cable to clip.









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Fig. 3: Adjusting Temperature Control Cable (Typical)
Courtesy of Mitsubishi Motor Sales of America.
INSIDE/OUTSIDE AIR SELECTION CABLE

Removal (Montero)
1) Move temperature control lever to WARM position. Drain
coolant from vehicle. Disconnect heater hoses from heater unit. See
Fig. 1.
2) Remove lap heater ducts. Remove hood release bracket.
Using screwdriver, release tabs and remove left and right demister
grilles. Remove glove box frame attaching screws, and remove glove
box. Remove passenger lap heater duct.
3) Using screwdriver and shop towel, carefully pry at top
center of instrument cluster cover, and remove cover. Remove 2 screws
at bottom of instrument panel and one bolt at top of instrument panel.
Gently pull instrument cluster out, and disconnect speedometer cable
and electrical connections. Remove instrument cluster.
4) Remove 4 screws, and disconnect electrical connections on
back of instrument cluster. Remove instrument cluster. Handle
instrument cluster carefully. Instrument cluster can be damaged if
dropped.
5) Remove center console knobs and side screw plugs. Remove
screws, disconnect electrical connections and remove console. Remove 6
bolts and console bracket (center dash reinforcement). Disconnect
radio connections while removing console bracket.
6) Remove horn pad and steering wheel retaining nut. Mark
steering wheel and steering shaft for reassembly reference. Using
steering wheel puller, remove steering wheel.
7) Using screwdriver, carefully pry out dash plug at upper
center of dash panel. Remove 3 upper dash mounting nuts, one upper
screw above steering column, and 2 lower mounting screws. Remove dash
panel.
8) Remove control cables at heater unit. Remove heater unit
attaching screws. Remove heater ducts. Remove heater unit. Remove
heater control lever arm.
9) Remove heater control valve cover. Remove heater pipe and
heater control valve. Disconnect control arm linkage. Remove control
arm. Remove heater core by moving it sideways.
Installation
1) To install, reverse removal procedure. Insert heater hoses
fully into pipes, and clamp securely to prevent leaks. Connect heater
hoses with 1-1.2" (25-30 mm) overlap on outlet.
2) When filling radiator with coolant, first open heater
control valve fully and run engine to circulate coolant and discharge
air from inside heater and engine cooling system. Stop engine, and add
coolant.
3) Adjust all control cables. When installing heater hose
grommets, apply sealer. After installing heater control assembly,
ensure each lever operates smoothly.
Removal (Pickup & Ram-50)
1) Disconnect battery ground cable. Place heater control
lever to far right. Drain coolant. Using trim stick, pry out hazard
switch and remove electrical connection. Remove 4 instrument cluster
cover screws, and remove cover. Remove 4 instrument cluster screws.
Tilt instrument cluster out, and disconnect speedometer cable and
electrical connections. Remove cluster.
2) Remove fuse box cover and fuse box assembly. Remove glove
box. Remove defroster air ducts. Disconnect heater control cables.
Using trim stick, pry under and remove speaker grilles. Remove clock
or coin box in center of dash. Remove center dash hole cover (located
above clock).
3) Remove 2 center support cover screws, and remove cover.
Remove shift knob and 6 console attaching screws. Remove console.
Ensure all electrical connections are free of dash panel. Remove 3 top
nuts, one bolt above steering column, and side and lower attaching

screws. Remove dash panel.
4) Remove blower duct, center duct and defroster ducts. See
Fig. 2. Disconnect heater wiring harness from heater unit. Remove
heater center support brackets. Remove heater unit. Remove heater core
cover plate and joint hose. Remove heater core from heater unit.
Installation
1) To install, reverse removal procedure. Insert heater hoses
fully into pipes, and clamp securely to prevent leaks.
2) When filling radiator with coolant, first open heater
control valve fully and run engine to circulate coolant and discharge
air from inside heater and engine cooling system. Stop engine, and add
coolant.
3) Adjust all control cables. When installing heater hose
grommets, apply sealer. After installing heater control assembly,
ensure each lever operates smoothly.
HEATER CONTROL PANEL
Removal (Montero)
1) Remove heater control knob and heater fan switch knob.
Remove center console. Remove defroster nozzle at temperature control
cable side.
2) Remove lap heater duct and glove box stopper, and push
glove box forward and down. Disconnect inside/outside control cable
from blower assembly.
3) Disconnect control cables from heater unit. Remove heater
control panel mounting screws, and pull out panel slightly. Disconnect
heater fan switch harness connectors. Remove heater control panel.
Remove heater fan switch from heater control panel.
Installation
1) Place air outlet change-over lever at closed position.
With heater side air outlet change-over damper lever in position,
connect inner cable to lever, and secure cable casing using clips.
2) Place heater control lever at OFF position. With heater
control lever in position, connect inner cable to lever, and secure
cable casing using clips.
3) Place inside/outside air change-over lever at INSIDE
position. With heater side inside/outside air change-over damper lever
in position, connect inner cable to lever, and secure cable casing
using clips.
4) Set control lever to each position to check for correct
operation. If lever does not operate correctly, adjust by moving outer
wire at clipped point. Ensure each control lever moves smoothly. If
any noise or stiff movement exists, apply multipurpose grease to all
moving parts.
NOTE: When mounting heater control panel to instrument panel,
tighten upper bolts to instrument panel so they also secure
center panel.
Removal & Installation (Pickup & Ram-50)
Remove cluster panel. Remove all control cables at heater.
Remove heater control panel. To install, reverse removal procedure.
Adjust cables as necessary.
WIRING DIAGRAMS

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