wiring MITSUBISHI MONTERO 1998 Service Manual
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 1998, Model line: MONTERO, Model: MITSUBISHI MONTERO 1998Pages: 1501, PDF Size: 25.81 MB
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HEATER HOSES
HIGH PRESSURE RELIEF VALVES (HPRV)
IDLERS
IN-LINE FILTERS
METAL FITTINGS
METAL LINES
MIX AND AIR CONTROL DOORS (BLEND DOORS)
O-RINGS
ORIFICE TUBES
PILOT-OPERATED ABSOLUTES (POAS)
PLENUMS
PRESSURE CONTROL VALVES
PRESSURE SENSORS
PULLEYS
RADIATORS
RECEIVER-DRIERS
REFRIGERANT
REFRIGERANT OIL
RELAYS
SEALS
SERVICE PORTS
SPRING LOCK COUPLINGS
SUCTION THROTTLING VALVES (STVS)
SWITCHES (ELECTRICAL)
TENSIONERS
THERMISTORS AND PRESSURE SENSORS
THERMOSTATS AND HOUSINGS
VACUUM HOSES AND TUBES
VACUUM RESERVOIRS
VACUUM TUBES
VALVES IN RECEIVER (VIRS)
WATER PUMPS (ELECTRIC AUXILIARY)
WIRING HARNESSES AND CONNECTORS
MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt
(1) a Pledge of Assurance to their Customers and (2) the Motorist
Assurance Program Standards of Service. All participating service
providers have agreed to subscribe to this Pledge and to adhere to the
promulgated Standards of Service demonstrating to their customers that
they are serious about customer satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection communication standards
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required.
Fitting type incorrect
(such as compression
fitting) ............... B ............ Require replacement.
Flange leaking .......... A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Restricted internally ... A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
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CONNECTORS
See WIRING HARNESSES AND CONNECTORS .
CONTROL CABLES
CONTROL CABLE INSPECTION \
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Binding ................. A .. Require repair or replacement.
Bracket bent, affecting
performance ............ A .. Require repair or replacement.
Bracket bent, not
affecting performance .. .. ........ No service suggested or
required.
Bracket broken, affecting
performance ............ A ............ Require replacement.
Bracket broken, not
affecting performance .. .. ........ No service suggested or
required.
Bracket corroded,
affecting performance .. A .. Require repair or replacement.
Bracket corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Bracket cracked, affecting
performance ............ A .. Require repair or replacement.
Bracket cracked, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket holes elongated,
affecting performance .. A .. Require repair or replacement.
Bracket holes elongated,
not affecting
performance ............ .. ........ No service suggested or
required.
Bracket loose, affecting
performance ............ A .. Require repair or replacement.
Bracket loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket missing ......... C ............ Require replacement.
Broken .................. A .. Require repair or replacement.
Cracked ................. 2 .. Suggest repair or replacement.
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Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted,
affecting performance .. A ........... (1) Require repair or
replacement.
Connector melted, not
affecting performance .. 2 ........... ( 1) Suggest repair or
replacement.
Connector missing ....... C ............ Require replacement.
Inoperative ............. A ........ ( 2) Require replacement.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 ............ Suggest replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Vibration ............... 1 .. Suggest replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Inoperative includes intermittent operation or out of
OEM specification.
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WIRING HARNESSES AND CONNECTORS
WIRING HARNESS AND CONNECTOR INSPECTION \
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Condition Code Procedure
Application incorrect ... B .. Require repair or replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Circuit open ............ A .. Require repair or replacement.
Circuit resistance
(voltage drop) out of
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settings.
2) Set blower/fan on high speed. Close doors and windows.
Insert thermometer in center vent. Operate system for 20 minutes to
allow system to stabilize. Measure temperature.
3) Discharge air temperature must be 37-44
F (3-7C) at
center vent, with high side and low side pressures within
specification. See A/C SYSTEM SPECIFICATIONS table at beginning of
article.
A/C CONTROL UNIT (ACCU)
1) Locate A/C Control Unit (ACCU) on top of evaporator case
and disconnect 10-pin connector. Inspect connector and wiring for
damage. Turn ignition and A/C on. Set temperature control to maximum
cooling and blower switch to high. Using a DVOM set to appropriate
test function, inspect harness side of connector. See Fig. 3. Go to
next step. If all test readings are as specified, replace ACCU.
2) Terminal No. 1 (Green/Yellow wire) is ACCU output. With
A/C and blower motor on, battery voltage should be present when ACCU
has received signals from pressure and temperature sensors confirming
A/C operation is okay.
3) Terminal No. 3 (Green/Blue wire) is ACCU power supply whe\
n
A/C switch is in A/C mode. With ignition and blower on, and A/C switch
at second level setting, battery voltage should be present.
4) Terminal No. 5 (Green/Red wire) is ACCU power supply when\
A/C switch is in ECONO mode. With ignition and blower on, and A/C
switch at first level setting, battery voltage should be present.
Terminals No. 2 and 7 (Black wire) are ACCU grounds. There should be
zero volts at all times.
5) Turn ignition off. Reconnect 10-pin connector. Turn
ignition on. Turn A/C on. Set temperature control to maximum cooling
and blower switch to high. Backprobe 10-pin connector. Go to next
step. If all test readings are as specified, replace ACCU.
6) Terminal No. 10 (Blue/White wire) is air thermosensor
power supply. With ignition, blower and A/C on, approximately 5.5
volts should be present.
7) Terminal No. 8 (Blue/Yellow wire) is air thermosensor
signal. When temperature of evaporator outlet portion is 77
F (25C),
there should be approximately 3.6 volts present.
8) Terminal No. 4 (White/Blue wire) is air inlet sensor powe\
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supply. With ignition, blower and A/C on, approximately 5.5 volts
should be present.
9) Terminal No. 9 (Yellow/Green wire) is air inlet sensor
signal. When temperature of evaporator outlet portion is 77
F (25C),
there should be approximately 1.5 volts present.
Fig. 1: Testing ACCU
Courtesy of Mitsubishi Motor Sales of America.
A/C SWITCH
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Switch Continuity Between
Position Terminal No.
OFF .................................................. (1)
Low ......................................... 1 & 8; 3 & 5
Medium-Low .................................. 1 & 8; 5 & 6
Medium-High .............................. 1, 4 & 8; 2 & 5
High ..................................... 1, 4 & 8; 5 & 7
( 1) - Continuity should not exist between any terminals.
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DUAL-PRESSURE SWITCH
Disconnect dual-pressure connector, and connect a jumper wire
across harness connector terminals. Connect manifold gauge set to
system, and check operating pressures. Dual-pressure switch will allow
compressor operation when system pressure is within specification.
When high or low pressure side of dual-pressure switch is at operation
pressure (ON), condition is normal if there is continuity between the
respective terminals. If continuity is not present when switch is ON,
replace dual-pressure switch. See PRESSURE SWITCH SPECIFICATIONS
table.
PRESSURE SWITCH SPECIFICATIONS TABLE ( 1)
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Application ON Pressure OFF Pressure
psi (kg/cm) psi (kg/cm)
High Pressure ......... 455 (32) .............. 541 (38)
Low Pressure .......... 32 (2.2) .............. 28 (2.0)
( 1) - With ambient temperature at 80
F (27C). \
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COMPRESSOR CLUTCH
Disconnect wiring to compressor clutch. Connect battery
voltage directly to A/C compressor clutch wiring harness terminals. If
click is heard, clutch engagement is okay. If click is not heard,
pulley and armature are not making contact. Repair or replace as
necessary.
RELAYS
4-Terminal Relay
1) Remove relay from relay box located in engine compartment.
Using an ohmmeter, check continuity between relay terminals.
Continuity should exist between terminals No. 2 and 4, but not between
terminals No. 1 and 3. See Fig. 6.
2) Connect battery voltage to terminal No. 2, and ground
terminal No. 4. Ensure continuity now exists between terminals No. 1
and 3. If continuity is not as specified, replace relay.
Page 92 of 1501
Fig. 6: Testing 4-Terminal Relay
Courtesy of Mitsubishi Motor Sales of America.
REMOVAL & INSTALLATION
* PLEASE READ THIS FIRST *
WARNING: To avoid injury from accidental air bag deployment, read and
carefully follow all SERVICE PRECAUTIONS and DISABLING &
ACTIVATING AIR BAG SYSTEM procedures in AIR BAG RESTRAINT
SYSTEM article.
NOTE: For removal and installation procedures not covered in this
article, see HEATER SYSTEM article.
A/C CONTROL UNIT (ACCU)
Removal & Installation
Lower glove box. Remove 2 clips on top of evaporator, and
remove ACCU. Disconnect wiring harness from ACCU. To install, reverse
removal procedure. See Fig. 7.
Fig. 7: Locating A/C Control Unit (ACCU)
Courtesy of Mitsubishi Motor Sales of America.
Page 93 of 1501
A/C SWITCH
Removal & Installation
Lower glove box. Remove instrument cover. Remove lap cooler
and foot shower ducts. Remove center panel and A/C-heater control
panel. Remove bezel and knob. Disconnect A/C switch connector, and
remove A/C switch. To install, reverse removal procedure.
A/C ENGINE COOLANT TEMPERATURE SWITCH
Removal & Installation
Drain coolant below level of thermostat housing. See Fig. 8.
Remove A/C engine coolant temperature switch wiring harness connector,
and unscrew A/C engine coolant temperature switch from thermostat
housing. To install, reverse removal procedure. Tighten A/C engine
coolant temperature switch to specification. See TORQUE SPECIFICATIONS
. Add coolant and check for leaks.
Fig. 8: Locating A/C Engine Coolant Temperature Switch
Courtesy of Mitsubishi Motor Sales of America.
BLOWER MOTOR & RESISTOR
Removal & Installation
Remove right side foot shower duct. Disconnect blower and/or
resistor. Remove blower motor and/or resistor. See Fig. 9. To install,
reverse removal procedure.
Page 99 of 1501
Removal & Installation
Discharge A/C system, using approved refrigerant
recovery/recycling equipment. Disconnect refrigerant temperature
sensor wiring connector. Remove temperature sensor from compressor. To
install, reverse removal procedure. Use new "O" ring on temperature
sensor.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLE \
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Application Ft. Lbs. (N.m)
A/C Compressor Bolt/Nut .................... 17-20 (23-27)
A/C Compressor Bracket Bolt/Nut .................. 37 (50)
A/C Compressor Clutch Coil Nut ................... 12 (16)
A/C Engine Coolant Temperature Switch ............ 26 (35)
INCH Lbs. (N.m)
Blower Motor Bolts/Nuts ........................... 44 (5)
Condenser Bolts/Nuts ............................ 106 (12)
Dual-Pressure Switch ............................. 89 (10)
Evaporator Assembly Bolts/Nuts .................... 44 (5)
Heater Assembly Bolts/Nuts ........................ 44 (5)
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WIRING DIAGRAMS
Page 100 of 1501
Fig. 14: Manual A/C-Heater System Wiring Diagram
Courtesy of Mitsubishi Motor Sales of America.
Page 108 of 1501
When ignition switch is turned to ON or START position, SRS
warning light on instrument panel should come on for about 7 seconds
and then go off. This indicates SRS-ECU has determined SRS is
functioning properly. If SRS warning light flashes, stays on all the
time, or does not come on, a fault exists in SRS. See
DIAGNOSIS & TESTING.
FRONT IMPACT SENSORS
Sensors are inertia switches that verify direction and
severity of impact. If impact is great enough, switch contacts close,
completing an electrical circuit. Front impact sensors are located
under front fenders. See Fig. 1.
AIR BAG MODULE(S)
An inflator assembly in the air bag module produces nitrogen
gas to fill air bag. See Fig. 1. When a small amount of current from
SRS-ECU is applied, ignitor starts a thermal reaction, which spreads
to a pellet-filled canister that produces nitrogen gas. Gas pressure
builds and discharges from inflator through a diffuser and screen
assembly, forcing trim cover to burst along its seams until air bag is
fully inflated. When air bag is fully inflated, gas escapes through
vents on sides of air bag.
SRS AIR BAG CONTROL UNIT (ECU)
SRS-ECU (with integral safing and analog impact sensor) is
located behind front floor console assembly. See Fig. 1. If a system
fault occurs, SRS-ECU memory stores a diagnostic trouble code (DTC).
DATA LINK CONNECTOR (DLC)
DLC is located under left side of dash. See Fig. 1. DLC is
used to access SRS self-diagnostics through Mitsubishi Multi-Use
Tester II (MUT-II) (MB991502).
CLOCKSPRING
Clockspring connects driver-side air bag module to steering
column wiring, forming SRS circuit. See Fig. 1. Clockspring is a flat,
ribbon-like cable that winds and unwinds when steering wheel is
turned. Because of clockspring's constant movement, it is the most
fragile part in the system.
SYSTEM OPERATION CHECK
WARNING: After servicing, always turn ignition on from passenger-side
of vehicle in case of accidental air bag deployment.
Turn ignition switch to ON position. SRS warning light on
instrument panel should come on for about 7 seconds and then turn off.
This indicates SRS is functioning properly. If SRS warning light does
not come on, stays on, or comes on while driving, SRS is
malfunctioning and needs repair. See DIAGNOSIS & TESTING.
SERVICE PRECAUTIONS
Observe the following precautions when working with SRS:
* Disable SRS before servicing any SRS or steering column