1987 MITSUBISHI MONTERO Ground

Service Manual
MONTERO
1987 : Volume 2
FOREWORD
This Service Manual has been prepared with the
latest service information available at the time of
publication. It is subdivided into various group
categories and each section contains diagnosis,
disassembly, repair, and installation procedures
along with complete specifications and tightening
references. Use of this manual will aid in properly
performing any servicing necessary to maintain or
restore the high levels of performance and reliability
designed into these outstanding vehicles.
WE SUPPORT
VOLUNTARY TECHNICIAN
CERTIFICATION THROUGH
MITSUBISHI MOTOR SALES OF AMERICA. Inc.
Mitsubishi Motors corporation reserves the right to make changes in
design or to make additions to or improvements in its products without
imposing any obligations upon itself to install them on its products
previously manufactured.
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GROUP/SECTION INDEX ‘kme-.
INTRODUCTION ..............................
Electrical ...........................................
Electrical System Parts
Location .........................................
Relays, Control Units, Sensors,
Fuses, Groundings
Inspection of Harness
Connector ......................................
Wiring Harness .............................
Charging System ..........................
Starting System ............................
Ignition System .............................
Meters and Gauges ......................
Lighting System .............................
Wiper and Washer System ..........
Horn ...............................................
Accessory ......................................
Audio System ................................
Back Door Window Defogger ......
Automatic Free-wheeling Hub
Indicator System ..........................
Heaters and Air-conditioning .........
Heaters ..........................................
Air-conditioning ............................
**, For Engine Chassis & Body refer to
0 1986 Mitsubishi Motors Corporation Printed in Japan

INTRODUCTION - Towing and Hoisting
TOWING AND HOISTING NOOGA-
This vehicle can only be towed from the front with convention-
al sling-type equipment and tow chain with grab hooks.
If a vehicle is towed from the rear, use a tow dolly.
A lumber spacer (4” x 4” x 55” wood beam) should be placed
forward of under guard and under towing hook/shipping tie
down hook.
Then, attach J-hook to the lower arm.
A safety chain system must be used. This system must be
completely independent of the primary lifting and towing
attachment. Care must be taken in the installation of safety
chains to insure they do not cause damage to bumper, painted
surfaces or lights.
LIFT!NG-GROUND CLEARANCE
Towed vehicle should be raised until wheels are a minimum of
10 cm (4 in.) from the ground. Be sure there is adequate
ground clearance at the opposite end of the vehicle, especially
when towing over rough terrain or when crossing sharp rises
such as curbs. If necessary, ground clearance can be in-
creased by removing the wheels from the lifted end of the
disabled vehicle and carrying the lifted end closer to the
ground. A 20 cm (8 in.) ground clearance must be maintained
between brake drums and ground.
FRONT TOWING PICKUP
The vehicle may be towed on its rear wheels for extended
distances, provided the parking brake is released.
Make cartain the transmission remains in “NEUTRAL”.
SAFETY PRECAUTIONS
The following precautions should be taken when towing the
vehicle.
1. Remove exhaust tips and any other optional equipment,
that interface with the towing sling. Padding (heavy shop
towel or carpeting) should be placed between the towing
sling cross bar and any painted surfaces, and bumper
surfaces.
2. A safety chain system completely independent of the
primary lifting and towing attachment must be used.
3. Any loose or protruding parts of damaged vehicle such as
hoods, doors, fenders, trim, etc., should be secured prior
to moving the vehicle.
4. Operator should refrain from going under a vehicle unless
the vehicle is adequately supported by safety stands.
5. Never allow passengers to ride in a towed vehicle.
6. State and local rules and regulations must be followed
when towing a vehicle.
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INTRODUCTION - Geraeral Data and Specifications 17
GENERAL DATA AND SPECIFICATIONS
NOOHA-A
OOW556
Description L042G VNJ LFIH VRJLFIH
TNSLFIH TRSLF/H
Vehicle dimensions mm (in.)
Overall length
Without tire
spare 0 3,960 (155.9) 3,960 (155.9) 3,960 (155.9) 3,960 (155.9)
With tire spare 0 3,995 (157.3) 3,995 (157.3) 3,995 (157.3) 3,995 (157.3)
Overall width 0 1,680 (66.1) 1,680 (66.1) 1,680 (66.1) 1,680 (66.1)
Overall height 0 1,840 (72.4) 1,840 (72.4) 1,850 (72.8) 1,850 (72.8)
Wheelbase 0 2,350 (92.5) 2,350 (92.5) 2,350 (92.5) 2,350 (92.5)
Tread Front @ 1,400 (55.1) 1,400 (55.1) 1,400 (55.1) 1,400 (55.1)
Rear 0 1,375 (54.1) 1,375 (54.1) 1,375 (54.1) 1,375 (54.1)
Overhang Front @ 745 (29.3) 745 (29.3) 745 (29.3) 745 (29.3)
Rear @ 900 (35.4) 900 (35.4) 900 (35.4) 900 (35.4)
Height at curb weight
(wt.)
Front bumper to ground
@ 480 (18.9) 480 (18.9) 480(18.9) 480 (18.9)
Rear bumper to ground 440(17.3) 440(17.3) 440(17.3) 440(17.3)
Minimum running ground : 210 (8.3) 210 (8.3) 210 (8.3) 210 (8.3)
clearance
Angle of approach @ 38 38 38” 38
Angle of departure @ 28 28” 28 28
Ramp breakover angle
@ 21” 21” 21” 21”
Vehicle weights kg (Ibs.)
Curb weight 1,479 (3,260) 1,493 (3,290) 1,440 (3,175) 1,460 (3,219)
Gross vehicle weight rating 1,910 (4,210) I,91 0 (4,210) 1,910(4,210) I,91 0 (4.210)
Gross axle Front 1 ,I 00 (2,425) 1 ,I 00 (2,425) 1 ,I 00 (2,425) 1,100 (2,425)
weight ratin!g~:+y~ Rear 1,450 (3,197) 1,450 (3,197) 1,450 (3,197) 1,450 (3,197)
Seating,c&ac&~ 4 4 2 2
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8-1
ELECTRICAL
CONTENTS
NOBAA-
ACCESSORY ......................................................
188
Cigarette Lighter ............................................
,190
Clock ...............................................................
,191
AUDIO SYSTEM ................................................
.192
AUTOMATIC FREE-WHEELING HUB
INDICATOR SYSTEM ........................................
208
Automatic Free-wheeling Hub
Indicator Control Unit
..................................... ,216
Pulse Generator ..............................................
215
BACK DOOR WINDOW DEFOGGER
................ .203
Defogger switch ............................................
,206
Printed Heater Lines
...................................... ,207
CHARGING SYSTEM .........................................
71
Alternator ........................................................
83
Service Adjustment Procedures
..................... 77
Battery Charging ........................................
82
Inspection of Battery ..................................
81
Output Current Test ...................................
78
Regulated Voltage Test ..............................
79
Voltage Drop Test of Alternator Output
Wire ............................................................
77
ELECTRICAL SYSTEM PARTS LOCATION
...... 2
Diode ...............................................................
5
Fusible Link and Fuse
..................................... 6
Grounding .......................................................
7
Relay and Control Unit ....................................
2
Sensor .............................................................
4
HORN ..................................................................
184
Horn Switch
.................................................... 187
IGNITION SYSTEM ............................................
105
Ignition Switch
................................................ 122
Ignition System ...............................................
1 14
Service Adjustment Procedures
.................... .l 1 1
Checking Ignition System
..........................
11 1
Checking Ignition Timing
...........................
11 1
Spark Plug Cable Test
................................
1 12
Spark Plug Test
.......................................... 1 12 INSPECTION OF HARNESS CONNECTOR ...... 9
Check for Improper Engagement of
Terminal .......................................................... 9
Continuity and Voltage Test for Connector .... 9
Engaging and Disengaging of Connector
Terminal ..........................................................
9
LIGHTING SYSTEM ........................................... 143
Column Switch
................................ .
.............. .I59
Dimmer Control Switch
................................. .I62
Hazard Warning Switch
................................. .I61
Headlight ........................................................ ,158
Service Adjustment Procedures
.................... .I57
Headlight Aiming .......................................
157
METERS AND GAUGES .................................... 123
Service Adjustment Procedures
.................... .I30
Fuel Gauge Simple Test ................................. .I31
Fuel Gauge Unit Inspection ........................... .I31
Oil Pressure Gauge Simple Test
.................... .I32
Oil Pressure Gauge Unit Simple Test
............ ,132
Speedometer Inspection
............................... .I30
Tachometer Inspection .................................. ,130
Voltage Meter Simple Test
............................ .I33
Water Temperature Gauge Simple Test
....... ..I3 1
Water Temperature Gauge Unit Inspection
. ..I3 2
STARTING SYSTEM .......................................... 91
Starter Motor ............ ....................................... 97
WIPER AND WASHER SYSTEM
....................... .163
WIRING HARNESS ............................................ 13
Centralized Junction ....................................... 69
Circuit Diagram ............................................... 34
Configuration Diagram .................................... 27
How to Read Wiring Diagrams ....................... 20
Troubleshooting .............................................. 13

ELECTRICAL SYSTEM PARTS LOCATION -Grounding 8-7
GROUNDING
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Headlight
washer relay,
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8-8 ELECTRICAL SYSTEM PARTS LOCATION -Grounding
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8-14 WIRING HARNESS - Troubleshooting
1680222
Changeover knob 1680224
1680225 1
1680226
INSPECTION
1. Visual and aural checks
Check relay operation, blower motor rotation, light illumina-
tion, etc. visually or aurally. The flow of current is invisible but
can be checked by the operation of the parts.
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2. Simple checks
For example, if a headlight does not come on and a faulty fuse
or poor grounding is suspected, replace the fuse with a new
one or ground the light to the body by a jumper wire to deter-
mine which part is responsible for the problem.
3. Checking with instruments
Use an appropriate instrument in an adequate range and read
the indication correctly. You must have sufficient knowledge
and experience to handle instruments correctly.
INSPECTION INSTRUMENTS
In inspection, make use of the following instruments.
1. Test lamps
A test lamp consists of a 12 V bulb and lead wires. It is used
to check voltages or shortcircuits.
2. Self-power test lamp
A self-power test lamp consists of a bulb, battery and lead
wires connected in series. It is used to check continuity or
grounding.
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WIRING HARNESS - Troubleshooting 8-15
1660227
Black lead wire
Ground y
1680228
Normal open (NO) type
OFF
ax
Current does not flow ON
Current flows
Normal close (NC) type
OFF
l-2
Current flows ON
-op--
IX
Current does not flow
1680229
pm I 3. Jumper wire
A jumper wire is used to close an open circuit. Never use one
to connect a power supply directly to a load.
4. Voltmeter
A voltmeter is used to measure the circuit voltage. Normally,
the positive (red lead) probe is applied to the point of voltage
measurement and the negative (black lead) probe to the body
ground.
5. Ohmmeter
An ohmmeter is used to.check continuity or measure resis-
tance of a switch or coil. If the measuring range has been
changed, the zero point must be adjusted before measure-
ment.
CHECKING SWITCHES In a circuit diagram, a switch is represented by a symbol and in the
idle state.
1. Normal open or normal close switch
Switches are classified into those which make the circuit open
and those which make the circuit closed when off.
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