1991 MITSUBISHI MONTERO bulb

FUEL GAUGE
Simple Test
Disconnect fuel sending unit connector wire in luggage
compartment, cargo space, or at tank unit. Connect a 12-volt, 3.4-watt
bulb to harness side of connector, between power terminal and ground
(Yellow and Black wires on Montero). On Pickup and Ram-50 see Fig. 1.
Turn ignition switch to ON position. Ensure test bulb flashes, or
stays on, and fuel gauge needle moves. If bulb or gauge needle does
not function as described, check and repair fuel gauge circuit.
CAUTION: Gauge coils can be damaged if wire is grounded too long.
Perform test as quickly as possible.
Fig. 1: Identifying Fuel Gauge Test Connection (Pickup & Ram-50)
Courtesy of Chrysler Motors.
NOTE: The following test must be completed with instrument panel
cluster removed. Use ohmmeter for all measurements. If
resistance is extremely low, there may be a short in the
coil. If resistance is extremely high, there may be a broken
wire or similar problem in the gauge.
Resistance Test
Remove instrument cluster. See INSTRUMENT CLUSTER under
REMOVAL & INSTALLATION. Measure resistance between appropriate
terminals of instrument cluster or combination gauges. See Fig. 2 or

Calibration Test
Adjust tire pressure to standard value. Using a calibrated,
reliable speedometer tester, compare reading of vehicle speedometer to
speedometer tester. See SPEEDOMETER ALLOWABLE VARIATION table. Replace
speedometer if necessary.
SPEEDOMETER ALLOWABLE VARIATION TABLE









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MPH (km/h) Allowable Variation MPH (km/h)
20 (32) .......................... 19-22 (31-35)
40 (64) .......................... 38-44 (61-71)
60 (97) ......................... 57-66 (92-106)
80 (129) ....................... 76-88 (122-142)
100 (161) ..................... 94-110 (151-177)









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TACHOMETER
NOTE: DO NOT reverse polarity when installing tachometer, as diode
and transistor may be damaged.
Calibration Test
Connect a calibrated, reliable tach-dwell meter to vehicle
ignition system. Operate engine at various speeds (RPM). See
TACHOMETER ALLOWABLE VARIATION table. If comparison between tach-dwell
meter and vehicle tachometer readings do not fall in the standard
range of permissible variation, replace vehicle tachometer.
TACHOMETER ALLOWABLE VARIATION TABLE









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Engine Speed (RPM) Allowable Variation (RPM)
1000 .................................. 900-1100
3000 ................................. 2850-3150
5000 ................................. 4750-5250
6000 ................................. 5700-6300









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TEMPERATURE GAUGE
CAUTION: DO NOT connect sender wire directly to ground during test.
Circuit Test
Disconnect temperature sender wire from sending unit. Connect
a 12-volt, 3.4-watt test bulb between connector terminal and ground.
Turn ignition switch to ON position. If test bulb flashes and
temperature gauge needle moves, go to SENSOR RESISTANCE TEST. If test
light does not flash and gauge needle does not move, repair wiring to
sending unit.
Sensor Resistance Test
Remove thermosensor (sending unit) from engine block. Place
sending unit in hot water of 158
F (70C) temperature. Check sensor
resistance with an ohmmeter. Thermosensor resistance should be 90-117
ohms at 158
F (70C). If thermosensor resistance in okay, go to GAUGE
RESISTANCE TEST. Replace thermosensor if resistance is not as
specified.
Gauge Resistance Test
Remove instrument cluster from instrument panel. See
INSTRUMENT CLUSTER under REMOVAL & INSTALLATION. Measure resistance
between temperature gauge terminals at rear of cluster or combination

CATALYTIC CONVERTER
Continued operation of vehicle with a severe malfunction
could cause converter to overheat, resulting in possible damage to
converter and vehicle.
COOLANT (PROPYLENE-GLYCOL FORMULATIONS)
CAUTION: To avoid possible damage to vehicle use only ethylene-glycol
based coolants with a mixture ratio from 44-68% anti-freeze.
DO NOT use 100% anti-freeze as it will cause the formation
of cooling system deposits. This results in coolant
temperatures of over 300
\b F (149\bC) which can melt plastics.
100% anti-freeze has a freeze point of only -8\b F (-22\bC).
CAUTION: Propylene-Glycol Mixtures has a smaller temperature range
than Ethylene-Glycol. The temperature range (freeze-boil)
of a 50/50 Anti-Freeze/Water Mix is as follows:
Propylene-Glycol -26
\b F (-32\bC) - 257\b F (125\bC)
Ethylene-Glycol -35\b F (-37\bC) - 263\b F (128\bC)
CAUTION: Propylene-Glycol/Ethylene-Glycol Mixtures can cause the
destabilization of various corrosion inhibitors. Also
Propylene-Glycol/Ethylene-Glycol has a different specific
gravity than Ethylene-Glycol coolant, which will result in
inaccurate freeze point calculations.
ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS
WARNING: Many solid state electrical components can be damaged by
static electricity (ESD). Some will display a warning label,
but many will not. Discharge personal static electricity by
touching a metal ground point on the vehicle prior to
servicing any ESD sensitive component.
ENGINE OIL
CAUTION: Never use non-detergent or straight mineral oil.
FUEL SYSTEM SERVICE
WARNING: Relieve fuel system pressure prior to servicing any fuel
system component (fuel injection models).
HALOGEN BULBS
WARNING: Halogen bulbs contain pressurized gas which may explode if
overheated. DO NOT touch glass portion of bulb with bare
hands. Eye protection should be worn when handling or working
around halogen bulbs.
RADIATOR CAP
CAUTION: Always disconnect the fan motor when working near the
radiator fan. The fan is temperature controlled and could
start at any time even when the ignition key is in the OFF
position. DO NOT loosen or remove radiator cap when cooling
system is hot.
RADIATOR FAN

MAIN TE N AN CE R EM IN DER L IG HT R ESET P R O CED URES
1991 M it s u bis h i M onte ro
1983-96 MAINTENANCE
Chrysler Motors/Mitsubishi Maintenance Reminder Lights
Dodge; Challenger, Colt, Colt Vista, Conquest, Raider,
Ram-50
Eagle; Summit, Summit Wagon
Plymouth; Colt, Colt Vista, Sapporo
Mitsubishi; 3000GT, Cordia, Diamante, Eclipse,
Expo/Expo LRV, Galant, Mirage, Montero, Pickup, Precis,
Sigma, Starion, Tredia, Van/Wagon
EGR/MAINTENANCE REQUIRED WARNING LIGHT
1) On some models, an EGR or MAINTENANCE REQUIRED warning
light in dash will come on as a reminder to have EGR system serviced
(each 50,000 miles), oxygen sensor replaced (each 80,000 miles) or
evaporative carbon canister replaced (100,000 miles).
2) After servicing or replacing components, reset mileage
counter. On all models except 1987-95 Pickup and 1987-93 Ram-50, reset
switch is located on back of instrument cluster.
3) On 1987-95 Pickup and 1987-93 Ram-50, reset switch is on
lower right corner of instrument cluster, behind instrument cluster
face trim. Slide switch to other side to reset indicator light.
4) Remove warning light bulb after 150,000 mile servicing on
Colt Vista and Wagon. Remove bulb after 120,000 mile servicing on Ram-
50.
Fig. 1: Locating Warning Light Reset Switch (Colt Vista; Colt
Wagon is Similar)
Courtesy of Chrysler Motors.

touching a metal ground point on the vehicle prior to
servicing any ESD sensitive component.
ENGINE OIL
CAUTION: Never use non-detergent or straight mineral oil.
FUEL SYSTEM SERVICE
WARNING: Relieve fuel system pressure prior to servicing any fuel
system component (fuel injection models).
HALOGEN BULBS
Halogen bulbs contain pressurized gas which may explode if
overheated. DO NOT touch glass portion of bulb with bare hands. Eye
protection should be worn when handling or working around halogen
bulbs.
POWER STEERING FLUID
When adding power steering fluid, avoid spilling. Damage to
alternator, located beneath power steering reservoir, could result.
RADIATOR CAP
CAUTION: Always disconnect the fan motor when working near the
radiator fan. The fan is temperature controlled and could
start at any time even when the ignition key is in the OFF
position. DO NOT loosen or remove radiator cap when cooling
system is hot.
RADIATOR FAN
WARNING: Keep hands away from radiator fan. Fan is controlled by a
thermostatic switch which may come on or run for up to 15
minutes even after engine is turned off.
SERVICE POINT LOCATIONS
Fig. 1: Service Point Locations (1987-91 2.6L 4-Cylinder Engine)
Courtesy of Mitsubishi Motor Sales of America.

Light comes on with the ignition switch in the "ON" position
as a bulb check, but should go out shortly after engine is started. If
light remains on or comes on while driving, it indicates low oil
pressure and possible system malfunction. Have the system checked and
serviced immediately. Do not operate vehicle until cause is located
and corrected.
ALTERNATOR WARNING LIGHT
Light comes on with the ignition switch in the "ON" position
as a bulb check and goes out after engine is started. If light remains
on or comes on while driving, it indicates possible fault in the
electrical charging system. The alternator belt may be loose or
broken. Have the system checked and serviced promptly. Do not drive
vehicle if alternator belt is loose or broken.
"BRAKE" WARNING LIGHT
Light comes on with the ignition switch in the "ON" position
as a bulb check and goes out after engine is started. Light will also
come on with the parking brake fully or partially engaged. If light
remains on or comes on at any other time, it indicates low brake fluid
level in the master cylinder reservoir or the parking brake switch may
be damaged. Have the system checked and serviced immediately if brake
fluid level is low. Do not continue driving if further trouble is
experienced.
"CHECK ENGINE" WARNING LIGHT (IF EQUIPPED)
Light is designed to come on briefly with the ignition switch
in the "ON" position as a bulb check. If light remains on or comes on
while driving, it indicates fault in an exhaust gas related component
and the system is not functioning properly. Have the system checked
and serviced as soon as possible.
"MAINTENANCE REQUIRED" WARNING LIGHT (IF EQUIPPED)
Light comes on at 50,000 miles, 80,000 miles, 100,000 miles
and 120,000 miles (150,000 miles on 1990-91 models) as a service
reminder that it is time for the periodic maintenance of the emission
control system. Have the system inspected and serviced as necessary
when light comes on. Continued operation of vehicle without having
system serviced after warning light comes on may adversely affect
proper performance of the emission control system. Reset warning
light, after the system has been checked, by pushing the reset switch
in front of the combination meter. Remove the warning light bulb after
the last maintenance service at 120,000 miles (150,000 miles on 1990-
91 models).
"A/T TEMPERATURE" WARNING LIGHT (IF EQUIPPED)
Light comes on when the automatic transmission fluid
temperature becomes abnormally high. If light comes on, reduce engine
speed, stop car and put it in "P" (Park) position. Leave engine
running until light goes out. Normal vehicle operation may be resumed
after light has gone out. If light does not go out, have the system
checked and serviced as necessary.
WHEEL LOCK INDICATOR LIGHT (IF EQUIPPED)
Light comes on when automatic free-wheeling hubs are locked.
If ignition is turned off, indicator light will not come on when

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AIR RIDE SUSPENSION - WARNING LAMPS
AIR RIDE SUSPENSION - WARNING LAMP INSPECTION








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Condition Code Procedure
Bulb burned out ......... A ............ Require replacement.
Warning light does
not come on during
bulb check ............. .. . Further inspection required to
determine cause.
Warning light flashes ... .. . Further inspection required to
determine cause.
Warning light is
intermittent ........... .. . Further inspection required to
determine cause.
Warning light stays
on after initial
bulb check ............. .. . Further inspection required to
determine cause.









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AIR RIDE SUSPENSION - WIRING HARNESSES
AIR RIDE SUSPENSION - WIRING HARNESS INSPECTION








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Condition Code Procedure
Connector bent .......... A .. Require repair or replacement.
Connector broken ........ A .. Require repair or replacement.
Connector loose ......... A .. Require repair or replacement.
Damaged (cut, burned, or
chafed) ................ A .. Require repair or replacement.
Excessive resistance .... B .. Require repair or replacement.
Fuse blown .............. A ............ Require replacement.
Fusible link blown ...... A ............ Require replacement.
Open .................... A .. Require repair or replacement.
Poor ground ............. A .. Require repair or replacement.
Routed incorrectly ...... B .. Require rerouting according to
vehicle manufacturer's
specifications.
Shorted ................. A .. Require repair or replacement.
Terminal bent ........... A .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal corroded ....... A .. Require repair or replacement.
Terminal loose .......... A .. Require repair or replacement.









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BALL JOINTS
Before requiring or suggesting ball joint replacement, the
approved OEM procedure must be used to measure ball joint wear. The
measurement(s) obtained, along with the vehicle manufacturer's
specifications, must be noted on the inspection report. Some states
require that these measurements also appear on the invoice.
NOTE: The term "perceptible movement," defined as any visible
movement in any direction, has been the industry standard
for determining the need for replacement of follower ball
joints. Some vehicle manufacturers are now publishing
specifications for follower ball joints that were

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