1991 MITSUBISHI MONTERO fuel filter

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

Air in fuel system Bleed air from system
Incorrect or contaminated Replace fuel
fuel
Injector nozzle malfunction Check nozzles, see
FUEL SYSTEMS









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Engines Starts Injection pump timing Reset pump timing, see
and Idles Rough incorrect FUEL SYSTEMS
W/out Smoke or Engine not fully broken in Put more miles on
Noise, But Clears engine
After Warm-Up Air in system Bleed air from system
Injector nozzle malfunction Check nozzles, see
FUEL SYSTEMS









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Engine Idles Blocked fuel filter Replace fuel filter
Correctly, Injection pump timing Reset pump timing, see
Misfires Above incorrect FUEL SYSTEMS
Idle Incorrect or contaminated Replace fuel
fuel









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Engine Won't Fast idle adjustment Reset fast idle, see
Return To Idle incorrect TUNE-UP
Internal injection pump Replace injection pump,
malfunction see FUEL SYSTEMS
External linkage binding Check linkage and
remove binding









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Fuel Leaks On Loose or broken fuel line Check lines and
Ground connections
Internal injection pump Replace injection pump,
seal leak see FUEL SYSTEMS









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Cylinder Injector nozzles sticking Test injectors, see
Knocking Noise open FUEL SYSTEMS
Very low nozzle opening Test injectors and/or
pressure replace









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Loss of Engine Restricted air intake Remove restriction
Power EGR valve malfunction Replace EGR valve
Blocked or damaged exhaust Remove restriction
system and/or replace
components
Blocked fuel tank filter Replace filter
Restricted fuel filter Remove restriction
and/or replace filter
Block vent in gas cap Remove restriction
and/or replace cap
Tank-to-injection pump fuel Check fuel lines and
supply blocked connections
Blocked fuel return system Remove restriction
Incorrect or contaminated Replace fuel
fuel
Blocked injector nozzles Check nozzle for
blockage, see FUEL
SYSTEMS
Low compression Check valves, rings,
pistons, see ENGINES









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Loud Engine Basic timing incorrect Reset timing, see
Noise With Black FUEL SYSTEMS
Smoke EGR valve malfunction Replace EGR valve
Internal injection pump Replace injection pump,
malfunction see FUEL SYSTEMS

Low fuel pressure Test pressure regul-
ator and fuel pump,
check for restricted
lines and filters
No distributor reference Repair ignition
pulses system as necessary
Open coolant temperature Test sensor and
sensor circuit wiring
Shorted W.O.T. switch in Disconnect W.O.T.
T.P.S. switch, engine
should start
Defective ECM Replace ECM
Fuel tank residual pressure Test for fuel
valve leaks pressure drop after
shut down









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Hard Starting Disconnected hot air tube Reconnect tube and
to air cleaner test control valve
Defective Idle Air Control Test valve operation
(IAC) valve and circuit
Shorted, open or misadjusted Test and adjust or
T.P.S. replace T.P.S.
EGR valve open Test EGR valve and
control circuit
Poor Oxygen sensor signal Test for shorted or
circuit
Incorrect mixture from PCV Test PCV for flow,
system check sealing of oil
filter cap









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Poor High Speed Low fuel pump volume Faulty pump or
Operation restricted fuel
lines or filters
Poor MAP sensor signal Test MAP sensor,
vacuum hose and
wiring
Poor Oxygen sensor signal Test for shorted or
open sensor or
circuit
Open coolant temperature Test sensor and
sensor circuit wiring
Faulty ignition operation Check wires for
cracks or poor con-
nections, test
secondary voltage
with oscilloscope
Contaminated fuel Test fuel for water

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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
Fires With Key Flywheel runout contributes
released. Engine to the intermittent nature
Fires and Cranks
Normally









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TUNE-UP TROUBLE SHOOTING - GAS ENGINE VEHICLES
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 SPARK PLUG TROUBLE SHOOTING CHARTS









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CONDITION POSSIBLE CAUSE CORRECTION








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Normal Spark Light Tan or Gray deposits No Action
Plug Condition
Electrode not burned or No Action
fouled
Gap tolerance not changed No Action









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Cold Fouling or Overrich air/fuel mixture Adjust air/fuel
Carbon Deposits mixture, see ENGINE
PERFORMANCE section
Faulty choke Replace choke
assembly, see ENGINE
PERFORMANCE section
Clogged air filter Clean and/or replace
air filter
Incorrect idle speed or Reset idle speed and/
dirty carburetor or clean carburetor
Faulty ignition wires Replace ignition
wiring
Prolonged operation Shut engine off
at idle during long idle
Sticking valves or worn Check valve train
valve guide seals









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Wet Fouling Worn rings and pistons Install new rings and
or Oil Deposits pistons

Engine cold and choke too Adjust choke and
lean allow engine to warm-
up
Defective spark plugs Replace spark plugs
Defective coil Replace coil









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Faulty Low Speed Clogged idle transfer slots Clean idle transfer
Operation slots, see FUEL
Restricted idle air bleeds Disassemble and clean
and passages carburetor, see FUEL
Clogged air cleaner Replace air filter
Defective spark plugs Replace spark plugs
Defective ignition wires Replace ignition wire
see ENGINE PERFORMANCE
Defective distributor cap Replace distributor
cap









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Faulty High Speed Incorrect ignition timing Reset ignition timing
Operation see ENGINE PERFORMANCE
Defective distributor Replace advance
centrifugal advance mechanism
Defective distributor Replace advance unit
vacuum advance
Incorrect spark plugs or Check gap and/or
plug gap replace spark plugs
Faulty choke operation Check choke and
repair as required
Clogged vacuum passages Remove restrictions
Improper size or clogged Check jet size and
main jet clean, see FUEL
Restricted air cleaner Check filter and
replace as necessary
Defective distributor cap, Replace cap, rotor or
rotor or coil coil









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Misfire at All Defective spark plugs Replace spark plugs
Speeds
Defective spark plug wires Replace spark plug
wires
Defective distributor cap, Replace cap, rotor,
rotor, or coil or coil
Cracked or broken vacuum Replace vacuum hoses
hoses

Vacuum leaks Repair vacuum leaks
Fuel lines clogged Remove restriction









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Hesitation Cracked or broken vacuum Replace vacuum hoses
hoses
Vacuum leaks Repair Vacuum leaks
Binding carburetor linkage Eliminate binding
Binding throttle linkage Eliminate binding
Binding choke linkage or Eliminate binding
fast idle cam
Improper float setting Readjust float
setting, see FUEL
Cracked or broken ignition Replace ignition
wires wires









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Rough idle, Incorrect curb idle or fast Reset idle speed, see
Missing or idle speed see ENGINE PERFORMANCE
Stalling
Incorrect basic timing Reset ignition timing
see ENGINE PERFORMANCE
Improper idle mixture Reset idle mixture,
adjustment see ENGINE PERFORMANCE
Improper feedback system Check feedback system
operation see ENGINE PERFORMANCE
Incorrect spark plug gap Reset spark plug gap,
see ENGINE PERFORMANCE
Moisture in ignition Dry components
components
Loose or broken ignition Replace ignition
wires wires
Damaged distributor cap or Replace distributor
or rotor cap or rotor
Faulty ignition coil Replace ignition coil
Fuel filter clogged or worn Replace fuel filter
Damaged idle mixture screw Replace idle mixture
screw, see FUEL
Improper fast idle cam Reset fast idle cam
adjustment adjustment, see TUNE-
see ENGINE PERFORMANCE
Improper EGR valve operation Replace EGR valve
Faulty PCV valve air flow Replace PCV valve
Choke binding or improper Reset choke or
choke setting eliminate binding

Vacuum leak Repair vacuum leak
Improper float bowl fuel Reset float
level adjustment, see FUEL
Clogged air bleed or idle Clean carburetor
passages passages, see FUEL
Clogged or worn air cleaner Replace air filter
filter
Faulty choke vacuum Replace diaphragm,
diaphragm see ENGINE PERFORMANCE
Exhaust manifold heat valve Replace heat valve
inoperative
Improper distributor spark Check distributor
advance operation
Leaking valves or valve Check and repair
components valvetrain
Improper carburetor Remove and remount
mounting carburetor
Excessive play in Replace distributor
distributor shaft
Loose or corroded wiring Repair or replace as
connections required









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Engine Surges Improper PCV valve airflow Replace PCV valve
Vacuum leaks Repair vacuum leaks
Clogged air bleeds Remove restriction
EGR valve malfunction Replace EGR valve
Restricted air cleaner Replace air filter
filter
Cracked or broken vacuum Replace vacuum hoses
hoses
Cracked or broken ignition Replace ignition
wires wires
Vacuum advance malfunction Check unit and
replace as necessary
Defective or fouled spark Replace spark plugs
plugs









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Ping or Spark Incorrect ignition timing Reset ignition timing
Knock see ENGINE PERFORMANCE
Distributor centrifugal or Check operation and
vacuum advance malfunction replace as necessary
Carburetor setting too lean Readjust mixture

WIR IN G D IA G RAM S

1991 M it s u bis h i M onte ro
1991 Wiring Diagrams
Mitsubishi
Montero
IDENTIFICATION
COMPONENT LOCATION MENU
COMPONENT LOCATIONS TABLE








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Component Figure No. (Location)
A/C RELAYS .......................... 4 (C 12), 4 (A-B 15)
A/C SYSTEM ................................. 4 (A-C 12-15)
ALTERNATOR ................................... 1 (B-C 1-2)
ALTERNATOR RELAY ............................... 1 (C 1-2)
AUTO FREE-WHEELING HUB CONTROL UNIT ............. 3 (D 11)
BACK DOOR LOCK SW ............................... 7 (B 27)
BACK-UP LT SW (M/T) ............................. 7 (A 26)
BATTERY .......................................... 1 (A 1)
BLOWER SWITCH ................................. 4 (A-B 12)
BUZZER .......................................... 5 (E 17)
CARGO LIGHT ..................................... 6 (A 23)
CIG LIGHTER ..................................... 3 (E 11)
CLOCK ........................................... 3 (E 11)
COLUMN SW ..................................... 5 (A-E 19)
CRUISE CONTROL SYSTEM ...................... 4 (D-E 13-15)
DEFOGGER ...................................... 7 (C-D 27)
DIAG CONNECTION .................................. 2 (E 7)
DIMMER CONTROL SWITCH ............................ 3 (E 8)
DIR FLASHER ..................................... 5 (C 16)
DIR SWITCH ...................................... 5 (C 19)
DOME LT ............................... 6 (A 23), 7 (A 24)
DOOR LOCK SYSTEM ........................... 6 (D-E 21-23)
DOOR SWITCHES ......................... 5 (D 17), 6 (C 23)
FRONT WIPER SYSTEM ........................... 5 (A 16-17)
FUEL GAUGE UNIT ................................. 6 (C 22)
FUEL PUMP ........................................ 2 (C 4)
FUSE BLOCK .................................... 3 (C 9-10)
HAZARD FLASHER .................................. 5 (C 16)
HAZARD SW ....................................... 5 (B 16)
HEAD LIGHT WASHER RELAY ....................... 5 (C-D 17)
HEATER RELAY .................................... 4 (A 12)
HORN SWITCH ..................................... 5 (E 19)
IGNITION COIL .................................... 2 (E 4)
IGNITION SW ..................................... 3 (A 11)
ILLUMINATION LIGHTS ............................ 3 (D-E 8)
INHIBITOR SW ..................................... 3 (A 9)
INSTRUMENT CLUSTER ............................ 6 (A-D 20)
KEY REMINDER SW ................................. 5 (E-17)
LIGHT CONTROL RELAY ............................. 5 (E 19)
LIGHT SWITCH .................................... 5 (D 19)
MAIN FUSE LINKS ................................ 1 (A 1-2)
METER UNIT ...................................... 6 (E 20)
MPI CONTROL RELAY ................................ 2 (B 4)
MPI CONTROL UNIT ............................... 2 (A 4-7)
NOISE FILTER ..................................... 2 (E 6)
OVERDRIVE CONTROL RELAY .......................... 3 (A 8)