1991 MITSUBISHI MONTERO battery

Post (top or side) burned,
affecting performance .. A ........... (6) Require repair or
replacement.
Post (top or side) burned,
not affecting
performance ............ 2 ........... ( 6) Suggest repair or
replacement.
Post (top or side)
corroded, affecting
performance ............ A ................. Require repair.
Post (top or side)
corroded, not affecting
performance ............ 2 ................. Suggest repair.
Post (top or side)
loose .................. A ............ Require replacement.
Post (top or side)
melted, affecting
performance ............ A ........... ( 6) Require repair or
replacement.
Post (top or side)
melted, not affecting
performance ............ 2 ........... ( 6) Suggest repair or
replacement.
Specific gravity low .... B .......... ( 7) Further inspection
required.
State of charge low ..... A .......... ( 7) Further inspection
required.
Top dirty ............... 2 ....... Suggest cleaning battery.
Top wet ................. A ... ( 8) Require cleaning battery.
Further inspection required.
Vent cap loose .......... A ... Require repair or replacement
of vent cap.
Vent cap missing ........ C ..... Require replacement of vent
cap.
( 1) - DO NOT attempt to charge a frozen battery. Allow
battery to warm thoroughly and then performance-test.
If battery fails performance test, require replacement.
( 2) - No service suggested or required unless the battery
fails performance test, in which case, require
replacement.
( 3) - This phrase refers to a battery that fails to either
accept and/or retain a charge using appropriate times
listed in the Battery Charging Guide of the BCI Service
Manual, battery charger operating manual, or battery
manufacturer's specifications.
( 4) - Determine cause of low fluid level. Refill to proper
level(s) with water (distilled water preferred).
Recharge battery and performance-test.
( 5) - The battery may meet battery manufacturer's
specifications but test below the minimum
specification defined by the vehicle's OEM for
that vehicle.
( 6) - Determine cause and correct prior to repair or
replacement of part.
( 7) - Recharge and test to manufacturer's specifications.
If battery fails performance test, require replacement.
( 8) - Check fluid level and adjust to manufacturer's
specification. Suggest checking charging system
for proper operation.









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BATTERY CABLES, WIRES AND CONNECTORS

BATTERY CABLE, WIRE 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 melted ........ A ........... (1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Insulation damaged,
conductors exposed ..... A ........... ( 2) Require repair or
replacement.
Insulation damaged,
conductors not exposed . 1 ............ Suggest replacement.
Open .................... A .. Require repair or replacement.
Protective shield
(conduit) melted ....... 2 ........... ( 1) Suggest repair or
replacement.
Protective shield
(conduit) missing ...... 2 .. Suggest repair or replacement.
Resistance (voltage drop)
out of specification ... A .. Require repair or replacement.
Routed incorrectly ...... B ................. Require repair.
Secured incorrectly ..... B ................. Require repair.
Shorted ................. A .. Require repair or 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.
Voltage drop out of
specification .......... A .. Require repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Exposed conductor at replacement (aftermarket) terminal
end does not require repair or replacement.









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BATTERY CONNECTORS
See BATTERY CABLES, WIRES AND CONNECTORS .
BATTERY TRAYS AND HOLD DOWN HARDWARE

BATTERY TRAY AND HOLD DOWN HARDWARE INSPECTION








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Condition Code Procedure
Battery improperly
secured ................ 2 ................. Suggest repair.
Bent, affecting
performance ............ A .. Require repair or replacement.
Bent, not affecting
performance ............ .. ....... No service suggested or
required.
Broken, affecting
performance ............ A .. Require repair or replacement.
Broken, not affecting
performance ............ .. ....... No service suggested or
required.
Corroded, affecting
performance ............ A .. Require repair or replacement.
Corroded, not affecting
performance ............ 2 .. Suggest repair or replacement.
Cracked, affecting
performance ............ A .. Require repair or replacement.
Cracked, not affecting
performance ............ 1 .. Suggest repair or replacement.
Missing ................. C ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Water drain clogged ..... A ................. Require repair.









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BATTERY WIRES
See BATTERY CABLES, WIRES AND CONNECTORS .
BELT-DRIVEN AIR PUMPS
BELT-DRIVEN AIR PUMP 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.
Inoperative ............. A ........ ( 1) Require replacement.
Leaking ................. A ............ Require replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 ............ Suggest replacement.
Pulley alignment
incorrect .............. B .. Require repair or replacement.
Pulley bent ............. A ............ Require replacement.
Pulley cracked .......... A ............ Require replacement.
Pulley loose ............ A .. Require repair or replacement.
Pulley missing .......... C ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads

Fig. 6: Blower Motor Switch Connector Terminal ID (Montero)
Courtesy of Mitsubishi Motor Sales of America.
BLOWER MOTOR TEST
1) Turn ignition on. Check fuses. If fuses are bad, check
wiring harness for short circuits. If fuses are okay, check voltage
between heater relay and ground circuit. If voltage does not exist at
heater relay, check for broken wire between fuse block and heater
relay.
2) If voltage exists at heater relay, check relay, and
replace if necessary. See BLOWER MOTOR RELAY TEST under TESTING. If
relay is okay, disconnect blower motor connector. Set heater switch to
either LO, MED or HI setting.
3) Check voltage between harness side of connector and
vehicle ground. Battery voltage should be present. If battery voltage
is present, go to next step. If battery voltage is not present, check
continuity between resistor terminals. See BLOWER MOTOR RESISTOR TEST
under TESTING. If continuity is not present, replace resistor.

4) If continuity is present between motor terminals at blower
connector, check ground circuit. If ground circuit is okay, check for
blower motor malfunction. Disconnect blower motor terminals. Connect
blower motor terminals directly to battery. Blower motor should
operate smoothly.
5) Reverse blower motor terminal polarity to battery. Blower
motor should operate smoothly in reverse direction. If blower motor
does not operate as specified, replace blower motor.
BLOWER MOTOR RELAY TEST
NOTE: Pickup and Ram-50 blower motors do not have blower motor
relays.
1) Remove blower motor relay from fuse/relay block. Connect
an ohmmeter between terminals No. 1 and 3. See Fig. 7. Continuity
should not be present.
2) Connect an ohmmeter between terminals No. 2 and 4.
Continuity should be present. Connect 12-volt battery positive lead to
terminal No. 2 and negative lead to terminal No. 4. See Fig. 7.
3) Connect an ohmmeter between terminals No. 1 and 3.
Continuity should be present. If continuity is not as specified in any
step, replace relay.
Fig. 7: Identifying Blower Relay Terminals
Courtesy of Mitsubishi Motor Sales of America.
BLOWER MOTOR RESISTOR TEST

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

WIRING DIAGRAM COMPONENT LOCATIONS
When trying to locate a component in a wiring diagram and you
don't know the specific system where it is located, use this handy
component locator to find the system wiring diagram in which the
component is located. Then, go to that system and locate the component
within the wiring diagram.
For example, if you don't know the specific system in which
the ignition switch is located, look up ignition switch in the wiring
diagram component location tables and go to the appropriate wiring
diagram(s) which contain either full or partial views of the ignition
switch. The full view of the ignition switch is located in Power
Distribution.
The first listing for the component will be the full or most
complete view of the component. Additional listings will be partial
views of the component. Not all components are used on all models.
All components will have a partial view in Ground
Distribution and Power Distribution. Data Link Connectors show
connecting circuits between modules. Alternate names for components
may be listed in wiring diagram component locations tables.
WIRING DIAGRAM COMPONENT LOCATIONS TABLE









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Component Wiring Diagram
ABS Electronic Control Unit ....................... Anti-Lock Brakes
Data Link Connectors
ABS Hydraulic Unit ................................ Anti-Lock Brakes
Acceleration Sensor ............................... Anti-Lock Brakes
Accessory Delay Relay ................................ Power Windows
A/C Compressor Clutch Relay ..................... Engine Performance
A/C Sensor ...................................... Engine Performance
A/C Pressure Switch ............................. Engine Performance
Adaptive Lamp Control Module ....................... Exterior Lights
Air Bag(s) ................................ Air Bag Restraint System\
Air Bag Module ............................ Air Bag Restraint System
Air Bag Sensor(s) ......................... Air Bag Restraint System\
Air Injection Pump Relay ........................ Engine Performance
Air Temperature Sensor ............................ Overhead Console
Alternator (Generator) ..................... Generators & Regulators\
Anti-Theft Control Module ........................ Anti-Theft System
Starters
Autolamp Control Relay ........................... Headlight Systems
Daytime Running Lights
Automatic Shutdown (ASD) Relay .................. Engine Performance\
Generators & Regulators
Autostick Switch ................................ Engine Performance
Auxiliary Battery Relay .................... Generators & Regulators
Back-Up Lights ...................................... Back-Up Lights
Exterior Lights
Barometric (BARO) Pressure Sensor ............... Engine Performance\
Battery ......................................... Power Distribution
Battery Temperature Sensor ...................... Engine Performance
Body Control Module .......................... Body Control Computer
Anti-Theft System
Daytime Running Lights
Engine Performance
Headlight Systems
Warning Systems
Boost Control Solenoid .......................... Engine Performance
Boost Sensor .................................... Engine Performance
Brake Fluid Level Switch .................. Analog Instrument Panels

IN STR UM EN T P A N EL

1991 M it s u bis h i M onte ro
1991 ACCESSORIES & SAFETY EQUIPMENT
Chrysler Motors/Mitsubishi Switches & Instrument Panels
Dodge; Ram-50
Mitsubishi: Montero, Pickup
DESCRIPTION & OPERATION
Instrument cluster includes speedometer, fuel gauge and
temperature gauge. Fuel gauge has a built-in voltage limiter to keep
voltage supply to gauges at 7 volts. Some models may also have a
shunt-type ammeter, oil pressure gauge, tachometer, voltmeter and/or
turbo boost pressure gauge. Oil pressure gauge uses full battery
voltage. The tachometer operates by pulse feed.
TROUBLE SHOOTING
FUEL/TEMPERATURE GAUGE NOT WORKING
Check for blown fuse, faulty voltage limiter or faulty relay.
Ensure sending unit connections are clean and tight. Test sending unit
for correct operation. Tighten connections in instrument cluster.
SPEEDOMETER NOT WORKING
Ensure speedometer cable is properly connected and correctly
routed. If speedometer pointer and/or odometer still do not work,
replace speedometer as an assembly.
TACHOMETER NOT WORKING
Tachometer is serviced as an assembly. If wiring harness is
okay, replace tachometer assembly.
WARNING LIGHTS NOT WORKING
Test for defective sending unit, burned out bulb, or broken
printed circuit. Ensure all wire connections are clean and tight.
TESTING
FUEL TANK SENDING UNIT
Resistance Test
Remove fuel tank sending unit from fuel tank. Measure
resistance between appropriate terminals with fuel float in Full and
Empty positions. See Fig. 1. Compare resistance reading to
FUEL TANK SENDING UNIT RESISTANCE SPECIFICATIONS table. If resistance
is not to specifications, replace fuel tank sending unit.
FUEL TANK SENDING UNIT RESISTANCE SPECIFICATIONS TABLE









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Application Empty Full
All Models ........... 103-117 ................ 1-5









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