1991 MITSUBISHI MONTERO Service Manual

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

Disconnect harness connector from resistor terminals. Using
an ohmmeter, check resistance between terminals indicated in BLOWER
MOTOR RESISTOR RESISTANCE table. See Fig. 8. If resistance is not as
shown, replace resistor.
BLOWER MOTOR RESISTOR RESISTANCE TABLE









\









\









\









\









\





Terminal Nos. Ohms
Montero
1-2 ..................................... 1.22
1-3 ...................................... .41
1-4 ..................................... 2.25
1-5 ........................................ 0
Pickup & Ram-50
1-2 ..................................... 1.19
1-3 ...................................... .50
1-4 ..................................... 2.33
1-5 ........................................ 0









\









\









\









\









\





Fig. 8: Identifying Blower Resistor Terminals
Courtesy of Mitsubishi Motor Sales of America.
REMOVAL & INSTALLATION
HEATER CORE

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

screws. Remove dash panel.
4) Remove blower duct, center duct and defroster ducts. See
Fig. 2. Disconnect heater wiring harness from heater unit. Remove
heater center support brackets. Remove heater unit. Remove heater core
cover plate and joint hose. Remove heater core from heater unit.
Installation
1) To install, reverse removal procedure. Insert heater hoses
fully into pipes, and clamp securely to prevent leaks.
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.
HEATER CONTROL PANEL
Removal (Montero)
1) Remove heater control knob and heater fan switch knob.
Remove center console. Remove defroster nozzle at temperature control
cable side.
2) Remove lap heater duct and glove box stopper, and push
glove box forward and down. Disconnect inside/outside control cable
from blower assembly.
3) Disconnect control cables from heater unit. Remove heater
control panel mounting screws, and pull out panel slightly. Disconnect
heater fan switch harness connectors. Remove heater control panel.
Remove heater fan switch from heater control panel.
Installation
1) Place air outlet change-over lever at closed position.
With heater side air outlet change-over damper lever in position,
connect inner cable to lever, and secure cable casing using clips.
2) Place heater control lever at OFF position. With heater
control lever in position, connect inner cable to lever, and secure
cable casing using clips.
3) Place inside/outside air change-over lever at INSIDE
position. With heater side inside/outside air change-over damper lever
in position, connect inner cable to lever, and secure cable casing
using clips.
4) Set control lever to each position to check for correct
operation. If lever does not operate correctly, adjust by moving outer
wire at clipped point. Ensure each control lever moves smoothly. If
any noise or stiff movement exists, apply multipurpose grease to all
moving parts.
NOTE: When mounting heater control panel to instrument panel,
tighten upper bolts to instrument panel so they also secure
center panel.
Removal & Installation (Pickup & Ram-50)
Remove cluster panel. Remove all control cables at heater.
Remove heater control panel. To install, reverse removal procedure.
Adjust cables as necessary.
WIRING DIAGRAMS

Fig. 9: Heater System Wiring Diagram (Montero)

Fig. 10: Heater System Wiring Diagram (1992 Montero)

Fig. 11: Heater System Wiring Diagram (Pickup & Ram-50)

Fig. 12: Heater System Wiring Diagram (1992 Pickup & Ram-50)