Mitsubishi Montero 1987

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ELECTRICAL SYSTEM PARTS LOCATION -

Relay

and

Control Unit

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-Headlight washer relay

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1 STB Revision

Main Page

Group/Section Index1
Service Procedures2
Contents2
Text2
Page Numbers2
Vehicle Identification4
Vehicle Identification Code Chart Plate4
Vehicle Identification Number Location4
Vehicle Identification Number List5
Vehicle Information Code Plate5
Chassis Number6
Stamping Location6
Vehicles Safety Certification Label6
Engine Model Stamping6
Body Color Code7
Parts to be Replaced8
Precautions before Service8
Special Tools8
Protecting the Vehicle8
Parts9
Vehicle Washing9
Servicing the Electrical System9
Wiring Harnesses9
Electrical Components11
Fuses and Fusible Links11
Brake Fluid12
Lubricants12
Tubes and Other Rubber Parts12
Note on Installation of Radio Equipment13
Standing - Wave Ratio13
Towing and Hoisting14
Lifting-Ground Clearance14
Front Towing Pickup14
Safety Precautions14
Hoisting15
Post Type15
Floor Jack15
Emergency Jacking15
Frame Contact Support Locations16
Lifting and Jacking Support Locations16
General Data and Specifications17
Tightening Torque19
Table of Contents21
Electrical21
Electrical System Parts Location22
Relay and Control Unit22
Sensor24
Diode25
Fusible Link and Fuse26
Grounding27
Engaging and Disengaging of Connector Terminal29
Inspection of Harness Connector29
Check for Improper Engagement of Terminal29
Continuity and Voltage Test for Connector29
Round Waterproof Connector30
Inspection30
- Rectangular Waterproof Connector31
- Injector Connector31
- Wiring Harness33
- Test Lamps34
- Self-Power Test Lamp34
- Simple Checks34
- Visual and Aural Checks34
- Checking Switches35
- Jumper Wire35
- Voltmeter35
- Ohometer35
- Switch Connection36
- Checking Relays36
- Checking Fuses37
- Checking Cables and Wires38
- Handling On-Vehicle Battery38
Terminal38
- Checking Continuity39
- Checking Shortcircuits39
- How to Read Wiring Diagrams40
- How to Read Circuit Diagrams42
- Indication of Shielded Cables44
- Shapes of Connectors44
- Identifying Connectors45
- Symbolic Marks46
- Wire Color Codes46
- Overall Wiring Diagram47
- Engine Compartment48
- Interior and Frame50
- Instrument Panel52
- Starting Circuit54
- Ignition Circuit56
- Charging Circuit57
- Feed Back Carburetor Circuit58
- Layout of Components60
- Overdrive Control System Circuit62
Lighting65
- Headlight Circuit66
- Dome Light Circuit67
- Turn Signal and Hazard Light Circuit68
Dimmer69
- Stop Light Circuit70
- Instrument Panel Illumination Circuit71
- Meter Circuit72
- Horn Circuit74
- Heater Circuit75
- Air Conditioner Circuit76
- Wiper and Washer Circuit78
Headlight ,20779
- Radio/Cassette Deck Circuit ]80
- Cigarette Lighter/Clock Circuit82
- Defogger Circuit83
- Power Window Circuit84
- Buzzer Circuit86
- Automatic Free-Wheeling Hub Indicator System Circuit87
- Back Door Lock Circuit88
- Centralized Junction89
- Main Fusible Link89
- Sub Fusible Link89
- Dedicated Fuse89
- Multi-Purpose Fuse90
- Charging System91
- Maintenance Free Type Battery92
- Specifications93
- Torque Specifications94
- Voltage Drop Test of Alternator Output Wire97
- Inspection of the Charging System97
- Service Adjustment Procedures97
- Output Current Test98
- Regulated Voltage Test99
- Regulating Voltage Table100
- Inspection of Battery101
- Visual Inspection of Battery101
- Battery Charging102
- Charge Rate102
- Charge Rate Chart102
- Installation of Alternator103
- Service Points of Installations103
- Alternator103
- Removal of Front Bracket/16 Rear Bracket107
- Removal of Regulator and Brush Holder107
- Rotor Inspection107
- Stator108
- Rectifier108
- Positive Rectifier Test108
- Negative Rectifier Test108
- Replacement of Brush109
- Diode Trio Test109
- Reassembly of Rotor Assembly110
- Starting System111
- Starting System Specifications113
- Starting System Troubleshooting114
- Test of Magnetic Switch118
- Hold-In Test of Magnetic Switch118
- Free Running Test119
- Return Test to Magnetic Switch119
- Installation of Starter Motor119
- Starting System Disassembly and Reassembly120
- Service Points of Disassembly121
- Cleaning Starter Motor Parts121
- Checking Commutator121
- Front and Rear Bracket Bushing122
- Overrunning Clutch122
- Replacement of Brushes and Springs123
- Testing Armature for Short-Circuit123
- Testing Armature for Grounding123
- Reassembly of Stop Ring124
- Snap Ring124
- Ignition System125
- Distributor126
- Igniter Operation126
- Spark Plug127
- Ignition Switch127
- Ignition Coil127
- Ignition System Specifications127
- Checking Ignition Timing131
- Ignition Timing Adjustment131
- Checking Centrifugal Advance Equipment131
- Checking Negative Pressure Advance Equipment132
- Spark Plug Cable Test132
- Spark Plug Test132
- Spark Test - Engine Cannot be Cranked133
- Ignition System Removal and Installation134
- Cleaning and Inspection of Spark Plugs135
- Removal of Distributor135
- High Tension Cable135
- Caution of Spark Plug Cables135
- Checking Spark Plug Cable136
- Checking the Ignition Coil136
- Installation of Distributor137
- Installation of Spark Plug Cable137
- Spark Plug Cable Installation138
- Distributor Disassembly and Reassembly139
- Disassembly of Rotor Shaft140
- Signal Rotor140
- Disassembly of Spring Retainer140
- Governor Spring140
- Reassembly of Signal Rotor141
- Adjustment of Air Gap141
- Reassembly of Breaker Plate141
- Reassembly of Driven Gear141
- Ignition Switch Removal and Installation142
- Ignition Switch Inspection142
- Meters and Gauges143
- Tachometer145
- Fuel Gauge145
- Water Temperature Gauge146
- Oil Pressure Gauge146
- Brake Warning Light147
- EGR Warning Light147
- Circuit Diagram148
- Speedometer Inspection150
- Tachometer Inspection150
- Fuel Gauge Simple Test151
- Fuel Gauge Unit Inspection151
- Fuel Gauge Unit Float Position Check151
- Fuel Gauge Unit Resistance Check151
- Water Temperature Gauge Unit Inspection152
- Oil Pressure Gauge Simple Test152
- Water Temperature Gauge Unit Resistance Check152
- Oil Pressure Gauge Unit Current Check153
- Voltage Meter Simple Test153
- Buzzer154
- Reed Switch154
- Combination Meter Removal and Installation154
- Installation of Speedometer Cable155
- 3-Meter Unit157
- Inclinometer158
- Inclinometer Outline159
- Inclinometer Construction159
- Inclinometer Operation159
- Side-To-Side Inclination160
- Forward or Backward Inclination160
- Combined Forward or Backward and Side-To-Side Inclination160
- Indicator and Warning Lights161
- EGR Warning System162
- Reset Switch162
- Lighting System163
- Exterior and Interior Lights163
- Relay and Flasher Unit163
- Column Switch164
- Hazard Warning Switch164
- Dimmer Control Switch164
- Headlight165
- Back-Up Light166
- Dome Light167
- Turn Signal Light and Hazard Light167
- Stop Light168
- Headlight Aiming177
- Pre-Aiming Instructions177
- Luminous Intensity Measurement177
- Headlight Removal and Installation178
- Headlight Control Relay178
- Column Switch Removal and Installation179
- Service Points of Removal179
- Removal of Steering Wheel179
- Hazard Warning Switch Removal and Installation181
- Dimmer Control Switch Removal and Installation182
- Wiper and Washer System183
- Windshield/Rear Wipers and Washer186
- Headlight Washer187
Wiper189
- Wiper Blade Rubber Replacement190
- Windshield Wiper190
- Windshield Wipers Removal and Installation191
- Wiper Motor191
- Installation of Wiper Arms192
- Low Speed Operation Check192
- High Speed Operation Check192
- Automatic Stop Operation Check192
- Continuity Check193
- Intermittent Wiper Relay193
- Intermittent Operation Check194
- Washer Interlock Operation Check194
- Rear Wiper Removal and Installation194
- Installation of Wiper Blade195
- Operation Check196
- Automatic Operation Check196
- Windshield Washer Removal and Installation197
- Washer Motor and Pump197
- Rear Washer Removal and Installation198
- Headlight Washer Removal and Installation199
- Washer Operation Check200
- Headlight Washer Relay200
- Wiper-Washer Switch202
- Rear Wiper and Washer Switch203
- Removal of Rear Wiper and Washer Switch203
- Horn Specifications204
- Horn Removal and Installation206
- Horn Adjustment206
- Horn Switch207
- Accessory208
- Cigarette Lighter210
- Clock Removal and Installation211
- Audio System212
- Noise Source of Vehicle Equipment213
- Source of Electrical System Noise213
- Noise Sources213
- Radio/Cassette Deck Circuit214
- Antenna Trimmer216
- Antenna Trimmer Adjustment216
- Radio and Tape Player217
- Front Speaker218
- Rear Speaker218
- Antenna219
- Removal of Mounting Nut219
- Noise Suppression220
- Prevention of Ignition Circuit Noise220
- Prevention of Other Circuit Noise220
- Noise Suppression Chart221
- Noise Suppresor Location222
- Back Door Window Defogger223
- Defogger Switch226
- Removal of Defigger Switch226
- Printed Heater Lines227
- Operational Characteristics of the System229
- Explanation of Indicator Operation230
- Automatic Free-Wheeling Hub in Locked Condition230
- Pulse Generator231
- Automatic Free-Wheeling Hub in Free Condition231
- Automatic Free-Wheeling Hub Indicator Control Unit232
- Vehicle-Speed Sensor (Reed-Type Switch)232
- Checking Pulse Generator Resistance235
- Heaters and Air-Conditioning237
- Temperature Control System Adjustment241
- Mode Selection Lever241
- Adjustment of the Mode Selection Control Wire241
- Adjustment of the Damper241
- Temperature Control Lever243
- Adjustment of the Blend Air Damper243
- Water Valve Replacement244
- Heater Control Removal and Installation245
- Removal of Glove Box Stoppers245
- Blower Switch Inspection246
- Removal of Mode Selection Control Wire246
- Removal of Air Selection Control Wire246
- Application of Grease to Heater Control Assembly247
- Installation of Water Valve Control Wire247
- Installation of Mode Selection Control Wire247
- Installation of Air Selection Control Wire247
- Heater Unit Removal and Installation248
- Disconnection of Heater Hoses248
- Heater Core Replacement249
- Removal of Instrument Panel249
- Blower Assembly250
- Removal of Glove Box250
- Blower Motor251
- Removal of Blower Assembly251
- Resistor251
- Ventilators252
- Removal of Demister Grill252
- Removal of Lap Heater Garnish253
- Removal of Lap Heater Duct253
- Removal of Air Duct253
- Air Conditioning System Components256
- Manifold Gauge Set Installation260
- Receiver Drier260
- Sight Glass Refrigerant Level Test260
- To Test the Low Pressure Switch (Engine Off)266
- Low Pressure Switch266
- Fusible Plug266
- Freeze up Control267
- Water Temperature Switch267
- To Test the Thermistor267
- Air Conditioner Switch268
- Magnetic Clutch268
- Compressor268
- To Test the Air Conditioner Switch268
- Testing System for Leaks269
- Lost Charge270
- Low Charge270
- Refrigerant Leak Repair Procedure270
- Performance Test270
- Correcting Low Refrigerant Level271
- Discharging the System272
- Evacuating the System272
- Charging the System273
- Charging with Small Cans273
- Handling Tubing and Fittings275
- O-Ring Installation276
- Compressor Drive Belt Adjustment276
- Compressor Noise277
- Liquid Pipe279
- Application of Compressor Oil to Suction Hose279
- Evaporator279
- Removal of Clip280
- Removal of Expansion Valve280
- Application of Compressor Oil to Expansion Valve280
- Receiver Drier, Condenser, Compressor Clutch Assembly281
- Removal of Rotor Assembly283
- Installation of Shaft Plate283
- Installation of Shaft Seal283
- Installation of Clutch Coil284
- Adjustment of Clutch Clearance284
- Refill of Compressor Oil284
- Clearance Adjustment Shims284

Mitsubishi Montero 1987 - Page 23

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