I - SYSTEM/COMPONENT TESTS

1991 Mitsubishi Montero

1991 ENGINE PERFORMANCE

System & Component Testing

Chrysler Motors: Ram-50

Mitsubishi: Montero, Pickup

INTRODUCTION
Before testing separate components or systems, perform
procedures in F - BASIC TESTING article in the ENGINE PERFORMANCE
Section. Since many computer controlled and monitored components set a
trouble code if they malfunction, also perform procedures in G - TESTS
W/CODES article in the ENGINE PERFORMANCE Section.

NOTE: Testing individual components does not isolate shorts or

opens. Perform all voltage tests with a Digital
Volt-Ohmmeter (DVOM) with a minimum 10-megohm input
impedance, unless stated otherwise in test procedure. Use
ohmmeter to isolate wiring harness shorts or opens.

COMPUTERIZED ENGINE CONTROLS

CONTROL UNIT
NOTE: To identify ECU power and ground circuits, see appropriate
L - WIRING DIAGRAMS article in the ENGINE PERFORMANCE
Section.

Ground Circuits
1) ECU is located near right kick panel. Turn ignition off.
Using an ohmmeter, check for continuity between ground and ECU
terminals No. 101 and 106. Resistance should be zero ohms. If
resistance is not zero ohms, repair open circuit between ECU connector
and ground.
2) Connect voltmeter negative lead to ground. Connect
positive lead to ECU ground terminals as in step 1). With vehicle
running, voltmeter should indicate less than one volt. If voltmeter
reading is greater than one volt, check for open, corrosion or loose
connection in ground circuit.

Power Circuits
ECU is located near right kick panel. Turn ignition on. Check
for battery voltage on ECU terminals No. 102 and 107. If battery
voltage is not present, check operation of MPI control relay. See
RELAYS under MOTORS, RELAYS & SOLENOIDS.

ENGINE SENSORS & SWITCHES

BAROMETRIC PRESSURE SENSOR

Sensor is a component part of airflow sensor assembly. See G
- TESTS W/CODES article in the ENGINE PERFORMANCE Section.

COOLANT TEMPERATURE SENSOR

1) Remove coolant temperature sensor located near thermostat
housing (2-wire connector). Place end of sensor in water with terminal
connector portion of sensor slightly above water.
2) Gradually heat water and read resistance values across
terminal connectors. See COOLANT TEMPERATURE SENSOR RESISTANCE table.
If resistance is not within specification, replace sensor.

COOLANT TEMPERATURE SENSOR RESISTANCE TABLE

Temperature
 
F ( C) Ohms

Montero & Pickup 3.0L

32 (0) ............................. 5900
68 (20) ............................ 2500
104 (40) ........................... 2700
176 (80) ............................ 300
All Others
32 (0) ............................. 5900
68 (20) ............................ 2500
104 (40) ........................... 1100
176 (80) ............................ 300

CRANK ANGLE SENSOR

See IGNITION SYSTEM.

DETONATION SENSOR
See IGNITION SYSTEM.

EGR TEMPERATURE SENSOR

California
See EXHAUST GAS RECIRCULATION (EGR) under EMISSION SYSTEMS &
SUB-SYSTEMS.

IDLE POSITION SWITCH

NOTE: Idle position switch is incorporated in idle speed control
motor assembly, motor position sensor or throttle position
sensor, depending upon vehicle application.

Pickup 2.4L & Ram-50 2.4L

1) Disconnect motor position sensor (MPS) connector. Connect
ohmmeter lead between ground and MPS connector terminal No. 4. See
Fig. 2.
2) With accelerator pedal pressed, no continuity should be
present. With accelerator pedal released, continuity should be
present. If switch continuity is not as specified, replace MPS.

Montero, Pickup 3.0L & Ram-50 3.0L

1) Disconnect throttle position sensor (TPS) connector.
Connect ohmmeter between TPS connector terminals No. 1 and 2. See
Fig. 6.
2) With accelerator pedal pressed, no continuity should be
present. With accelerator pedal released, continuity should be
present. If idle switch continuity is not as specified, replace TPS.

INHIBITOR SWITCH
Automatic Transmission
Switch is mounted to automatic transaxle, near shift lever
mechanism. Testing information is not available from manufacturer. See
appropriate wiring diagram in L - WIRING DIAGRAMS article in the
ENGINE PERFORMANCE Section.

INTAKE AIR TEMPERATURE SENSOR

1) Sensor is incorporated in airflow sensor assembly inside
air filter housing. Disconnect airflow sensor connector. See Fig. 1.

Fig. 1: Airflow Sensor Connector Terminal ID

Courtesy of Mitsubishi Motor Sales of America.

2) Measure resistance between terminals No. 4 and 6 of

airflow sensor connector (sensor side of connector). For
specifications, see INTAKE AIR TEMPERATURE SENSOR RESISTANCE table.
Replace airflow sensor assembly if air temperature sensor resistance
is not within specification.
INTAKE AIR TEMP SENSOR RESISTANCE TABLE








































Temperature
 
F ( C) Ohms

All Models
32 (0) ........................ 6000
68 (20) ....................... 2700
176 (80) ....................... 400

MOTOR POSITION SENSOR

NOTE: Some engines are not equipped with Motor Position Sensor
(MPS). MPS may be a separate unit mounted to throttle body
or it may be incorporated in ISC motor assembly, depending
upon vehicle application.

Pickup 2.4L & Ram-50 2.4L

1) Disconnect MPS connector. See Fig. 2. Connect ohmmeter
lead to ground. Connect other ohmmeter lead to terminal No. 3 of
sensor connector. If continuity is not present, repair wiring harness
as necessary. If continuity is present, go to next step.

Fig. 2: Motor Pos. Sensor Connector Term. ID

Courtesy of Mitsubishi Motor Sales of America.

2) Connect ohmmeter leads to terminals No. 2 and 3.

Resistance should be 4000-6000 ohms. If resistance is not within
specified range, replace MPS.

CAUTION: DO NOT apply more than 6 volts to ISC motor.

3) Operate ISC motor by connecting a 6-volt source directly

to appropriate terminals of ISC motor connector. For ISC motor
operation test procedures, see IDLE SPEED CONTROL (ISC) MOTOR
OPERATION TEST under IDLE CONTROL SYSTEM.
4) While operating ISC motor, measure resistance between MPS
connector terminals No. 3 and 5. Observe ohmmeter during ISC motor
operation. If MPS resistance does not vary within a 4000-6000 ohm
range or if resistance does not change smoothly, replace MPS (vehicles
equipped with separate MPS) or ISC motor assembly (vehicles equipped
with MPS incorporated in ISC).

OXYGEN SENSOR
1-Wire Or 2-Wire
 1) On all
 models, warm engine until coolant temperature is
185-205 F (85-96 C). Disconnect oxygen sensor connector. See Fig. 3 or
4.
2) Connect digital voltmeter between terminal No. 1 and
ground. Repeatedly race engine and observe oxygen sensor output
voltage. If output is not 0.6-1.0 volt, replace oxygen sensor.

Fig. 3: O2 Sensor Connector Terminal ID (1 Wire)

Courtesy of Mitsubishi Motor Sales of America.
Fig. 4: O2 Sensor Connector Terminal ID (2 Wire)
Courtesy of Mitsubishi Motor Sales of America.

4-Wire Heated 
1) Warm engine until coolant temperature is 185-205 F (85-
 
95 C). Disconnect oxygen sensor connector. See Fig. 5. Connect
ohmmeter between heater terminals of oxygen sensor connector as
specified in OXYGEN SENSOR 4-WIRE CONNECTOR TERMINAL IDENTIFICATION
table. This test checks resistance of oxygen sensor heater element.

Fig. 5: O2 Sensor Connector Term. ID

Courtesy of Mitsubishi Motor Sales of America.
 
2) When oxygen sensor is at 68 F (20 C), resistance should be
approximately 12 ohms (20 ohms on 3.0L models). If resistance is not
within specification, replace oxygen sensor.

CAUTION: DO NOT apply battery voltage to oxygen sensor output

terminals. Damage to oxygen sensor could result.

3) Apply battery voltage to oxygen sensor heater terminals as

specified in OXYGEN SENSOR 4-WIRE CONNECTOR TERMINAL IDENTIFICATION
table. This heats oxygen sensor heater element.
4) Connect digital voltmeter between output terminals
specified in OXYGEN SENSOR 4-WIRE CONNECTOR TERMINAL IDENTIFICATION
table. Repeatedly race engine and observe oxygen sensor output
voltage. If oxygen sensor output voltage is not within 0.6-1.0 volt,
replace oxygen sensor.

OXYGEN SENSOR 4-WIRE CONNECTOR TERMINAL ID TABLE

Heater Output
 Circuit Circuit
Application Terminals Terminals

Montero, Pickup 3.0L & Ram-50 3.0L ..... 2 & 4 ............. 1 & 3

POWER STEERING OIL PRESSURE SWITCH

1) Power steering oil pressure switch is mounted on power
steering pump. Disconnect single wire connector at switch. Start
engine.
2) Connect ohmmeter between switch terminal and ground. If
continuity is present with steering wheel in straight-ahead position,
replace switch. If continuity is not present while turning steering
wheel, perform POWER STEERING IDLE-UP SYSTEM TEST. See IDLE-UP SYSTEMS
under IDLE CONTROL SYSTEM.

THROTTLE POSITION SENSOR

1) TPS is mounted to throttle body, at end of throttle shaft.
Disconnect TPS connector. See Fig. 6. Using ohmmeter, measure total
resistance between TPS connector terminals as specified in TPS
CONNECTOR TERMINAL IDENTIFICATION table. If resistance is not 3500-
6500 ohms, replace TPS.
2) Using an analog (needle-type) ohmmeter, measure variable
resistance between TPS connector terminals as specified in TPS
CONNECTOR TERMINAL IDENTIFICATION table.
3) Operate throttle valve from closed to wide open throttle.
If rate of resistance does not change smoothly within 3500-6500 ohms
throughout range of throttle valve movement, replace TPS.

Fig. 6: TPS Sensor Connector Terminal ID

Courtesy of Mitsubishi Motor Sales of America.

TPS CONNECTOR TERMINAL IDENTIFICATION TABLE

 Terminal
Application Numbers

Total Resistance .................... 1 & 4

Variable Resistance
Montero, Pickup 3.0L,
& Ram-50 3.0L .................... 1 & 3
All Others ........................ 2 & 4

VEHICLE SPEED SENSOR

1) Vehicle Speed Sensor (VSS) is located in speedometer
assembly. Connect an ohmmeter between sensor terminals on back of
instrument panel. See Fig. 7 or 8.
2) Rotate speedometer cable. For each revolution of
speedometer cable, sensor should make and break continuity 4 times. If
ohmmeter reading does not fluctuate between continuity and no
continuity or if sensor does not make and break continuity 4 times for
each revolution, replace sensor.

Fig. 7: VSS Sensor Connector Term. ID (Montero)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 8: VSS Sensor Connector Term. ID (P/U & Ram 50)

Courtesy of Mitsubishi Motor Sales of America.

MOTORS, RELAYS & SOLENOIDS

 MOTORS
ISC Motor
See IDLE CONTROL SYSTEM.

RELAYS
NOTE: For internal wiring diagram of MPI control relay, see
appropriate L - WIRING DIAGRAMS article in the ENGINE
PERFORMANCE Section.

MPI Control Relay (Montero, Pickup 3.0L & Ram-50 3.0L)

1) MPI control relay is located near right kick panel. Check
for battery voltage at terminal No. 10 of relay connector. See Fig. 9.
If battery voltage is present, go to step 3). If battery voltage is
not present, check circuit between relay and battery, including
fusible link No. 1.

Fig. 9: MPI Control Relay Connector Term. ID (10 Pin)

Courtesy of Mitsubishi Motor Sales of America.

2) Apply battery voltage to terminal No. 10. Battery voltage

should not be present at terminals No. 4 and 5. Apply battery voltage
to terminal No. 10, and ground terminal No. 8. Battery voltage should
now be present at terminals No. 4 and 5.
3) Apply battery voltage to terminal No. 3. Battery voltage
should not be present at terminal No. 2. Apply battery voltage to
terminal No. 3, and ground terminal No. 7. Battery voltage should now
be present at terminal No. 2.
4) Apply battery voltage to terminal No. 9. Battery voltage
should not be present at terminal No. 2. Apply battery voltage to
terminal No. 9, and ground terminal No. 6. Battery voltage should now
be present at terminal No. 2. Replace relay if it does not test as
specified.

MPI Control Relay (Pickup 2.4L & Ram-50)

1) MPI control relay is located near right kick panel. Check
for battery voltage at terminal No. 4 of relay connector. See Fig. 10.
If battery voltage is present, go to step 3). If battery voltage is
not present, check circuit between relay and battery, including
fusible link No. 1.

Fig. 10: MPI Control Relay Connector Term. ID (8 Pin)

Courtesy of Mitsubishi Motor Sales of America.

2) Disconnect wiring harness connector at relay. Remove

relay. Check continuity between terminals No. 1 and 4, terminals No. 2
and 4 and terminals No. 3 and 4. If there is no continuity, go to next
step. If there is continuity, replace relay.
3) Check diode operation between terminals No. 6 and 8. If
there is continuity in only one direction, go to next step. If there
is no continuity in either direction or if there is continuity in both
directions, replace relay.
4) Measure resistance between terminals No. 6 and 7. If
resistance is approximately 35 ohms, go to next step. If resistance is
not approximately 35 ohms, replace relay.
5) Measure resistance between terminals No. 2 and 5 and
between terminals No. 3 and 5. In both tests, if resistance is
approximately 95 ohms, go to next step. If resistance is not
approximately 95 ohms, replace relay.
6) Connect positive lead of 12-volt source to terminal No. 7
and negative lead to terminal No. 6. If there is continuity between
terminals No. 1 and 4, go to next step. If there is no continuity,
replace relay.
7) Connect positive lead of 12-volt source to terminal No. 5
and negative lead to terminal No. 2. If there is continuity between
terminals No. 1 and 4, go to next step. If there is no continuity,
replace relay.
8) Connect positive lead of 12-volt source to terminal No. 5
and negative lead to terminal No. 3. If there is continuity between
terminals No. 1 and 4, go to next step. If there is no continuity,
replace relay.
9) Connect positive lead of 12-volt source to terminal No. 8
and negative lead to terminal No. 6. If there is continuity between
terminals No. 3 and 4 and between terminals No. 2 and 4, relay is
okay. If there is no continuity, replace relay.

SOLENOIDS
Fuel Pressure Control Solenoid Valve
See FUEL DELIVERY under FUEL SYSTEM.

Fuel Injector Solenoids

See FUEL CONTROL under FUEL SYSTEM.

FUEL SYSTEM

FUEL DELIVERY
NOTE: For fuel system pressure testing, see F - BASIC TESTING
article in the ENGINE PERFORMANCE Section.

FUEL CONTROL
Fuel Injectors
1) Using a stethoscope, check operating sound of injector(s)
during engine cranking or idling. If clicking sound is heard,
injectors are okay. If clicking sound is not heard at each injector,
go to step 2).
2) Disconnect injector electrical connector. Measure
 
resistance between injector connector terminals. At 68 F (20 C), if
resistance is not 13-16 ohms, replace injector.
3) If resistance is within specification, check injector
wiring circuit for open or short to ground. If wiring circuit tests
okay, replace injector.

IDLE CONTROL SYSTEM

NOTE: ISC motor adjusts throttle plate angle to regulate idle air
 by-pass volume.

IDLE SPEED CONTROL (ISC) MOTOR OPERATION TEST

CAUTION: DO NOT apply more than 6 volts to ISC motor.

Pickup 2.4L & Ram-50 2.4L

Connect 6-volt DC source across terminals No. 1 and 2 of ISC
motor connector. See Fig. 11. Reverse leads of 6-volt source. If motor
does not operate in both directions, replace ISC motor assembly.

Fig. 11: ISC Motor Connector Term. ID (2 Pin)

Courtesy of Mitsubishi Motor Sales of America.

Montero, Pickup 3.0L & Ram-50 3.0L

1) Remove throttle body from intake plenum. Remove ISC motor
from throttle body. Apply 6-volt source parallel to terminals No. 2
and 5 of ISC motor connector. See Fig. 12.
Fig. 12: ISC Motor Connector Term. ID (6 Pin)
Courtesy of Mitsubishi Motor Sales of America.

2) Apply source ground lead to ISC motor connector terminals

No. 3 and 6. Note slight movement of ISC motor plunger. Remove ground
leads from terminals No. 3 and 6.
3) Apply and remove source ground at terminals No. 1 and 6, 1
and 4, 3 and 4, and 3 and 6. Note slight movement of ISC motor plunger
during each phase of test.
4) Beginning at terminal No. 6, reverse grounding sequence
following same procedure specified in step 2). If motor does not
operate when grounding any of specified terminals, replace ISC motor.

IDLE SPEED CONTROL (ISC) MOTOR RESISTANCE TEST

Pickup 2.4L & Ram-50 2.4L
Disconnect ISC motor connector. Connect ohmmeter between
terminals No. 1 and 2 of ISC motor connector.
 See Fig. 11. If
resistance is not 5-35 ohms at 68 F (20 C), replace ISC motor
assembly.

Montero, Pickup 3.0L & Ram-50 3.0L

Measure resistance between terminals No. 1 and 2, 2 and 3, 4
and 5, and 5 and 6 of ISC motor connector.
 See
 Fig. 12. In each case,
if resistance is not 28-33 ohms at 68 F (20 C), replace ISC motor
assembly.

IDLE-UP SYSTEMS
Power Steering Idle-Up System Test
1) Disconnect pressure hose from power steering pump. Connect
 a pressure gauge and hoses capable of handling 300 psi (21
in-line
kg/cm ). Also connect a shut-off valve in-line with pressure gauge.
See Fig. 13.

Fig. 13: Connecting Pressure Gauge Shutoff Valve Assembly

Courtesy of Mitsubishi Motor Sales of America.

2) Bleed air from system by disabling ignition system and

cranking engine while turning steering wheel completely from left to
right several times. Start engine, and turn steering wheel back and
forth to raise fluid temperature to approximately 122-140 F (50-60 C).
3) With engine idling, gradually close shutoff valve of
pressure gauge to increase hydraulic pressure. If idle speed does not

increase 200-250 RPM when fluid pressure reaches 213-284 psi (15-20
kg/cm ), replace power steering idle-up switch.
4) Gradually open shutoff valve. If engine speed  does not
return to curb idle speed between 100-142 psi (7-10 kg/cm ), replace
power steering idle-up switch. Remove testing equipment. Bleed air
from system as in step 2).

IGNITION SYSTEM
NOTE: For basic ignition checks, see F - BASIC TESTING article in
ENGINE PERFORMANCE Section.

TIMING CONTROL SYSTEMS

Crank Angle Sensor
Crank angle sensor is located inside distributor on SOHC
engines and is attached to cylinder head on DOHC engines. If
malfunction occurs, Code 22 will set. For testing procedure, see
appropriate G - TESTS W/CODES article in the ENGINE PERFORMANCE
Section.

EMISSION SYSTEMS & SUB-SYSTEMS

EXHAUST GAS RECIRCULATION (EGR)

System Testing (Federal)
1) Disconnect Green-striped hose from throttle body, and
connect vacuum pump to hose end. Plug nipple
 where
 hose was connected
to throttle body. When engine is cold, 122 F (50 C) or less, and at
idle, apply vacuum to disconnected hose. If idle does not change and
vacuum bleeds down, system is okay.  
2) When engine is hot, 205 F (95 C), and at idle, apply 1.8
in. Hg. If idle does not change and vacuum holds, system is okay.
Using a vacuum pump, apply 7.7 in. Hg. If idle becomes unstable or
engine stalls (and vacuum holds), system is okay.

System Testing (California)

1) Connect vacuum "T" fitting into Green-striped hose from
EGR valve, and connect
 vacuum
 gauge to vacuum tee. When engine coolant
temperature is 68 F (20 C) or less and engine is idling, snap throttle
open to race engine. If no change in vacuum reading is detected on
gauge, system is okay.  
2) When engine coolant temperature is 158 F (70 C) or more
and engine is idling, snap throttle open to race engine. If vacuum
increases to 3.9 in. Hg or higher, system is okay.
3) Using vacuum pump, apply specified vacuum to open EGR
valve. See EGR VALVE SPECIFICATIONS table. If idle becomes unstable or
engine stalls, system is okay.

EGR Control Solenoid Valve (Pickup & Ram-50, California)

1) EGR control solenoid valve is located near left shock
tower. Label and disconnect vacuum hoses and wiring harness from
solenoid valve.
2) Connect hand vacuum pump to vacuum nipple where Green-
striped vacuum hose was connected. Apply vacuum and ensure vacuum does
not hold. Apply battery voltage to one terminal of solenoid, and
ground other. Ensure vacuum holds.
 3) Using an ohmmeter, measure resistance between terminals of
solenoid valve. At room temperature, reading should be 36-44 ohms.
Replace solenoid if not to specification.

NOTE: EGR temperature sensor only determines if EGR is operating.

An inoperative sensor will not affect driveability or
exhaust emissions.

EGR Temperature Sensor (California)

1) Remove EGR temperature sensor from EGR valve. Place EGR
temperature sensor in water. While increasing water temperature,
measure resistance between wire terminals.
 
2) At a temperature
 of 122 F (50 C), resistance should be 60,
000-80,000 ohms. At 212 F (100 C), resistance should be 11,000-14,000
ohms. Replace EGR temperature sensor if resistance differs
significantly from specifications.

EGR Valve
1) Remove EGR valve. Check valve for sticking, carbon
deposits and damage. Clean valve with solvent if necessary. Apply 19.8
in. Hg to valve diaphragm. If valve does not hold vacuum, replace
valve.
2) Apply specified vacuum to valve diaphragm. See CLOSED IN.
HG in EGR VALVE SPECIFICATIONS table. If valve begins to open below
specification, replace valve.
3) Apply specified vacuum to valve diaphragm. See OPEN IN. HG
in EGR VALVE SPECIFICATIONS table. If valve is not completely open at
or above specification, replace valve.

EGR VALVE SPECIFICATIONS TABLE

Application Closed Open
In. Hg In. Hg

Montero ....................... 2.4 ........... 6.7

Pickup & Ram-50 ............... 1.2 ........... 9.4

FUEL EVAPORATION
System Test
1) Disconnect Red-striped purge hose from throttle body, and
connect to hand vacuum pump. Plug nipple on throttle body where purge
hose was removed.  
2) With engine coolant temperature at 140 F (60 C) or less
and engine idling, apply 14.8 in. Hg. Vacuum should hold. Raise engine
speed to 3000 RPM and again apply 14.8 in. Hg. Vacuum
 should
 hold.
3) With engine coolant temperature at 158 F (70 C) or more
and engine idling, apply 14.8 in. Hg. Vacuum should hold. Turn engine
off. Start engine and within 3 minutes of starting engine, apply
vacuum. Vacuum should bleed down.
4) With engine running for more than 3 minutes after
starting, raise engine speed to 3000 RPM and apply 14.8 in. Hg. Vacuum
should hold momentarily and then bleed down.

NOTE: In step 4), vacuum should bleed down continuously if vehicle

is at an altitude of 7200 ft.  (2200  m) or higher or if
intake air temperature is 122 F (50 C) or higher.
Purge Control Solenoid Valve
1) Purge control solenoid valve is located near left shock
tower. Label and disconnect both vacuum hoses from solenoid valve.
Disconnect electrical connector. Connect hand vacuum pump to solenoid
valve nipple where Red-striped hose was connected. Apply vacuum to
solenoid valve. Vacuum should hold.
2) Apply battery voltage to terminals of solenoid valve.
Vacuum should bleed down when voltage is applied to terminals. Using
an ohmmeter, check resistance
 across
 solenoid valve terminals. Reading
should be 36-44 ohms at 68 F (20 C). If reading is not within
specification, replace valve.

POSITIVE CRANKCASE VENTILATION (PCV)

PCV Valve
Remove PCV valve, and insert thin screwdriver into threaded
end of valve to ensure plunger moves.