Thanks in advance for reading! (Long)

I have an 89 3.0 V6 Montero LS with automatic transmission. It has gotten some issues of late that I can't seem to get my arms around.

1) Diagonostic (trouble codes). I have searched without success for an OBD1 port on this vehicle. According to Chilton Manual I should find it under the fuse panel. NOT (unless I am looking for some other type of port (non OBD1) that I dont recognize as the diagnostic port, I don't see any port there I would guess to be diagnostics).

2) My check engine light stays on constantly and does not flash. Most OBD1 vehicles I have owned in the past and present have a flashing light when a code is present. What is the likely cause of a "constant light"? On a Mitsubishi, does a constant light indicate a stored code?

3) Starter Issue. I have installed 2 rebuilt starter solenoids and a rebuild starter with solenoid (that would be 3 solenoids) total. I'm still getting an intermitent failure of the starter drive gear to engage the fly wheel. It just 'clicks'. If I turn the key enough times (i.e. click it several times) it will eventually catch. What could this be other than the solenoid? My battery was replaced this Spring and shows 12 plus volts when engine is off. There is no indication that I have insufficient voltage to the starter. I have not attempted to meassure cranking amps under load, as I'm not familiar with that test, but should I check that? Would a weak battery (interms of cranking amps) cause this issue.? I can have Schuck's Auto check this for me if needed.

4) Cold Start Issue. When I first crank it over in the morning (48 - 60 degrees ambient air temperature), if issue 3 is resolved and the engine cranks, it tries to start but sputters. The next try it runs a bit longer and then dies. After several progressively longer sputtering idle runs it will finally keep running and then smooth out. No problems the rest of the day with initial start once it cranks (ref. Issue 3).

Any help or suggestions will be greatly appreciated!

Tom

1) The diagnostic port is on the passenger side, behind the glove box.

2) The CEL is set only by accumulated mileage - there's a re-set switch on the rear of the instrument cluster.

3) There are about 17 electrical connections between the battery and the starter solenoid switch - all of which can contribute to voltage drop - particularly under load. Common problems other than a bad solenoid switch include the electrical portion of the ignition switch which is easily replaced. Search under my name for installing a secondary relay to send full battery voltage directly to the starter solenoid switch by using a Ford type relay triggered by the original solenoid wiring. The Ford relay will throw with as little as 6 volts without drawing a large load.

4) You need to download the FSM on MontyMcV's site and go through the normal diagnostic trouble-shooting regime.

Frank

1) In my '89 Raider the diagnostic connector is behind the glove box. Go here: not-so-sooper-sekret-linky and get the Factory Service Manuals for the '89 if you don't already have them. There you will find a wealth of information regarding the codes, how to read them with a standard analog voltmeter, etc. Be sure to shoot Bill (MontyMcV) a BIG "Thank You!" for that site.<img src="/forums/images/graemlins/kewl.gif" alt="" />

2)I don't think these vehicles have a flashing check engine light, but I could be wrong. Mine's always been solid on.

3) Sounds like possibly a dirty ground? I recall there's some issues with the way the starting circuit is wired (again, the link in #1 gets you the wiring diagrams) and I think some on this forum (FrankR perhaps?) have done some bypass wiring with a relay to hook directly to the battery to get around these issues. The search tool (while kind of finicky and cranky) will be your friend here. Use "+" in front of the terms you search for, such as +starter +ground, etc.

4) Sounds like a fuel pump getting ready to fail. When mine went, it had similar symptoms. It lasted about a week before failing completely. Fortunately you can access the fuel pump from the access plate in the back of the truck and don't have to drop the fuel tank to replace it. If you end up replacing the fuel pump, be aware that the high pressure fuel line can be very difficult to get off. Search my user name to find some longish, rambling posts about what I went through to replace my pump. Lots of good anecdotal stuff about what not to do <img src="/forums/images/graemlins/rolleyes.gif" alt="" />

Good luck, and be sure to post up what you find out -- it's always good to hear how people's troubles get resolved <img src="/forums/images/graemlins/kewl.gif" alt="" />

Eric W.

Dang it, Frank... you typed faster than me <img src="/forums/images/graemlins/cyclops.gif" alt="" />

Eric W.

Re #4, I suspect the engine ecu coolant temp sensor, on the thermostat housing. Two wires, contacts in a tee shape. Engine is not getting cold start enrichment and runs too lean until it warms up some. You have exactly the same symptoms mine had when my CTS failed. This is a pretty cheap part, and usually available at your local parts house.

Re the starter, see if it cranks fine if you jumper 12v from the fat starter wire to the solenoid wire after you get a clicky no start. If so, I'd replace the electrical part of the ign. switch if all the wiring connections are good. Start with cleaning the solenoid wire connector, as it's the one out in the weather...

First of all, thanks Guys(89IsMine, fasteddy, and FrankR) for the replies. Very informative and I know it takes time to read and respond. Very much appreciated!

1) My Chilton suggested the port be under the left side of the dash near the fuse panel. :-(
2) Had no clue about the CEL reset FrankR. Thanks
3) Will read your post FrankR
4) Headed for MontyMcV's now

I love these old Monty's and tinkering with them, but some issues leave me clueless. This forum is great! I will no longer even waste my time on the other forums related to Mitsubishi Montys.

Tom

Tom,

Since you have an 89 v6, I'd suggest downloading the factory service manual for future reference. Once you have that, you'll likely put the chiltons to more effective use as a door stop or bbq fire starter material. <img src="/forums/images/graemlins/lol.gif" alt="" />

Glad to hear your passion for Montero's & especially glad you found the wire. It is IMHO without equal as the best online resource for our rigs. <img src="/forums/images/graemlins/kewl.gif" alt="" />

Guys I guess I'm being a bit slow in understanding where I go to download the FSM? Thanks

No worries. If you had 200 posts and were asking where to find it, I might say that's a problem but with 12 posts.. not an issue. <img src="/forums/images/graemlins/smile.gif" alt="" /> <img src="/forums/images/graemlins/cheers.gif" alt="" />

Did I hear the mailman?

Tom, in my original reply there was a link you could click that would take you there. If that doesn't work for some reason, copy/paste http://www.mitsubishilinks.com into your browser and that will take you there too. Once there, find the links for the appropriate Factory Service Manual for your year (or whatever is closest) and clink the link to download.

Eric W.