Mitsubishi Montero Sport (2004+). Manual - part 542

HEADLIGHT

TSB Revision

CHASSIS ELECTRICAL

54-155

HEADLIGHT RELAY CHECK

DRL RELAY (LOWER AND UPPER) CHECK 

BATTERY 
VOLTAGE

TESTER 
CONNECTION

SPECIFIED 
CONDITION

Not applied

4 

− 5

Open circuit

• Connect terminal 3 

to the positive 
battery terminal

• Connect terminal 1 

to the negative 
battery terminal

4 

− 5

Less than 2 
ohms

AC309547AB

HEADLIGHT
RELAY

BATTERY 
VOLTAGE

TESTER 
CONNECTION

SPECIFIED 
CONDITION

Not applied

1 

− 3

Open circuit

• Connect terminal 4 

to the positive 
battery terminal

• Connect terminal 2 

to the negative 
battery terminal

1 

− 3

Less than 2 
ohms

AC202569

1

2

3

4

DRL RELAY 
(LOWER)

DRL RELAY 
(UPPER)

AC

FOG LIGHT

TSB Revision

CHASSIS ELECTRICAL

54-156

FOG LIGHT

LIGHTING SYSTEM DIAGNOSIS

INTRODUCTION TO FOG LIGHT DIAGNOSIS

M1542010500508

If the fog light cannot be on, the fuse fog light relay or 
fog light switch may be faulty.

FOG LIGHT DIAGNOSTIC TROUBLESHOOTING STRATEGY

M1542010600129

Use these steps to plan your diagnostic strategy. If 
you follow them carefully you will be sure that you 
have exhausted most of the possible ways to find a 
fog light fault.

1. Gather information from the customer.
2. Verify that the condition described by the 

customer exists.

ON-VEHICLE SERVICE

FOG LIGHT AIMING

M1542001100267

PRE-AIMING INSTRUCTIONS

1. Inspect for badly rusted or faulty headlight assemblies.
2. These conditions must be corrected before a satisfactory 

adjustment can be made.

3. Inspect tire inflation, and adjust if necessary.
4. If the fuel tank is not full, place a weight in luggage room of 

vehicle to simulate weight of a full tank [3 kg (6.5 pounds) 
per gallon.]

5. There should be no other load in the vehicle other than 

driver or substituted weight of approximately 70 kg (150 
pounds) placed in driver's position.

6. Thoroughly clean fog light lenses.
7. Place the vehicle on a level floor, perpendicular to a flat 

screen 7.62 m (25.0 feet) away from the bulb center-marks 
on the fog light lens.

8. Rock vehicle sideways to allow vehicle to assume its normal 

position.

9. Bounce the front suspension through three (3) oscillations 

by applying the body weight to hood or bumper.

10.Measure the center of the fog lights as shown in the 

illustration.

AC002787 AB

FOG LIGHT BULB CENTER

FOG LIGHT

TSB Revision

CHASSIS ELECTRICAL

54-157

11.Four lines of adhesive tape (or equivalent markings) are 

required on screen or wall:

(1) Position a vertical tape or mark so that it is aligned with 

the vehicle center line.

(2) Measure the distance from the center-marks on the fog 

light lens to the floor. Transfer the measurement to the 
screen. Horizontal tape or mark on the screen is for 
reference of vertical adjustment.

(3) Measure the distance from the center line of the vehicle 

to the center of each fog light. Transfer the measurement 
to the screen. Vertical tape or mark on the screen with 
reference to the center line of each fog light bulb.

FOG LIGHT ADJUSTMENT

1. The fog light will project on the screen upper edge of the 

high intensity zone.

2. Turn the adjusting screws to achieve the specified upper 

edge of the high intensity zone on the aiming screen.

Standard value:

(Vertical direction): Top of the hot zone should be 

101 mm (4.0 inches) (0.76

°) downward from the 

height of the fog light center.

Limit:

(Vertical direction): Top of the hot zone should be 

15.24 cm (1.14

°) in maximum downward from the 

height of the fog light center.

NOTE: The horizontal direction is non-adjustable. If the devia-
tion of the light beam axis exceeds the standard value, check 
for improper/defective mounting location.

CAUTION

When making the aiming adjustment, be sure to block the 
beam of those lights which are not being adjusted.

 BULB REPLACEMENT

M1542001300346

1. Remove the fog light.
2. Loosen the shown screws to remove the cover.

AC005167

SCREEN

(1)

(2)

(3)

(3)

FOG LIGHT CENTER

VEHICLE CENTER  
LINE

7.62m (25.0 ft)

AD

AC100547

HEIGHT OF FOG

LIGHT CENTER

VERTICAL CENTER LINE 

AHEAD OF FOG LIGHT

UPPER MOST LEVEL 

OF HOT ZONE

HOT ZONE

mm (in)

AB

152 (6.0)

101 (4.0)

598 (23.5)

598 (23.5)

AC002788AB

ADJUSTING SCREW

AC002789AB

COVER

FOG LIGHT

TSB Revision

CHASSIS ELECTRICAL

54-158

CAUTION

• Do not touch the surface of the bulb with hands or dirty 

gloves. If the surface does become dirty, clean it with 
alcohol or thinner, and let it dry thoroughly before 
installing.

• Improper installation of the under cover causes a unit. 

Make sure that the under cover is installed properly.

3. Unlock the spring which secures the bulb and then remove 

the bulb.

FOG LIGHT

REMOVAL AND INSTALLATION

M1542001500287

AC003019

SPRING

AB

AC002791

1

2

AB

3

1. FOG LIGHT SWITCH

FOG LIGHT REMOVAL STEPS

2. INTERCOOLER GRILL
3. FOG LIGHT