MITSUBISHI MONTERO 1991 Service Manual

Manufacturer: MITSUBISHI, Model Year: 1991, Model line: MONTERO, Model: MITSUBISHI MONTERO 1991
Pages: 1333, PDF Size: 24.61 MB
Search: (ABS, wheelbase, steering, maintenance schedule, dashboard, dead battery)
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Page 501 of 1333

Missing (if original
equipment) ............. C ........... Require replacement.
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COOLING FAN MOTOR MODULES
See COOLING FAN MOTOR RELAYS AND MODULES .
COOLING FAN MOTOR RELAYS AND MODULES
COOLING FAN MOTOR RELAY AND MODULE INSPECTION\
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... ( 1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Housing cracked ......... 2 .. Suggest repair or replacement.
Malfunctioning .......... A ........... ( 2) Require repair or
replacement.
Missing ................. C ............ Require replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Includes inoperative, intermittent operation, failure
to perform all functions, or out of OEM specification.
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COOLING FAN MOTOR RESISTORS
COOLING FAN MOTOR RESISTOR INSPECTION\
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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... (1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Missing ................. C ............ Require replacement.
Open .................... A ............ Require replacement.
Resistance out of
specification .......... B .. Require repair or replacement.
Shorted ................. A ............ Require replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance ... 2 . Suggest repair or replacement.
Terminal corroded,
affecting performance ... A . Require repair or replacement.
Terminal corroded, not
affecting performance ... 2 . Suggest repair or replacement.
Terminal loose, affecting
performance ............. B . Require repair or replacement.
Terminal loose, not
affecting performance ... 1 . Suggest repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
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COOLING FAN MOTOR SENSORS AND SWITCHES
COOLING FAN MOTOR SENSOR AND SWITCH INSPECTION\
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Condition Code Procedure
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware threads
damaged ................ A ... Require repair or replacement
of hardware.
Attaching hardware
threads stripped
(threads missing) ...... A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector melted ........ A ........... ( 1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Contaminated ............ A ........... ( 2) Require repair or

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replacement.
Inoperative ............. B ........... (3) Require repair or
replacement. Further
inspection required.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Resistance out of
specification .......... B .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Determine source of contamination, such as engine
coolant, fuel, metal particles, or water. Require
repair or replacement.
( 3) - Inoperative includes intermittent operation or out of
OEM specification. Some components may be serviceable;
check for accepted cleaning procedure.
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COOLING FAN MOTOR SWITCHES
See COOLING FAN MOTOR SENSORS AND SWITCHES .
COOLING FAN MOTORS
COOLING FAN MOTOR INSPECTION\
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Condition Code Procedure
Attaching hardware
broken ................. A .. Require repair or replacement
of hardware.
Attaching hardware
missing ................ C ......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A .. Require repair or replacement
of hardware.
Connector broken ........ A . Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A . Require repair or replacement.

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Connector melted ........ A .......... (1) Require repair or
replacement.
Connector missing ....... C ........... Require replacement.
Hydraulic fan motor
leaking ................ A . Require repair or replacement.
Inoperative ............. A ....... ( 2) Require replacement.
Missing ................. C ........... Require replacement.
Noisy ................... 2 ........... Suggest replacement.
Rotation incorrect for
application ............ B . Require repair or replacement.
Terminal broken ......... A . Require repair or replacement.
Terminal burned, affecting
performance ............ A .......... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 . Suggest repair or replacement.
Terminal corroded,
affecting performance .. A . Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 . Suggest repair or replacement.
Terminal loose, affecting
performance ............ B . Require repair or replacement.
Terminal loose, not
affecting performance .. 1 . Suggest repair or replacement.
Vibration ............... 1 ........... Suggest replacement.
Wire lead conductors
exposed ................ B . Require repair or replacement.
Wire lead corroded ...... A . Require repair or replacement.
Wire lead open .......... A . Require repair or replacement.
Wire lead shorted ....... A . Require repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Check fan motor/controls. Inoperative includes
intermittent operation or out of OEM specification.
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CRANKSHAFT POSITION SENSORS
CRANKSHAFT POSITION SENSOR INSPECTION\
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Condition Code Procedure
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of hardware.
Attaching hardware
threads stripped
(threads missing) ...... A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... ( 1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Contaminated ............ A .. Require repair or replacement.
Inoperative ............. B .. Require repair or replacement.
Further inspection required.
Leaking ................. A .. Require repair or replacement.

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Missing ................. C ............ Require replacement.
Resistance out of
specification .......... B .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... (1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Determine source of contamination, such as engine
coolant, fuel, metal particles, or water. Require
repair or replacement.
( 3) - Inoperative includes intermittent operation or out of OEM
specification. Some components may be serviceable; check
for accepted cleaning procedure.
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DECEL VALVES
See ASPIRATOR, CHECK AND DECEL VALVES .
DEFLECTORS
See SHROUDS, BAFFLES AND DEFLECTORS .
DIP STICKS AND TUBES
DIP STICK AND TUBE INSPECTION\
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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Bent .................... 2 .. Suggest repair or replacement.
Broken, affecting
performance (for example,
fuel mixture) .......... A .. Require repair or replacement.
Broken, not affecting
performance ............ 2 .. Suggest repair or replacement.
Leaking, affecting
performance (for example,
fuel mixture) .......... A .. Require repair or replacement.
Leaking, not affecting
performance ............ 2 .. Suggest repair or replacement.
Missing C Require replacement.

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DIP STICK TUBES
See DIP STICKS AND TUBES .
DISTRIBUTOR ADVANCES AND RETARDERS (MECHANICAL AND VACUUM)
DISTRIBUTOR ADVANCE AND RETARDER (MECHANICAL AND VACUUM) INSPECTION\
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Binding ................. A .. Require repair or replacement.
Inoperative ............. A ........... ( 1) Require repair or
replacement.
Leaking ................. A ............ Require replacement.
Out of specification .... B .. Require repair or replacement.
( 1) - Inoperative includes intermittent operation.
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DISTRIBUTOR BOOTS AND SHIELDS
DISTRIBUTOR BOOT AND SHIELD INSPECTION\
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Deteriorated ............ A ............ Require replacement.
Leaking ................. A ............ Require replacement.
Missing ................. A ............ Require replacement.
Torn .................... A ............ Require replacement.
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DISTRIBUTOR CAPS
DISTRIBUTOR CAP INSPECTION\
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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Arcing .................. A ............ Require replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.

Page 507 of 1333

Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Burned .................. A ............ Require replacement.
Carbon button missing ... A ............ Require replacement.
Carbon button worn,
affecting performance .. A ............ Require replacement.
Carbon button worn, not
affecting performance .. 1 ............ Suggest replacement.
Carbon-tracked .......... A ............ Require replacement.
Cracked ................. A ............ Require replacement.
Loose ................... 2 .. Suggest repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... (1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal eroded, affecting
performance ............ A .. Require repair or replacement.
Terminal eroded, not
affecting performance .. .. ........ No service suggested or
required.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
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DISTRIBUTOR RETARDERS (MECHANICAL AND VACUUM)
See
DISTRIBUTOR ADVANCES AND RETARDERS (MECHANICAL AND VACUUM) .
DISTRIBUTOR ROTORS
DISTRIBUTOR ROTOR INSPECTION\
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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Carbon-tracked .......... A ............ Require replacement.
Contact burned .......... A ............ Require replacement.
Corroded ................ 1 ............ Suggest replacement.

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Eroded .................. 1 ............ Suggest replacement.
Loose ................... A .. Require repair or replacement.
Out of specification .... B ............ Require replacement.
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DISTRIBUTOR SHIELDS
See DISTRIBUTOR BOOTS AND SHIELDS .
DISTRIBUTORS
DISTRIBUTOR INSPECTION\
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Bushings worn, affecting
performance ............ A .. Require repair or replacement.
Bushings worn, not
affecting performance .. 1 .. Suggest repair or replacement.
Cam lobes worn, affecting
performance ............ A .. Require repair or replacement.
Cam lobes worn, not
affecting performance .. 1 .. Suggest repair or replacement.
Gear broken ............. A .. Require repair or replacement.
Gear worn, affecting
performance ............ A ............ Require replacement.
Gear worn, not affecting
performance ............ .. ........ No service suggested or
required.
Integrated pickup
triggering device
loose .................. A .. Require repair or replacement.
Integrated pickup
triggering device
magnetism incorrect .... A .. Require repair or replacement.
Leaking oil internally .. A .. Require repair or replacement.
Noisy ................... 2 .. Suggest repair or replacement.
Pickup triggering device
(reluctor) broken ...... A .. Require repair or replacement.
Pickup triggering device
(reluctor) loose ....... A .. Require repair or replacement.
Pickup triggering device
(reluctor) weak ........ A .. Require repair or replacement.
Reluctor (pickup
triggering device)
broken ................. A .. Require repair or replacement.
Reluctor (pickup
triggering device)
loose .................. A .. Require repair or replacement.
Reluctor (pickup
triggering device)
weak ................... A .. Require repair or replacement.
Shaft bent .............. A ............ Require replacement.
Thrust washer broken .... A .. Require repair or replacement.

Page 509 of 1333

Thrust washer missing ... C .. Require repair or replacement.
Thrust washer worn,
affecting performance .. A .. Require repair or replacement.
Thrust washer worn, not
affecting performance .. 1 .. Suggest repair or replacement.
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EARLY FUEL EVAPORATION VALVES (HEAT RISER ASSEMBLIES)
EARLY FUEL EVAPORATION VALVE (HEAT RISER ASSEMBLY) INSPECTION\
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Condition Code Procedure
Broken .................. A . Require replacement of affected
parts.
Diaphragm inoperative ... A .......... ( 1) Further inspection
required.
Leaking ................. A .. Require repair or replacement.
Noisy ................... 2 .. Suggest repair or replacement.
Seized .................. A . Require replacement of affected
parts.
Spring broken ........... B .......... Require replacement of
spring(s).
Spring inoperative ...... A ...... ( 2) Require replacement of
spring(s).
( 1) - Inoperative includes intermittent operation or out of
OEM specification. If the inoperative diaphragm is
separate from the heat riser, then require replacement
of the inoperative diaphragm. If the inoperative
diaphragm is part of the heat riser, then replace the
heat riser.
( 2) - Inoperative includes intermittent operation or out of OEM
specification.
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EGR COOLERS
See EGR PLATES AND COOLERS .
EGR EXHAUST MANIFOLD PASSAGES
See EGR INTAKE AND EXHAUST MANIFOLD PASSAGES .
EGR INTAKE AND EXHAUST MANIFOLD PASSAGES
EGR INTAKE AND EXHAUST MANIFOLD PASSAGE INSPECTION\
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Condition Code Procedure
Leaking ................. A .. Require repair or replacement.
Restricted, affecting
performance ............ A .. Require repair or replacement.
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EGR PLATES AND COOLERS
EGR PLATE AND COOLER INSPECTION\
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Condition Code Procedure
Leaking ................. A .. Require repair or replacement.

Page 510 of 1333

Missing ................. C ............ Require replacement.
Restricted, affecting
performance ............ A .. Require repair or replacement.
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ELECTRONIC SPARK CONTROL MODULES
ELECTRONIC SPARK CONTROL MODULE INSPECTION\
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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of hardware.
Attaching hardware
threads stripped
(threads missing) ...... A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... ( 1) Require repair or
replacement.
Connector missing ....... A ................. Require repair.
Contaminated ............ A ........... ( 2) Require repair or
replacement.
Leaking ................. A .. Require repair or replacement.
Malfunctioning .......... A ........... ( 3) Require repair or
replacement.
Missing ................. C ............ Require replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Determine source of contamination, such as engine coolant,
fuel, metal particles, or water. Require repair or
replacement of source.
( 3) - Includes inoperative, intermittent operation, failure to

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