bulb MITSUBISHI MONTERO 1991 Service Manual

\003* B RAK E S YSTE M U NIF O RM IN SPEC TIO N G UID ELIN ES *
1 991 M it s u bis h i M onte ro
GENERAL INFORMATION
Brake Systems - Motorist Assurance Program
Standards For Automotive Repair
All Makes & Models
CONTENTS
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS
ACCELEROMETERS (G SENSOR OR LATERAL)
ACCUMULATORS
ANCHOR PINS
ANTI-LOCK BRAKE SYSTEMS
BACKING PLATES
BRAKE FLUID
BRAKE FRICTION MATERIAL
BRAKE PADS
BRAKE PEDALS
BRAKE SHOES
BRAKE SHOE HARDWARE
BRAKE STOPLIGHT SWITCHES
BULB SOCKETS
BULBS AND LEDS
CALIPER HARDWARE
CALIPERS
CONTROLLERS
DIGITAL RATIO AXLE CONTROLLERS AND BUFFERS (DRAC AND DRAB)
DISABLE SWITCHES
DRUMS
ELECTRICAL PUMPS AND MOTORS
ELECTRONIC CONTROLLERS
FLUID
FLUID LEVEL SENSOR SWITCHES
FOUR WHEEL DRIVE SWITCHES
FRICTION MATERIAL
G SENSORS
HOSES
HYDRAULIC MODULATORS
HYDRO-BOOSTERS
HYDRO-ELECTRIC BOOSTERS (POWERMASTER)
IGNITION DISABLE SWITCHES
LATERAL ACCELERATION SWITCHES
LEDS
LENSES
MASTER CYLINDERS
MODULATORS
MOTORS
PARKING BRAKE SWITCHES
PARKING BRAKE SYSTEMS
PADS
PEDAL TRAVEL SWITCHES
PEDALS
POWERMASTER
PUMPS
PRESSURE DIFFERENTIAL SWITCHES
PRESSURE SWITCHES
RELAYS
ROTORS
SELF-ADJUSTING SYSTEMS

Connector melted ........ A ........ (1) Require replacement.
Connector missing ....... C ............ Require replacement.
Missing ................. C ............ Require replacement.
Out of adjustment ....... B ........... Require adjustment or
replacement.
Output signal incorrect . B ............ Require replacement.
Terminal burned, affecting
performance ............ A .............. ( 2) 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.
( 1) - Determine cause and correct prior to replacement of part.
( 2) - Determine cause and correct prior to repair or replacement
of part.









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BULB SOCKETS
BULB SOCKET 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.
Broken .................. A .. Require repair or replacement.
Bulb seized in socket ... A .. Require repair or replacement.
Burned, affecting
performance ............ A .............. ( 1) Require repair
or replacement.
Burned, not affecting
performance ............ 2 .............. ( 1) Suggest repair
or replacement.
Connector broken ........ A .. Require repair or replacement.
Connector missing ....... C ............ Require replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A .............. ( 2) Require repair
or replacement.
Corroded, affecting
performance ............ A .. Require repair or replacement.
Corroded, not affecting
performance ............ 2 .. Suggest repair or replacement.
Leaking ................. A .. Require repair or replacement.
Melted .................. A ........ ( 2) Require replacement.

Shorted ................. A .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A .............. (2) 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 socket.
( 2) - Determine cause and correct prior to repair or
replacement of part.









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BULBS AND LEDS
NOTE: Copied from Electrical UIGs and modified. Does not
include soldered-in components.
BULB AND LED INSPECTION









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Condition Code Procedure
Application incorrect ... B ........ ( 1) Require replacement.
Base burned, affecting
performance ............ A .............. ( 2) Require repair
or replacement.
Base burned, not affecting
performance ............ 2 .............. ( 2) Suggest repair
or replacement.
Base corroded, affecting
performance ............ A .. Require repair or replacement.
Base corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Base loose, affecting
performance ............ B .. Require repair or replacement.
Base loose, not affecting
performance ............ 1 .. Suggest repair or replacement.
Burned out .............. A ............ Require replacement.
Intermittent ............ A ............ Require replacement.
Missing ................. C ............ Require replacement.
Seized in socket ........ A .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A .............. ( 2) Require repair
or replacement.
Terminal burned, not
affecting performance .. 2 .............. ( 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) - Application incorrect includes wrong bulb coating
or color.
( 2) - Determine cause and correct prior to repair or
replacement of part.









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CALIPER HARDWARE
CALIPER HARDWARE INSPECTION








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Condition Code Procedure
Bent ................... A .. Require repair or replacement.
Broken .................. A .. Require repair or replacement.
Corroded, affecting
performance ............ A .. Require repair or replacement.
Dust boots on slider pin
(bolt) missing ......... C ... Require replacement of boots.
Dust boots on slider pin
(bolt) torn ............ A ... Require replacement of boots.
Missing ................. C ............ Require replacement.
Shim bent ............... A ............. ( 1) Require removal
or replacement.
Shim (OE standard)
missing ................ C ........ ( 2) Require replacement.
Shim out of position .... B ............. ( 1) Require removal
or replacement.
Shim worn ............... A ............. ( 1) Require removal
or replacement.
Slider pin (bolt) bent .. B ... Require replacement of slider
pin or bolt and lubricants.
Slider pin (bolt)
rust-pitted ............ A ... Require replacement of slider
pin or bolt and lubricants.
Slider pin (bolt) worn .. A ... Require replacement of slider
pin or bolt and lubricants.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Worn, affecting
performance ............ A ............ Require replacement.
( 1) - Removal is acceptable if shim is not OE.
( 2) - Aftermarket shims may be suggested to reduce noise.









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CALIPERS
You are not required to replace or rebuild calipers in axle
sets. However, when replacing or rebuilding a caliper due to the
conditions that follow, you may suggest servicing, rebuilding, or
replacement of the other caliper (on the same axle) for improved
performance and preventive maintenance (for example, the part is close
to the end of its useful life, replacing the caliper may extend pad
life, or contribute to more balanced braking).
CAUTION: When installing loaded calipers, it is required that
friction material be matched in axle sets for consistent
braking characteristics.

LATERAL ACCELERATION SWITCHES
See ACCELEROMETERS .
LEDS
See BULBS AND LEDS .
LENSES
LENSE INSPECTION








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Condition Code Procedure
Application incorrect ... A ............ 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.
Broken, affecting
performance ............ A ............ Require replacement.
Broken, not affecting
performance ............ .. ........ No service suggested or
required.
Cracked ................. A ............ Require replacement.
Discolored .............. A ............ Require replacement.
Leaking ................. A .. Require repair or replacement.
Melted, affecting
performance ............ A ............ Require replacement.
Melted, not affecting
performance ............ 2 ............ Suggest replacement.
Missing ................. C ............ Require replacement.









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MASTER CYLINDERS
MASTER CYLINDER INSPECTION








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Condition Code Procedure
Brake fluid leaking from
rear of master cylinder
bore ................... B .. Require repair or replacement.
Brake pedal drops
intermittently ......... A ........... ( 1) Require repair or
replacement.
Fluid level low ......... .. ......... ( 2) Further inspection
required.
Internal valve failure .. A .. Require repair or replacement.
Master cylinder leaking
brake fluid internally . A .. Require repair or replacement.
Piston does not return .. A .. Require repair or replacement.
Ports plugged ........... A .. Require repair or replacement.
Rubber master cylinder
cover gasket distorted
and gummy .............. A .. ( 3) Require replacement of the
gasket.

reconditioning ......... B ........ (3) Require replacement.
Surface is rust-pitted .. B ....... Require reconditioning or
replacement of rotor according
to OEM specifications.
Surface is scored ....... B ... ( 4) Require reconditioning or
replacement of rotor according
to OEM specifications.
Thickness variation
(parallelism) exceeds OEM
specifications .......... B ....... Require reconditioning or
replacement of rotor according
to OEM specifications.
( 1) - Examples of severe corrosion are: composite plate
separated from friction surfaces and cooling fins
cracked or missing.
( 2) - Only applies to vehicles for which OEM "machine to"
specifications exist. If OEM does not supply "machine
to" specifications, the rotor may be worn to discard
specifications.
( 3) - If OEM does not supply "machine to" specifications,
you may machine to discard specifications.
( 4) - Scoring is defined as grooves or ridges in the friction
contact surface. Some vehicle manufacturers require
machining when scoring exceeds their allowable
specifications.









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SELF-ADJUSTING SYSTEMS
SELF-ADJUSTING SYSTEM INSPECTION








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Condition Code Procedure
Bent .................... A ... Require repair or replacement
of bent part.
Broken .................. A ... Require repair or replacement
of broken part.
Inoperative ............. A ........... ( 1) Require repair or
replacement of inoperative
parts.
Missing ................. C .......... Require replacement of
missing part.
Star wheel does not turn
freely ................. A .. Require repair or replacement.
( 1) - Inoperative includes intermittent operation.









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SHOE HARDWARE
See BRAKE SHOE HARDWARE .
SHOES
See FRICTION MATERIAL .
SOCKETS
See BULB SOCKETS.
SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)

\003
DEFO GGER - R EA R W IN DO W

1991 M it s u bis h i M onte ro
1991 ACCESSORIES & SAFETY EQUIPMENT
Chrysler Corp./Eagle/Mitsubishi Defoggers - Rear Window
Dodge; Colt, Colt Vista, Colt 200, Stealth
Eagle; Summit
Mitsubishi: Eclipse, Galant, Mirage, Montero, 3000GT
Plymouth; Colt, Colt Vista, Colt 200
DESCRIPTION & OPERATION
The rear window defogger is a heating wire grid bonded to the
inside of the window. Heat is regulated by a control switch located on
the instrument panel.
TROUBLE SHOOTING
DEFOGGER DOES NOT WORK
Check for blown fuse, poor contact, defective defogger
switch, poor connection or open wire.
INDICATOR LIGHT DOES NOT WORK
Check for burned out bulb, open wire or poor connection.
TESTING
NOTE: Testing information for all components on all vehicles is
not available from manufacturer.
DEFOGGER SWITCH TEST
NOTE: Remove window defogger switch and disconnect switch
connector for the following test.
Colt, Colt 200, Mirage & Summit
Turn defogger switch to OFF position. Check switch continuity
using ohmmeter. Continuity should be present between terminals No. 3
and 6. See Fig. 1. Turn defogger switch to ON position. Continuity
should be present between terminals No. 1 and 5, 2 and 4, and 3 and 6.
Colt Vista
Turn defogger switch to OFF position. Check switch continuity
using ohmmeter. Continuity should be present between terminals No. 3
and 6, and terminals No. 4 and 1. See Fig. 1. Turn defogger switch to
ON position. Continuity should exist between terminals No. 5 and 2, 3
and 6, and 4 and 1.
Eclipse
Turn defogger switch to OFF position. Check switch continuity
using ohmmeter. Continuity should be present between terminals No. 1
and 5, and terminals No. 2 and 6. Turn defogger switch to ON position.
Continuity should be present between terminals No. 3 and 4, 1 and 5,
and 2 and 6. See Fig. 1.
Galant
Turn defogger switch to OFF position. Check switch continuity

\003
* E LE C TR IC AL S YSTE M U NIF O RM IN SPEC TIO N G UID ELIN ES *

1 991 M it s u bis h i M onte ro
GENERAL INFORMATION
Electrical System Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
ACTUATOR MOTORS (SOLENOIDS) (ELECTRIC)
ACTUATOR MOTORS (VACUUM)
AIR BAGS
ALTERNATORS AND GENERATORS
AMPLIFIERS
ANTENNAS
BATTERIES
BATTERY CABLES
BATTERY CABLES
BATTERY HOLD DOWN HARDWARE
BATTERY TRAYS AND HOLD DOWN HARDWARE
BATTERY WIRES
BELTS
BULB SOCKETS
BULBS, SEALED BEAMS AND LEDS
CD PLAYERS
CIGARETTE LIGHTER ASSEMBLIES
CIRCUIT BREAKERS
CLUTCH SWITCHES
CONNECTORS
CONTROL MODULES
CRUISE CONTROL BRAKE SWITCHES
CRUISE CONTROL CABLES
CRUISE CONTROL CLUTCH SWITCHES
CRUISE CONTROL LINKAGES AND CABLES
CRUISE CONTROL RESERVOIRS
CRUISE CONTROL TUBES
CRUISE CONTROL VACUUM DUMP RELEASE VALVES
CRUISE CONTROL VACUUM HOSES, TUBES AND RESERVOIRS
CRUISE CONTROL VEHICLE SPEED SENSORS
DEFOGGERS
DEFROSTERS
DELAYS
DIMMERS
ELECTRIC HEATERS
EQUALIZERS
FUSE BLOCKS
FUSE BOXES AND BLOCKS
FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS
FUSIBLE LINKS
GAUGES
GENERATORS
GROUND CABLES AND STRAPS
GROUND STRAPS
HEADLIGHT ADJUSTERS
HEATING ELEMENTS (DEFROSTERS, DEFOGGERS, ELECTRIC HEATERS AND SEATS)
HORNS AND SIRENS

performance ............ .. ........ No service suggested or
required.
Broken, affecting
performance ............ A .. Require repair or replacement.
Broken, not affecting
performance ............ .. ........ No service suggested or
required.
Corroded, affecting
performance ............ A .. Require repair or replacement.
Corroded, not affecting
performance ............ 2 .. Suggest repair or replacement.
Cracked, affecting
performance ............ A .. Require repair or replacement.
Cracked, not affecting
performance ............ 1 .. Suggest repair or replacement.
Missing ................. C ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Water drain clogged ..... A ................. Require repair.









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BATTERY WIRES
See BATTERY CABLES, WIRES AND CONNECTORS .
BELTS
BELT INSPECTION








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Condition Code Procedure
Alignment incorrect ..... B .......... ( 1) Further inspection
required.
Cracked ................. 1 ............ Suggest replacement.
Frayed .................. 1 ............ Suggest replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .......... ( 2) Further inspection
required.
Plies separated ......... A ............ Require replacement.
Tension out of
specification .......... B ........... Require adjustment or
replacement.
Worn beyond adjustment
range .................. B ............ Require replacement.
Worn so it contacts bottom
of pulley .............. A ............ Require replacement.
( 1) - Determine cause of incorrect alignment and require repair.
( 2) - Determine cause of noise and suggest repair.









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BULB SOCKETS
BULB SOCKET 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.
Bulb seized in socket ... A .. Require repair or replacement.
Burned, affecting
performance ............ A ........... (1) Require repair or
replacement.
Burned, not affecting
performance ............ 2 ........... ( 1) Suggest repair or
replacement.
Broken .................. A .. Require repair or replacement.
Connector broken ........ A .. Require repair or replacement.
Connector missing ....... C ............ Require replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... ( 1) Require repair or
replacement.
Corroded, affecting
performance ............ A .. Require repair or replacement.
Corroded, not affecting
performance ............ 2 .. Suggest repair or replacement.
Leaking ................. A .. Require repair or replacement.
Melted .................. A ........ ( 2) Require replacement.
Shorted ................. A .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 2) 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 socket.
( 2) - Determine cause and correct prior to replacement of part.









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BULBS, SEALED BEAMS AND LEDS
NOTE: Does not include soldered-in components.
BULB, SEALED BEAM AND LED INSPECTION









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Condition Code Procedure
Adjustment out of
specification .......... B .. Require repair or replacement.
Application incorrect ... B ........ ( 1) Require replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not