air condition MITSUBISHI MONTERO 1998 Service Manual

ABBREVIATIONS
1998 Mitsubishi Montero
GENERAL INFORMATION
COMMONLY USED ABBREVIATION
"A" ABBREVIATION TABLE
"A" ABBREVIATION TABLE







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ABBREVIATION DEFINITION 










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A Amperes 

A/C Air Conditioning 

A/T Automatic Transmission/Transaxle 

AAP Auxiliary Accelerator Pump 

AB Air Bleed 

ABCV Air Bleed Control Valve 

ABDC After Bottom Dead Center 

ABRS Air Bag Restraint System 

ABS Anti-Lock Brake System 

AC Alternating Current 

ACC A/C Clutch Compressor 

ACCS A/C Cycling Switch 

ACCUM Accumulator 

ACCY Accessory 

ACT Air Charge Temperature Sensor 

ACV Thermactor Air Control Valve 

ADJ Adjust or Adjustable 

ADV Advance 

AFS Airflow Sensor 

AI Air Injection 

AIR or A.I.R. Air Injection Reactor 

AIS Air Injection System 

ALCL Assembly Line Communications Link 

ALDL Assembly Line Diagnostic Link 

ARC Automatic Ride Control 

ASCD Automatic Speed Control Device 

ASCS Air Suction Control Solenoid 

ASD Auto Shutdown 

ASDM Air Bag System Diagnostic Module 

ASV Air Suction Valve 

ATC Automatic Temperature Control 

ATDC After Top Dead Center 

ATF Automatic Transmission Fluid 

ATS Air Temperature Sensor 

AXOD Automatic Transaxle Overdrive 

Abs. Absolute 

Accy. Accessory 

Alt. Alternator or Altitude 

Amp. Ampere 

Assy. Assembly 

Auto. Automatic 

Aux. Auxiliary 

Avg. Average 











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"B" ABBREVIATION TABLE
"B" ABBREVIATION TABLE

Only NEW, moisture-free refrigerant oil should be used in the
air conditioning system. This oil is highly refined and dehydrated so
moisture content is less than 10 parts per million. The oil container
must be tightly closed at all times when not in use, or moisture from
the air will be absorbed into the refrigerant oil.
SERVICING PRECAUTIONS
DISCHARGING SYSTEM
Discharge A/C system, using approved refrigerant
recovery/recycling equipment that meets SAE J2210 requirements. Always
follow recovery/recycling equipment manufacturer's instructions. After
refrigerant recovery process is completed, replace any refrigerant oil
removed with the same amount of NEW refrigerant oil.
DISCONNECTING LINES & FITTINGS
After system is discharged, carefully clean area around all
fittings to be opened. Always use 2 wrenches when tightening or
loosening fittings. Some refrigerant lines are connected with a
coupling. Special tools may be required to disconnect lines. Cap or
plug all openings as soon as lines are removed. DO NOT remove shipping
caps from replacement components until ready to install.
CONNECTING LINES & FITTINGS
NOTE: Ensure all replacement component connections match
connections of system being worked on.
Always use a NEW gasket or "O" ring when connecting lines or
fittings. Coat "O" ring with NEW refrigerant oil and ensure it is not
twisted during installation. Always use two wrenches to prevent damage
to lines and fittings.
PLACING SYSTEM IN OPERATION
After component service or replacement has been completed and
all connections have been made, thoroughly evacuate system with a
vacuum pump. Charge system with proper amount of refrigerant and
perform leak test. See REFRIGERANT OIL & REFRIGERANT SPECIFICATIONS
table for system capacities. Ensure there are no leaks at any fitting
that has been opened. After system has been leak tested, check system
performance.
NIPPONDENSO 10-CYL.
Eclipse 2.0L Non-Turbo & Montero
Replacement compressor is shipped with NEW refrigerant oil.
Drain, measure and discard refrigerant oil from old compressor. Drain
NEW refrigerant oil from replacement compressor equal to difference
between amount drained from old compressor and amount shipped in
replacement compressor. If any other components are replaced, add NEW
refrigerant oil as specified. See COMPONENT REFRIGERANT OIL CAPACITIES
(MITSUBISHI - NIPPONDENSO 10-CYL.) table.
COMPONENT REFRIGERANT OIL CAPACITIES TABLE (NIPPONDENSO)









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Component Ounces
Compressor ( 1)

* A/C-HEATER SYSTEM UNIFORM INSPECTION GUIDELINES *
1998 Mitsubishi Montero
GENERAL INFORMATION
A/C-Heater System Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
Motorist Assurance Program (MAP)
OVERVIEW
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Heating, Ventilation and Air Conditioning
ACCUMULATORS
ACTUATORS (ELECTRICAL)
ACTUATORS (VACUUM)
AIR CONDITIONING FITTINGS
AIR CONDITIONING HOSES
AIR CONDITIONING METAL LINES, HOSES AND FITTING ASSEMBLIES
AIR CONTROL DOORS
AIR DAMS (EXTERNAL)
AIR DISTRIBUTION SYSTEM
BELTS
BLEND DOORS
BLOWER FANS (BLOWER WHEEL OR SQUIRREL CAGE)
BLOWER MOTORS
BLOWER RESISTORS
BLOWER SWITCHES
CABIN AIR FILTERS
CIRCUIT BREAKERS
COMPRESSOR CLUTCH ASSEMBLIES
COMPRESSORS
CONDENSER AIR SEALS
CONDENSER FAN MOTORS
CONDENSERS
CONNECTORS
CONTROL CABLES
CONTROL HEADS (FUNCTION SELECTORS)
CONTROL LINKAGES
CONTROL MODULES
COOLANT
COOLING FAN BLADES
COOLING FAN CLUTCHES
COOLING FAN MOTORS
EVAPORATOR DRAIN TUBES
EVAPORATOR PRESSURE REGULATORS (EPRS)
EVAPORATORS
EXPANSION VALVES
FUNCTION SELECTORS
FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS
FUSIBLE LINKS
GASKETS
HEATER CASES
HEATER CONTROL VALVES
HEATER CORES

are continually republished. In addition to these, standards for Drive
Train and Transmissions have recently been promulgated. Participating
shops utilize these Uniform Inspection & Communication Standards as
part of the inspection process and for communicating their findings to
their customers.
The Motorist Assurance Program continues to work
cooperatively and proactively with government agencies and consumer
groups toward solutions that both benefit the customer and are
mutually acceptable to both regulators and industry. We maintain the
belief that industry must retain control over how we conduct our
business, and we must be viewed as part of the solution and not part
of the problem. Meetings with state and other government officials
(and their representatives), concerned with auto repair and/or
consumer protection, are conducted. Feedback from these sessions is
brought back to the association, and the program adjusted as needed.
To assure auto repair customers recourse if they were not
satisfied with a repair transaction, the Motorist Assurance Program
offers mediation and arbitration through MAP/BBB-CARE and other non-
profit organizations. MAP conducted pilot programs in twelve states
before announcing the program nationally in October, 1998. During the
pilots, participating repair shops demonstrated their adherence to the
Pledge and Standards and agreed to follow the UICS in communicating
the results of their inspection to their customers. To put some
"teeth" in the program, an accreditation requirement for shops was
initiated. The requirements are stringent, and a self-policing method
has been incorporated which includes the "mystery shopping" of
outlets.
We welcome you to join us as we continue our outreach... with
your support, both the automotive repair industry and your customers
will reap the benefits. Please visit MAP at our Internet site www.
motorist.org or contact us at:
1444 I Street, NW Suite 700
Washington, DC 20005
Phone (202) 712-9042 Fax (202) 216-9646
January 1999
MAP UNIFORM INSPECTION GENERAL GUIDELINES
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
It is MAP policy that all exhaust, brake, steering,
suspension, wheel alignment, drive-line, engine performance and
maintenance, and heating, ventilation and air conditioning, and
electrical services be offered and performed under the standards and
procedures specified in these sections.
Before any service is performed on a vehicle, an inspection
of the appropriate system must be performed. The results of this
inspection must be explained to the customer and documented on an
inspection form. The condition of the vehicle and its components will
indicate what services/part replacements may be "Required" or
"Suggested". In addition, suggestions may be made to satisfy the
requests expressed by the customer.
When a component is suggested or required to be repaired or
replaced, the decision to repair or replace must be made in the
customer's best interest, and at his or her choice given the options
available.
This section lists the various parts and conditions that
indicate a required or suggested service or part replacement.
Although this list is extensive, it is not fully inclusive. In
addition to this list, a technician may make a suggestion. However,
any suggestions must be based on substantial and informed experience,

or the vehicle manufacturer's recommended service interval and must be
documented.
Some conditions indicate that service or part replacement is
required because the part in question is no longer providing the
function for which it is intended, does not meet a vehicle
manufacturer's design specification or is missing.
Example:
An exhaust pipe has corroded severely and has a hole in it
through which exhaust gases are leaking. Replacement of the
exhaust pipe in this case is required due to functional
failure.
Example:
A brake rotor has been worn to the point where it measures
less than the vehicle manufacturer's discard specifications.
Replacement of the rotor is required because it does not meet
design specifications.
Some conditions indicate that a service or part replacement
is suggested because the part is close to the end of its useful life
or addresses a customer's need, convenience or request. If a
customer's vehicle has one of these conditions, the procedure may be
only to suggest service.
Example:
An exhaust pipe is rusted, corroded or weak, but no leaks are
present. In this case, the exhaust pipe has not failed.
However, there is evidence that the pipe may need replacement
in the near future. Replacement of the pipe may be suggested
for the customer's convenience in avoiding a future problem.
Example:
The customer desires improved ride and/or handling, but the
vehicle's shocks or struts have not failed. In this case,
replacement may be suggested to satisfy the customer's
wishes. In this case, replacement of the shocks or struts may
not be sold as a requirement.
A customer, of course, has the choice of whether or not a
shop will service his or her vehicle. He or she may decide not to
follow some of your suggestions. When a repair is required, a MAP shop
must refuse partial service on that system if, in the judgment of the
service provider, proceeding with the work could create or continue an
unsafe condition. When a procedure states that required or suggested
repair or replacement is recommended, the customer must be informed of
the generally acceptable repair/replacement options whether or not
performed by the shop.
When presenting suggested repairs to the customer, you must
present the facts, allowing the customer to draw their own conclusions
and make an informed decision about how to proceed.
The following reasons may be used for required and suggested
services. These codes are shown in the "Code" column of the MAP
Uniform Inspection & Communications Standards that follow:
Reasons to Require Repair or Replacement
A - Part no longer performs intended purpose
B - Part does not meet a design specification (regardless of
performance)
C - Part is missing
NOTE: When a repair is required, the shop must refuse partial

service to the system in question, if the repair creates
or continues an unsafe condition.
Reasons to Suggest Repair or Replacement
1 - Part is close to the end of its useful life (just above
discard specifications, or weak; failure likely to occur
soon, etc.)
2 - To address a customer need, convenience, or request (to
stiffen ride, enhance performance, eliminate noise,
etc.)
3 - To comply with maintenance recommended by the vehicle's
Original Equipment Manufacturer (OEM)
4 - Technician's recommendation based on substantial and
informed experience
NOTE: Suggested services are always optional. When presenting
suggested repairs to the customer, you must present the
facts, allowing the customer to draw their own conclusions
and make an informed decision about how to proceed.
HEATING, VENTILATION, AND AIR CONDITIONING
SERVICE PROCEDURES REQUIRED AND SUGGESTED FOR PROPER VEHICLE
OPERATION
CAUTION: Before working on any air conditioning system, be sure
to review current local, state, federal, and EPA
regulations regarding charging, recycling, and disposal
of refrigerant.
ACCUMULATORS
ACCUMULATOR 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.
Beyond vehicle
manufacturer's service
interval ............... 3 ............ Suggest replacement.
Dessicant at the end of
its useful life (saturated
with moisture) ......... 1 .. Suggest repair or replacement.
Dessicant bag
deteriorated ........... A ........ ( 1) Require replacement.
Further inspection required.
Leaking ................. A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Tubing connection
leaking ................ A .. Require repair or replacement.

(1) - Inspect system to determine effects of dessicant bag
deterioration.









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ACTUATORS (ELECTRICAL)
ACTUATOR (ELECTRICAL) 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,
affecting performance .. A ........... ( 1) Require repair or
replacement.
Connector melted, not
affecting performance .. 2 ........... ( 1) Suggest repair or
replacement.
Connector missing ....... C ............ Require replacement.
Inoperative ............. A ........ ( 2) Require replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .. Suggest repair or replacement.
Out of adjustment ....... 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 .. 1 ........... ( 1) Suggest repair or
replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 1 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.









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ACTUATORS (VACUUM)
ACTUATOR (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.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted,
affecting performance .. A ........... (1) Require repair or
replacement.
Connector melted, not
affecting performance .. 2 ........... ( 1) Suggest repair or
replacement.
Connector missing ....... C ............ Require replacement.
Inoperative ............. A ........ ( 2) Require replacement.
Leaking (vacuum) ........ A .. Require repair or replacement.
Linkage bent, affecting
performance ............ A ... Require repair or replacement
of linkage.
Linkage bent, not
affecting performance .. 2 ... Suggest repair or replacement
of linkage.
Linkage binding, affecting
performance ............ A ... Require repair or replacement
of linkage.
Linkage binding, not
affecting performance .. 1 ... Suggest repair or replacement
of linkage.
Linkage broken .......... A ... Require repair or replacement
of linkage.
Linkage loose, affecting
performance ............ A ... Require repair or replacement
of linkage.
Linkage loose, not
affecting performance .. 1 ... Suggest repair or replacement
of linkage.
Linkage missing ......... C ............ Require replacement.
Linkage noisy ........... 2 .. Suggest repair or replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .. Suggest repair or replacement.
Out of adjustment ....... A .. Require repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Inoperative includes intermittent operation or out of
OEM specification.









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AIR CONDITIONING FITTINGS
See
AIR CONDITIONING METAL LINES, HOSES AND FITTING ASSEMBLIES .
AIR CONDITIONING HOSES
See
AIR CONDITIONING METAL LINES, HOSES AND FITTING ASSEMBLIES .
AIR CONDITIONING METAL LINES, HOSES AND FITTING ASSEMBLIES
AIR CONDITIONING METAL LINE, HOSE AND FITTING ASSEMBLY INSPECTION








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Condition Code Procedure

Abrasion damage,
affecting structural
integrity .............. A .. Require repair or replacement.
Abrasion damage, not
affecting structural
integrity .............. .. ........ No service suggested or
required.
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.
Clamp corroded, not
reusable ............... 1 ............ Suggest replacement.
Connected incorrectly ... A ................. Require repair.
Corroded, affecting
structural integrity ... A ............ Require replacement.
Corroded, not affecting
structural integrity ... .. ........ No service suggested or
required.
Cracked ................. A .. Require repair or replacement.
Fitting type incorrect
(such as compression
fitting) ............... B ............ Require replacement.
Flange leaking .......... A .. Require repair or replacement.
Insufficient clamping
force, allowing hose to
leak ................... A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Melted .................. 1 .. Suggest repair or replacement.
Missing ................. C ............ Require replacement.
Outer covering damaged to
the extent that the inner
fabric is visible ...... A ............ Require replacement.
Protective sleeves
damaged ................ 2 . Suggest replacement of sleeves.
Protective sleeves
missing ................ C . Require replacement of sleeves.
Restricted, affecting
performance ............ A .. Require repair or replacement.
Routed incorrectly ...... 2 ................. Require repair.
Swollen ................. 1 ............ Suggest replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Type incorrect .......... 1 .. Suggest repair or replacement.









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AIR CONTROL DOORS
See PLENUMS.
AIR DAMS (EXTERNAL)
AIR DAM (EXTERNAL) INSPECTION








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Condition Code Procedure

Application incorrect,
affecting air
conditioning
system performance ..... A .. Require repair or 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.
Bent, affecting air
conditioning system
performance ............ A .. Require repair or replacement.
Blocked, affecting air
conditioning system
performance ............ A .. Require repair or replacement.
Broken, affecting air
conditioning system
performance ............ A .. Require repair or replacement.
Cracked, affecting air
conditioning system
performance ............ A .. Require repair or replacement.
Loose, affecting air
conditioning system
performance ............ A ................. Require repair.
Loose, not affecting air
conditioning system
performance ............ 2 ................. Suggest repair.
Missing, affecting air
conditioning system
performance ............ C ............ Require replacement.









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AIR DISTRIBUTION SYSTEM
See PLENUMS.
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.
Serpentine belt routed
incorrectly ............ B ................. Require repair.
Tension out of
specification .......... B ........... Require adjustment or
replacement.
Worn beyond
adjustment range ....... B ............ Require replacement.