MITSUBISHI MONTERO 1991 Service Manual
Manufacturer: MITSUBISHI, Model Year: 1991, Model line: MONTERO, Model: MITSUBISHI MONTERO 1991Pages: 1333, PDF Size: 24.61 MB
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Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Wire lead burned ........ A .. Require repair or replacement.
Wire lead conductors
exposed ................ B .. 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, or failure
to perform all functions.
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CONTROL LINKAGES
CONTROL LINKAGE 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.
Bent .................... A . Require repair or replacement.
Binding ................. A . Require repair or replacement.
Bracket bent, affecting
performance ............ A . Require repair or replacement.
Bracket bent, not
affecting performance .. .. ....... No service suggested or
required.
Bracket broken, affecting
performance ............ A ........... Require replacement.
Bracket broken, not
affecting performance .. .. ....... No service suggested or
required.
Bracket corroded,
affecting performance .. A . Require repair or replacement.
Bracket corroded, not
affecting performance .. 2 . Suggest repair or replacement.
Bracket cracked, affecting
performance ............ A . Require repair or replacement.
Bracket cracked, not
affecting performance .. 1 . Suggest repair or replacement.
Bracket holes elongated,
affecting performance .. A . Require repair or replacement.
Bracket holes elongated,
not affecting
performance ............ .. ....... No service suggested or
required.
Bracket loose, affecting
performance ............ A . Require repair or replacement.
Bracket loose, not
affecting performance .. 1 . Suggest repair or replacement.
Bracket missing ......... C ........... Require replacement.
Broken .................. A ........... Require replacement.
Cracked ................. A . Require repair or replacement.
Disconnected ............ A . Require repair or replacement.
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Missing ................. C ........... Require replacement.
Noisy ................... 2 . Suggest repair or replacement.
Out of adjustment ....... B .......... (1) Require repair or
replacement.
Seized .................. A . Require repair or replacement.
( 1) - Follow OEM recommended adjustment procedures. Require
repair or replacement if out of specification.
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CONTROL MODULES
NOTE: Includes, but not limited to: IRCM, Coolant Fan Control
Module (CFCM), AC Controller, Amplifier, Programmers,
Control Heads, Power Modules, etc.
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.
Code set
(if applicable) ........ A .......... ( 1) Further inspection
required.
Connector broken ........ A .. Require repair or replacement.
Connector melted,
affecting performance .. A ........... ( 2) Require repair or
replacement.
Connector melted, not
affecting performance .. 2 ........... ( 2) Suggest repair or
replacement.
Connector missing ....... A ................. Require repair.
Contaminated ............ A ........... ( 3) Require repair or
replacement.
Inoperative ............. B ........... ( 4) Require repair or
replacement. Further
inspection required.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require 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.
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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) - Refer to manufacturer's diagnostic trouble code
procedure and require repair or replacement of
affected component(s).
( 2) - Determine cause and correct prior to repair or
replacement of part.
( 3) - Determine source of contamination, such as engine coolant,
fuel, metal particles, or water. Require repair or
replacement. Check for accepted cleaning procedure.
( 4) - Inoperative includes intermittent operation or out of
OEM specification. Some components may be serviceable.
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COOLANT
COOLANT INSPECTION \
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Condition Code Procedure
Acidity (pH) incorrect .. 1 ........... Suggest correction or
replacement.
Contaminated ............ B ...... ( 1) Require replacement or
recycling. Further
inspection required.
Level incorrect ......... B .......... ( 2) Require filling to
proper level.
Maintenance intervals ... 3 ........ ( 3) Suggest replacement.
Mixture incorrect ....... B ........... Require correction or
replacement.
Type incorrect .......... B ............ Require replacement.
( 1) - Determine source of contamination and require correction
prior to coolant replacement.
( 2) - Determine source of incorrect level and suggest repair.
( 3) - The system should be drained and/or flushed and
refilled with correct coolant according to OEM
recommended service interval and procedures.
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COOLING FAN BLADES
COOLING FAN BLADE 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.
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Bent .................... A ............ Require replacement.
Broken .................. A ............ Require replacement.
Cracked ................. A ............ Require replacement.
Loose ................... A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
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COOLING FAN CLUTCHES
NOTE: Some lateral movement, measured at the fan blade tip, may
be normal.
COOLING FAN CLUTCH 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.
Bearing noisy ........... A ............ Require replacement.
Bearing worn ............ A ............ Require replacement.
Fastener loose .......... A ... Require repair or replacement
of fastener.
Inoperative ............. A ........ ( 1) Require replacement.
Leaking ................. 1 ............ Suggest replacement.
Seized .................. A ............ Require replacement.
Slips (insufficient fan
speed) ................. A ............ Require replacement.
Thermal control
incorrect .............. B .. Require repair or replacement.
( 1) - Inoperative includes intermittent operation or out of
OEM specification.
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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.
Connector melted,
affecting performance .. A ........... ( 1) Require repair or
replacement.
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Connector melted, not
affecting performance .. 2 ........... (1) Suggest 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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EVAPORATOR DRAIN TUBES
EVAPORATOR DRAIN TUBE INSPECTION \
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Condition Code Procedure
Disconnected ............ A ................. Require repair.
Leaking ................. A ............ Require replacement.
Missing ................. C ............ Require replacement.
Restricted .............. A .. Require repair or replacement.
Routed incorrectly ...... B ................. Require repair.
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EVAPORATOR PRESSURE REGULATORS (EPRS)
EVAPORATOR PRESSURE REGULATOR (EPR) INSPECTION \
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Condition Code Procedure
Inoperative ............. A ........... ( 1) Require repair or
replacement.
( 1) - Inoperative includes intermittent operation or out of
OEM specification.
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![MITSUBISHI MONTERO 1991 Service Manual EVAPORATORS
EVAPORATOR INSPECTION \
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Condition](/img/19/57332/w960_57332-115.png "MITSUBISHI MONTERO 1991 Service Manual EVAPORATORS
EVAPORATOR INSPECTION \
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Condition")
EVAPORATORS
EVAPORATOR 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.
Air flow obstruction,
affecting 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.
Bracket bent, affecting
performance ............ A .. Require repair or replacement.
Bracket bent, not
affecting performance .. .. ........ No service suggested or
required.
Bracket broken, affecting
performance ............ A ............ Require replacement.
Bracket broken, not
affecting performance .. .. ........ No service suggested or
required.
Bracket corroded,
affecting performance .. A .. Require repair or replacement.
Bracket corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Bracket cracked, affecting
performance ............ A .. Require repair or replacement.
Bracket cracked, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket holes elongated,
affecting performance .. A .. Require repair or replacement.
Bracket holes elongated,
not affecting
performance ............ .. ........ No service suggested or
required.
Bracket loose, affecting
performance ............ A .. Require repair or replacement.
Bracket loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket missing ......... C ............ Require replacement.
Corroded, affecting
structural integrity ... A ............ Require replacement.
Corroded, not affecting
structural integrity ... .. ........ No service suggested or
required.
Evaporator foam seal
leaking ................ A ............ Require replacement.
Evaporator foam seal
missing ................ C ............ Require replacement.
Fitting type incorrect
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(such as compression
fitting) ............... B ............ Require replacement.
Flange leaking .......... A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Restricted internally ... A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
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EXPANSION VALVES
EXPANSION VALVE 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.
Corroded internally ..... 1 ............ Suggest replacement.
Filter screen torn ...... A .. Require replacement of screen.
Inoperative ............. A ........... ( 1) Require repair or
replacement.
Leaking ................. A ............ Require replacement.
Restricted .............. A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Expansion valve operation may be affected by capillary
tube location, corrosion, and insulation tape.
Inoperative includes intermittent operation.
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FUNCTION SELECTORS
See CONTROL HEADS (FUNCTION SELECTORS) .
FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS
FUSE, FUSIBLE LINK AND CIRCUIT BREAKER INSPECTION \
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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Blown ................... A ........ ( 1) Require replacement.
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.
Inoperative ............. A ... ( 2) Require replacement.
Insulation damaged,
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conductors exposed ..... A .. Require repair or replacement.
Insulation damaged,
conductors not exposed . 1 .. Suggest repair or replacement.
Missing ................. C ............ Require replacement.
Routed incorrectly ...... B ................. Require repair.
Secured incorrectly ..... B ................. Require repair.
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 replacement
of part.
( 2) - Inoperative includes intermittent operation.
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FUSIBLE LINKS
See FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS .
GASKETS
GASKET INSPECTION \
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Condition Code Procedure
Leaking ................. A ........... ( 1) Require repair or
replacement.
( 1) - Require inspection of mating and sealing surface and
repair or replace as necessary.
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HEATER CASES
See PLENUMS.
HEATER CONTROL VALVES
HEATER CONTROL VALVE 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
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of hardware.
Binding ................. 2 .. Suggest repair or replacement.
Coolant leak ............ A .. Require repair or replacement.
Disconnected ............ A .. Require repair or replacement.
Malfunctioning .......... A ........... (1) Require repair or
replacement.
Missing ................. C ............ Require replacement.
Restricted .............. A .. Require repair or replacement.
Seized .................. A .. Require repair or replacement.
Vacuum leak ............. A .. Require repair or replacement.
( 1) - Includes inoperative, intermittent operation, or
failure to perform all functions.
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HEATER CORES
HEATER CORE INSPECTION \
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Condition Code Procedure
Air flow obstruction .... 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.
Connection leaking ...... A .. Require repair or replacement.
Corroded ................ 1 .. Suggest repair or replacement.
Disconnected ............ A .. Require repair or replacement.
Fins damaged, affecting
performance ............ A .. Require repair or replacement.
Fins damaged, not
affecting performance .. .. ........ No service suggested or
required.
Internal restrictions,
affecting performance .. A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
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HEATER HOSES
HEATER HOSE INSPECTION \
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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Connected incorrectly ... A ................. Require repair.
Corroded, not reusable .. 1 ............ Suggest replacement.
Cracked ................. A .. Require repair or replacement.
Hard (brittle) .......... 1 .. Suggest repair or replacement.
Inner fabric (webbing)
damaged ................ A ............ Require replacement.
Insufficient clamping
force, allowing hose to
leak ................... A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Maintenance intervals ... 3 ............ Suggest replacement.
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Melted .................. 1 .. Suggest repair or replacement.
Missing ................. C ............ Require replacement.
Outer covering damaged .. 1 ............ Suggest 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 ................ 2 . Suggest replacement of sleeves.
Restricted, affecting
performance ............ A .. Require repair or replacement.
Restricted, not affecting
performance ............ 2 .. Suggest repair or replacement.
Routed incorrectly ...... 2 ................. Suggest repair.
Safety clip missing ..... C ............ Require replacement.
Spongy .................. 1 .. Suggest repair or replacement.
Stripped ................ A ............ Require replacement.
Surface cracks (dry-
rotted) ................ 1 .. Suggest repair or replacement.
Swollen ................. B ............ Require 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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HIGH PRESSURE RELIEF VALVES (HPRV)
HIGH PRESSURE RELIEF VALVE (HPRV) INSPECTION \
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Condition Code Procedure
Inoperative ............. A ........... ( 1) Require repair or
replacement.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Inoperative includes intermittent operation or out of
OEM specification.
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IDLERS
See TENSIONERS.
IN-LINE FILTERS
IN-LINE FILTER INSPECTION \
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Condition Code Procedure
Connection leaking ...... B .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Restricted .............. A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
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