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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Outer ring slipped out of
position ............... A ........... Require replacement.
Positioned incorrectly .. A . Require repair or replacement.
Rubber damping material
deteriorated ........... 1 ........... Suggest replacement.
Seal surface worn, causing
a leak ................. A . Require repair or replacement.
Threads damaged ......... A . Require repair or replacement.
Threads stripped (threads
missing) ............... A ........... Require replacement.
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HEATER CONTROL VALVES
HEATER CONTROL VALVE 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.
Bypassed ................ A ............ Require replacement.
Coolant leak ............ A .. Require repair or replacement.
Malfunctioning .......... A ........... ( 1) Require repair or
replacement.
Missing ................. C ............ Require replacement.
Restricted .............. 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 restriction .... 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.
Bypassed ................ A .. Require repair or replacement.
Connection leaking ...... A .. Require repair or replacement.
Corroded ................ 1 .. Suggest repair or replacement.
Fins damaged, affecting
performance ............ A .. Require repair or replacement.
Fins damaged, not
affecting performance .. 2 .. Suggest repair or replacement.
Internal restrictions,
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affecting performance .. A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
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HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS
NOTE: When replacing fuel lines and hoses, replace with product
that meets or exceeds OEM design specifications.
HOSE AND TUBE COUPLER, CONNECTOR AND CLAMP 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 replacement.
Insufficient clamping
force, allowing hose to
leak ................... A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Safety clip missing (not
leaking) ............... C ... Require replacement of safety
clip.
Stripped ................ A ............ Require replacement.
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HOSE CLAMPS
See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS .
HOSE CONNECTORS
See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS .
HOSE COUPLERS
See HOSE AND TUBE COUPLERS, CONNECTORS AND CLAMPS .
HOSES AND TUBES (FUEL LINES, RADIATOR, VACUUM, BY PASS,
HEATER, RECOVERY TANK AND OIL COOLERS)
HOSE AND TUBE (FUEL LINE, RADIATOR, VACUUM, BY PASS, HEATER,
RECOVERY TANK AND OIL COOLER) 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 replacement.
Dry-rotted .............. 1 .. Suggest repair or replacement.
Hard .................... 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 or replacement.
Safety clip missing ..... C ............ Require replacement.
Spongy .................. 1 .. Suggest repair or replacement.
Stripped ................ A ............ Require 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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HOUSINGS
See THERMOSTATS AND HOUSINGS .
IDLE AIR CONTROLS
IDLE AIR CONTROL 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 ........... ( 2) Require repair or
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.
Restricted, affecting
performance ............ A .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
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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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IDLE SPEED CONTROL ACTUATORS
IDLE SPEED CONTROL ACTUATOR 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 ........... ( 2) Require repair or
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.
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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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IGNITION BOOTS
See
IGNITION WIRES, BOOTS, COIL TOWERS AND TERMINALS (SECONDARY) .
IGNITION COIL TOWERS
See
IGNITION WIRES, BOOTS, COIL TOWERS AND TERMINALS (SECONDARY) .
IGNITION COILS
IGNITION COIL INSPECTION \
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Condition Code Procedure
Arcing .................. 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.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... ( 1) Require repair or
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replacement.
Connector missing ....... C ............ Require replacement.
Corroded, affecting
performance ............ A ............ Require replacement.
Corroded, not affecting
performance ............ 2 ............ Suggest replacement.
Distorted ............... .. .... (2) No service suggested or
required.
Inoperative ............. A ........ ( 3) Require replacement.
Oil leaking ............. A ............ Require replacement.
Out of specification .... B ............ 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) - Distortion may be the result of overheating; coil should
be tested.
( 3) - Inoperative includes intermittent operation.
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IGNITION CONTROL MODULES (ICM)
IGNITION CONTROL MODULE (ICM) 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 (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... ( 2) Require repair or
replacement.
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Connector missing ....... A ................. Require repair.
Contaminated ............ A ........... (3) Require repair or
replacement.
Leaking ................. A .. Require repair or replacement.
Malfunctioning .......... A ........... ( 4) 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.
Threads damaged ......... A .. Require 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) - 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.
( 4) - Includes inoperative, intermittent operation, or failure to
perform all functions.
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IGNITION SWITCHES
See SWITCHES.
IGNITION TERMINALS
See
IGNITION WIRES, BOOTS, COIL TOWERS AND TERMINALS (SECONDARY) .
IGNITION WIRES, BOOTS, COIL TOWERS AND TERMINALS (SECONDARY)
NOTE: You are not required to replace ignition wires in sets.
However, you may suggest replacement of the entire
secondary wire set for preventive maintenance.
IGNITION WIRE, BOOT, COIL TOWER AND TERMINAL (SECONDARY) INSPECTION
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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
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Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Carbon-tracked .......... A ............ Require replacement.
Corroded ................ 1 .. Suggest repair or replacement.
Insulation leaking
(shorted) .............. A .. Require repair or replacement.
Metal heat shield bent .. 2 .. Suggest repair or replacement.
Missing ................. C ............ Require replacement.
Oil-soaked (spongy) ..... 1 ............ Suggest replacement.
Resistance incorrect .... B ............ Require replacement.
Routed incorrectly ...... 2 ............. (1) Suggest repair.
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) - If improper routing affects the performance of other
systems, require repair. Proper routing, hardware,
heatshields, etc., are intended to prevent premature
failure of secondary ignition components.
( 2) - Determine cause and correct prior to repair or
replacement of part.
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IN-TANK FUEL STRAINERS
IN-TANK FUEL STRAINER INSPECTION \
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Condition Code Procedure
Missing ................. C ............ Require replacement.
Restricted .............. A .. Require repair or replacement.
Torn .................... A ............ Require replacement.
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INERTIA FUEL SHUT-OFF SWITCHES
INERTIA FUEL SHUT-OFF SWITCH 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
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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 replacement.
Inoperative ............. 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.
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.
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INTAKE AIR TEMPERATURE SENSORS
INTAKE AIR TEMPERATURE 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 ........... ( 2) Require repair or
replacement.
Inoperative ............. B ........... ( 3) Require repair or
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replacement. Further
inspection required.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Resistance out of
specification .......... B .. Require repair or replacement.
Restricted, affecting
performance ............ A .. 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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INTAKE MANIFOLDS
INTAKE MANIFOLD INSPECTION \
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Condition Code Procedure
Corroded, affecting
sealability ............ A .. Require repair or replacement.
Integrated air or fuel
control components
inoperative ............ A ........... ( 1) Require repair or
replacement.
Internal air or fuel
components damaged,
affecting performance .. A ... Require repair or replacement
of component.
Internal air or fuel
components damaged, not
affecting performance .. .. ........ No service suggested or
required.
Internal air or fuel
components missing ..... C .......... Require replacement of