1991 MITSUBISHI MONTERO air condition

(3) - Inspect for conditions related to wheel cylinder.
( 4) - Leaking is defined as a drop or more. Dampness is normal.









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WIRING HARNESSES
NOTE: Copied from Electrical UIGs.
WIRING HARNESS INSPECTION









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Condition Code Procedure
Application incorrect ... B .. 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.
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.
Insulation damaged,
conductors exposed ..... A .. Require repair or replacement.
Insulation damaged,
conductors not exposed . 1 ............ Suggest replacement.
Open .................... A .. Require repair or replacement.
Protective shield
(conduit) melted ....... 2 ........... ( 1) Suggest repair or
replacement.
Protective shield
(conduit) missing ...... 2 .. Suggest repair or replacement.
Resistance (voltage drop)
out of specification ... A .. Require repair or replacement.
Routed incorrectly ...... B ................. Require repair.
Secured incorrectly ..... B ................. Require repair.
Shorted ................. 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.
Voltage drop out of
specification .......... A .. Require repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.









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Test No. 5 (Vehicle Speed Sensor Circuit)
When vehicle moves slowly, 0-2 or more volts should alternate
at terminal No. 19 of cruise control unit. If circuit does not test
correctly, replace sensor as necessary or repair harness.
Test No. 6 (Vacuum Pump Circuit)
1) When cruise system is in deceleration or release mode,
battery voltage should be present on terminals No. 26 and 13 of cruise
control unit. If circuit does not test correctly, replace vacuum pump
as necessary or repair harness.
2) When cruise system is in release mode, battery voltage
should be present on terminal No. 12 of cruise control unit. When
cruise system is in hold mode, voltage on terminals No. 12, 13 and 26
will go from battery voltage to zero volts depending on driving
conditions. If circuit does not test correctly, replace vacuum pump as
necessary or repair harness.
Test No. 7 (Stoplight Switch Circuit)
When brake pedal is pressed, battery voltage should be
present on terminal No. 15 of cruise control unit. If voltage is not
present, adjust or replace brake switch. If circuit does not test
correctly, replace switch as necessary or repair harness.
Test No. 8 (Clutch Switch Circuit)
When clutch pedal is pressed, battery voltage should be
present at terminal No. 1 of cruise control unit. If circuit does not
test correctly, replace switch as necessary or repair harness.
Test No. 9 (Inhibitor Switch Circuit)
When transmission is in Neutral position, battery voltage
should be present on terminal No. 1 of cruise control unit. If circuit
does not test correctly, replace switch as necessary or repair
harness.
Test No. 10 (Overdrive Switch Circuit)
When overdrive switch is pushed to ON position, battery
voltage should be present on terminal No. 11 of cruise control unit.
If circuit does not test correctly, replace switch as necessary or
repair harness.
Test No. 11 (Idle Switch & Throttle Position Sensor Circuit)
1) When accelerator pedal is pressed, 4.5-5.5 volts should be
present on terminal No. 4 (idle switch) of cruise control unit. When
accelerator pedal is released, voltage should not be present on
terminal No. 4 of cruise control unit.
2) When accelerator pedal is pressed to wide open throttle,
4.0-5.5 volts should be present on terminal No. 5 (throttle position
sensor) of cruise control unit. When accelerator pedal is released, .
5-.7 volts should be present on terminal No. 5 of cruise control unit.
If circuit does not test correctly, replace sensor as necessary or
repair harness.
Fig. 22: 1992 Cruise Control Unit Connector
Courtesy of Mitsubishi Motor Co.

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.
DRIVE/POWER TRAIN ASSEMBLIES
SERVICE PROCEDURES REQUIRED AND SUGGESTED FOR PROPER
VEHICLE OPERATION

NOTE: Whenever transmission or drivetrain service is performed
that affects the suspension alignment, for example,
removing the engine cradle, it is required that the
alignment be checked and corrected if necessary.
AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLIES
AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLY INSPECTION








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Condition Code Procedure
Any internal component
failure that requires
removal of the assembly
from the vehicle for
service. ( 1) ........... A ........... ( 2) Require repair or
replacement of the automatic
transmission/transaxle
assembly.
( 1) - It is Required that the torque converter and all other
failure related components be inspected for cause and
condition.
( 2) - For components not requiring removal of the assembly,
refer to the component listing in this document.









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DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES
NOTE: Does not include half shafts.
DIFFERENTIAL AND FINAL DRIVE ASSEMBLY INSPECTION









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Condition Code Procedure
Any internal component
failure that requires
removal of the assembly
from the vehicle for
service. ( 1) ........... A ... Require repair or replacement
of the differential assembly.
( 1) - For components not requiring removal of the assembly,
refer to the component listing in this document.









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MANUAL TRANSMISSION/TRANSAXLE ASSEMBLIES
MANUAL TRANSMISSION/TRANSAXLE ASSEMBLY INSPECTION








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Condition Code Procedure
Any internal component
failure that requires
removal of the assembly
from the vehicle for
service. ( 1) ........... A ... Require repair or replacement
of the manual
transmission/transaxle
assembly.
( 1) - For components not requiring removal of the assembly,

refer to the component listing in this document.








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TRANSFER CASE ASSEMBLIES
TRANSFER CASE ASSEMBLY INSPECTION








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Condition Code Procedure
Any internal component
failure that requires
removal of the assembly
from the vehicle for
service. ( 1) ........... A ... Require repair or replacement
of the transfer case
differential assembly.
( 1) - For components not requiring removal of the assembly,
refer to the component listing in this document.









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DRIVE TRAIN/COMPONENTS
The conditions listed for the components included in this
section assume that the problem has been isolated to the specific
component through proper testing.
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.
(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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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.
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.
( 2) - Inoperative includes intermittent operation or out
of OEM specification.









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AXLES
AXLE INSPECTION








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Condition Code Procedure
Bent .................... A ............ Require replacement.
Broken .................. A ............ Require replacement.
End play exceeds
specifications ......... B .. Require repair or replacement.
Flange bent ............. A ............ Require replacement.
Flange threads stripped . A .. Require repair or replacement.
Twisted ................. A ............ Require replacement.
Worn, affecting
performance ............ A ............ Require replacement.









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BEARINGS AND RACES
NOTE: When replacing or repacking bearings, grease seal
replacement is required. You are not required to replace
these components in axle sets. Determine the need to
replace based upon the individual component conditions
that follow.
BEARING AND RACE INSPECTION









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Condition Code Procedure
Bearing end-play exceeds
specifications ......... B .. Require adjustment of bearing,
if possible. If proper
adjustment cannot be obtained,
require replacement of bearing
assembly.
Bearing rollers, balls or
races are worn, pitted, or