1991 MITSUBISHI MONTERO brake sensor

specifications.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
(1) - If a sensor is not adjustable, further inspection is
required to identify and correct cause.
( 2) - Determine cause and correct prior to repair or
replacement of part.
( 3) - Determine source of contamination, such as metal
particles or water. Require repair or replacement.
( 4) - Inoperative includes intermittent operation or out of OEM
specification. Some components may be serviceable; check
for accepted cleaning procedure.









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STEEL BRAKE LINES
STEEL BRAKE LINE 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.
Corroded, affecting
structural integrity ... A ............ Require replacement.
Fitting incorrect (for
example, compression
fitting) ............... B ............ Require replacement.
Flare type incorrect .... B .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Line material incorrect
(copper, etc.) ......... B ............ Require replacement.
Restricted .............. A ............ Require replacement.
Routed incorrectly ...... B ..... Require routing correction.
Rust-pitted ............. 1 ............ Suggest replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped
(threads missing) ...... A ............ Require replacement.









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STOPLIGHT SWITCHES
See BRAKE STOPLIGHT SWITCHES .
SWITCHES
NOTE: Copied from Electrical UIGs & added "float saturated" from
old fluid level sensor switches.
STEEL BRAKE LINE INSPECTION









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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.

Installation
To install, reverse removal procedure. Tighten wheel bearings
to 22 ft. lbs. (30 N.m). Loosen nut, and then retighten to 72 INCH
lbs. (8 N.m). Install cotter pin. If pin does not align, loosen nut up\
to a maximum of 30 degrees.
REAR BRAKE DRUM & SHOES
Removal
1) Raise and support vehicle. Remove wheel and brake drum.
Remove shoe return spring and brake shoe adjuster. See Fig. 8. Remove
adjusting spring, shoe retaining spring and shoe hold-down pins.
2) Remove shoe and lining assembly with parking brake lever.
Remove cable from parking lever. Remove parking brake lever snap ring,
and disengage lever from brake shoe.
Fig. 8: Exploded View of Rear Brake Assembly
Courtesy of Mitsubishi Motor Sales of America.
Installation
1) To install, reverse removal procedure. Apply Lubriplate to
backing plate bosses, adjuster assembly threads and parking brake
lever pin.
2) Set adjustment assembly so brake shoes lightly contact
brake drum. Depress brake pedal to center shoes, and check pedal
travel. Rotate brake drum to ensure free movement.
WHEEL CYLINDERS
Removal & Installation
Raise and support vehicle. Remove rear brake drum and shoes.
See REAR BRAKE DRUM & SHOES under REMOVAL & INSTALLATION. Remove wheel
cylinder and seal assembly. To install, reverse removal procedure.
Bleed brakes.
MASTER CYLINDER
Removal
Drain brake fluid from master cylinder. Remove sensor
connector (if equipped). Disconnect brake lines from master cylinder,
and install plugs to prevent brake fluid spillage. Remove master
cylinder from booster unit and separate reservoirs from housing (if
necessary).
Installation
To install, reverse removal procedure. Before installation,
check and adjust clearance between back of master cylinder piston and
power brake push rod. Refer to MASTER CYLINDER PUSH ROD under
ADJUSTMENTS. After installation, adjust the brake pedal height. Refer
to BRAKE PEDAL HEIGHT & FREE PLAY under ADJUSTMENTS. Bleed brake
system. See BLEEDING BRAKE SYSTEM .

Test No. 1 (Power & Ground Circuit)
1) Turn ignition on. When cruise control main switch is
turned to ON position, battery voltage should be present on terminal
No. 7 of cruise control unit connector.
2) If voltage is not present, check fuse No. 3 and replace as
necessary. If fuse is okay, check and repair harness as necessary.
Terminal No. 10 should be grounded at all times. If terminal No. 10 is
not grounded, repair harness.
Test No. 2 (Set Switch Circuits)
When set switch is turned to ON position, voltage should not
be present on terminal No. 5 of cruise control unit. When set switch
is turned to OFF position, battery voltage should be present on
terminal No. 5 of cruise control unit. If circuit does not test
correctly, replace switch as necessary or repair harness.
Test No. 3 (Resume Switch Circuit)
When resume switch is turned to ON position, voltage should
not be present on terminal No. 4 of cruise control unit. When resume
switch is turned to OFF position, battery voltage should be present on
terminal No. 4 of cruise control unit. If circuit does not test
correctly, replace switch as necessary or repair harness.
Test No. 4 (Vehicle Speed Sensor Circuit)
When vehicle moves slowly, voltage should alternate from zero
volts to 3-5 volts at terminal No. 15 of cruise control unit. If
circuit does not test correctly, replace sensor as necessary or repair
harness.
Test No. 5 (Actuator Circuit)
1) When cruise control main switch is in On position, voltage
should not be present on terminal No. 8 of cruise control unit.
2) When vehicle is accelerated using resume switch, voltage
should not be present on terminal No. 9 of cruise control unit. When
vehicle is coasting by using set switch, battery voltage should be
present on terminal No. 9.
3) When vehicle is accelerated using resume switch, battery
voltage should be present on terminal No. 20 of cruise control unit.
When vehicle is coasting by using set switch, voltage should not be
present on terminal No. 20 of cruise control unit. If circuit does not
test correctly, replace actuator as necessary or repair harness.
Test No. 6 (Stoplight Switch Circuit)
1) When brake pedal is pressed, battery voltage should be
present on terminal No. 3 of cruise control unit. If voltage is not
present, adjust or replace brake switch.
2) Battery voltage should be present at all times on terminal
No. 11 of cruise control unit. If voltage is not present, check fuse
no. 7. If fuse is okay, repair harness.
Test No. 7 (Inhibitor Switch Circuit)
1) When gear shift lever is moved to Neutral or Park
position, voltage should not be present on terminal No. 2 of cruise
control unit.
2) When gear shift lever is moved to any other position,
battery voltage should be present on terminal No. 2 of cruise control
unit. 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 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.

Replace cruise control switch if it does not test correctly.
Main Switch (1992)
1) In each switch position, continuity should be present
between terminals No. 2 and 7 for switch illumination. See Figs. 22-
29. When switch is moved to Neutral position, continuity should be
present between terminals No. 1 and 4.
2) When switch is moved to ON position, continuity should be
present between terminals No. 1, 4 and 5. Connect battery voltage to
terminal No. 5 and ground terminal No. 4.
3) Battery voltage should then be present on terminal No. 1
when main switch is moved to On position. Replace switch if it does
not test correctly.
BRAKELIGHT/STOPLIGHT SWITCH TEST
Disconnect switch connector. When brake pedal is pressed,
continuity should be present between terminals No. 2 and 3. See
Figs. 22 -29. When brake pedal is released, continuity should be
present between terminals No. 1 and 4. Replace switch if it does not
test correctly.
IDLE SWITCH & THROTTLE POSITION SENSOR TESTS
Throttle Position Sensor (1992)
1) Disconnect sensor connector. Resistance between terminals
No. 1 and 4 should be 3500-6500 ohms. Use an analog ohmmeter to
measure resistance between terminals No. 1 and 3. See Figs. 22-29.
2) Slowly open throttle valve to wide open throttle.
Resistance should change smoothly as throttle is opened. Replace
throttle position sensor if it does not test correctly.
Idle Switch (1992)
1) Disconnect throttle position sensor connector. Continuity
should be present between terminals No. 1 and 2 with accelerator pedal
released. See Figs. 22-29. Continuity should not be present with
accelerator pedal pressed.
2) If continuity is not present with accelerator released,
loosen throttle position sensor mounting screw. Turn throttle position
sensor completely clockwise. Recheck continuity. Replace throttle
position sensor if idle switch does not test correctly.
INHIBITOR SWITCH TEST
Disconnect switch connector. Shift transaxle into Neutral and
Park positions. On 1991 models, continuity should be present between
Black/Yellow wire terminals No. 3 and 4. On 1992 models, continuity
should be present between terminals No. 7 and 12. See Figs. 22-29. On
all models, if continuity is not present, adjust inhibitor switch. If
switch is adjusted properly, replace switch.
VACUUM PUMP TEST
1992
1) Remove vacuum pump connector. Resistance should be 50-60
ohms between terminal No. 1 and terminals No. 2 and 3. See Figs. 22-
29. Ensure solenoid valve makes operating noise when battery voltage
is applied between terminal No. 1 and terminals No. 2 and 3.
2) If solenoid valve does not make noise, replace vacuum pump
assembly. Apply battery voltage to terminals No. 1 and 4, motor should
operate. Replace vacuum pump if motor does not operate.

VEHICLE SPEED SENSORS
VENTS
VIBRATION DAMPERS
WHEEL ATTACHMENT HARDWARE
WHEEL SPEED SENSORS
WIRING HARNESSES AND CONNECTORS
YOKES AND SLIP YOKES
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt
(1) a Pledge of Assurance to their Customers and (2) the Motorist
Assurance Program Standards of Service. All participating service
providers have agreed to subscribe to this Pledge and to adhere to the
promulgated Standards of Service demonstrating to their customers that
they are serious about customer satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection were recently published.
Further, revisions to all of these inspection communication standards
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

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* 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

SUPER CHARGERS
SWITCHES
THERMAL VACUUM VALVES
THERMOSTATIC AIR DOOR ASSEMBLIES
THERMOSTATS AND HOUSINGS
THROTTLE BODIES
THROTTLE CABLES
THROTTLE LINKAGES AND CABLES
THROTTLE POSITION SENSORS
THROTTLE POSITION SWITCHES
TIMING BELT SPROCKETS
TIMING BELTS
TORQUE STRUTS
TRANSMISSION RANGE SWITCHES
TUBE CLAMPS
TUBE CONNECTORS
TUBE COUPLERS
TUBES
TURBO CHARGERS
VACUUM CONNECTIONS
VACUUM HOSES, TUBES AND CONNECTIONS (NON-METALLIC)
VACUUM REGULATOR SOLENOIDS
VACUUM TUBES
VEHICLE SPEED SENSORS
VOLUME AIR FLOW SENSORS
WASTE GATE CONTROL SOLENOIDS
WASTE GATES AND BOOST CONTROL MECHANISMS
WATER PUMPS (ELECTRIC)
WATER PUMPS (NON-ELECTRIC)
WIRING HARNESSES AND CONNECTORS
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt
(1) a Pledge of Assurance to their Customers and (2) the Motorist
Assurance Program Standards of Service. All participating service
providers have agreed to subscribe to this Pledge and to adhere to the
promulgated Standards of Service demonstrating to their customers that
they are serious about customer satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection communication standards
are continually re-published. In addition to these, standards for
Drive Train and Transmissions have recently been promulgated.
Participating shops utilize these Uniform Inspection & Communication