1991 MITSUBISHI MONTERO Service Manual

roof rack service wiring diagram air conditioning fuel filter run flat

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$MITSUBISHI MONTERO 1991 Service Manual WIRING HARNESS AND CONNECTOR INSPECTION��\ ��\ ��\ ��\ ��\ ��\ ��\ �� Condition$

WIRING HARNESS AND CONNECTOR 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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$MITSUBISHI MONTERO 1991 Service Manual \003 A - E N G IN E/V IN ID 1991 M it s u bis h i M onte ro 1991 ENGINE PERFORMANCE Chrysler Motors/Mitsubishi Introduction MODEL COVERAGE MODEL COVERAGE TABLE (MIT$

\003
A - E N G IN E/V IN ID

1991 M it s u bis h i M onte ro
1991 ENGINE PERFORMANCE
Chrysler Motors/Mitsubishi Introduction
MODEL COVERAGE
MODEL COVERAGE TABLE (MITSUBISHI)\
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Body Engine Fuel Ignition

Model Code (
1) Engine ( 2) ID ( 3)System System ( 4)

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\b\
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\b\
\b\b\
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1.8L SOHC (
5) T PFI Optical

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\b\
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Eclipse S,T 2.0L DOHC (
6) R PFI DIS

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\b\
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2.0L DOHC Turbo (
6) U PFI DIS

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\b\
\b\
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\b\
\b\b\
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2.0L SOHC (
6) V PFI Optical

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\b\b\
\b\
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Galant R,X 2.0L DOHC (
6) R PFI DIS

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\b\b\
\b\
\

2.0L DOHC Turbo (
6) U PFI DIS

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\b\
\b\
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\b\
\b\b\
\

1.5L SOHC (
7) A PFI Optical

Mirage U
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\b\b\
\b\
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1.6L DOHC (
8) Y PFI DIS

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\b\
\b\
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\b\
\b\b\
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Montero J 3.0L V6 SOHC (
9) S PFI Optical

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2.4L SOHC (
10) W PFI Optical

Pickup L,M
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\b\
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3.0L V6 SOHC (
9) S PFI Optical

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\b\
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\b\b\
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Precis A,F,D 1.5L SOHC (
11) J PFI Optical

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\b\
\b\
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3.0L V6 DOHC (
9) B PFI DIS

3000GT D,E
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3.0L V6 DOHC C PFI DIS

Turbo (
9)

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(
1) - Body Code is 5th digit of VIN. VIN is located on upper left

corner of instrument panel.

(
2) - See ENGINE CODE LOCATION.

(
3) - Engine ID is 8th digit of VIN.

(
4) - Ignition timing is computer controlled. On all models with

Distributorless Ignition System (DIS), crank angle sensor is

mounted where distributor is normally mounted.

(
5) - 4G37 engine.

(
6) - 4G63 engine.

(
7) - 4G15 engine.

(
8) - 4G61 engine.

(
9) - 6G72 engine.

(
10 ) - 4G64 engine.

(
11 ) - G4AJK engine.

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VIN DEFINITION
Numbers preceding the explanations in the legend below refer
to the sequence of characters as listed on VIN identification label.

Page 579 of 1333

MITSUBISHI MONTERO 1991 Service Manual (VIN) J B 3 C U 1 4 X 1 M U 1 2 3 4 5 6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
1 - Indicates Nation of Origin.
2 - Indicates Manufacturer.

Page 580 of 1333

MITSUBISHI MONTERO 1991 Service Manual Fig. 2: Engine Code Location, Eclipse & Galant, 1.8L & 2.0L
Courtesy of Chrysler Motors.
Fig. 3: Engine Code Location, Montero 3.0L
Courtesy of Chrysler Motors.

Page 581 of 1333

MITSUBISHI MONTERO 1991 Service Manual Fig. 4: Engine Code Location, Pickup 2.4L
Courtesy of Chrysler Motors.
Fig. 5: Engine Code Location, Pickup 3.0L
Courtesy of Chrysler Motors.

Page 582 of 1333

MITSUBISHI MONTERO 1991 Service Manual Fig. 6: Engine Code Location, Precis 1.5L
Courtesy of Chrysler Motors.
Fig. 7: Engine Code Location, 3000GT 3.0L
Courtesy of Chrysler Motors.

Page 583 of 1333

$MITSUBISHI MONTERO 1991 Service Manual \003 * E XH AU ST S YSTE M U NIF O RM IN SPEC TIO N G UID ELIN ES * 1 991 M it s u bis h i M onte ro GENERAL INFORMATION Exhaust Systems Motorist Assurance Program$

\003
* E XH AU ST 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
Exhaust Systems Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
Motorist Assurance Program (MAP)
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS
Exhaust
CATALYTIC CONVERTERS
EXHAUST AND TAIL PIPES
EXHAUST CONNECTIONS
HANGERS
HEAT RISERS (MECHANICAL EFE DEVICES)
HEAT SHIELDS
MANIFOLDS (CAST AND TUBE TYPE)
MECHANICAL EFE DEVICES
MUFFLERS AND RESONATORS
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

Page 584 of 1333

MITSUBISHI MONTERO 1991 Service Manual 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 govern

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 AND 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

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