1991 MITSUBISHI MONTERO brake

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

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.

\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

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

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 - 20 Amp (Yellow)
Hazard Light, Dome Light, Clock
2 - 10 Amp (Red)
Taillights
3 - 10 Amp (Red)
Turn Signal Lights
4 - 10 Amp (Red)
Back-Up Lights, Gauges
5 - 15 Amp (Light Blue)
Defogger
6 - 20 Amp (Yellow)
Heater
7 - 15 Amp (Light Blue)
Stoplights
8 - 15 Amp (Light Blue)
Horn, Wiper, Washer
9 - 10 Amp (Red)
Rear Wiper, Rear Washer
10 - 15 Amp (Light Blue)
Cigarette Lighter, Radio
CAUTIONS & WARNINGS
RADIATOR FAN & CAP
DO NOT loosen or remove radiator cap when cooling system is
hot. The system is under high pressure, and hot steam or boiling
liquid could gush out if cap is loosened or removed while system is
hot.
BRAKE FLUID
Be careful when handling brake fluid as it is harmful to eyes
and may damage painted surfaces.
REPLACING BLOWN FUSE
Before replacing a blown fuse, remove ignition key, turn off
all lights and accessories to avoid damaging the electrical system. Be
sure to use fuse with the correct indicated amperage rating. The use
of an incorrect amperage rating fuse may result in a dangerous
electrical system overload.

GEA R T O OTH C O NTA C T P A TTE R NS

1991 M it s u bis h i M onte ro
GENERAL INFORMATION
Gear Tooth Contact Patterns
* PLEASE READ THIS FIRST *
The following article is for GENERAL INFORMATION purposes
only. Information does not SPECIFICALLY apply to all years, makes and
models, but is to be used as a general reference guide.
INSPECTION
PRELIMINARY INSPECTION
Wipe lubricant from internal parts. Rotate gears and inspect
for wear or damage. Mount dial indicator to housing, and check
backlash at several points around ring gear. Backlash must be within
specifications at all points. If no defects are found, check gear
tooth contact pattern.
GEAR TOOTH CONTACT PATTERN
NOTE: Drive pattern should be well centered on ring gear teeth.
Coast pattern should be centered, but may be slightly toward
toe of ring gear teeth.
1) Paint ring gear teeth with marking compound. Wrap cloth or
rope around drive pinion flange to act as brake. Rotate ring gear
until clear tooth contact pattern is obtained.
2) Contact pattern will indicate whether correct pinion
bearing mounting shim has been installed and if drive gear backlash
has been set properly. Backlash between drive gear and pinion must be
maintained within specified limits, until correct tooth pattern is
obtained.

WIRING DIAGRAM COMPONENT LOCATIONS
When trying to locate a component in a wiring diagram and you
don't know the specific system where it is located, use this handy
component locator to find the system wiring diagram in which the
component is located. Then, go to that system and locate the component
within the wiring diagram.
For example, if you don't know the specific system in which
the ignition switch is located, look up ignition switch in the wiring
diagram component location tables and go to the appropriate wiring
diagram(s) which contain either full or partial views of the ignition
switch. The full view of the ignition switch is located in Power
Distribution.
The first listing for the component will be the full or most
complete view of the component. Additional listings will be partial
views of the component. Not all components are used on all models.
All components will have a partial view in Ground
Distribution and Power Distribution. Data Link Connectors show
connecting circuits between modules. Alternate names for components
may be listed in wiring diagram component locations tables.
WIRING DIAGRAM COMPONENT LOCATIONS TABLE









\









\









\









\









\









\









\







Component Wiring Diagram
ABS Electronic Control Unit ....................... Anti-Lock Brakes
Data Link Connectors
ABS Hydraulic Unit ................................ Anti-Lock Brakes
Acceleration Sensor ............................... Anti-Lock Brakes
Accessory Delay Relay ................................ Power Windows
A/C Compressor Clutch Relay ..................... Engine Performance
A/C Sensor ...................................... Engine Performance
A/C Pressure Switch ............................. Engine Performance
Adaptive Lamp Control Module ....................... Exterior Lights
Air Bag(s) ................................ Air Bag Restraint System\
Air Bag Module ............................ Air Bag Restraint System
Air Bag Sensor(s) ......................... Air Bag Restraint System\
Air Injection Pump Relay ........................ Engine Performance
Air Temperature Sensor ............................ Overhead Console
Alternator (Generator) ..................... Generators & Regulators\
Anti-Theft Control Module ........................ Anti-Theft System
Starters
Autolamp Control Relay ........................... Headlight Systems
Daytime Running Lights
Automatic Shutdown (ASD) Relay .................. Engine Performance\
Generators & Regulators
Autostick Switch ................................ Engine Performance
Auxiliary Battery Relay .................... Generators & Regulators
Back-Up Lights ...................................... Back-Up Lights
Exterior Lights
Barometric (BARO) Pressure Sensor ............... Engine Performance\
Battery ......................................... Power Distribution
Battery Temperature Sensor ...................... Engine Performance
Body Control Module .......................... Body Control Computer
Anti-Theft System
Daytime Running Lights
Engine Performance
Headlight Systems
Warning Systems
Boost Control Solenoid .......................... Engine Performance
Boost Sensor .................................... Engine Performance
Brake Fluid Level Switch .................. Analog Instrument Panels