1991 MITSUBISHI MONTERO AUX

HEATER HOSES
HIGH PRESSURE RELIEF VALVES (HPRV)
IDLERS
IN-LINE FILTERS
METAL FITTINGS
METAL LINES
MIX AND AIR CONTROL DOORS (BLEND DOORS)
O-RINGS
ORIFICE TUBES
PILOT-OPERATED ABSOLUTES (POAS)
PLENUMS
PRESSURE CONTROL VALVES
PRESSURE SENSORS
PULLEYS
RADIATORS
RECEIVER-DRIERS
REFRIGERANT
REFRIGERANT OIL
RELAYS
SEALS
SERVICE PORTS
SPRING LOCK COUPLINGS
SUCTION THROTTLING VALVES (STVS)
SWITCHES (ELECTRICAL)
TENSIONERS
THERMISTORS AND PRESSURE SENSORS
THERMOSTATS AND HOUSINGS
VACUUM HOSES AND TUBES
VACUUM RESERVOIRS
VACUUM TUBES
VALVES IN RECEIVER (VIRS)
WATER PUMPS (ELECTRIC AUXILIARY)
WIRING HARNESSES AND CONNECTORS
MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW
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

Bracket cracked, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket holes elongated,
affecting performance .. A .. Require repair or replacement.
Bracket holes elongated,
not affecting
performance ............ .. ........ No service suggested or
required.
Bracket loose, affecting
performance ............ A .. Require repair or replacement.
Bracket loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket missing ......... C ............ Require replacement.
Connection damaged ...... B .. Require repair or replacement.
Contaminated, affecting
performance ............ A ............ Require replacement.
Corroded internally ..... 1 ............ Suggest replacement.
Dessicant bag
deteriorated ........... A ........ (1) Require replacement.
Further inspection required.
Dessicant at the end of
its useful life
(saturated
with moisture) ......... 1 .. Suggest repair or replacement.
Filter screen torn ...... A .. Require replacement of screen.
Fitting damaged ......... B .. Require repair or replacement.
Fusible plug leaking .... A .... Require replacement of plug.
Inoperative ............. A ........... ( 2) Require repair or
replacement.
Leaking ................. A .. Require repair or replacement.
Pressure relief device
leaking ................ A . Require replacement of pressure
relief device.
Restricted .............. A .. Require repair or replacement.
Sight glass no longer
transparent ............ 2 ... Suggest replacement of drier.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Tubing connection
leaking ................ A .. Require repair or replacement.
( 1) - Inspect system to determine effects of dessicant bag
deterioration.
( 2) - Inoperative includes intermittent operation or out of
OEM specification.









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WATER PUMPS (ELECTRIC AUXILIARY)
WATER PUMP (ELECTRIC AUXILIARY) 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.

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Condition Code Procedure
Tire diameter incorrect,
affecting ABS or TCS ... A ............ Require replacement.
Tire pressure incorrect,
affecting ABS or TCS ... A .. Require repair or replacement.
Tire size incorrect,
affecting ABS or TCS ... A ............ Require replacement.









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TOOTHED RINGS (TONE WHEEL)
NOTE: Copied from Drivetrain UIGs.
If the toothed ring requires replacement and cannot be
replaced as a separate component, replace the assembly of which the
ring is a part.
TOOTHED RING INSPECTION









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Condition Code Procedure
Alignment incorrect ..... B ............... Require repair or
replacement.
Bent .................... B ............ Require replacement.
Contaminated, affecting
performance ............. A ........ Require repair. Identify
and correct cause.
Cracked ................. B ............ Require replacement.
Loose ................... A ............. Require replacement
of worn parts.
Missing ................. C ............ Require replacement.
Number of teeth
incorrect .............. B ............ Require replacement.
Teeth broken ............ A ............ Require replacement.
Teeth damaged, affecting
performance ............ A ............ Require replacement.









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VACUUM BOOSTERS
VACUUM BOOSTER INSPECTION








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Condition Code Procedure
Applies too much assist
(oversensitive) ........ 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.
Auxiliary vacuum pump
inoperative ............ A ........... ( 1) Require repair or
replacement.
Check valve grommet
deteriorated, affecting
performance ............ A .. Require replacement of grommet.

FLANGES
FLEX PLATES
FLUID LEVEL INDICATORS
FLUIDS AND LUBRICANTS
FLYWHEELS
FORCE MOTORS
GUIDES
HALF SHAFTS
HOSES, LINES AND TUBES
HOUSINGS (BELL, CASE, TAIL (EXTENSION) AND AUXILIARY)
INTERMEDIATE SHAFT SUPPORT BEARINGS
KEY INTERLOCK SYSTEMS
LIMITED SLIPS
LINES
LINKAGES (EXTERNAL)
LOCKING HUB ASSEMBLIES
LOCKING HUB CONTROL KNOBS
LUBRICANTS
METAL-CLAD SEALS
METALASTIC JOINTS
MODULATOR PINS
MODULATORS
MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION)
ODOMETER DRIVES (MECHANICAL)
ODOMETER HEADS (MECHANICAL)
OIL PANS
PANS
PILOT HOLES
PRESSURE PLATES
PRESSURE SWITCHES
RACES
RUBBER JOINTS (METALASTIC)
SCREENS
SEALS
SEALS (METAL-CLAD)
SELECTOR INTERLOCK SYSTEMS
SERVOS
SHIFT INTERLOCK SYSTEMS (SELECTOR AND KEY INTERLOCK SYSTEMS)
SENSORS
SIDE COVERS
SLIP YOKES
SOLENOIDS
SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)
SPEEDOMETER-DRIVEN GEAR HOUSINGS
SPEEDOMETER/ODOMETER DRIVES (MECHANICAL)
SPEEDOMETER/ODOMETER HEADS (MECHANICAL)
SPEEDOMETERS AND ODOMETERS (ELECTRONIC)
SWITCHES
TONE WHEELS
TOOTHED RINGS (TONE WHEELS)
TORQUE CONVERTERS
TRANSAXLE MOUNTS
TRANSDUCERS (TRANSMISSION)
TRANSMISSION COOLERS
TRANSMISSION MOUNTS
TRANSMISSION PANS
TRANSMISSION RANGE INDICATORS (PRNDL)
TUBES
UNIVERSAL JOINTS (CARDON OR CROSS TYPE)
VACUUM CONTROLS
VACUUM HOSES
VACUUM MOTORS
VACUUM-OPERATED SWITCHES

feel rough when rotated as
an assembly ............ B .. Require replacement of bearing
assembly.









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BELL CRANKS
BELL CRANK 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.
Bent .................... A .. Require repair or replacement.
Broken .................. A .. Require repair or replacement.
Cracked ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Worn, affecting
performance ............ A .. Require repair or replacement.









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BELL HOUSINGS
See HOUSINGS (BELL, CASE, TAIL (EXTENSION) AND AUXILIARY) .
BUSHINGS (EXTERNAL)
BUSHING (EXTERNAL) INSPECTION








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Condition Code Procedure
Attaching hardware
bent ................... B ... Require repair or replacement
of bent part if available;
otherwise, replace bushing.
Attaching hardware
broken ................. A ... Require replacement of broken
part if available; otherwise,
replace bushing.
Attaching hardware
corroded, affecting
structural integrity ... A . Require replacement of corroded
part if available; otherwise,
replace bushing.
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part if available;
otherwise, replace bushing.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part if available;
otherwise, replace bushing.
Attaching hardware
missing ................ C .. Require replacement of missing
part if available; otherwise,
replace bushing.

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.
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 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 (BELL, CASE, TAIL (EXTENSION) AND AUXILIARY)
HOUSING (BELL, CASE, TAIL (EXTENSION) AND AUXILIARY) INSPECTION








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Condition Code Procedure
Bearing race loose
in bore ................ A .. Require repair or replacement.
Broken, affecting
performance ............ A .. Require repair or replacement.
Cracked ................. A .. Require repair or replacement.
Dowel pin holes worn,
affecting performance .. A ........... ( 1) Require repair or
replacement.
Machined surfaces damaged,
affecting performance .. A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Worn, affecting
performance ............ A .. Require repair or replacement.
( 1) - See DOWEL PINS, GUIDES AND PILOT HOLES .









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Fig. 3: Typical Thermostatic Air Cleaner System
FUEL EVAPORATIVE SYSTEM (EVAP)
The EVAP system allows for proper fuel system ventilation
while preventing fuel vapors from reaching the atmosphere. This means
that vapors must be caught and stored while the engine is off, which
is when most fuel evaporation occurs. When the engine is started,
these fuel vapors can be removed from storage and burned. In most
systems, storage is provided by an activated charcoal (or carbon)
canister. See Fig. 4. On a few early systems, charcoal canisters are
not used. Instead, fuel vapors are vented into the PCV system and
stored inside the crankcase.
The main components of a fuel evaporation system are a sealed
fuel tank, a liquid-vapor separator and vent lines to a vapor-storing
canister filled with activated charcoal. The filler cap is normally
not vented to the atmosphere, but is fitted with a valve to allow both
pressure and vacuum relief.
Although a few variations do exist between manufacturers,
basic operation is the same for all systems. Check for presence of
vapor storage canister or crankcase storage connections when required.
Ensure required hoses, solenoids, etc., are present and connected
properly. Check for proper type fuel tank cap. Check for any non-OEM
or auxiliary fuel tanks for compliance and the required number of
evaporation canisters.

converter with the exception of the catalyst. See Fig. 5. The TWC
converter uses rhodium, with or without platinum, as its catalyst.
Rhodium helps reduce NOx emissions, as well as HC and CO.
Visually check for presence of catalytic converter(s). Also
check for presence of any required air supply system for the oxidizing
section of the converter. Check for external damage such as severe
dents, removed or damaged heat shields, etc. Check for pellets or
pieces of converter in the tailpipe.
Three-Way Catalyst + Oxidation Catalyst (TWC + OC)
This system contains a TWC converter and an OC converter in a
common housing, separated by a small air space. See Fig. 6. The 2
catalysts are referred to as catalyst beds. Exhaust gases pass through
the TWC first. The TWC bed performs the same function as it would as a
separate device, reducing all 3 emissions. As exhaust gases leave the
bed, they pass through the air space and into the second (OC)
converter catalyst bed.
Visually check for presence of catalytic converter(s). Check
for external damage such as severe dents, removed or damaged heat
shields, etc. Check for pellets or pieces of converter in the
tailpipe.
Fig. 6: Typical Three-Way + Oxidation Catalytic Converter
Courtesy of General Motors Corp.
FILL PIPE RESTRICTOR (FR)
A fuel tank fill pipe restrictor is used to prohibit the
introduction of leaded fuel into the fuel tank. Unleaded gasoline pump
dispensers have a smaller diameter nozzle to fit fuel tank of vehicle
requiring the use of unleaded fuel (vehicles equipped with catalytic
converter).
Visually inspect fill pipe restrictor(s) for tampering, i.e.,\
restrictor is oversize or the flapper is non-functional. If vehicle is
equipped with an auxiliary fuel tank, ensure auxiliary fuel tank is
also equipped with a fill pipe restrictor.
EXHAUST GAS RECIRCULATION (EGR) SYSTEM