Mitsubishi Montero (1991+). Manual — part 147

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.

EXHAUST

SERVICE PROCEDURES REQUIRED AND SUGGESTED FOR PROPER

VEHICLE OPERATION

WARNING: Federal EPA rules prohibit altering an exhaust system in

any way that defeats the emission reduction components of a

vehicle. Be sure to review and adhere to EPA policy on

removing and replacing catalytic converters. Where state or

local laws are stricter, they take precedence over these

guidelines.

NOTE: Some exhaust systems are of a welded design. It is not

required that the entire system be replaced. Determine the

need to replace individual components based on conditions of

component.

CATALYTIC CONVERTERS

CAUTION: Before working on an exhaust system, review EPA

regulations on removing and replacing catalytic converters.

NOTE: Any time a converter has failed, further diagnosis is

required to determine the reason(s) for converter failure.

CATALYTIC CONVERTER INSPECTION

Condition Code Procedure

Air injection tube

broken . . . . . A ... Require repair or replacement

of injection tube or

replacement of catalytic

converter.

Air injection tube

burnt . . . . .. A ... Require repair or replacement

of injection tube or

replacement of catalytic

converter.

Air injection tube

leaking . . . . A ... Require repair or replacement

of injection tube or

replacement of catalytic

converter.

Air injection tube

loose . . . . .. A ... Require repair or replacement

of injection tube or

replacement of catalytic

converter.

Air injection tube

restricted . . . . A ... Require repair or replacement

of injection tube or

replacement of catalytic

converter.

Air injection tube

threads damaged . . A ... Require repair or replacement

of injection tube or

replacement of catalytic

converter.

Air injection tube

threads stripped

(threads missing) . .. A ... Require repair or replacement

of injection tube or

replacement of catalytic

converter.

Body cracked . . . B .. Require repair or replacement.

Converter empty . . . A .. Require repair or replacement.

Converter fill plug

missing . . . . C .. Require repair or replacement.

Converter missing . ... C . . . Require replacement.

Exhaust gases leaking ... A .. Require repair or replacement.

Flanges leaking . . . A ... Require repair or replacement

of flanges.

Inlet pipes cracked . . B .. Require repair or replacement.

Internal rattle (except

pellet-type) . . ... 2 . . .. ( 1) Further inspection

required.

Mounting brackets that

are part of converter

broken . . . . . A .. Require repair or replacement.

Obvious overheating . . .. . . . ( 2) Require testing of

converter.

Outlet pipes cracked . B .. Require repair or replacement.

Pieces of catalyst

material found

downstream . . . . 1 . . . Suggest replacement.

Plugged . . . . . A . . (3) Require replacement.

Testing has determined

that existing converter

has been lead-poisoned,

contaminated, or failed

testing . . . . A .. Require repair or replacement.

(1) - If the converter is breaking up, suggest converter

replacement. If an object has fallen into the converter,

remove the object.

(2) - Overheating is caused by something other than the

converter. Further diagnosis is required to determine

the cause of the overheating.

(3) - Determine cause and correct to ensure that new converter

will not become plugged.

EXHAUST AND TAIL PIPES

NOTE: For pipes with resonators, also see MUFFLERS AND RESONATORS.

EXHAUST AND TAIL PIPE INSPECTION

Condition Code Procedure

Bracket broken . . .. A .. Require repair or replacement.

Pipe bent out of

position . . . ... B .. Require repair or replacement.

Pipe broken . . . . A .. Require repair or replacement.

Pipe cracked . . . B .. Require repair or replacement.

Pipe leaking . . . A . . . Require replacement.

Pipe missing . . . C . . . Require replacement.

Pipe plugged . . . A . . . Require replacement.

Pipe weak due to

corrosion, but no leaks

present . . . . 1 . . . Suggest replacement.

Weld broken . . . . A .. Require repair or replacement.

EXHAUST CONNECTIONS

EXHAUST CONNECTION INSPECTION

Condition Code Procedure

Attaching hardware

incorrect . . . .. B . . . Require replacement of

hardware.

Clamp broken . . . A . . ... Require replacement.

Clamp loose . . . . A . Require repair or replacement.

Clamp missing . . ... C . . ... Require replacement.

Corroded, affecting

structural integrity ... 1 . . ... Suggest replacement.

Incorrect type (i.e.

flange, ball & socket

etc.) . . . . .. B . . ... Require replacement.

Leaking . . . . . A . . . . Require repair.

Loose . . . . ... A . . . . Require repair.

HANGERS

HANGER INSPECTION

Condition Code Procedure

Broken . . . . .. A . . . Require replacement.

Corroded, affecting

structural integrity ... 1 . . . Suggest replacement.

Incorrect type . . .. B . . . Require replacement.

Loose . . . . ... A .. Require repair or replacement.

Missing . . . . . C . . . Require replacement.

Out of position . . . B .. Require repair or replacement.

Rubber deteriorated . . 1 . . . Suggest replacement.

HEAT RISERS (MECHANICAL EFE DEVICES)

HEAT RISER (MECHANICAL EFE DEVICE) INSPECTION

Condition Code Procedure

Broken . . . . .. A . . .. Require replacement of

affected parts.

Diaphragm inoperative ... A . . (1) Require replacement.