Mitsubishi Montero Sport (2004+). Manual - part 63

 

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Mitsubishi Montero Sport (2004+). Manual - part 63

 

 

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

TSB Revision

GENERAL <BODY AND CHASSIS>

00-11

CONNECTOR MEASUREMENT SERVICE POINTS 

Turn the ignition switch to "OFF" when connecting and discon-
necting the connectors. Turn the ignition switch to "ON" when 
measuring if there are no instructions to the contrary.

.

IF INSPECTING WITH THE CONNECTOR CONNECTED 
<WATERPROOF CONNECTORS>
Be sure to use special tool. Never insert a test probe from the 
harness side, as this will reduce the waterproof performance 
and result in corrosion.

.

IF INSPECTING WITH THE CONNECTOR CONNECTED 
<ORDINARY (NON-WATERPROOF) CONNECTORS> 
Check by inserting the multi-meter test probe from the harness 
side. Note that if the connector (control unit, etc.) is too small to 
permit insertion of the test probe, it should not be forced; use 
the backprobing tool for this purpose.

.

IF INSPECTING WITH THE CONNECTOR DISCONNECTED 
<WHEN INSPECTING A FEMALE PIN>
From front side of the connector

Required Special Tool:

• MB991219: Inspection Harness (Included in MB991223, 

Harness Set)

The inspection harness for connector pin contact pressure 
should be used. The test probe should never be forcibly 
inserted, as it may cause a defective contact.

ACX00863AE

SPECIAL TOOL

AC001606AB

CONNECTOR

ACX00865 AB

MB991219

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

TSB Revision

GENERAL <BODY AND CHASSIS>

00-12

From back side of the connector (SRS-ECU harness side con-
nector)
Since the SRS-ECU harness connector is plated to improve 
conductivity, observe the warning below when checking this 
connector.

WARNING

Insert the backprobing tool into the connector from 
the harness side, and connect the tester to the back-
probing tool. If any tool other than the backprobing 
tool is used, it may cause damage to the harness and 
other components. Furthermore, measurement 
should not be carried out by touching the backprob-
ing tool directly against the terminals from the front 
of the connector. The terminals are plated to increase 
their conductivity, so that if they are touched directly 
by the backprobing tool, the plating may break, which 
will decrease reliability. 

.

IF INSPECTING WITH THE CONNECTOR DISCONNECTED 
<WHEN INSPECTING A MALE PIN>

CAUTION

At this time, be careful not to short the connector pins with 
the test probes. To do so may damage the circuits inside 
the ECU.
Touch the pin directly with the test bar.

AC001607

SRS-ECU HARNESS
CONNECTOR

AB

ACX00867 AB

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

TSB Revision

GENERAL <BODY AND CHASSIS>

00-13

CONNECTOR INSPECTION SERVICE POINTS

.

VISUAL INSPECTION

• Connector is disconnected or improperly connected

• Connector pins are pulled out

• Stretched an broken wires at terminal section

• Low contact pressure between male and female terminals

• Low connection pressure due to rusted terminals or foreign 

matter lodged in terminals

.

CONNECTOR PIN INSPECTION
If the connector pin stopper is damaged, the terminal connec-
tions (male and female pins) will not be perfect even when the 
connector body is connected, because the pins may pull out of 
the back side of the connector. Therefore, gently pull the wires 
one by one to make sure that no pins pull out of the connector.

.

ACX00868AC

CONNECTOR DISCONNECTED OR 
IMPROPERLY CONNECTED

STRETCHED OR BROKEN WIRES

HARNESS WIRE BREAKAGE
AT TERMINAL SECTION

LOW CONTACT
PRESSURE

GOOD

BAD

ACX00869AB

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

TSB Revision

GENERAL <BODY AND CHASSIS>

00-14

CONNECTOR ENGAGEMENT INSPECTION

Required Special Tool:
MB991219: Inspection Harness (contained in MB991223 Test 

Harness)

Use special tool, MB991219 to inspect the engagement of the 
male pins and female pins. [Pin drawing force: 1 N (0.2 pound) 
or more]

HOW TO COPE WITH INTERMITTENT 
MALFUNCTIONS

Most intermittent malfunctions occur under certain 
conditions. If those conditions can be identified, the 
cause will be easier to find.

.

TO COPE WITH INTERMITTENT MALFUNCTION

1. Ask the customer about the malfunction

• Ask what it feels like, what it sounds like, etc. 

Then ask about driving conditions, weather, fre-
quency of occurrence, and so on.

2. Determine the conditions from the customer's 

responses

• Typically, almost all intermittent malfunctions 

occur from conditions like vibration, temperature 
and/or moisture change, poor connections. From 
the customer's responses, it should be reasoned 
which condition is most likely.

3. Use simulation test

• In the cases of vibration or poor connections, use 

the simulation tests below to attempt to duplicate 
the customer's complaint. Determine the most 
likely circuit(s) and perform the simulation tests 
on the connectors and parts of that circuit(s). Be 
sure to use the inspection procedures provided 
for diagnostic trouble codes and trouble symp-
toms.
For temperature and/or moisture condition 
related intermittent malfunctions, try to change 
the conditions of the suspected circuit compo-
nents, then use the simulation tests below.

4. Verify the intermittent malfunction is elimi-

nated

• Repair the malfunctioning part and try to dupli-

cate the condition(s) again to verify the intermit-
tent malfunction has been eliminated.

.

ACX00870 AB

MB991219

 

 

 

 

 

 

 

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