1991 MITSUBISHI MONTERO Service Manual

spare wheel radiator recommended oil rear view mirror service interval reset parking sensors

Page 793 of 1333

MITSUBISHI MONTERO 1991 Service Manual Grease fitting missing .. C ... Require replacement of grease
fitting.
Grease fitting
wont seal ............. A ... Require replaceme

Grease fitting missing .. C ... Require replacement of grease
fitting.
Grease fitting
won't seal ............. A ... Require replacement of grease
fitting.
Grease seal missing ..... 2 ........ (5) Suggest replacement.
Grease seal torn ........ 2 ........ ( 4) Suggest replacement.
Looseness (perceptible
horizontal movement) ... 1 ........ ( 6) Suggest replacement.
Looseness that is
excessive .............. B ..... ( 6)( 7) Require replacement.
Seized .................. A ............ Require replacement.
Stud bent ............... B ........ ( 8) Require replacement.
Stud broken ............. A ........ ( 8) Require replacement.
Stud loose in
taper hole ............. A ........... ( 8) Require repair or
replacement.
Taper hole elongated .... A ........ ( 9) Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ........ ( 8) Require replacement.
Wear exceeds
manufacturer's
specifications ......... B ............ Require replacement.
( 1) - If greaseable, grease joint. If problem persists or
joint is non-greaseable, require replacement.
( 2) - Cracked grease boot will allow contaminants to enter
the joint and will accelerate wear.
( 3) - Lack of grease boot will allow contaminants to enter
the joint and will accelerate wear.
( 4) - Torn grease boot will allow contaminants to enter the
joint and will accelerate wear.
( 5) - Missing grease seal will allow contaminants to enter
the joint and will accelerate wear.
( 6) - If manufacturer's procedures for inspection exist, use
those procedures; otherwise, use an approved inspection
method such as the dry park check.
CAUTION: DO NOT use pliers or pry bar to check ball and
socket movement. Use only moderate hand pressure.
( 7) - Excessive looseness is defined as being significant
enough to affect vehicle handling or structural
integrity.
( 8) - Check for damaged taper hole.
( 9) - Check for damaged stud.
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ELECTRONIC RIDE CONTROL SHOCKS AND STRUTS
NOTE: This section covers the electronic damping control portion
of the electronic shock or strut. For dampening portion of
shock or strut conditions and procedures, refer to the
SHOCK ABSORBERS, STRUT CARTRIDGES AND STRUT ASSEMBLIES
section.
ELECTRONIC RIDE CONTROL SHOCK AND STRUT INSPECTION
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Condition Code Procedure
Connector bent .......... A .. Require repair or replacement.
Connector broken ........ A .. Require repair or replacement.
Connector loose ......... A .. Require repair or replacement.
Electronic valve control

Page 794 of 1333

MITSUBISHI MONTERO 1991 Service Manual inoperative ............ 2 ........ (1) Suggest replacement.
Terminal bent ........... A .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Te

inoperative ............ 2 ........ (1) Suggest replacement.
Terminal bent ........... A .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal corroded ....... A .. Require repair or replacement.
Terminal loose .......... A .. Require repair or replacement.
( 1) - It is acceptable to replace with a non-electronically
controlled unit, where available.
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IDLER ARMS
IDLER ARM INSPECTION\
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require replacement of broken
part, if available; otherwise,
replace idler arm.
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part, if available;
otherwise, replace idler arm.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace idler arm.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace idler arm.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace idler arm.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
idler arm.
Binding ................. A .......... ( 1) Further inspection
required.
Grease boot cracked ..... 2 ........ ( 2) Suggest replacement.
Grease boot missing ..... 2 ........ ( 3) Suggest replacement.
Grease boot torn ........ 2 ........ ( 4) Suggest replacement.
Grease fitting broken ... A ... Require replacement of grease
fitting.
Grease fitting missing .. C ... Require replacement of grease
fitting.
Grease fitting
won't seal ............. A ... Require replacement of grease
fitting.
Grease seal missing ..... 2 ........ ( 5) Suggest replacement.
Grease seal torn ........ 2 ........ ( 4) Suggest replacement.
Greaseable joint will not
take grease ............ 2 ...... ( 1) Suggest replacement of
grease fitting.
Looseness at frame
bracket end ............ B ........ ( 6)( 7) Require repair or
replacement.

Page 795 of 1333

MITSUBISHI MONTERO 1991 Service Manual Looseness at link end
(perceptible horizontal
movement) .............. 1 ........ (8) Suggest replacement.
Looseness at link end
that is excessive ...... B ..... ( 8)( 9) Require replacemen

Looseness at link end
(perceptible horizontal
movement) .............. 1 ........ (8) Suggest replacement.
Looseness at link end
that is excessive ...... B ..... ( 8)( 9) Require replacement.
Mounted out of position
(center link
not parallel) .......... B .......... Require repositioning.
Nut on stud loose ....... A .......... ( 10) Require repair or
replacement.
Seized .................. A ............ Require replacement.
Stud bent ............... B ....... ( 11) Require replacement.
Stud broken ............. A ....... ( 11) Require replacement.
Taper hole elongated .... A ....... ( 12) Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ....... ( 11) Require replacement.
Wear exceeds
manufacturer's
specifications ......... B ............ Require replacement.
( 1) - If greaseable, grease joint. If problem persists or
joint is non-greaseable, require replacement.
( 2) - Cracked grease boot will allow contaminants to enter
joint and will accelerate wear.
( 3) - Lack of grease boot will allow contaminants to enter
joint and will accelerate wear.
( 4) - Torn grease boot will allow contaminants to enter
joint and will accelerate wear.
( 5) - Missing grease seal will allow contaminants to enter
joint and will accelerate wear.
( 6) - If manufacturer's procedures and specifications exist,
use those procedures and specifications; otherwise, use
an approved inspection method such as the dry park check.
( 7) - Looseness is defined as movement that creates excessive
toe change.
( 8) - If manufacturer's procedures for inspection exist, use
those procedures; otherwise, use an approved inspection
method such as the dry park check.
CAUTION: DO NOT use pliers or pry bar to check ball and
socket movement. Use only moderate hand pressure.
( 9) - Excessive looseness is defined as significant enough
to affect vehicle handling or structural integrity.
( 10 ) - Check for bent stud or damaged taper hole.
( 11 ) - Check for damaged taper hole.
( 12 ) - Check for damaged stud.
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KING PINS
You are not required to replace king pins in axle sets.
However, when replacing a king pin due to wear exceeding
manufacturer's specifications, you may suggest replacement of the
other king pin on the axle if its measurement shows it is close to the
end of its useful life.
KING PIN INSPECTION
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Condition Code Procedure
Bearing balls pitted .... A ........... Require replacement.
Bearing balls worn ...... A ........... Require replacement.
Bearing races pitted .... A ........... Require replacement.

Page 796 of 1333

MITSUBISHI MONTERO 1991 Service Manual Bearing races worn ...... A ........... Require replacement.
Bearing rollers pitted .. A ........... Require replacement.
Bearing rollers worn .... A ........... Require replacement.
Beari

Bearing races worn ...... A ........... Require replacement.
Bearing rollers pitted .. A ........... Require replacement.
Bearing rollers worn .... A ........... Require replacement.
Bearing seal bent ....... 2 . Suggest replacement of seal or
bearing.
Bearing seal missing .... 2 . Suggest replacement of seal or
bearing.
Bearing seal torn ....... 2 . Suggest replacement of seal or
bearing.
Binding ................. A .. Require repair or replacement
of affected parts.
End caps missing ........ C . Require replacement of missing
part, if available; otherwise,
replace king pin.
End play exceeds
specifications ......... B ................ Require repair.
Grease fitting broken ... A .. Require replacement of grease
fitting.
Grease fitting missing .. C .. Require replacement of grease
fitting.
Grease fitting
won't seal ............. A .. Require replacement of grease
fitting.
Locating pins missing ... C . Require replacement of missing
part, if available; otherwise,
replace king pin.
Looseness exceeds
manufacturer's
specifications ......... B .... Require replacement of worn
parts.
Seized .................. A ........... Require replacement.
Threads damaged ......... A . Require repair or replacement.
Threads stripped (threads
missing) ............... A ........... Require replacement.
Will not take grease .... 2 ..... (1) Suggest replacement of
grease fitting.
( 1) - If king pin will not take grease after replacement of
grease fitting, suggest replacement of king pin.
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PITMAN ARMS
PITMAN ARM INSPECTION\
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Condition Code Procedure
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part, if available;
otherwise, replace pitman arm.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace pitman arm.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace pitman arm.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,

Page 797 of 1333

MITSUBISHI MONTERO 1991 Service Manual replace pitman arm.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part

replace pitman arm.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
pitman arm.
Bent .................... B ............ Require replacement.
Binding ................. A .......... (1) Further inspection
required.
Grease boot cracked ..... 2 ........ ( 2) Suggest replacement.
Grease boot missing ..... 2 ........ ( 3) Suggest replacement.
Grease boot torn ........ 2 ........ ( 4) Suggest replacement.
Grease fitting broken ... A ...... Require replacement grease
fitting.
Grease fitting missing .. C ... Require replacement of grease
fitting.
Grease fitting
won't seal ............. A ... Require replacement of grease
fitting.
Grease seal missing ..... 2 ......... ( 3) Suggest replacement
of seal.
Grease seal torn ........ 2 ......... ( 4) Suggest replacement
of seal.
Looseness (perceptible
horizontal movement) ... 1 ........ ( 5) Suggest replacement.
Looseness that is
excessive .............. B ..... ( 5)( 6) Require replacement.
Nut on stud loose ....... A ........... ( 7) Require repair or
replacement.
Seized .................. A ............ Require replacement.
Splines damaged ......... A .. Require repair or replacement.
Splines stripped
(splines missing) ...... A ............ Require replacement.
Stud bent ............... B ........ ( 8) Require replacement.
Stud broken ............. A ........ ( 8) Require replacement.
Stud loose in
taper hole ............. A ........... ( 8) Require repair or
replacement.
Taper hole elongated .... A ........ ( 9) Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ........ ( 8) Require replacement.
( 1) - If greaseable, grease joint. If problem persists or
joint is non-greaseable, require replacement.
( 2) - Cracked grease boot will allow contaminants to enter
joint and will accelerate wear.
( 3) - Lack of grease boot will allow contaminants to enter
joint and will accelerate wear.
( 4) - Torn grease boot will allow contaminants to enter joint
and will accelerate wear.
( 5) - If manufacturer's procedures for inspection exist, use
those procedures; otherwise, use an approved inspection
method such as the dry park check.
CAUTION: DO NOT use pliers or pry bar to check ball and socket
movement. Use only moderate hand pressure.
( 6) - Excessive looseness is defined as being significant
enough to affect vehicle handling or structural integrity.
( 7) - Check for bent stud of damaged taper hole.
( 8) - Check for damaged taper hole.
( 9) - Check for damaged stud.
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Page 798 of 1333

$MITSUBISHI MONTERO 1991 Service Manual POWER STEERING HOSES POWER STEERING HOSE INSPECTION��\ ��\ ��\ ��\ ��\ ��\ ��\$

POWER STEERING HOSES
POWER STEERING HOSE INSPECTION\
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Condition Code Procedure
Blistered ............... B ........... Require replacement.
Blocked ................. A . Require repair or replacement.
Fitting threads damaged . A . Require repair or replacement.
Fitting threads stripped
(threads missing) ...... A ........... Require replacement.
Inner fabric
(webbing) cut .......... A ........... Require replacement.
Leaking ................. A . Require repair or replacement.
Missing ................. C ........... Require replacement.
Outer covering is cracked
to the extent that
the inner fabric of
hose is visible ........ B ........... Require replacement.
Restricted .............. A . Require repair or replacement.
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POWER STEERING (HYDRAULIC) PUMPS
If diagnosis has determined that complete disassembly is
necessary to determine the extent of the system failure, the
suggestion may be made to rebuild or replace the power steering pump.
Repair or replacement of the following components may be required if
performed as part of a power steering pump overhaul or rebuild service
to meet a minimum rebuild standard.
POWER STEERING (HYDRAULIC) PUMP INSPECTION
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Condition Code Procedure
Attaching hardware bent . B ... Require repair or replacement
of bent part.
Attaching hardware
broken ................. A ... Require replacement of broken
part.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part.
Attaching hardware
missing ................ C .. Require replacement of missing
part.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Belt alignment
incorrect .............. B .......... ( 1) Further inspection
required.
Belt cracked ............ 1 ............ Suggest replacement.
Belt frayed ............. 1 ............ Suggest replacement.
Belt missing ............ C ............ Require replacement.
Belt noisy .............. 2 .......... ( 2) Further inspection
required.
Belt plies separated .... A ............ Require replacement.

Page 799 of 1333

MITSUBISHI MONTERO 1991 Service Manual Belt tension out of
specification .......... B ........... Require adjustment or
replacement.
Belt worn beyond
adjustment range ....... B

Belt tension out of
specification .......... B ........... Require adjustment or
replacement.
Belt worn beyond
adjustment range ....... B ............ Require replacement.
Belt worn so it contacts
bottom of pulley ....... A ............ Require replacement.
Binding ................. A .. Require repair or replacement.
Fluid at or beyond
service interval ....... 3 ........... Suggest fluid change.
Fluid contaminated ...... B ........ (3) Require flushing and
refilling of the system.
Fluid level incorrect ... B ..... Require adjustment of fluid
level.
Inadequate assist ....... A .......... ( 4) Further inspection
required.
Leaking ................. A .. Require repair or replacement.
Noise ................... 2 .......... ( 5) Further inspection
required.
Pulley bent ............. A ... Require repair or replacement
of pulley.
Pulley missing .......... C .. Require replacement of pulley.
Remote reservoir
leaking ................ A .......... Require replacement of
reservoir,
Reservoir cap broken .... A ..... Require replacement of cap.
Reservoir cap missing ... C ..... Require replacement of cap.
Seized .................. A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped
(threads missing) ...... A ............ Require replacement.
( 1) - Determine cause of incorrect alignment and require repair.
( 2) - Determine cause of noise and suggest repair.
( 3) - Determine and correct source of contamination. OEM
specifications must be followed for fluid type.
( 4) - If pump is source of inadequate assist, require
repair or replacement.
( 5) - If noise is isolated to pump, suggest repair or
replacement.
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RADIUS ARMS
RADIUS ARM INSPECTION\
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require replacement of broken
part.
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part.
Attaching hardware
missing ................ C .. Require replacement of missing
part.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads.

Page 800 of 1333

MITSUBISHI MONTERO 1991 Service Manual Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Bent .................... B

Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Bent .................... B ............ Require replacement.
Corroded, affecting
structural integrity ... A ............ Require replacement.
Holes distorted ......... A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped
(threads missing) ...... A ............ Require replacement.
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RELAY RODS
RELAY ROD INSPECTION\
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Condition Code Procedure
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part, if available;
otherwise, replace relay rod.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace relay rod.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace relay rod.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace relay rod.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
relay rod.
Bent .................... B ............ Require replacement.
Binding ................. A .......... ( 1) Further inspection
required.
Grease boot cracked ..... 2 ........ ( 2) Suggest replacement.
Grease boot missing ..... 2 ........ ( 3) Suggest replacement.
Grease boot torn ........ 2 ........ ( 4) Suggest replacement.
Grease fitting broken ... A ...... Require replacement grease
fitting.
Grease fitting missing .. C ... Require replacement of grease
fitting.
Grease fitting
won't seal ............. A ... Require replacement of grease
fitting.
Grease seal missing ..... 2 ........ ( 3) Suggest replacement.
Grease seal torn ........ 2 ........ ( 4) Suggest replacement.
Looseness (perceptible
horizontal movement) ... 1 ........ ( 5) Suggest replacement.
Looseness that is
excessive .............. B ..... ( 5)( 6) Require replacement.
Seized .................. A ............ Require replacement.
Stud bent ............... B ........ ( 7) Require replacement.

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