1991 MITSUBISHI MONTERO Service Manual

tire type spark plugs weight dimensions coolant level fuel pressure

Page 817 of 1333

$MITSUBISHI MONTERO 1991 Service Manual TIE ROD END (INNER AND OUTER) INSPECTION��\ ��\ ��\ ��\ ��\ ��\ ��\ �� Condition$

TIE ROD END (INNER AND OUTER) INSPECTION\
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Condition Code Procedure
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part, if available;
otherwise, replace tie rod end.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace tie rod end.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace tie rod end.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace tie rod end.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
tie rod end.
Adjusting sleeve bent ... B ... Require replacement of sleeve
or tie rod end.
Adjusting sleeve clamps
out of position ........ B ................. Require repair.
Adjusting sleeve
corroded, affecting
structural integrity ... A ... Require replacement of sleeve
or tie rod end.
Adjusting sleeve
missing ................ C ... Require replacement of sleeve
or tie rod end.
Adjusting sleeve
seized ................. A ........... (1) Require repair or
replacement.
Adjusting sleeve
threads damaged ........ A ... Require repair or replacement
of sleeve or tie rod end.
Adjusting sleeve
threads stripped
(threads missing) ...... A ... Require replacement of sleeve
or tie rod end.
Binding ................. A .......... ( 2) Further inspection
required.
Grease boot cracked ..... 2 ........ ( 3) Suggest replacement.
Grease boot missing ..... 2 ........ ( 4) Suggest replacement.
Grease boot torn ........ 2 ........ ( 5) 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 ......... ( 4) Suggest replacement
of seal.

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MITSUBISHI MONTERO 1991 Service Manual Grease seal torn ........ 2 ......... (5) Suggest replacement
of seal.
Greaseable tie rod end
wont take grease ...... 2 ...... ( 6) S

Grease seal torn ........ 2 ......... (5) Suggest replacement
of seal.
Greaseable tie rod end
won't take grease ...... 2 ...... ( 6) Suggest replacement of
grease fitting.
Looseness (perceptible
horizontal movement) ... 1 ........ ( 7) Suggest replacement.
Looseness exceeds
manufacturer's
specifications ......... B ............ Require replacement.
Looseness that is
excessive .............. B ..... ( 7)( 8) Require replacement.
Nut on stud loose ....... A ........... ( 9) Require repair or
replacement of nut.
Seized .................. A ............. Require replacement
Stud bent ............... B ....... ( 10) Require replacement.
Stud broken ............. A ....... ( 10) Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped
(threads missing) ...... A ....... ( 10) Require replacement.
( 1) - Only required if toe needs to be adjusted.
( 2) - If greaseable, grease joint. If problem persists or
joint is non-greaseable, require replacement.
( 3) - Cracked grease boot will allow contaminants to enter
joint and will accelerate wear.
( 4) - Lack of grease boot will allow contaminants to enter
joint and will accelerate wear.
( 5) - Torn grease boot will allow contaminants to enter joint
and will accelerate wear.
( 6) - If greaseable tie rod end will not take grease after
replacing the grease fitting, suggest replacement of
tie rod end.
( 7) - 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.
( 8) - Excessive looseness is defined as being significant enough
to affect vehicle handling or structural integrity.
( 9) - Check for bent stud or damaged taper hole.
( 10 ) - Check for damaged taper hole.
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TRACK BARS
TRACK BAR INSPECTION\
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Condition Code Procedure
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part, if available;
otherwise, replace track bar.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace track bar.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace track bar.
Attaching hardware

Page 819 of 1333

MITSUBISHI MONTERO 1991 Service Manual threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,

threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace track bar.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
track bar.
Bent .................... B ............ Require replacement.
Corroded, affecting
structural integrity ... A ............ Require replacement.
Grease boot cracked ..... 2 ........ (1) Suggest replacement.
Grease boot missing ..... 2 ........ ( 2) Suggest replacement.
Grease boot torn ........ 2 ........ ( 3) Suggest replacement.
Holes distorted ......... A ............ Require replacement.
Looseness (perceptible
horizontal movement) ... 1 ........ ( 4) Suggest replacement.
Looseness that is
excessive .............. B ..... ( 4)( 5) Require replacement.
Nut on stud loose ....... A ........... ( 6) Require repair or
replacement of nut.
Seized .................. A ............ Require replacement.
Stud bent ............... B ........ ( 7) Require replacement.
Stud broken ............. A ........ ( 7) Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ........ ( 7) Require replacement.
Wear exceeds
manufacturer's
specifications ......... B ............ Require replacement.
( 1) - Cracked grease boot will allow contaminants to enter
joint and will accelerate wear.
( 2) - Lack of grease boot will allow contaminants to enter
joint and will accelerate wear.
( 3) - Torn grease boot will allow contaminants to enter joint
and will accelerate wear.
( 4) - 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.
( 5) - Excessive looseness is defined as being significant
enough to affect vehicle handling or structural integrity.
( 6) - Check for bent stud or damaged taper hole.
( 7) - Check for damaged taper hole.
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TRAILING ARMS
TRAILING ARM INSPECTION\
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require replacement of broken
part, if available; otherwise,
replace trailing arm.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;

Page 820 of 1333

MITSUBISHI MONTERO 1991 Service Manual otherwise, replace trailing
arm.
Attaching hardware
missing ................ C .. Require replac

otherwise, replace trailing
arm.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace trailing arm.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace trailing arm.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
trailing arm.
Bent .................... B ............ Require replacement.
Bushing hole oversized .. 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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WHEEL BEARINGS, RACES AND SEALS
NOTE: When replacing or repacking wheel bearings, grease seal
replacement is required. You are not required to replace
these components in axle sets. Determine the need to
replace based upon the individual component conditions
that follow.
WHEEL BEARING, RACE AND SEAL INSPECTION
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Condition Code Procedure
Rear axle seal on rear-
wheel drive leaking .... A ..... Require replacement of seal
and inspection of axle,
bearing, housing,
and vent tube.
Seal bent ............... 1 ............ Suggest replacement.
Seal leaking ............ A . Require replacement of seal and
inspection of bearings.
Seal missing ............ C ............ Require replacement.
Seal torn ............... A ............ Require replacement.
Wheel bearing
assembly feels rough
when rotated ........... A .. Require replacement of bearing
assembly.
Wheel bearing balls
are pitted ............. A .. Require replacement of bearing
assembly.
Wheel bearing balls
are worn ............... A .. Require replacement of bearing
assembly.
Wheel bearing end-play
exceeds vehicle
manufacturer's
specifications ......... B .. Require adjustment of bearing,

Page 821 of 1333

MITSUBISHI MONTERO 1991 Service Manual if possible. If proper
adjustment cannot be obtained,
require repair or replacement

if possible. If proper
adjustment cannot be obtained,
require repair or replacement
of worn component.
Wheel bearing race
is loose in the
hub bore ............... A ...... Require replacement of hub
assembly and wheel bearings.
Wheel bearing races
are pitted ............. A .. Require replacement of bearing
assembly.
Wheel bearing races
are worn ............... A .. Require replacement of bearing
assembly.
Wheel bearing rollers
are pitted ............. A .. Require replacement of bearing
assembly.
Wheel bearing rollers
are worn ............... A .. Require replacement of bearing
assembly.
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WHEEL ALIGNMENT
WHEEL ALIGNMENT
Wheel alignment is defined as the measurement, analysis, and
adjustment of steering and suspension angles to conform to OEM
specifications. These angles usually include, but are not limited to:
caster, camber, toe, and thrust angle. Where these angles are not
adjustable and not in specification, component replacement or
correction kits may be required. Errors in set-back and steering axis
inclination (SAI) are often attributable to failed or damaged
components and must be corrected prior to performing an alignment.
Failure to replace or correct suggested parts or service may
prevent a proper alignment.
Before performing an alignment check, inspect and verify the
following:
* Tire pressure and size
* Vehicle loading
* Ride height
* Steering and suspension parts
If the inspection reveals that all the above are within
published specifications, a wheel alignment check and an alignment, if
needed, may be performed.
CAUTION: Under no circumstances should a technician bend or heat
any steering or suspension component, unless specified by
the vehicle manufacturer, for example, Ford forged twin
"I" beam axles. All measurements and specifications must
be noted on the inspection report.
WHEEL ALIGNMENT INSPECTION
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Condition Code Procedure
Dog tracking, shown
to be caused by
faulty alignment ....... 2 ................ Suggest repair.
Lead, shown to

Page 822 of 1333

MITSUBISHI MONTERO 1991 Service Manual be caused by
faulty alignment ....... A ............. Require alignment.
Part has been changed,
affecting alignment .... A ....... Require alignment check.
Pull, shown to be caused
by faul

be caused by
faulty alignment ....... A ............. Require alignment.
Part has been changed,
affecting alignment .... A ....... Require alignment check.
Pull, shown to be caused
by faulty alignment .... A ............. Require alignment.
Steering wheel
off-center ............. 2 ............. Suggest alignment.
Tire wear, shown
to be caused by
faulty alignment ....... A ............. Require alignment.
Wander, shown
to be caused by
faulty alignment ....... A ............. Require alignment.
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WHEELS AND TIRES
TIRES
These guidelines do not apply to split rims. Some vehicle
manufacturers restrict replacement of tires to specific brands, types,
or sizes.
WARNING: High pressure temporary compact spare tires should not be
used with any other rims or wheels, nor should standard
tires, snow tires, wheel covers, or trim rings be used
with high pressure compact spare rims or wheels.
Attempting to mount a tire of one diameter on a wheel of
a different diameter or flange type may result in serious
injury or death.
WARNING: Only specially trained persons should dismount or mount
tires. Explosions of tire and wheel assembly can result
from improper mounting, possibly causing serious injury
or death.
WARNING: Consult the vehicle owner's manual or vehicle placard for
correct size, speed rating, designation, and cold
inflation pressure of the original tires. DO NOT exceed
the maximum load or inflation capacity of the tire
specified by the Tire and Rim Association
WARNING: When replacing tires, it is suggested that the
replacement tires match or exceed the OEM speed rating
designation. If tires of different speed rating
designations are mixed on the same vehicle, the tires may
vary in handling characteristics. DO NOT mix different
speed rating designations on the same axle.
WARNING: DO NOT mix radials with non-radial tires on the same
axle, as this may affect vehicle handling and stability.
If radial tires and bias or bias-belted ply tires are
mixed on the same vehicle, the radials must be on the
rear. High-pressure temporary compact spare tires are
exempt from this rule.
WARNING: DO NOT mix size or type (all season, performance, mud and
snow) of tires on the same axle.
TIRE INSPECTION
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Page 823 of 1333

MITSUBISHI MONTERO 1991 Service Manual Condition Code Procedure
Air pressure incorrect .. B .................. Require repair
Bead broken ............. A ............ Require replacement.
Be

Condition Code Procedure
Air pressure incorrect .. B .................. Require repair
Bead broken ............. A ............ Require replacement.
Bead leaking, caused
by tire ................ A .. Require repair or replacement.
Bead wire/cord exposed .. A ............ Require replacement.
Cord or belt material
exposed ................ A ............ Require replacement.
Cord ply separations .... A ............ Require replacement.
Directional/asymmetrical
tires mounted
incorrectly ............ B ....... Require remounting and/or
repositioning.
Irregular tread wear,
affecting performance .. 2 ........ (1) Suggest replacement.
Load ratings less
than OEM
specifications ......... B ............ Require replacement.
Mixed tread types (all
season, performance, mud
and snow) on same axle . A ............ Require replacement.
Number of punctures
exceeds manufacturer's
limit .................. B ............ Require replacement.
Out of balance .......... B . Require rebalance of tire/wheel
assembly.
Ply separation .......... A ............ Require replacement.
Pull or lead, caused
by tire ................ A .. Require repair or replacement.
Radial and bias or
bias-belted ply tires
on same axle ........... B .. Require repair or replacement.
Radials are on the front
and not on the rear .... B ........... ( 2) Require repair or
replacement.
Run flat damage ......... A ............ Require replacement.
Shoulder cut ............ A ............ Require replacement.
Shoulder puncture ....... A ............ Require replacement.
Shoulder with plug ...... A ............ Require replacement.
Sidewall bulge .......... A ............ Require replacement.
Sidewall cut ............ A ............ Require replacement.
Sidewall indentation .... .. ......... No service required or
suggested.
Sidewall puncture ....... A ............ Require replacement.
Sidewall with plug ...... A ............ Require replacement.
Speed rating
designations
different
on same axle ........... 2 .. Suggest repair or replacement.
Tire and wheel assembly
has excessive run-out .. B ........... ( 3) Require repair or
replacement of appropriate
part.
Tires with more than
1/4" diameter difference
on a four-wheel drive
vehicle ................ B ............ Require replacement.
Tread area puncture larger
in diameter than
manufacturer's
specifications ......... B ............ Require replacement.
Tread missing pieces

Page 824 of 1333

MITSUBISHI MONTERO 1991 Service Manual (chunking),
exposing cord .......... A ............ Require replacement.
Tread missing pieces
(chunking), not
exposing cord .......... 1 ............ Suggest replacement.
Tread separations

(chunking),
exposing cord .......... A ............ Require replacement.
Tread missing pieces
(chunking), not
exposing cord .......... 1 ............ Suggest replacement.
Tread separations A ............ Require replacement.
Tube in tubeless tire 3 .... (4) Suggest removal of tube.
Weather-checking ........ .. ......... No service required or
suggested.
Worn to tread wear
indicators ............. B ............ Require replacement.
( 1) - Determine and correct cause of irregular tire wear.
( 2) - If radials and bias or bias-belted ply tires are on the
same vehicle, the radials must be on the rear axle,
except for high-pressure temporary spares.
( 3) - Excessive is defined as enough to contribute to
performance problems. Match mounting may correct
run-out. If not, require replacement of appropriate
part. Refer to manufacturer's specifications.
( 4) - Most manufacturers do not recommend tubes in tubeless
tires. Inspect tire and wheel assembly to determine
the reason for a tube in tubeless tire. Recommendation
for repair or replacement should be based upon condition
of tires and/or wheel listed in these guidelines.
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VALVE STEMS
VALVE STEM INSPECTION\
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Condition Code Procedure
Bent .................... 1 ........... Suggest replacement.
Broken .................. A ........... Require replacement.
Cut, but not leaking .... 1 ........... Suggest replacement.
Deteriorated
(cracking, dry rot) .... 1 ........... Suggest replacement.
Leaking ................. A . Require repair or replacement.
Missing ................. C ........... Require replacement.
Threads damaged ......... A . Require repair or replacement.
Threads stripped ........ A ........... Require replacement.
Valve cap missing ....... C .... Require replacement of cap.
Weather-checking ........ 1 ........... Suggest replacement.
Won't take air .......... A . Require repair or replacement.
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WHEEL ATTACHMENT HARDWARE
For conditions noted below, also check conditions of wheel
stud holes.
CAUTION: Proper lug nut torque is essential. Follow recommended
torque specifications and tightening sequence. DO NOT
lubricate threads unless specified by the vehicle
manufacturer.
WHEEL ATTACHMENT HARDWARE INSPECTION
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Condition Code Procedure
Bent .................... A ............ Require replacement.
Broken .................. A ........ ( 1) Require replacement.

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