1991 MITSUBISHI MONTERO power steering fluid

piston rod movement. If dents don't restrict movement, no
service is suggested or required. Especially critical on
mono-tube dampers.
(2) - This condition can lead to damage of the piston rod,
which, in turn, causes premature piston rod seal wear.
( 3) - If noise is isolated to damper, suggest replacement.









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STEERING GEARS (EXCEPT RACK AND PINION)
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.
STEERING GEAR (EXCEPT RACK AND PINION) INSPECTION









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Condition Code Procedure
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.
Binding ................. A ... Require repair or replacement
Flex coupler binding .... A ... Require repair or replacement
of coupler.
Flex coupler loose ...... A ... Require repair or replacement
of coupler.
Flex coupler
missing parts .......... A ... Require repair or replacement
of coupler.
Flex coupler
soft/spongy ............ A . Require replacement of coupler.
Flex coupler torn ....... A . Require replacement of coupler.
Fluid contaminated ...... B ........ ( 1) Require flushing and
refilling of the system.
Gasket leaking .......... A ... Require repair or replacement
of gasket.
Housing leaking ......... A ............ Require replacement.
Hydraulic fittings
leaking ................ A ... Require repair or replacement
of fittings.
Inadequate power assist . A .......... ( 2) Further inspection
required.
See note below.
Lash exceeds
manufacturer's
specifications .......... B .. Require repair or replacement.
Seal leaking ............ A ... Require repair or replacement

of seal and/or mating part.
Splines damaged ......... A ... Require repair or replacement
of splines.
Splines stripped ........ A . Require replacement of splines.
Steering coupler
shield cracked ......... 2 ............ Suggest replacement.
Steering coupler
shield missing ......... C ............ Require replacement.
Threads damaged ......... A ... Require repair or replacement
of part with damaged threads.
Threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
U-joint binding ......... A ... Require repair or replacement
of joint.
U-joint loose ........... A ... Require repair or replacement
of joint.
Unequal power assist .... A .. Require repair or replacement.
(1) - Determine and correct source of contamination. OEM
specifications must be followed for fluid type.
( 2) - If steering gear is source of inadequate assist, require
repair or replacement.









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STEERING GEARS - RACK AND PINION
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.
STEERING GEARS - RACK AND PINION INSPECTION









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Condition Code Procedure
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.
Balance tube blocked .... A .. Require repair or replacement
of balance tube.
Balance tube missing .... C .. Require replacement of balance
tube.
Balance tube restricted . A ... Require repair or replacement
of balance tube.
Bellows boot
clamp missing .......... C ... Require replacement of clamp.
Bellows boot cracked

(not through) .......... 2 .. Suggest replacement of bellows
boot.
Bellows boot missing .... C .. Require replacement of bellows
boot.
Bellows boot
not sealing ............ A ... Require repair or replacement
of bellows boot.
Bellows boot torn ....... A .. Require replacement of bellows
boot.
Bellows boot twisted
(from toe adjustment) .. B ................. Require repair.
Fitting leaking ......... A .. Require repair or replacement.
Fitting missing ......... A . Require replacement of fitting.
Fitting threads
damaged ................ A ... Require repair or replacement
of part with damaged threads.
Fitting threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Flex coupler binding .... A ... Require repair or replacement
of coupler.
Flex coupler loose ...... A ... Require repair or replacement
of coupler.
Flex coupler
missing parts .......... A ... Require repair or replacement
of coupler.
Flex coupler
soft/spongy ............ A . Require replacement of coupler.
Flex coupler torn ....... A . Require replacement of coupler.
Fluid contaminated ...... B ........ (1) Require flushing and
refilling of the system.
Gasket leaking .......... A .. Require repair or replacement.
Hard steering on cold
start-up ............... 1 ........... ( 2) Suggest repair or
replacement.
Housing cracked,
affecting structural
integrity .............. B ............ Require replacement.
Housing leaking ......... A ............ Require replacement.
Inadequate power assist . A .......... ( 3) Further inspection
required.
Lash exceeds
manufacturer's
specifications ......... B .. Require repair or replacement.
Seal leaking ............ A .. Require repair or replacement.
Splines damaged ......... A .. Require repair or replacement.
Splines stripped
(splines missing) ...... A ............ Require replacement.
Steel line blocked ...... A ... Require repair or replacement
of line.
Steel line leaking ...... A ... Require repair or replacement
of line.
Steel line missing ...... C .... Require replacement of line.
Steel line restricted ... A ... Require repair or replacement
of line.
Steering coupler shield
cracked ................ 2 ............ Suggest replacement.
Steering coupler shield
missing ................ C ............ Require replacement.
Steering coupler shield
torn ................... 2 ............ Suggest replacement.
Threads damaged ......... A ... Require repair or replacement
of part with damaged threads.

Threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
U-joint binding ......... A ... Require repair or replacement
of joint.
U-joint loose ........... A ... Require repair or replacement
of joint.
Unequal power assist .... A .. Require repair or replacement.
(1) - Determine and correct source of contamination. Follow OE
specifications for fluid type.
( 2) - Indicates internal wear.
( 3) - If steering gear is source of inadequate assist, require
repair or replacement.









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STEERING KNUCKLES
STEERING KNUCKLE 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
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.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads.
Bent .................... B ............ Require replacement.
Broken .................. A ............ Require replacement.
Pinch bolt incorrect .... B ... Require replacement with bolt
that meets OE design.
Pinch bolt loose ........ B ................. Require repair.
Pinch bolt missing ...... B ............ Require replacement.
Pinch bolt tabs
deformed (pinched
together), .032"
or more before
clamping ............... B ........ ( 1) Require replacement.
Taper hole elongated .... A ........ ( 2) Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A .. Require repair or replacement.
( 1) - Steering knuckle deformation can cause pinch
bolt breakage.
( 2) - Check for damaged stud.

right several times. Start engine, and turn steering wheel back and
forth to raise fluid temperature to approximately 122-140F (50-60C).
3) With engine idling, gradually close shutoff valve of
pressure gauge to increase hydraulic pressure. If idle speed does not
increase 200-250 RPM when fluid pressure reaches 213-284 psi (15-20
kg/cm
), replace power steering idle-up switch.
4) Gradually open shutoff valve. If engine speed does not
return to curb idle speed between 100-142 psi (7-10 kg/cm
), replace
power steering idle-up switch. Remove testing equipment. Bleed air
from system as in step 2).
IGNITION SYSTEM
NOTE: For basic ignition checks, see F - BASIC TESTING article in
ENGINE PERFORMANCE Section.
TIMING CONTROL SYSTEMS
Crank Angle Sensor
Crank angle sensor is located inside distributor on SOHC
engines and is attached to cylinder head on DOHC engines. If
malfunction occurs, Code 22 will set. For testing procedure, see
appropriate G - TESTS W/CODES article in the ENGINE PERFORMANCE
Section.
EMISSION SYSTEMS & SUB-SYSTEMS
EXHAUST GAS RECIRCULATION (EGR)
System Testing (Federal)
1) Disconnect Green-striped hose from throttle body, and
connect vacuum pump to hose end. Plug nipple where hose was connected
to throttle body. When engine is cold, 122
F (50C) or less, and at
idle, apply vacuum to disconnected hose. If idle does not change and
vacuum bleeds down, system is okay.
2) When engine is hot, 205
F (95C), and at idle, apply 1.8
in. Hg. If idle does not change and vacuum holds, system is okay.
Using a vacuum pump, apply 7.7 in. Hg. If idle becomes unstable or
engine stalls (and vacuum holds), system is okay.
System Testing (California)
1) Connect vacuum "T" fitting into Green-striped hose from
EGR valve, and connect vacuum gauge to vacuum tee. When engine coolant
temperature is 68
F (20C) or less and engine is idling, snap throttle
open to race engine. If no change in vacuum reading is detected on
gauge, system is okay.
2) When engine coolant temperature is 158
F (70C) or more
and engine is idling, snap throttle open to race engine. If vacuum
increases to 3.9 in. Hg or higher, system is okay.
3) Using vacuum pump, apply specified vacuum to open EGR
valve. See EGR VALVE SPECIFICATIONS table. If idle becomes unstable or
engine stalls, system is okay.
EGR Control Solenoid Valve (Pickup & Ram-50, California)
1) EGR control solenoid valve is located near left shock
tower. Label and disconnect vacuum hoses and wiring harness from
solenoid valve.
2) Connect hand vacuum pump to vacuum nipple where Green-
striped vacuum hose was connected. Apply vacuum and ensure vacuum does
not hold. Apply battery voltage to one terminal of solenoid, and
ground other. Ensure vacuum holds.

Worn shaft serrations See STEERING COLUMN
article









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Growl in Excessive pressure in Restricted hoses, see
Steering Pump hoses POWER STEERING GEAR
article
Scored pressure plates See POWER STEERING GEAR
article
Scored thrust plates or See POWER STEERING GEAR
rotor article
Extreme wear of cam ring See POWER STEERING GEAR
article









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Rattle in Vanes not installed See POWER STEERING PUMP
Steering Pump article
Vanes sticking in rotor See POWER STEERING PUMP
article









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Swish noise in Defective flow control See POWER STEERING PUMP
Pump valve article









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Groan in Air in fluid See POWER STEERING PUMP
Steering Pump article
Poor pressure hose Tighten and check,
connection replace if necessary









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Squawk When Damper "O" ring on valve See POWER STEERING PUMP
Turning spool cut article









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Moan or Whine Pump shaft bearing scored Replace bearing and
in Pump fluid
Air in fluid or fluid See POWER STEERING PUMP
level low article
Hose or column grounded Check and replace if
necessary
Cover "O" ring missing See POWER STEERING PUMP
or damaged article
Valve cover baffle See POWER STEERING PUMP
missing or damaged article
Interference of See POWER STEERING PUMP
components in pump article
Loose or poor bracket Correct or replace if
alignment necessary









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Hissing When Internal leakage in Check valved assembly
Parking steering gear first









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Chirp in Loose or worn power Adjust or replace if
Steering Pump steering belt necessary









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Buzzing When Noisy pump See POWER STEERING PUMP
Not Steering article

Reaction ring sticking See POWER STEERING GEAR
in housing head article
Steering pump internal See POWER STEERING PUMP
leakage article
Steering gear-to-column See STEERING COLUMN
misalignment article
Lack of lubrication in Service front suspension
linkage
Lack of lubrication in Service front suspension
ball joints









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Increased Effort High internal pump leakage See POWER STEERING PUMP
When Turning article
Wheel Fast Power steering pump belt Adjust or replace if
Foaming, Milky slipping necessary
Power Steering
Fluid, Low Fluid Low fluid level Check and fill to
Level or Low proper level
Pressure
Engine idle speed to low Adjust to correct
setting
Air in pump fluid system See POWER STEERING PUMP
article
Pump output low See POWER STEERING PUMP
article
Steering gear See POWER STEERING GEAR
malfunctioning article









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Wheel Surges Low fluid level Check and fill to proper
or Jerks level
Loose fan belt Adjust or replace if
necessary
Insufficient pump See POWER STEERING PUMP
pressure article
Sticky flow control valve See POWER STEERING PUMP
article
Linkage hitting oil pan Replace bent components
at full turn









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Kick Back or Air in pump fluid system See POWER STEERING PUMP
Free Play article
Worn poppet valve in See POWER STEERING PUMP
steering gear article
Excessive over center See POWER STEERING GEAR
lash article
Thrust bearing out of See POWER STEERING GEAR
adjustment article

Free play in pot coupling See POWER STEERING PUMP
article
Steering gear coupling See POWER STEERING PUMP
loose on shaft article
Steering disc mounting Tighten or replace if
bolts loose necessary
Coupling loose on worm Tighten or replace if
shaft necessary
Improper sector shaft See POWER STEERING GEAR
adjustment article
Excessive worm piston See POWER STEERING GEAR
side play article
Damaged valve lever See POWER STEERING GEAR
article
Universal joint loose Tighten or replace if
necessary
Defective rotary valve See POWER STEERING GEAR
article









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No Power When Sticking flow control See POWER STEERING PUMP
Parking valve article
Insufficient pump See POWER STEERING PUMP
pressure output article
Excessive internal pump See POWER STEERING PUMP
leakage article
Excessive internal gear See POWER STEERING PUMP
leakage article
Flange rubs against gear See STEERING COLUMN
adjust plug article
Loose pump belt Adjust or replace if
necessary
Low fluid level Check and add proper
amount of fluid
Engine idle too low Adjust to correct
setting
Steering gear-to-column See STEERING COLUMN
misaligned article









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No Power, Left turn reaction seal See POWER STEERING GEAR
Left Turn "O" ring worn article
Left turn reaction seal See POWER STEERING GEAR
damaged/missing article
Cylinder head "O" ring See POWER STEERING PUMP
damaged article









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