1991 MITSUBISHI MONTERO Service Manual

steering winter tyres fuel pump air condition sensor fuel fill door release

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$MITSUBISHI MONTERO 1991 Service Manual CLUTCH SLAVE CYLINDERS (CONVENTIONAL OR EXTERNAL) CLUTCH SLAVE CYLINDER (CONVENTIONAL OR EXTERNAL) INSPECTION��\ ��\ ��\ ��\ �$

CLUTCH SLAVE CYLINDERS (CONVENTIONAL OR EXTERNAL)
CLUTCH SLAVE CYLINDER (CONVENTIONAL OR EXTERNAL) INSPECTION\
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Condition Code Procedure
Binding ................. A .. Require repair or replacement.
Bleeder port damaged (not
repairable) ............ A ........ ( 1) Require replacement.
Bleeder port damaged
(repairable) ........... A ............. ( 1) Require repair.
Bleeder screw broken off
in slave cylinder ...... A ........ ( 1) Require replacement.
Bleeder screw seized .... A ........ ( 2) Require replacement.
Bore corroded (pitted) .. B ............ Require replacement.
Bore grooved ............ A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Only required if the hydraulic system must be opened.
( 2) - Seized is defined as a bleeder screw that cannot be
removed after a practical attempt at removing it has
been made.
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COMPANION FLANGES
See YOKES AND SLIP YOKES .
CONNECTORS
See WIRING HARNESSES AND CONNECTORS .
COOLER BYPASS VALVES
COOLER BYPASS VALVE INSPECTION\
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Condition Code Procedure
Inoperative ............. A ............ Require replacement.
Installed incorrectly ... A ................. Require repair.
Leaking ................. A .. Require repair or replacement.
Restricted .............. A .. Require repair or replacement.
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COOLER LINES
COOLER LINE INSPECTION\
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Condition Code Procedure
Abrasion damage, affecting
structural integrity ... A .. Require repair or replacement.
Abrasion damage, not
affecting structural
integrity .............. .. ........ No service suggested or
required.
Application incorrect ... B ............ Require replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.

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MITSUBISHI MONTERO 1991 Service Manual Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............

Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Clamp corroded, not
reusable ............... 1 ............ Suggest replacement.
Connected incorrectly ... A ................. Require repair.
Corroded, affecting
structural integrity ... A ............ Require replacement.
Corroded, not affecting
structural integrity ... .. ........ No service suggested or
required.
Cracked ................. A .. Require repair or replacement.
Fitting type incorrect
(such as compression
fitting) ............... B ............ Require replacement.
Flange leaking .......... A .. Require repair or replacement.
Insufficient clamping
force, allowing hose to
leak ................... A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Melted .................. 1 .. Suggest repair or replacement.
Missing ................. C ............ Require replacement.
Outer covering damaged to
the extent that the inner
fabric is visible ...... A ............ Require replacement.
Protective sleeves
damaged ................ 2 . Suggest replacement of sleeves.
Protective sleeves
missing ................ C . Require replacement of sleeves.
Restricted, affecting
performance ............ A .. Require repair or replacement.
Routed incorrectly ...... 2 ................. Require repair.
Swollen ................. 1 ............ Suggest replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Type incorrect .......... 1 .. Suggest repair or replacement.
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COOLERS
See TRANSMISSION COOLERS .
CV JOINTS
CV JOINT INSPECTION\
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Condition Code Procedure
Bearing, bushing or seal
surface worn, affecting
performance ............ A .. Require repair or replacement.
Boot clamp broken ....... A ... Require repair or replacement
of clamp.
Boot clamp loose ........ A ... Require repair or replacement
of clamp.
Boot clamp missing ...... C ... Require repair or replacement
of clamp.
Boot leaking ............ A . Require replacement of CV boot.
Boot surface cracked,

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MITSUBISHI MONTERO 1991 Service Manual not leaking ............ 2 . Suggest replacement of CV boot.
Cage broken ............. A ... Require repair or replacement
of CV joint.
Ho

not leaking ............ 2 . Suggest replacement of CV boot.
Cage broken ............. A ... Require repair or replacement
of CV joint.
Housing damaged to the
extent that it no longer
performs its intended
function ............... A ........... (1) Require repair or
replacement of CV joint.
Housing worn to the extent
that it no longer performs
its intended function .. A ........... ( 1) Require repair or
replacement of CV joint.
Holes elongated ......... A ............ Require replacement.
Internal parts binding .. A .. Require repair or replacement.
Internal parts worn ..... A .. Require repair or replacement.
Lubricant missing ....... C ... Require cleaning, inspection,
and repacking of CV joint.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Housing assembly may appear blue in color from normal
manufacturing process of heat-treating the housing.
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DIP STICK TUBES
DIP STICK TUBE INSPECTION\
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Condition Code Procedure
Broken .................. A .. Require repair or replacement.
Checkball missing ....... C .. Suggest repair or replacement.
Cracked ................. A .. Require repair or replacement.
Hold down bracket
broken ................. A .. Require repair or replacement.
Hold down bracket
missing ................ C ............ Require replacement.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
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DIP STICKS (FLUID LEVEL INDICATORS)
DIP STICK (FLUID LEVEL INDICATOR) INSPECTION\
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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Broken .................. A ............ Require replacement.
Compressed .............. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Modified ................ A ............ Require replacement.
Stretched ............... A .. Require repair or replacement.
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DOWEL PINS, GUIDES AND PILOT HOLES
DOWEL PIN, GUIDE AND PILOT HOLE INSPECTION\
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Page 308 of 1333

MITSUBISHI MONTERO 1991 Service Manual Condition Code Procedure
Application incorrect ... B .. Require repair or replacement.
Cracked ................. A .. Require repair or replacement.
Di

Condition Code Procedure
Application incorrect ... B .. Require repair or replacement.
Cracked ................. A .. Require repair or replacement.
Distorted ............... A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Positioned incorrectly .. B .. Require repair or replacement.
Stepped ................. A .. Require repair or replacement.
Worn to the extent that it
no longer performs its
intended function ...... A .. Require repair or replacement.
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DRIVE SHAFT FLANGES
See COMPANION FLANGES .
DRIVE SHAFTS AND HALF SHAFTS
DRIVE SHAFT AND HALF SHAFT INSPECTION\
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Condition Code Procedure
Balance weight missing .. C .. Require repair or replacement.
Bearing cap bore
distorted .............. A .. Require repair or replacement.
Bent .................... A ............ Require replacement.
Bolt holes elongated .... A .. Require repair or replacement.
Bushing or seal surface
worn, affecting
performance ............ A .. Require repair or replacement.
Leaking through soft yoke
plug ................... A ... Require repair or replacement
of soft yoke plug.
Out of balance .......... A .. Require repair or replacement.
Retainer strap bent ..... A .......... Require replacement of
retainer strap.
Slip yoke broken ........ A ............ Require replacement.
Splines worn, affecting
performance ............ A ............ Require replacement.
Splines worn close to
the end of their
useful life ............ 1 ............ Suggest replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
U-bolt damaged, affecting
performance ............ A . Require replacement of U-bolts.
Yoke damaged, affecting
performance ............ A .. Require repair or replacement.
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DUST BOOTS
NOTE: Does not include CV boots.
DUST BOOT INSPECTION
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Condition Code Procedure
Cracked, not leaking .... 1 ............ Suggest replacement.
Missing ................. C ............ Require replacement.
Leaking ................. A .. Require repair or replacement.

Page 309 of 1333

$MITSUBISHI MONTERO 1991 Service Manual Torn .................... A ............ Require replacement.��\ ��\ ��\ ��\ ��\ ��\ ��$

Page 310 of 1333

$MITSUBISHI MONTERO 1991 Service Manual performs its intended function ............... A ............ Require replacement. Weights missing ......... A ............ Require replacement. ��\ ��\ ��$

performs its intended
function ............... A ............ Require replacement.
Weights missing ......... A ............ Require replacement.
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FLUID LEVEL INDICATORS
See DIP STICKS (FLUID LEVEL INDICATORS) .
FLUIDS AND LUBRICANTS
FLUID AND LUBRICANT INSPECTION\
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Condition Code Procedure
Application incorrect ... B ........ ( 1) Require replacement.
At service interval ..... 3 ............ Suggest replacement.
Beyond service interval . 3 ............ Suggest replacement.
Burned .................. .. ......... ( 2) Further inspection
required.
Contaminated, for example,
fluid other than hydraulic
fluid present .......... A or B .... ( 3)( 4) Require service.
Exceeding service
interval ............... 3 ............ Suggest replacement.
Hydraulic fluid
incorrect .............. B ............ ( 5) Require service.
Level incorrect ......... B ..... Require correction of fluid
level.
Near service interval ... 3 ............ Suggest replacement.
Rubber master cylinder
cover gasket distorted
and gummy .............. A ............ ( 3) Require service.
Varnished ............... .. ......... ( 6) Further inspection
required.
( 1) - Determine and correct cause.
( 2) - Fluid that is burned indicates a serious problem.
Determine and correct the cause.
( 3) - If a fluid other than hydraulic fluid is present in the
hydraulic system which DOES affect the rubber parts, the
required service is to: 1) remove all components having
rubber parts from the system, 2) flush lines with
denatured alcohol or hydraulic cleaner, 3) repair or
replace all components having rubber parts, and 4) bleed
and flush with correct hydraulic fluid. (Code A)
( 4) - If a fluid other than hydraulic fluid is present in the
hydraulic system which DOES NOT affect the rubber parts,
the required service is to flush and fill with the
correct hydraulic fluid. (Code B)
( 5) - If a fluid other than specification hydraulic fluid is
present in the hydraulic system, the required service
is to flush and fill with the correct hydraulic fluid.
( 6) - Fluid that is varnished may indicate a serious problem.
Determine and correct the cause.
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FLYWHEELS
NOTE: Clutch disc replacement does not necessitate flywheel
reconditioning, unless other conditions justify the
reason to do so.

Page 311 of 1333

$MITSUBISHI MONTERO 1991 Service Manual FLYWHEEL INSPECTION��\ ��\ ��\ ��\ ��\ ��\ ��\ �� Condition Code$

FLYWHEEL INSPECTION\
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Cracked (other than
mounting area) ......... A ...... (1) Require resurfacing or
replacement.
Cracks in mounting area . B ............ Require replacement.
Hard spots .............. B .. Require repair or replacement.
Ring gear broken ........ A ..... Require replacement of ring
gear.
Ring gear teeth worn,
affecting performance .. A ..... Require replacement of ring
gear.
Runout exceeds
specifications ......... B .. Require repair or replacement.
Scored .................. B .. Require repair or replacement.
Surface cracks after
resurfacing to
manufacturer's minimum
specifications ......... B ............ Require replacement.
Wear exceeds
specifications ......... B ............ Require replacement.
Worn close to the end of
its useful life ........ 1 ............ Suggest replacement.
Worn, affecting
performance ............ A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Some manufacturers allow slight surface cracking in the
friction surface.
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FORCE MOTORS
See ACTUATORS (ELECTRICAL) .
GUIDES
See DOWEL PINS, GUIDES AND PILOT HOLES .
HALF SHAFTS
See DRIVE SHAFTS AND HALF SHAFTS .
HOSES, LINES AND TUBES
HOSE, LINE AND TUBE INSPECTION\
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Condition Code Procedure

Page 312 of 1333

MITSUBISHI MONTERO 1991 Service Manual Application incorrect ... B ............ Require replacement.
Connected incorrectly ... A ................. Require repair.
Corroded, not reusable .. 1 ............ Suggest replacement.
Cr

Application incorrect ... B ............ Require replacement.
Connected incorrectly ... A ................. Require repair.
Corroded, not reusable .. 1 ............ Suggest replacement.
Cracked ................. A ............ Require replacement.
Dry-rotted .............. 1 .. Suggest repair or replacement.
Hard .................... 1 .. Suggest repair or replacement.
Inner fabric (webbing)
damaged ................ A ............ Require replacement.
Insufficient clamping
force, allowing hose to
leak ................... A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Maintenance intervals ... 3 ............ Suggest replacement.
Melted .................. 1 .. Suggest repair or replacement.
Missing ................. C ............ Require replacement.
Outer covering damaged .. 1 ............ Suggest replacement.
Outer covering damaged to
the extent that the inner
fabric is visible ...... A ............ Require replacement.
Protective sleeves
damaged ................ 2 . Suggest replacement of sleeves.
Protective sleeves
missing ................ 2 . Suggest replacement of sleeves.
Restricted, affecting
performance ............ A .. Require repair or replacement.
Restricted, not affecting
performance ............ 2 .. Suggest repair or replacement.
Routed incorrectly ...... 2 ............ Suggest replacement.
Safety clip missing ..... C ............ Require replacement.
Spongy .................. 1 .. Suggest repair or replacement.
Stripped ................ A ............ Require replacement.
Swollen ................. B ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Type incorrect .......... 1 .. Suggest repair or replacement.
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HOUSINGS (BELL, CASE, TAIL (EXTENSION) AND AUXILIARY)
HOUSING (BELL, CASE, TAIL (EXTENSION) AND AUXILIARY) INSPECTION\
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Condition Code Procedure
Bearing race loose
in bore ................ A .. Require repair or replacement.
Broken, affecting
performance ............ A .. Require repair or replacement.
Cracked ................. A .. Require repair or replacement.
Dowel pin holes worn,
affecting performance .. A ........... ( 1) Require repair or
replacement.
Machined surfaces damaged,
affecting performance .. A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Worn, affecting
performance ............ A .. Require repair or replacement.
( 1) - See DOWEL PINS, GUIDES AND PILOT HOLES .
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