1991 MITSUBISHI MONTERO Service Manual

park assist service interval oil change traction control rear view mirror air bleeding

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$MITSUBISHI MONTERO 1991 Service Manual AIR RIDE SUSPENSION - SWITCH (ON/OFF) INSPECTION��\ ��\ ��\ ��\ ��\ ��\ ��\ �� Conditio$

AIR RIDE SUSPENSION - SWITCH (ON/OFF) INSPECTION\
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Condition Code Procedure
Broken .................. A ............ Require replacement.
Missing ................. C ............ Require replacement.
Output signal incorrect . A ............ Require replacement.
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AIR RIDE SUSPENSION - TORSION SPRINGS (COUNTER BALANCING)
AIR RIDE SUSPENSION - TORSION SPRING (COUNTER BALANCING) 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.
Broken .................. A ............ Require replacement.
Missing ................. C ............ Require replacement.
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AIR RIDE SUSPENSION - TUBING
AIR RIDE SUSPENSION - TUBING INSPECTION\
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Condition Code Procedure
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.
Blocked ................. A .. Require repair or replacement.
Fitting incorrect ....... B ............ Require replacement.
Leaking ................. A .. Require repair or replacement.
Line type incorrect ..... B ............ Require replacement.
Missing ................. C ............ Require replacement.
Restricted .............. A .. Require repair or replacement.
Routed incorrectly ...... B ..... Require routing correction.

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$MITSUBISHI MONTERO 1991 Service Manual ��\ ��\ ��\ ��\ ��\ ��\ ��\ �� AIR RIDE SUSPENSION - WARNING LAMPS AIR RIDE SU$

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AIR RIDE SUSPENSION - WARNING LAMPS
AIR RIDE SUSPENSION - WARNING LAMP INSPECTION\
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Condition Code Procedure
Bulb burned out ......... A ............ Require replacement.
Warning light does
not come on during
bulb check ............. .. . Further inspection required to
determine cause.
Warning light flashes ... .. . Further inspection required to
determine cause.
Warning light is
intermittent ........... .. . Further inspection required to
determine cause.
Warning light stays
on after initial
bulb check ............. .. . Further inspection required to
determine cause.
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AIR RIDE SUSPENSION - WIRING HARNESSES
AIR RIDE SUSPENSION - WIRING HARNESS 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.
Damaged (cut, burned, or
chafed) ................ A .. Require repair or replacement.
Excessive resistance .... B .. Require repair or replacement.
Fuse blown .............. A ............ Require replacement.
Fusible link blown ...... A ............ Require replacement.
Open .................... A .. Require repair or replacement.
Poor ground ............. A .. Require repair or replacement.
Routed incorrectly ...... B .. Require rerouting according to
vehicle manufacturer's
specifications.
Shorted ................. A .. Require repair or 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.
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BALL JOINTS
Before requiring or suggesting ball joint replacement, the
approved OEM procedure must be used to measure ball joint wear. The
measurement(s) obtained, along with the vehicle manufacturer's
specifications, must be noted on the inspection report. Some states
require that these measurements also appear on the invoice.
NOTE: The term "perceptible movement," defined as any visible
movement in any direction, has been the industry standard
for determining the need for replacement of follower ball
joints. Some vehicle manufacturers are now publishing
specifications for follower ball joints that were

Page 787 of 1333

MITSUBISHI MONTERO 1991 Service Manual previously diagnosed by the "perceptible movement"
standard. Before requiring or suggesting any parts be
replaced based on "perceptible movement," consult your
rep

previously diagnosed by the "perceptible movement"
standard. Before requiring or suggesting any parts be
replaced based on "perceptible movement," consult your
repair manual to determine if OEM specifications exist.
You are not required to replace ball joints in axle sets.
However, when replacing a ball joint due to wear exceeding
manufacturer's specification, you may suggest replacement of the other
ball joint if its measurement shows it is close to the end of its
useful life, for preventive maintenance.
BALL JOINT INSPECTION
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Condition Code Procedure
Attaching hardware bent . B ... Require repair or replacement
of bent part if available;
otherwise, replace ball joint.
Attaching hardware
broken ................. A ... Require replacement of broken
part if available; otherwise,
replace ball joint.
Attaching hardware
corroded, affecting
structural integrity ... A . Require replacement of corroded
part if available; otherwise,
replace ball joint.
Attaching hardware
incorrect ............... A .......... Require replacement of
incorrect part if available;
otherwise, replace ball joint.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part if available;
otherwise, replace ball joint.
Attaching hardware
missing ................ C .. Require replacement of missing
part if available; otherwise,
replace ball joint.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads if
available; otherwise, replace
ball joint.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads if
available; otherwise, replace
ball joint.
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.
Greaseable ball joint will

Page 788 of 1333

MITSUBISHI MONTERO 1991 Service Manual not take grease ........ 2 ...... (5) Suggest replacement of
grease fitting.
Nut on ball joint loose . A ........... ( 6) Require repair or

not take grease ........ 2 ...... (5) Suggest replacement of
grease fitting.
Nut on ball joint loose . A ........... ( 6) Require repair or
replacement.
Pre-load adjustment
incorrect .............. B .. Require repair or replacement.
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) - If greaseable, grease ball joint. If problem persists
or joint is non-greaseable, require replacement.
( 2) - Cracked grease boot will allow contaminants to enter
the ball joint and will accelerate wear.
( 3) - Lack of grease boot will allow contaminants to enter
the ball joint and will accelerate wear.
( 4) - Torn grease boot will allow contaminants to enter the
ball joint and will accelerate wear.
( 5) - If the greaseable ball joint still will not take grease
after replacing the grease fitting, suggest replacement
of ball joint.
( 6) - Check for bent stud or damaged taper hole.
( 7) - Check for damaged taper hole.
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BUSHINGS
BUSHING INSPECTION\
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Condition Code Procedure
Attaching hardware bent . B ... Require repair or replacement
of bent part if available;
otherwise, replace bushing.
Attaching hardware
broken ................. A ... Require replacement of broken
part if available; otherwise,
replace bushing.
Attaching hardware
corroded, affecting
structural integrity ... A . Require replacement of corroded
part if available; otherwise,
replace bushing.
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part if available;
otherwise, replace bushing.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part if available;
otherwise, replace bushing.
Attaching hardware
missing ................ C .. Require replacement of missing
part if available; otherwise,
replace bushing.
Attaching hardware
threads damaged ........ A ... Require repair or replacement

Page 789 of 1333

MITSUBISHI MONTERO 1991 Service Manual of part with damaged threads if
available; otherwise, replace
bushing.
At

of part with damaged threads if
available; otherwise, replace
bushing.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads if
available; otherwise, replace
bushing.
Binding ................. A .. Require repair or replacement.
Deteriorated, affecting
performance ............ A .. Require repair or replacement.
Distorted, affecting
performance ............ A .. Require repair or replacement.
Leaking (fluid-filled
type) .................. A ............ Require replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .......... (1) Further inspection
required.
Rubber separating from
internal metal sleeve on
bonded bushing ......... A ............ Require replacement.
Seized .................. A ............ Require replacement.
Shifted (out of
position) .............. B .. Require repair or replacement.
Split ................... A ............ Require replacement.
Surface cracking (weather-
checked) ............... .. ........ No service suggested or
required.
( 1) - If noise isolated to bushing, suggest repair or
replacement.
CAUTION: Use only approved lubricant on rubber bushings.
Petroleum-based lubricants may damage rubber bushings.
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CENTER LINKS
CENTER LINK INSPECTION\
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Condition Code Procedure
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part, if available;
otherwise, replace center link.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace center link.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace center link.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace center link.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if

Page 790 of 1333

MITSUBISHI MONTERO 1991 Service Manual available; otherwise, replace
center link.
Bent .................... B ............ Require replacement.
Bi

available; otherwise, replace
center link.
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 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 ........ ( 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.
Stud broken ............. A ........ ( 7) Require replacement.
Stud loose in
taper hole ............. A ........... ( 7) Require repair or
replacement.
Taper hole elongated .... A ........ ( 8) 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) - 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) - 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 damaged taper hole.
( 8) - Check for damaged stud.
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CONTROL ARM SHAFTS
CONTROL ARM SHAFT INSPECTION\
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require replacement of broken

Page 791 of 1333

MITSUBISHI MONTERO 1991 Service Manual part, if available; otherwise,
replace shaft.
Attaching hardware
loose .................. A ... Require repai

part, if available; otherwise,
replace shaft.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace shaft.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace shaft.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace shaft.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
shaft.
Bent .................... B ............ Require replacement.
Shaft bushing surface
undersized (worn) ...... B ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
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CONTROL ARMS
CONTROL ARM INSPECTION\
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Condition Code Procedure
Attaching hardware
bent ................... B ... Require repair or replacement
of bent part, if available;
otherwise, replace control arm.
Attaching hardware
broken ................. A ... Require replacement of broken
part, if available; otherwise,
replace control arm.
Attaching hardware
corroded, affecting
structural integrity ... A . Require replacement of corroded
part, if available; otherwise,
replace control arm.
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part, if available;
otherwise, replace control arm.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace control arm.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace control arm.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads,

Page 792 of 1333

MITSUBISHI MONTERO 1991 Service Manual if available; otherwise,
replace control arm.
Attaching hardware
threads stripped
(threads missing) ...... A

if available; otherwise,
replace control arm.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
control arm.
Bent .................... B ............ Require replacement.
Bushing hole oversized .. B ............ Require replacement.
Ball joint hole oversized
(loose interference or
press fit) ............. B .......... (1) Further inspection
required.
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.
( 1) - If oversized ball joint is available, require
replacement of ball joint. If oversized ball joint
is not available, require replacement of control arm.
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DRAG LINKS
DRAG LINK INSPECTION\
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Condition Code Procedure
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part, if available;
otherwise, replace drag link.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace drag link.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace drag link.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace drag link.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
drag link.
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 of grease
fitting.

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