1991 MITSUBISHI MONTERO four wheel drive
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\003* B RAK E S YSTE M U NIF O RM IN SPEC TIO N G UID ELIN ES *
1 991 M it s u bis h i M onte ro
GENERAL INFORMATION
Brake Systems - Motorist Assurance Program
Standards For Automotive Repair
All Makes & Models
CONTENTS
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS
ACCELEROMETERS (G SENSOR OR LATERAL)
ACCUMULATORS
ANCHOR PINS
ANTI-LOCK BRAKE SYSTEMS
BACKING PLATES
BRAKE FLUID
BRAKE FRICTION MATERIAL
BRAKE PADS
BRAKE PEDALS
BRAKE SHOES
BRAKE SHOE HARDWARE
BRAKE STOPLIGHT SWITCHES
BULB SOCKETS
BULBS AND LEDS
CALIPER HARDWARE
CALIPERS
CONTROLLERS
DIGITAL RATIO AXLE CONTROLLERS AND BUFFERS (DRAC AND DRAB)
DISABLE SWITCHES
DRUMS
ELECTRICAL PUMPS AND MOTORS
ELECTRONIC CONTROLLERS
FLUID
FLUID LEVEL SENSOR SWITCHES
FOUR WHEEL DRIVE SWITCHES
FRICTION MATERIAL
G SENSORS
HOSES
HYDRAULIC MODULATORS
HYDRO-BOOSTERS
HYDRO-ELECTRIC BOOSTERS (POWERMASTER)
IGNITION DISABLE SWITCHES
LATERAL ACCELERATION SWITCHES
LEDS
LENSES
MASTER CYLINDERS
MODULATORS
MOTORS
PARKING BRAKE SWITCHES
PARKING BRAKE SYSTEMS
PADS
PEDAL TRAVEL SWITCHES
PEDALS
POWERMASTER
PUMPS
PRESSURE DIFFERENTIAL SWITCHES
PRESSURE SWITCHES
RELAYS
ROTORS
SELF-ADJUSTING SYSTEMS
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hardware.
Attaching hardware threads
damaged ................ A ... Require repair or replacement
of hardware.
Attaching hardware threads
stripped (threads
missing) ............... A ... Require repair or replacement
of hardware.
Code set (if
applicable) ............ A .......... (1) Further inspection
required.
Connector broken ........ A .. Require repair or replacement.
Connector melted ........ A ........... ( 2) Require repair or
replacement.
Connector missing ....... A ................. Require repair.
Contaminated ............ A .. Require repair or replacement.
Inoperative ............. B .. Require repair or replacement.
( 3) Further inspection required.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 2) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose, affecting
performance ............ B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
( 1) - Refer to manufacturer's diagnostic trouble code procedure
and require repair or replacement of affected component(s).
( 2) - Determine cause and correct prior to repair or replacement
of part.
( 3) - Inoperative includes intermittent operation or out of OEM
specification. Some components may be serviceable. Check
for accepted cleaning procedure.
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FLUID
See BRAKE FLUID.
FLUID LEVEL SENSOR SWITCHES
See SWITCHES.
FOUR WHEEL DRIVE SWITCHES
See SWITCHES.
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1994-96 (3.0L DOHC & 3.5L) .................. 9.0 Qts. (8.5L)
Cooling System
1983-88 ..................................... 8.5 Qts. (8.0L)
1989-96
2.6L ....................................... 9.7 Qts. (9.2L)
3.0L ...................................... 10.0 Qts. (9.5L)
3.5L ...................................... 10.0 Qts. (9.5L)
Differential
1983-88 ..................................... 1.9 Qts. (1.8L)
1989-93
2.6L ....................................... 1.9 Qts. (1.8L)
3.0L ....................................... 2.7 Qts. (2.6L)
1994-96
3.0L & 3.5L ................................ 2.7 Qts. (2.6L)
Engine Oil
1983-86 ..................................... 6.0 Qts. (5.8L)
1987 ........................................ 5.2 Qts. (5.0L)
1988 ........................................ 5.0 Qts. (4.8L)
1989-91 ..................................... 5.5 Qts. (5.3L)
1992-96 ..................................... 5.2 Qts. (4.9L)
Power Steering ................................ 1.1 Qts. (1.0L)
Fuel Tank
1983-88 .................................... 15.9 Gals. (60L)
1989-90
2.6L 2-Door ............................... 15.9 Gals. (60L)
3.0L 2-Door ............................... 19.9 Gals. (75L)
2.6L & 3.0L 4-Door .......................... 24 Gals. (92L)
1991-96 ...................................... 24 Gals. (92L)
Manual Transmission
1983-91 ..................................... 2.3 Qts. (2.2L)
1992 ........................................ 2.4 Qts. (2.3L)
1993-96 ..................................... 2.6 Qts. (2.5L)
Transfer Case
1983-91 ..................................... 2.3 Qts. (2.2L)
1992-96 ..................................... 2.4 Qts. (2.3L)
(1) - Use of R12 in a R134a system will result in SEVERE DAMAGE.
( 2) - 1983 model equipped with manual transmission only.
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WHEEL & TIRE SPECIFICATIONS
Tire specifications are imprinted on the tire side wall. The
recommended cold tire inflation pressures are listed on a label
attached to the rear face of the driver's door. These pressures
provide the best combination of ride comfort, tire wear and stability
under normal conditions.
CAUTION: DO NOT mix tires of different design such as radial ply
with bias or bias-belted tires. Mixing tire types will
adversely affect road handling and may lead to loss of
vehicle control. When using snow tires, they must be used
in set of four for maneuverability and safety. DO NOT use
tire chains on front wheels.
TIRE & WHEEL SPECIFICATIONS TABLE
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Wheel Size Tire Size
1983-86
15 x 6JJ (Steel) .............................. 215 SR15
1987-88
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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
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toe-in is not within specification, remove clips. Turn tie rods or
turnbuckles the same amount, but in opposite directions. Recheck toe-
in.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLE \
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Application Ft. Lbs. (N.m)
Shock Absorber-To-Crossmember Nut
Montero, Pickup & Ram-50 ............ 10-13 (14-18)
Shock Absorber-To-Lower Arm Bolt
Montero ............................. 11-16 (15-22)
Pickup & Ram-50 ........................... 10 (14)
Upper Arm Shaft To Crossmember
Montero, Pickup & Ram-50 ........... 72-87 (98-118)
Wheel Lug Nut
Colt Vista
Aluminum Wheels ................... 65-80 (88-108)
Steel Wheels ....................... 50-57 (68-77)
Eclipse, Pickup, Ram-50,
Stealth & 3000GT ................ 87-101 (118-137)
Montero ............................ 72-87 (98-118)
All Others ......................... 65-80 (88-108)
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WHEEL ALIGNMENT SPECIFICATIONS
WHEEL ALIGNMENT SPECIFICATIONS TABLE (COLT, COLT 200, MIRAGE, SUMMIT) \
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Application Preferred Range
Camber (Degrees)
Front ....................... 0 .................... -1/2 to 1/2
Rear ..................... -11/16 .............. -13/16 to -3/16
Caster (Degrees) ........... 2 5/16 ........... 1 13/16 to 2 13/16\
Toe-In (In. (mm))
Front .................... 0 (0) ........ -1/8 to 1/8 (-3 to 3\
)
Rear ..................... 0 (0) ...... -3/16 to 3/16 (-5 to 5\
)
Toe-In (Degrees)
Front ...................... 0 .................... -1/4 to 1/4
Rear ....................... 0 .................... -3/8 to 3/8
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WHEEL ALIGNMENT SPECIFICATIONS TABLE (COLT VISTA) \
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Application Preferred Range
Two Wheel Drive
Camber (Degrees)
Front ..................... 7/16 .............. -1/16 to 15/16.
Rear ..................... -9/16 .................. -1 1/8 to 0
Caster (Degrees) .......... 13/16 ................ 5/16 to 15/16\
Toe-In (In. (mm))
Front & Rear ............. 0 (0) ........ -1/8 to 1/8 (-3 to 3\
)
Toe-In (Degrees)
Front & Rear ............... 0 .................... -1/4 to 1/4
Toe-Out on Turns (Degrees)
Inner .................... 37 3/4 ....................... .....
Outer ................... 30 11/16 ...................... .....
Four Wheel Drive
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Camber (Degrees)
Front .................... 13/16 ................ 5/16 to 15/16
Rear ....................... 0 .................... -1/2 to 1/2
Caster (Degrees) .......... 13/16 ................ 5/16 to 15/16\
Toe-In (In. (mm))
Front & Rear ............. 0 (0) ........ -1/8 to 1/8 (-3 to 3\
)
Toe-In (Degrees)
Front & Rear ............... 0 .................... -1/4 to 1/4
Toe-Out on Turns (Degrees)
Inner ................... 37 3/4 ........................ .....
Outer .................. 30 11/16 ....................... .....
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WHEEL ALIGNMENT SPECIFICATIONS TABLE (ECLIPSE) \
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Application Preferred Range
1.8L Engine
Camber (Degrees)
Front ..................... 1/4 ................... -1/4 to 3/4
Rear ..................... -3/4 ................ -1 1/4 to -1/4
Caster (Degrees) ......... 2 5/16 ........... 1 13/16 to 2 13/16\
Toe-In (In. (mm))
Front & Rear ............. 0 (0) ........ -1/8 to 1/8 (-3 to 3\
)
Toe-In (Degrees)
Front & Rear ............... 0 .................... -1/4 to 1/4
2.0L Engine (2WD)
Camber (Degrees)
Front .................... 1/16 ................. -7/16 to 9/16
Rear ..................... -3/4 ................ -1 1/4 to -1/4
Caster (Degrees) ......... 2 3/8 ................ 1 7/8 to 2 7/8\
Toe-In (In. (mm))
Front & Rear ............. 0 (0) ........ -1/8 to 1/8 (-3 to 3\
)
Toe-In (Degrees)
Front & Rear ............... 0 .................... -1/4 to 1/4
2.0L Engine (4WD)
Camber (Degrees)
Front .................... 3/16 ................ -5/16 to 11/16
Rear ................... -1 9/16 ........... -2 1/16 to -1 1/16
Caster (Degrees) ......... 2 5/16 ........... 1 13/16 to 2 13/16\
Toe-In (In. (mm))
Front .................... 0 (0) ........ -1/8 to 1/8 (-3 to 3\
)
Rear .................. 9/64 (3.6) .. -1/32 to 1/4 (-.6 to 6.6\
)
Toe-In (Degrees)
Front ...................... 0 .................... -1/4 to 1/4
Rear ..................... 9/32 ................... 1/16 to 1/2
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WHEEL ALIGNMENT SPECIFICATIONS TABLE (GALANT) \
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Application Preferred Range
Two Wheel Drive
Camber (Degrees)
Front ..................... 3/8 ................... -1/8 to 7/8
Rear ..................... -3/4 ................ -1 1/4 to -1/4
Caster (Degrees) ............ 2 ................. 1 1/2 to 2 1/2\
Toe-In (In. (mm))
Front & Rear ............. 0 (0) ........ -1/8 to 1/8 (-3 to 3\
)
Toe-In (Degrees)
Front & Rear ............... 0 .................... -1/4 to 1/4
Four Wheel Drive
Camber (Degrees)
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Front ..................... 1/2 ........................ 0 to 1
Rear ...................... -1 ................. -1 1/2 to -1/2
Caster (Degrees) ........ 1 15/16 ............. 1 7/16 to 2 7/16\
Toe-In (In. (mm))
Front .................... 0 (0) ........ -1/8 to 1/8 (-3 to 3\
)
Rear .................... 1/8 (3) ......... 0 to 1/4 (0 to 6.4\
)
Toe-In (Degrees)
Front ...................... 0 .................... -1/4 to 1/4
Rear ...................... 1/4 ...................... 0 to 1/2
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WHEEL ALIGNMENT SPECIFICATIONS TABLE (MONTERO) \
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Application Preferred Range
Camber (Front) (1) ............. 1 .................. 1/2 to 1 1/2
Caster (1) .................. 2 15/16 ......... 1 15/16 to 3 15/16
Toe-In (Front) (2) ....... 7/32 (5.5) .. 3/32 to 11/32 (2.5-8.5)
Toe-In (Front) (1) ......... 7/16 ................ 3/16 to 11/16
Toe-Out on Turns (1)
Inner ..................... 32 1/2 ...................... .....
Outer ....................... 29 ........................ .....
(1) - Measurement in degrees.
(2) - Measurement in inches (mm).
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WHEEL ALIGNMENT SPECIFICATIONS TABLE (RAM-50 & PICKUP) \
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Application Preferred Range
Two Wheel Drive
Camber (Front) (1) ......... 11/16 .............. 3/16 to 1 3/16
Caster (1) ................. 2 1/2 .............. 1 1/2 to 3 1/2
Toe-In (Front) (2) ...... 7/32 (5.5) .. 3/32 to 11/32 (2.5-8.5)
Toe-In (Front) (1) ......... 7/16 ................ 3/16 to 11/16
Toe-Out on Turns (1)
Inner ...................... 37 ......................... .....
Outer .................... 30 3/8 ....................... .....
Four Wheel Drive
Camber (Front) (1) ........... 1 .................. 1/2 to 1 1/2
Caster (1) ................... 2 ........................ 1 to 3
Toe-In (Front) (2) ....... 7/32 (5.5) .. 3/32 to 11/32 (2.5-8.5)
Toe-In (Front) (1) ......... 7/16 ................ 3/16 to 11/16
Toe-Out on Turns (1)
Inner ...................... 30 ......................... .....
Outer ...................... 27 ......................... .....
(1) - Measurement in degrees.
(2) - Measurement in inches (mm).
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WHEEL ALIGNMENT SPECIFICATIONS TABLE (PRECIS) \
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Application Preferred Range
Camber (Degrees)
Front ........................ 0 ................... -1/2 to 1/2
Rear ...................... -11/16 ................. -1 to -3/16
Caster (Degrees)
With P/S .................. 1 11/16 ........... 1 3/16 to 2 3/16
Without P/S .................. 1 .................. 1/2 to 1 1/2
Toe-In (In. (mm))