1998 MITSUBISHI MONTERO power steering pump

90,000 MILE (144,000 KM) NORMAL SERVICE
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VERIFY 
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Last Major Service Was Performed 
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SERVICE 
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 Ball Joints With Grease Nipple (
6) 
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 Propeller Shaft Joints (
6) 
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INSPECT 
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 Fuel Hoses (
3) 
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 Drive Belt (For Generator, Water Pump, Power Steering Pump) 
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 Manual Transmission Oil 
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 Transfer Oil 
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 Disc Brake Pads (
4) 
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 Brake Hoses (
4) 
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 Ball Joint & Steering Linkage Seals (
3) 
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 Drive Shaft Boots (
4) 
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 Exhaust System (
3) 
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REPLACE 
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 Engine Oil (
1) 
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 Engine Oil Filter (
2) 
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 Engine Coolant 
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 Automatic Transmission Fluid 
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 Rear Axle Oil 
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 Air Cleaner Filter 
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(
1) - Change once a year or every 7,500 miles (12,000 KM). 

(
2) - If mileage is less than 7,500 miles (12,000 KM) each year, 

replace the oil filter at every oil change. 

(
3) - Or inspect every 2 years. 

(
4) - Or inspect every year. 

(
5) - Or change every 2 years. 

(
6) - Or lubricate grease every 2 years. 
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LUBRICATION SPECIFICATIONS 
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Material  Condition  Specification 
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Engine Oil  Ambient Temperature Less Than SAE 5W-30 

(
1)  0F (-18C) To 100F (38C)  

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Ambient Temperature Above 0F  SAE 10W-30 

 (-18C) To Over 100F (38C)  

 FLUID CAPACITIES 
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Item  Condition  Specification (1) 
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Engine Oil  Oil Pan  4.5 Qts. (4.3L) 

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 Oil Filter  0.32 Qts. (0.3L) 

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 Oil Cooler  0.32 Qts. (0.3L) 
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(
1) - Capacities are recommended or calculated levels. Always use 

dipstick to measure level. 
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120,000 MILE (200,000 KM) NORMAL SERVICE
120,000 MILE (200,000 KM) NORMAL SERVICE
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VERIFY 
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Last Major Service Was Performed 
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SERVICE 
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 Ball Joints With Grease Nipple (
6) 
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 Propeller Shaft Joints (
6) 
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INSPECT 
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 Fuel Hoses (
3) 
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 Fuel System (Tank, Pipe Line, Connection & Fuel Tank Filler 

 Tube Cap) (
3) 
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 Evaporative Emission Control System (Except Evaporative 

 Emission Canister) (
7) 
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 Drive Belt (For Generator, Water Pump, Power Steering Pump) 
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 Manual Transmission Oil 
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 Transfer Oil 
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 Disc Brake Pads (
4) 
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 Brake Hoses (
4) 
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 Ball Joint & Steering Linkage Seals (
3) 
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 Drive Shaft Boots (
4) 
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 Exhaust System (
3) 
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 Distributor Cap & Rotor (
7) 
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REPLACE 
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 Engine Oil (
1) 
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 Engine Oil Filter (
2) 
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HYDRAULIC SYSTEM PRESSURE TEST
1) Disconnect pressure hose from power steering pump. Attach
Pressure Gauge (MB990662-01) and Adapters (MB990993-01 and MB990994-
01). See Fig. 2. Tighten fittings to 22-29 ft. lbs. (30-39 N.m).
2) Bleed system. See HYDRAULIC SYSTEM BLEEDING under
LUBRICATION . Turn wheel several times to bleed air from gauge. Start
engine and let idle. Place thermometer in reservoir. Check fluid
level. Add fluid as necessary.
3) When fluid temperature reaches 122-140
F (50-60C), check
pressure. See POWER STEERING PUMP PRESSURE SPECIFICATIONS table.
Reinstall pressure hose. Do not twist hose or let hose interfere with
adjacent parts. Replace power steering pump if pressure is not within
specification. Bleed system.
CAUTION: DO NOT keep shutoff valve closed more than 3 seconds at a
time. DO NOT keep steering wheel turned to full lock
position for more than 10 seconds at a time.
POWER STEERING PUMP PRESSURE SPECIFICATIONS









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Application psi (kg/cm)
Valve Closed Or Wheel At Full Lock ............... 1204-1305 (83-90)\
Valve Open (Standard) ............................... 114-142 (8-10\
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Fig. 2: Connecting Pressure Gauge & Shutoff Valve
Courtesy of Mitsubishi Motor Sales of America.
P/S PRESSURE SWITCH

1) Disconnect pressure hose from power steering pump. Attach
Pressure Gauge (MB990662-01) and Adapters (MB990993-01 and MB990994-
01). See Fig. 2. Tighten fittings to 22-29 ft. lbs. (30-39 N.m).
2) Bleed system. See HYDRAULIC SYSTEM BLEEDING under
LUBRICATION . Turn wheel several times to bleed air from gauge. Start
engine and let idle. Place thermometer in reservoir. Check fluid
level. Add fluid as necessary.
3) When fluid temperature reaches 122-140
F (50-60C),
disconnect connector from P/S pressure switch. Connect ohmmeter across
switch terminals. Slowly close shut-off valve. Check pressure when
ohmmeter indicates switch has closed (continuity). Pressure should be
218-290 (15-20 N.m). Slowly open shut-off valve. Check pressure when
ohmmeter indicates switch has opened (no continuity). Pressure should
be 102-174 (7-12 N.m). Reinstall pressure hose. Do not twist hose or
let hose interfere with adjacent parts. Replace P/S pressure switch if
pressure is not within specification. Bleed system.
CAUTION: DO NOT keep shutoff valve closed more than 3 seconds at a
time. DO NOT keep steering wheel turned to full lock
position for more than 10 seconds at a time.
STEERING WHEEL TURNING FORCE
Stationary Test
1) Position vehicle on level surface. Place steering wheel in
straight-ahead position. Start engine and let idle. Using a spring
scale, measure steering wheel turning force clockwise and
counterclockwise.
2) On Montero, turning force should be 8.2 lbs. (3.7 kg) or
less. On Montero Sport, turning force should be 8.8 lbs. (3.9 kg) or
less. If turning force exceeds specification, check for loose or
damaged belt, insufficient fluid, air in power steering fluid, and
collapsed or twisted hoses. Repair or replace as necessary.
REMOVAL & INSTALLATION
IDLER ARM
Removal
Loosen relay rod-to-idler arm lock nut. Using Steering
Linkage Puller (MB991113 or MB990635), separate idler arm from relay
rod and remove relay rod-to-idler arm lock nut. Remove idler arm bolts
and nuts. Remove idler arm. On Montero, loosen, but DO NOT remove
idler arm-to-bracket nut. Press arm from bracket and remove nut and
arm.
Inspection
Check idler arm bushings for damage or wear. Check idler arm
ball stud for looseness.
Installation
1) Apply multipurpose grease to inside surface of bushing and
idler arm support shaft. Insert bushing in idler arm. Insert idler arm
support in idler arm.
2) Install washer (knurled side toward bushing) and NEW lock\
nut. Tighten lock nut to specification. See TORQUE SPECIFICATIONS.
Place idler arm assembly in vise. Using a spring gauge, measure
turning resistance.
3) On all models, turning resistance should be 3-18 INCH lbs.
(.3-2.0 N.m). On Montero, if turning resistance is not within
specification, loosen or tighten lock nut to obtain proper resistance.
4) Install idler arm bolts and nuts. Install relay rod-to-

idler arm. See TORQUE SPECIFICATIONS .
POWER STEERING GEAR
Removal & Installation
1) Drain power steering fluid. See FLUID REPLACEMENT under
LUBRICATION . Remove steering shaft-to-steering gear clamp bolt.
Disconnect pressure and return hoses from steering gear.
2) Remove cotter pin and castle nut from pitman arm. Using
Puller (C-3894-A), separate pitman arm from relay rod.
3) Remove steering gear mounting nuts. Disconnect steering
shaft from steering gear. Remove steering gear. To install, reverse
removal procedure.
POWER STEERING PUMP & RESERVOIR
Removal
Drain power steering fluid. See FLUID REPLACEMENT under
LUBRICATION . Disconnect hoses from reservoir. Remove reservoir.
Disconnect hoses from pump. Loosen pump retaining bolts. Remove belt.
Remove pump and mounting bracket(s).
Installation
To install, reverse removal procedure. Check power steering
pump bracket for slack. Tighten bracket (if necessary). Fill and bleed\
reservoir. See FLUID REPLACEMENT and HYDRAULIC SYSTEM BLEEDING under
LUBRICATION . Start engine and turn steering wheel lock-to-lock to
check for fluid leaks.
RELAY ROD
Removal
Remove inner tie rod end cotter pins and lock nuts. Separate
tie rod ends from relay rod. Remove cotter pins and castle nuts from
idler arm and pitman arm. Using a puller, separate relay rod from
idler arm and pitman arm.
Installation
To install relay rod, reverse removal procedure. Ensure dust
covers are well greased and lower edge of covers are coated with
packing sealer. Tighten relay rod-to-idler arm and relay rod-to-pitman
arm castle nuts to specification. See TORQUE SPECIFICATIONS.
TIE ROD ASSEMBLY
Removal
1) Remove skid plate (if necessary). Remove cotter pins and
loosen lock nuts from tie rod ball studs at steering knuckle and relay
rod end.
2) Using Steering Linkage Puller (MB991113 or MB990635),
separate tie rod ends from knuckle and relay rod end and remove lock
nuts. Loosen tie rod adjusting sleeve lock nuts, and unscrew tie rod
ends.
Inspection
Check tie rod ends for damage and ball studs for looseness.
On Montero, measure ball stud starting torque. Torque should be 9-27
INCH lbs. (1.0-3.0 N.m). If ball stud starting torque exceeds
specification, replace tie rod.
Installation
1) Install "O" ring on ball socket. Grease inside of tie rod

cross shaft and rack piston for wear and damage. Check contact part of
adjusting bolt for uneven wear. Check dust seal, oil seal and "O"
rings for wear and damage.
Reassembly
1) Install NEW cross shaft lower "U" packing (if removed).
Press lower cross shaft oil seal into gearbox housing. See Fig. 3.
Press bearing and oil seal into top cover. Install bearing race and
"O" ring.
2) Apply transmission fluid to seal ring contact areas on
mainshaft, and install seal rings firmly into valve grooves. Wrap
serrated part of mainshaft with vinyl tape. Mount valve body to valve
housing. Install cage and align hole in cage with channel in
mainshaft. Install bearing race and insert balls.
3) Install mainshaft into valve housing while pressing on
bearing race to prevent balls from falling out. Using spanner wrench,
install lock nut and tighten until it contacts bearing race.
4) Tighten lock nut while measuring mainshaft endplay using
dial indicator. When mainshaft endplay is .001" (.003 mm), use a punch\
to crimp circumference of lock nut. Ensure mainshaft rotates freely.
5) Apply transmission fluid to "O" ring and piston seal ring,
and install into gearbox housing. Install rack piston until it
contacts edge of mainshaft. Rotate mainshaft to align ball raceway
with insertion hole. Install 19 balls.
NOTE: Insert balls so no clearance exists between balls.
6) Place remaining 7 balls in circulator and install
circulator to rack piston. Install circulator holder. Install NEW
cross shaft upper "U" packing (if removed). Install upper cross shaft
"O" ring. Apply transmission fluid to rack piston seal ring and insert
valve housing. Rotate mainshaft until rack piston is centered (neutral
position).
7) Install adjusting plate so beveled part is facing upward.
Using a feeler gauge, measure clearance between adjusting bolt and
cross shaft. If clearance is greater than .002" (.05 mm), replace with\
appropriate adjusting plate.
8) Apply multipurpose grease to seal surface of "U" packing.
Apply transmission fluid to cross shaft teeth and side cover "O" ring.
Install cross shaft to side cover, and temporarily tighten adjusting
bolt lock nut.
CAUTION: DO NOT rotate side cover during installation, or damage to
cross shaft oil seal may result.
9) Apply transmission fluid to rack piston teeth and shaft
areas. Apply multipurpose grease to oil seal lip. Install side cover
assembly (with cross shaft) to gearbox.
10) Position mainshaft in straight-ahead position. While
turning adjusting bolt, measure mainshaft combined starting torque
using Preload Socket (MB990228-01) and an INCH-lb. torque wrench.
Combined starting torque should be 4-11 INCH lbs. (.5-1.3 N.m). Center\
reading should be 2 INCH lbs. (.2 N.m) higher than reading at either
end.
11) Tighten adjusting bolt lock nut to specification. See
TORQUE SPECIFICATIONS . Install pitman arm with mating marks aligned.
POWER STEERING PUMP
Disassembly
1) Remove suction connector bolts. Mount pump in a soft-jawed
vise. Remove pump cover bolts and cover. Using a plastic mallet, tap
pulley assembly shaft from pump housing. See Fig. 4.

2) Remove cam ring, vanes, shaft assembly and "O" rings.
Remove snap ring from shaft assembly. Remove collar, rotor and side
plate from shaft.
3) Pry oil seal out of housing. Remove pressure connector.
Remove flow control valve assembly, flow control spring and 2 "O"
rings. DO NOT disassemble flow control valve assembly.
Fig. 4: Exploded View Of Power Steering Pump
Courtesy of Mitsubishi Motor Sales of America.
Inspection
1) Inspect pump shaft oil seal lip and bushing end for

damage. Inspect groove of rotor vane and cam surface for stepped wear.
Check vane for damage. Install vane into rotor groove. Measure
clearance between vane and rotor groove. If clearance exceeds .0024"
(.061 mm), replace entire assembly.
2) Check ring and rotor sides for damage. Replace entire
assembly if any damage is present. Check sliding surfaces of control
valve for obstructions. Replace parts as required. If control valve is
replaced, always use valve with same identification mark as one being
replaced. Check power steering fluid pressure.
Reassembly
1) Lubricate "O" rings and internal pump components with ATF
before reassembly. Install flow control valve spring and control valve
in housing.
2) Install and tighten pressure connector. Depress control
valve to check for smooth operation. Apply grease to lip of oil seal.
Install oil seal into pump body. Install pulley assembly into pump
body.
3) Install rotor to pulley assembly with punch mark at pump
cover side. Install snap ring. Lift rotor to ensure that snap ring is
in countersunk part of shaft. Align cam ring dowel holes and install
cam ring with punch mark on pump body side.
4) Apply transmission fluid to vanes, and install vanes onto
rotor with rounded edges outward. Install "O" ring, cam case and pump
cover. Install and tighten suction connector.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
Adjusting Bolt Lock Nut .................................... 27 (37)\
Idler Arm Bracket-To-Frame Bolt & Nut
Montero ............................................ 40-47 (54-64)\
Montero Sport ............................................ 43 (59)\
Idler Arm-To-Bracket Lock Nut ............................. 101 (44)\
Oil Pump Cover Bolts ....................................... 15 (20)\
Pitman Arm-To-Cross Shaft Nut
Montero ........................................ 108-123 (146-176)\
Montero Sport .................................. 108-123 (147-167)\
Pressure Hose In-Line Fitting
Montero .................................................. 25 (34)\
Montero Sport ............................................ 16 (22)\
Relay Rod-To-Idler Arm Nut ................................. 33 (44)\
Relay Rod-To-Pitman Arm Nut ................................ 33 (44)\
Side Cover Bolts
Montero .................................................. 36 (49)\
Montero Sport ...................................... 41-47 (50-64)\
Steering Gear Hose Fittings ................................ 11 (15)\
Steering Gear-To-Frame Bolts ......................... 40-47 (54-64)\
Tie Rod Adjusting Sleeve Lock Nuts ......................... 69 (93)\
Tie Rod End Castle Nuts .................................... 33 (44)\
Valve Housing Bolts
Montero .................................................. 36 (49)\
Montero Sport ...................................... 41-47 (56-64)\
Valve Housing Lock Nut ......................................... ( 1)
( 1) - Tighten lock nut until it contacts bearing race.









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