service MITSUBISHI MONTERO 1998 Workshop Manual

Replacement of the rotor is required because it does not meet
design specifications.
Some conditions indicate that a service or part replacement
is suggested because the part is close to the end of its useful life
or addresses a customer's need, convenience or request. If a
customer's vehicle has one of these conditions, the procedure may be
only to suggest service.
Example:
An exhaust pipe is rusted, corroded or weak, but no leaks are
present. In this case, the exhaust pipe has not failed.
However, there is evidence that the pipe may need replacement
in the near future. Replacement of the pipe may be suggested
for the customer's convenience in avoiding a future problem.
Example:
The customer desires improved ride and/or handling, but the
vehicle's shocks or struts have not failed. In this case,
replacement may be suggested to satisfy the customer's
wishes. In this case, replacement of the shocks or struts may
not be sold as a requirement.
A customer, of course, has the choice of whether or not a
shop will service his or her vehicle. He or she may decide not to
follow some of your suggestions. When a repair is required, a MAP
shop must refuse partial service on that system if, in the judgment of
the service provider, proceeding with the work could create or
continue an unsafe condition. When a procedure states that required
or suggested repair or replacement is recommended, the customer must
be informed of the generally acceptable repair/replacement options
whether or not performed by the shop.
When presenting suggested repairs to the customer, you must
present the facts, allowing the customer to draw their own conclusions
and make an informed decision about how to proceed.
The following reasons may be used for required and suggested
services. These codes are shown in the "Code" column of the MAP
Uniform Inspection & Communications Standards that follow:
Reasons to Require Repair or Replacement
A - Part no longer performs intended purpose
B - Part does not meet a design specification (regardless of
performance)
C - Part is missing
NOTE: When a repair is required, the shop must refuse partial
service to the system in question, if the repair creates
or continues an unsafe condition.
Reasons to Suggest Repair or Replacement
1 - Part is close to the end of its useful life (just above
discard specifications, or weak; failure likely to occur
soon, etc.)
2 - To address a customer need, convenience, or request (to
stiffen ride, enhance performance, eliminate noise, etc.)
3 - To comply with maintenance recommended by the vehicle's
Original Equipment Manufacturer (OEM)
4 - Technician's recommendation based on substantial and
informed experience
NOTE: Suggested services are always optional. When presenting
suggested repairs to the customer, you must present the
facts, allowing the customer to draw their own conclusions

and make an informed decision about how to proceed.
BRAKES
SERVICE PROCEDURES REQUIRED & SUGGESTED FOR PROPER
VEHICLE OPERATION
Some states may have specifications that differ from OEM.
Check your local/state regulations. Where state or local laws are
stricter, they take precedence over these guidelines.
ACCELEROMETERS (G SENSOR OR LATERAL)
ACCELEROMETER INSPECTION








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Condition Code Procedure
Broken .................. A ............ Require replacement.
Connector loose ......... A .. Require repair or replacement.
Loose ................... B .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Out of position ......... B ....... Require re-positioning to
vehicle manufacturer's
specifications.
Output signal incorrect . B ............ Require replacement.









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ACCUMULATORS
ACCUMULATOR INSPECTION








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Condition Code Procedure
Leaking ................. B ............ Require replacement.
Missing ................. C ............ Require replacement.
Pre-charge incorrect .... B ............ Require replacement.









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ANCHOR PINS
See BACKING PLATES .
ANTI-LOCK BRAKE SYSTEMS
NOTE: Anti-lock brakes are an integral part of the brake system. It
is essential that the anti-lock brakes function properly when
brake service is performed.
Anti-lock brake systems are commonly referred to as "ABS" and
will be referred to as "ABS" throughout these guidelines. Some ABS
components also function as part of a traction control system (TCS).
WARNING: When diagnosing and servicing high pressure components,
observe safety procedures and equipment requirements
established by the vehicle manufacturer to reduce the
possibility of serious personal injury.
NOTE: Intermittent electrical conditions are often caused by a loss
of ground, poor connection, or water intrusion into the
wiring harness.

NOTE: Electro-magnetic interference (EMI) may be caused by
incorrect installation of accessories or components. EMI can
result in improper system operation.
BACKING PLATES
BACKING PLATE INSPECTION








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Condition Code Procedure
Anchor pin bent ......... B .. Require repair or replacement.
Anchor pin broken ....... A ............ Require replacement.
Anchor pin worn, affecting
structural integrity ... B ............ Require replacement.
Backing plate bent ...... B .. Require repair or replacement.
Backing plate broken .... A ............ Require replacement.
Backing plate cracked ... B .. Require repair or replacement.
Corroded, affecting
structural integrity .... A ............ Require replacement.
Loose ................... B .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Shoe lands worn ......... A .. Require repair or replacement.









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BRAKE FLUID
CAUTION: Most manufacturers prohibit the use of DOT 5 brake fluid
in a system equipped with ABS.
DOT 3, DOT 4, and DOT 5.1 brake fluids are clear or light
amber in color. DOT 5 brake fluid is violet in color. Correct fluid
required for the brake system is stamped on the master cylinder cover.
BRAKE FLUID INSPECTION









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Condition Code Procedure
Beyond service interval . 3 .. Suggest flushing and refilling
with correct fluid.
Brake fluid type
incorrect .............. B .. Require flushing and refilling
with correct fluid.
Contaminated, for example,
fluid other than brake
fluid present .......... A or B ....... ( 1) Require service.
Hydraulic component ..... 3 .. Suggest flushing and refilling
overhaul or replacement with correct fluid.
Rubber master cylinder
cover gasket distorted
and gummy .............. A .......... ( 2) Require replacement
of gasket.
( 1) - If a fluid other than brake fluid is present in the brake
system which DOES affect the rubber parts, the required
service is to:
* Remove all components having rubber parts from the
system.
* Flush lines with denatured alcohol or brake cleaner
* Repair or replace all components having rubber parts
* Flush and fill with correct brake fluid. (Code A)
If a fluid other than brake fluid is present in the brake

system which DOES NOT affect the rubber parts, the required
service is to flush and fill with the correct brake fluid.
(Code B)
( 2) - This condition may indicate contaminated brake fluid.









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BRAKE FRICTION MATERIAL
See FRICTION MATERIAL .
BRAKE PADS
See FRICTION MATERIAL .
BRAKE PEDALS
BRAKE PEDAL INSPECTION








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Condition Code Procedure
Bent, affecting
performance ............ A .. Require repair or replacement.
Broken .................. A .. Require repair or replacement.
Pedal pad missing ....... C .... Require replacement of pedal
pad.
Pedal pad worn .......... 1 ............ Suggest replacement.
Pivot bushings worn,
affecting performance .. A .... Require replacement of pivot
bushings.









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BRAKE SHOES
See FRICTION MATERIAL .
BRAKE SHOE HARDWARE
See also SELF-ADJUSTING SYSTEMS .
BRAKE SHOE HARDWARE INSPECTION









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Condition Code Procedure
Broken .................. A ............ Require replacement.
Distorted ............... A ............ Require replacement.
Missing ................. C ............ Require replacement.
Surfaces rust-pitted .... 1 ............ Suggest replacement.
Worn, affecting
performance ............ A ............ Require replacement.









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BRAKE STOPLIGHT SWITCHES
BRAKE STOPLIGHT INSPECTION








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Condition Code Procedure
Bent .................... B ............ Require replacement.
Broken .................. A ............ Require replacement.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.

CALIPER INSPECTION








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Condition Code Procedure
Bleeder port damaged .... A ... Require repair or replacement
of caliper.
Bleeder screw broken off
in caliper ............. A ........... (1) Require repair or
replacement of caliper.
Bleeder screw plugged ... A ........... ( 1) Require repair or
replacement of bleeder screw.
Bleeder screw seized .... A ......... ( 2) Require replacement
of caliper.
Casting corroded,
affecting structural
integrity .............. A ............ Require replacement.
Casting damaged, affecting
structural integrity ... A ............ Require replacement.
Dust boot around caliper
torn ................... A ..... Require replacement of dust
boot.
Leaking ................. A .. Require repair or replacement.
Mounting pin threads
damaged ................ A ... Require repair or replacement
of component with damaged
threads.
Mounting pin threads
stripped in caliper
bracket (threads
missing) ............... A ... Require repair or replacement
of caliper bracket.
Mounting pin threads
stripped in steering
knuckle (threads
missing) ............... A ... Require repair or replacement
of steering knuckle.
Mounting pin threads
stripped (threads
missing) ............... A ... Require repair or replacement
of component with stripped
threads.
Parking brake cable
support, lever, or return
spring bent ............ A ... Require replacement of parts.
Parking brake cable
support, lever, or return
spring broken .......... A ... Require replacement of parts.
Parking brake mechanism in
caliper inoperative .... A .. Require repair or replacement.
Piston corroded (pitted
or peeling chrome
plating) ............... B ... Require replacement of piston
and rebuilding or replacement
of caliper.
Piston damaged, affecting
performance ............ B ... Require replacement of piston
and rebuilding or replacement
of caliper.
Piston damaged, not
affecting performance .. .. ........ No service suggested or
required.
Piston finish worn off .. B ... Require replacement of piston
and rebuilding or replacement

same axle to eliminate uneven braking behavior. Always wash drums
after servicing or before installing.
DRUM INSPECTION









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Condition Code Procedure
Balance weight missing .. .. ........ No service suggested or
required.
Bell-mouthed, affecting
performance ............ A ....... Require reconditioning or
replacement.
Cooling fin broken ...... .. ........ No service suggested or
required.
Cracked ................. B ............ Require replacement.
Drum diameter is greater
than OEM "machine to"
specifications but less
than "discard at"
specifications, and the
drum does not require
reconditioning ......... 1 ........ (1) Suggest replacement.
Drum diameter will exceed
OEM "machine to"
specifications after
required
reconditioning ......... B ........ ( 2) Require replacement.
Hard-spotted ............ 2 ....... Suggest reconditioning or
replacement.
Measured diameter is
greater than OEM discard
specifications ......... B ............ Require replacement.
Out-of-round (runout),
affecting performance .. A ....... Require reconditioning or
replacement.
Out-of-round (runout),
exceeding manufacturer's
specifications ......... B ....... Require reconditioning or
replacement.
Scored .................. B ....... Require reconditioning or
replacement.
Surface threaded due to
improper machining ..... B ....... Require reconditioning or
replacement.
Tapered, affecting
performance ............ A ....... Require reconditioning or
replacement.
( 1) - Only applies to vehicles for which OEM "machine to"
specifications exist. If OEM does not supply "machine to"
specifications, the drum may be worn to discard
specifications.
( 2) - If OEM does not supply "machine to" specifications, you
may machine to discard specifications.









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ELECTRICAL PUMPS AND MOTORS
Copied fuel pump conditions from engine UIGs & deleted
pulsator from leaking conditions.
ELECTRICAL PUMP AND MOTOR INSPECTION









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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.

FRICTION MATERIAL
NOTE: Original Equipment Manufacturer (OEM) specifications
designate replacement at different thicknesses.
CAUTION: It is required that friction material be matched in axle
sets for consistent braking characteristics.
FRICTION MATERIAL INSPECTION









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Condition Code Procedure
Contaminated, for example,
fluid that leaked from
caliper, wheel cylinder,
or axle seal ........... A ........ ( 1) Require replacement.
Cracked through ......... B Require replacement.
Flaking or chunking ..... B Require replacement.
Glazed (shiny) .......... .. ........ No service suggested or
required.
Grooves or ridges ....... .. .... ( 2) No service suggested or
required.
Permanently attached
hardware bent .......... A ............ Require replacement.
Permanently attached
hardware broken ........ A ............ Require replacement.
Permanently attached
hardware loose ......... A ............ Require replacement.
Permanently attached
hardware missing ....... C ............ Require replacement.
Permanently attached
hardware seized ........ A .. Require repair or replacement.
Rivets loose ............ B ............ Require replacement.
Separating from backing . B ............ Require replacement.
Shoe table or web bent .. B ............ Require replacement.
Shoe table or web
cracked ................ A ............ Require replacement.
Shoe table or web worn,
affecting performance .. A ............ Require replacement.
Surface cracking ........ .. ........ No service suggested or
required. Further inspection
may be necessary to determine
cause.
Tapered wear ............ B ........ ( 3) Suggest replacement.
Thickness of one pad is
greater than opposite pad
in the same caliper
(uneven wear) .......... .. .... ( 4) Replacement of friction
material not suggested or
required. Further inspection
required. See CALIPERS
and CALIPER HARDWARE.
Wear indicator device
(electronic) contacts
rotor .................. B ...... ( 5) Require replacement of
appropriate parts.
Wear indicator device
(mechanical) bent ....... .. .......... ( 6) Further inspection
required.
Wear indicator device
(mechanical) broken .... .. ......... ( 6) Further inspection
required.

LATERAL ACCELERATION SWITCHES
See ACCELEROMETERS .
LEDS
See BULBS AND LEDS .
LENSES
LENSE INSPECTION








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Condition Code Procedure
Application incorrect ... A ............ Require replacement.
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.
Broken, affecting
performance ............ A ............ Require replacement.
Broken, not affecting
performance ............ .. ........ No service suggested or
required.
Cracked ................. A ............ Require replacement.
Discolored .............. A ............ Require replacement.
Leaking ................. A .. Require repair or replacement.
Melted, affecting
performance ............ A ............ Require replacement.
Melted, not affecting
performance ............ 2 ............ Suggest replacement.
Missing ................. C ............ Require replacement.









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MASTER CYLINDERS
MASTER CYLINDER INSPECTION








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Condition Code Procedure
Brake fluid leaking from
rear of master cylinder
bore ................... B .. Require repair or replacement.
Brake pedal drops
intermittently ......... A ........... ( 1) Require repair or
replacement.
Fluid level low ......... .. ......... ( 2) Further inspection
required.
Internal valve failure .. A .. Require repair or replacement.
Master cylinder leaking
brake fluid internally . A .. Require repair or replacement.
Piston does not return .. A .. Require repair or replacement.
Ports plugged ........... A .. Require repair or replacement.
Rubber master cylinder
cover gasket distorted
and gummy .............. A .. ( 3) Require replacement of the
gasket.

(1) - This condition may be normal on some vehicles equipped with
anti-lock brakes.
( 2) - Refer to OEM procedures for adjusting low fluid level.
Inspect for brake hydraulic system leaks and friction
material wear.
( 3) - This condition may indicate contaminated brake fluid.
See BRAKE FLUID .









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MODULATORS
See HYDRAULIC MODULATORS .
MOTORS
See ELECTRICAL PUMPS AND MOTORS .
PARKING BRAKE SWITCHES
See SWITCHES.
PARKING BRAKE SYSTEMS
NOTE: The parking brake is an integral part of the brake
system. It is important that the parking brake function
properly when brake service is performed.
PARKING BRAKE SYSTEM 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.
Cable improperly
adjusted ............... B ....... Require cable adjustment.
Cable or individual
wires in the cable
are broken ............. A .... Require replacement of cable
assembly.
Cable sticking .......... A ...... Require cable lubrication.
Cable stuck inside conduit
and cannot be lubricated
so that parking brake
functions properly ..... A .... Require replacement of cable
assembly.
Inoperative ( 1) ......... A .......... Require replacement of
inoperative parts.
Parking brake
parts bent ............. B ... Require repair or replacement
of bent parts.
Parking brake
parts broken ........... A ... Require replacement of broken
parts.
Parking brake parts