brake MITSUBISHI MONTERO 1991 Owners Manual

UPPER CONTROL ARM R & I
REMOVAL
1) Remove shock absorber. Support lower control arm with jack
stand. Remove wheel assembly. Loosen anchor bolt lock nut. See Fig. 1.
2) Mark anchor bolt for reassembly reference. Loosen anchor
bolt to release torsion bar tension. Disconnect and plug brake hose at
frame mount bracket. Remove cotter pin from ball joint stud. Loosen
but DO NOT remove ball joint stud knuckle nut.
3) Using ball joint fork, loosen ball joint from steering
knuckle. Remove ball joint stud nut. Remove rebound stopper and brake
hose support from control arm. Remove upper control arm mounting
bolts. Note direction of bolt installation and location of camber
adjustment shims. Remove control arm.
4) If clearance is inadequate for control arm removal, move
control arm toward rear of vehicle and pull out front part of arm.
Rotate control arm pivot shaft and remove arm. If arm still cannot be
removed, loosen 10 front body mounting nuts. Raise body and remove
arm.
NOTE: On Montero, rotating control arm shaft will alter caster
setting.
INSPECTION
1) Inspect control arm for cracks or deformation. On Montero,
mount control arm in soft-jawed vise using control arm shaft. Attach
spring scale to upper end of control arm, near ball joint.
2) Using spring scale, measure starting torque required to
rotate control arm on the shaft. Replace control arm if starting
torque exceeds 1.4 lbs. (6.5 N).
3) On all models, check ball joints. See BALL JOINT CHECKING
under ADJUSTMENTS & INSPECTION. Inspect ball joint dust cover for
damage and replace as necessary.
INSTALLATION
1) To install, reverse removal procedure. On Montero, ensure
control arm shaft is correctly positioned before installing. Rotate
control arm shaft to obtain correct measurement. See Fig. 6.
Fig. 6: Positioning Upper Control Arm Shaft (Montero)
Courtesy of Mitsubishi Motor Sales of America.
2) On Ram-50 & Pickup, install control arm-to-crossmember
bolts from the inside of crossmember, with nuts against control arm

shaft.
3) On Montero, install control arm-to-crossmember bolts from
the outside of control arm, with nuts against crossmember.
4) Ensure alignment shims are placed in original location.
When installing shock absorber, ensure White paint mark on lower end
of shock faces toward the outside of vehicle. Tighten shock absorber
upper nut until distance from end of threads to nut is .27-.31" (7-8
mm). Install shock lock nut.
5) Tighten bolts to specification. See TORQUE SPECIFICATIONS
table at end of article. Bleed brakes. Adjust anchor bolt to proper
torsion bar setting. See TORSION BAR under REMOVAL & INSTALLATION.
Check wheel alignment and adjust if necessary.
WHEEL BEARINGS R & I
REMOVAL
1) Raise and support vehicle. Remove wheel assembly. Remove
caliper assembly. Remove locking hub. See LOCKING HUB under REMOVAL &
INSTALLATION.
2) Remove lock washer. Using Socket (MB990954), remove lock
nut. Remove front hub assembly from steering knuckle.
3) Remove oil seal and bearings from hub. If bearing races
need to be replaced, drive bearing races from hub using brass drift
and hammer.
INSTALLATION
1) Before installing, lubricate outside surfaces of bearing
outer races with grease. Install bearing outer races in hub. Ensure
bearing races are fully seated.
2) Pack bearings with grease. Install inner bearing in hub.
On Montero, install seal in hub using Seal Installer (MB990955). On
Pickup, use Seal Installer (MB990985).
3) Install seal until seal is even with hub surface. To
complete installation, reverse removal procedure. Adjust wheel
bearings. See WHEEL BEARINGS under ADJUSTMENTS & INSPECTION. Tighten
bolts to specification. See TORQUE SPECIFICATIONS table.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLE








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Application Ft. Lbs. (N.m)
Anchor Bolt Lock Nut ............. 29-36 (39-49)
Automatic Hub Cover .............. 13-25 (18-34)
Ball Joint Nut
Lower ....................... 87-130 (118-176)
Upper .......................... 43-65 (58-88)
Ball Joint-to-Lower
Control Arm Bolt ............... 39-54 (53-73)
Caliper Bolt ..................... 58-72 (79-98)
Control Arm-to-Frame Bolt
Lower ................. ( 1) 101-116 (137-157)
Upper ......................... 72-87 (98-118)
Locking Hub-to-Hub/Rotor Bolt .... 36-43 (49-58)
Manual Hub Cover Bolt .................. 10 (14)
Shock Absorber Lower Mount Bolt
Montero ........................ 11-16 (15-22)
Ram-50 & Pickup ...................... 10 (14)

TIE ROD ENDS (INNER AND OUTER)
TRACK BARS
TRAILING ARMS
WHEEL BEARINGS, RACES AND SEALS
Wheel Alignment
WHEEL ALIGNMENT
Wheels and Tires
TIRES
VALVE STEMS
WHEEL ATTACHMENT HARDWARE
WHEELS (RIMS)
MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt
1) a Pledge of Assurance to their Customers and 2) the Motorist
Assurance Program Standards of Service. All participating service
providers have agreed to subscribe to this Pledge and to adhere to the
promulgated Standards of Service demonstrating to their customers that
they are serious about customer satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection communication standards
are continually re-published. In addition to these, standards for
Drive Train and Transmissions have recently been promulgated.
Participating shops utilize these Uniform Inspection & Communication
Standards as part of the inspection process and for communicating
their findings to their customers.
The Motorist Assurance Program continues to work
cooperatively and proactively with government agencies and consumer
groups toward solutions that both benefit the customer and are
mutually acceptable to both regulators and industry. We maintain the
belief that industry must retain control over how we conduct our
business, and we must be viewed as part of the solution and not part
of the problem. Meetings with state and other government officials
(and their representatives), concerned with auto repair and/or
consumer protection, are conducted. Feedback from these sessions is
brought back to the association, and the program adjusted as needed.
To assure auto repair customers recourse if they were not
satisfied with a repair transaction, the Motorist Assurance Program
offers mediation and arbitration through MAP/BBB-CARE and other non-

profit organizations. MAP conducted pilot programs in twelve states
before announcing the program nationally in October, 1998. During the
pilots, participating repair shops demonstrated their adherence to the
Pledge and Standards and agreed to follow the UICS in communicating
the results of their inspection to their customers. To put some
"teeth" in the program, an accreditation requirement for shops was
initiated. The requirements are stringent, and a self-policing method
has been incorporated which includes the "mystery shopping" of
outlets.
We welcome you to join us as we continue our outreach... with
your support, both the automotive repair industry and your customers
will reap the benefits. Please visit MAP at our Internet site www.
motorist.org or contact us at:
1444 I Street, NW Suite 700
Washington, DC 20005
Phone (202) 712-9042 Fax (202) 216-9646
January 1999
MAP UNIFORM INSPECTION GENERAL GUIDELINES
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
It is MAP policy that all exhaust, brake, steering,
suspension, wheel alignment, drive-line, engine performance and
maintenance, and heating, ventilation and air conditioning, and
electrical services be offered and performed under the standards and
procedures specified in these sections.
Before any service is performed on a vehicle, an inspection
of the appropriate system must be performed. The results of this
inspection must be explained to the customer and documented on an
inspection form. The condition of the vehicle and its components will
indicate what services/part replacements may be "Required" or
"Suggested". In addition, suggestions may be made to satisfy the
requests expressed by the customer.
When a component is suggested or required to be repaired or
replaced, the decision to repair or replace must be made in the
customer's best interest, and at his or her choice given the options
available.
This section lists the various parts and conditions that
indicate a required or suggested service or part replacement.
Although this list is extensive, it is not fully inclusive. In
addition to this list, a technician may make a suggestion. However,
any suggestions must be based on substantial and informed experience,
or the vehicle manufacturer's recommended service interval and must be
documented.
Some conditions indicate that service or part replacement is
required because the part in question is no longer providing the
function for which it is intended, does not meet a vehicle
manufacturer's design specification or is missing.
Example:
An exhaust pipe has corroded severely and has a hole in it
through which exhaust gases are leaking. Replacement of the
exhaust pipe in this case is required due to functional
failure.
Example:
A brake rotor has been worn to the point where it measures
less than the vehicle manufacturer's discard specifications.
Replacement of the rotor is required because it does not meet
design specifications.

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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SHOCK ABSORBERS, STRUT CARTRIDGES AND STRUT ASSEMBLIES
You are not required to replace shocks or struts in axle
sets. However, when replacing a shock or strut due to the conditions
that follow, you may suggest replacement of the other shock or strut
on the same axle for improved performance and preventive maintenance.
* Part is close to the end of its useful life
* To extend tire life
* To balance ride and handling
* To improve stopping distance
When replacing steering and/or suspension components which
may affect an alignment angle, you are required to check and adjust
alignment as needed. Refer to the OEM specifications.
Under no circumstances should a technician bend struts or
strut housings.
A vehicle's load-carrying and handling abilities are limited
by its suspension, tires, brakes, and driveline. Installing coil over
shocks or any other load assist device does not increase the vehicle's
load capacity. See the vehicle owner's manual for more details.
NOTE: If vehicle is equipped with original equipment coil over
shocks, apply the conditions for coil springs from the
SPRINGS - COIL, LEAF AND TORSION BAR section of the
STEERING AND SUSPENSION guidelines. If the vehicle is
equipped with add-on coil over shocks, you may suggest
replacing the shocks with standard shocks for any spring-
related condition.
SHOCK ABSORBER, STRUT CARTRIDGE AND STRUT ASSEMBLY INSPECTION









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Condition Code Procedure
Attaching hardware bent . B ... Require repair or replacement
of bent part, if available;
otherwise, replace shock or
strut.
Attaching hardware
broken ................. A ... Require replacement of broken
part, if available; otherwise,
replace shock or strut.
Attaching hardware
corroded, affecting
structural integrity ... A . Require replacement of corroded
part, if available; otherwise,
replace shock or strut.
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part, if available;
otherwise, replace shock or
strut.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace shock or
strut.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace shock or strut.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace shock or strut.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
shock or strut.
Binding ................. A ............ Require replacement.
Body dented ............. A .......... (1) Further inspection
required.
Body punctured .......... A ............ Require replacement.
Brake hose bracket
bent ................... B .. Require repair or replacement.
Brake hose bracket
missing ................ C ............ Require replacement.
Brake hose bracket
threads damaged ........ A .. Require repair or replacement.
Brake hose bracket
threads stripped
(threads missing) ...... C ............ Require replacement.
Compression bumper
missing ................ C .......... Require replacement of
compression bumper.
Compression bumper
split .................. 1 .......... Suggest replacement of
compression bumper.
Damping (none) .......... A ............ Require replacement.
Dust boot (bellows)
split .................. 2 ......... ( 2) Suggest replacement
of boot.

Fig. 7: Brakes, Steering, & Suspension
Fig. 8: Air Conditioning, Heater & Ventilation

that all of the engine control systems are operating as they were
designed to. Therefore, they are not the cause of the driveability
problem.
The following additional items can not be overlooked as possible
causes of a driveability problem.
1. THROTTLE VALVE AREA - Dirt or ice buildup causing rough idle and
stalling.
2. ENGINE IGNITION TIMING - Must be set with timing terminal
grounded.
3. ENGINE VACUUM - Must be normal for your altitude.
4. ENGINE VALVE TIMING - To specifications.
5. ENGINE COMPRESSION - To specifications.
6. ENGINE P.C.V. SYSTEM - Must flow freely.
7. ENGINE EXHAUST SYSTEM - Must be free of any restrictions.
8. POWER BRAKE BOOSTER - No internal vacuum leaks.
9. TORQUE CONVERTER CONDITION - May cause very low power at breakaway
or high speed (Only 1 condition at a time).
10. FUEL CONTAMINATION - High alcohol or water content.
11. FUEL INJECTORS - Rough idle may be caused by injector wiring not
connected to correct injector.
12. ENGINE SECONDARY IGNITION CHECK - Abnormal scope patterns.
13. TECHNICAL SERVICE BULLETINS - Any that apply to vehicle.
14. All air intake piping and vacuum hoses must be in place and
secure. The proper air filter element must be used.
15. FUEL PRESSURE - Must be correct.
Specification: With no vacuum at the regulator:
48 PSI on V6 & non-turbo 4 Cyl. engines
36 PSI on turbo engines
NS-1: TESTING IGNITION CIRCUIT - 1.6L
Fig. 75: Circuit Diagram NS-1 (1.6L)

The following additional items can not be overlooked as
possible causes of a driveability problem.
1. ENGINE IGNITION TIMING - Must be set with timing terminal
grounded.
2. ENGINE VACUUM - Must be normal for your altitude.
3. ENGINE VALVE TIMING - To specifications.
4. ENGINE COMPRESSION - To specifications.
5. ENGINE P.C.V. SYSTEM - Must flow freely.
6. ENGINE EXHAUST SYSTEM - Must be free of any restrictions.
7. POWER BRAKE BOOSTER - No internal vacuum leaks.
8. TORQUE CONVERTER CONDITION - May cause very low power at breakaway
or high speed (Only 1 condition at a time).
9. FUEL CONTAMINATION - High alcohol or water content.
10. FUEL INJECTORS - Rough idle may be caused by injector wiring not
connected to correct injector.
11. ENGINE SECONDARY IGNITION CHECK - Abnormal scope patterns.
12. TECHNICAL SERVICE BULLETINS - Any that apply to vehicle.
13. All air intake piping and vacuum hoses must be in place and
secure. The proper air filter element must be used.
14. FUEL PRESSURE - Must be correct.
Specification: With no vacuum at the regulator:
48 PSI on V6 & non-turbo 4 Cyl. engines
36 PSI on turbo engines
NS-VER: NO START VERIFICATION PROCEDURE - 1.6L
Fig. 168: Flow Chart NS-VER (1.6L)
DR-VER: DRIVEABILITY VERIFICATION PROCEDURE - 1.6L

2. ENGINE IGNITION TIMING - Must be set with timing terminal
grounded.
3. ENGINE VACUUM - Must be normal for your altitude.
4. ENGINE VALVE TIMING - To specifications.
5. ENGINE COMPRESSION - To specifications.
6. ENGINE P.C.V. SYSTEM - Must flow freely.
7. ENGINE EXHAUST SYSTEM - Must be free of any restrictions.
8. POWER BRAKE BOOSTER - No internal vacuum leaks.
9. TORQUE CONVERTER CONDITION - May cause very low power at breakaway
or high speed (Only 1 condition at a time).
10. FUEL CONTAMINATION - High alcohol or water content.
11. FUEL INJECTORS - Rough idle may be caused by injector wiring not
connected to correct injector.
12. ENGINE SECONDARY IGNITION CHECK - Abnormal scope patterns.
13. TECHNICAL SERVICE BULLETINS - Any that apply to vehicle.
14. All air intake piping and vacuum hoses must be in place and
secure. The proper air filter element must be used.
15. FUEL PRESSURE - Must be correct.
Specification: With no vacuum at the regulator:
48 PSI on V6 & non-turbo 4 Cyl. engines
36 PSI on turbo engines
NS-1: IGNITION CHECK FLOW CHARTS - 2.0L
Fig. 235: NS-1 Flow Chart & Circuit Diagram (2.0L) (1 of 5)