oil MITSUBISHI MONTERO 1991 Service Manual
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 1991, Model line: MONTERO, Model: MITSUBISHI MONTERO 1991Pages: 1333, PDF Size: 24.61 MB
Page 775 of 1333
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)
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\003
* S U SPEN SIO N 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
Steering, Suspension, Wheel Alignment, Wheels and Tires
Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
Motorist Assurance Program (MAP)
OVERVIEW
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Steering and Suspension
AIR RIDE SUSPENSION
AIR RIDE SUSPENSION - AIR SHOCKS AND AIR STRUTS
AIR RIDE SUSPENSION - AIR SPRING VALVES
AIR RIDE SUSPENSION - AIR SPRINGS
AIR RIDE SUSPENSION - COMPRESSORS
AIR RIDE SUSPENSION - HEIGHT SENSORS
AIR RIDE SUSPENSION - MODULES
AIR RIDE SUSPENSION - RELAYS (COMPRESSOR)
AIR RIDE SUSPENSION - SWITCHES (ON/OFF)
AIR RIDE SUSPENSION - TORSION SPRINGS (COUNTER BALANCING)
AIR RIDE SUSPENSION - TUBING
AIR RIDE SUSPENSION - WARNING LAMPS
AIR RIDE SUSPENSION - WIRING HARNESSES
BALL JOINTS
BUSHINGS
CENTER LINKS
CONTROL ARM SHAFTS
CONTROL ARMS
DRAG LINKS
ELECTRONIC RIDE CONTROL SHOCKS AND STRUTS
IDLER ARMS
KING PINS
PITMAN ARMS
POWER STEERING HOSES
POWER STEERING (HYDRAULIC) PUMPS
RADIUS ARMS
RELAY RODS
SHOCK ABSORBERS, STRUT CARTRIDGES AND STRUT ASSEMBLIES
SPINDLES
SPRINGS - COIL, LEAF AND TORSION BAR
STEEL POWER STEERING LINES
STEERING ARMS
STEERING DAMPERS
STEERING GEARS (EXCEPT RACK AND PINION)
STEERING GEARS - RACK AND PINION
STEERING KNUCKLES
STRIKE OUT BUMPERS
STRUT RODS
STRUT UPPER BEARING PLATE ASSEMBLIES
SWAY BAR LINKS
SWAY BARS
Page 781 of 1333
the facts, allowing the customer to draw their own
conclusions and make an informed decision about how to
proceed.
STEERING AND SUSPENSION
SERVICE PROCEDURES REQUIRED AND SUGGESTED FOR PROPER VEHICLE
OPERATION
Steering and suspension are complex systems made up of a
variety of interdependent components. For proper vehicle handling,
ride, and tire wear, a thorough inspection is required whenever
suspension work is being performed.
Conditions listed assume that the problem has been isolated
to the specific component by proper testing procedures.
NOTE: 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.
CAUTION: DO NOT use ride height altering or load compensating
components, such as variable rate springs and coil over
shocks, on vehicles with height or load sensing
proportioning valve-equipped braking systems, unless
these components are original equipment.
AIR RIDE SUSPENSION
NOTE: Depending on the air suspension design, there are some
aftermarket products available to eliminate the air ride
suspension on certain vehicles. If the system has been
eliminated with one of these products, then no service is
suggested or required.
AIR RIDE SUSPENSION - AIR SHOCKS AND AIR STRUTS
NOTE: This section covers the air spring portion of the
air shock or strut. For damping portion of shock
or strut conditions and procedures, refer to the
SHOCK ABSORBERS, STRUT CARTRIDGES AND STRUT ASSEMBLIES
section.
AIR RIDE SUSPENSION - AIR SHOCK AND AIR STRUT INSPECTION
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Condition Code Procedure
Inner fabric of air bag
damaged ................ A ............ Require replacement.
Leaking ................. A .. Require repair or replacement.
Outer covering of air bag
is cracked to the extent
that inner fabric of air
bag is visible ......... 1 ............ Suggest replacement.
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AIR RIDE SUSPENSION - AIR SPRING VALVES
AIR RIDE SUSPENSION - AIR SPRING VALVE INSPECTION \
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Condition Code Procedure
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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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Dust boot (bellows)
missing ................ 2 ......... (2) Suggest replacement
of boot.
Dust boot (bellows)
torn ................... 2 ......... ( 2) Suggest replacement
of boot.
Dust shield broken ...... 2 ........ ( 2) Suggest replacement.
Dust shield missing ..... 2 ........ ( 2) Suggest replacement.
Gland nut (strut housing
cap) is not removable
using appropriate tool . A .. ( 3) Require replacement of nut
and/or housing.
Gland nut (strut housing
cap) threads damaged ... A ... Require repair or replacement
of nut.
Gland nut (strut housing
cap) threads stripped
(threads missing) ...... A ..... Require replacement of nut.
Housing dented .......... A .......... ( 1) Further inspection
required.
Housing punctured ....... A ............ Require replacement.
Jounce bumper missing ... C ... Require replacement of jounce
bumper.
Jounce bumper split ..... 1 ... Suggest replacement of jounce
bumper.
Leaking oil, enough for
fluid to be running down
the body ............... A ........ ( 4) Require replacement.
Noise ................... 2 .......... ( 5) Further inspection
required.
Piston rod bent ......... A ............ Require replacement.
Piston rod broken ....... A ............ Require replacement.
Piston rod has surface
defect ................. 2 ............ Suggest replacement.
Piston rod threads
damaged ................ A .. Require repair or replacement.
Piston rod threads
stripped (threads
missing) ............... A ............ Require replacement.
Seized .................. A ............ Require replacement.
Shock missing ........... C ............ Require replacement.
Strut housing bent ...... A ............ Require replacement.
Strut housing cap (gland
nut) is not removable
using appropriate tool . A ......... ( 3) Require replacement
of nut and/or housing.
Strut housing cap (gland
nut) threads damaged ... A ... Require repair or replacement
of nut.
Strut housing cap (gland
nut) threads stripped
(threads missing) ...... A ..... Require replacement of nut.
Strut housing severely
corroded, affecting
structural integrity ... A ............ Require replacement.
Strut housing threads
damaged ................ A .. Require repair or replacement.
Strut housing threads
stripped (threads
missing) ............... A ............ Require replacement.
Tire cupping ............ A .......... ( 6) Further inspection
required.
Page 804 of 1333
(1) - Require replacement of units where dents restrict shock
or strut piston rod movement. If dents don't restrict
movement, no service is suggested or required. Especially
critical on mono-tube shocks.
( 2) - This condition can lead to damage of the piston rod,
which, in turn, causes premature piston rod seal wear.
( 3) - Only required if replacing cartridge.
( 4) - CAUTION: If the strut cartridge has been replaced previously,
the oil on the strut housing may be filler oil. The
technician must identify the source of the oil.
( 5) - If noise is isolated to shock or strut, suggest
replacement.
( 6) - Although shocks or struts may have contributed to tire
cupping, an inspection is needed of the entire suspension
system. If the shock or strut is found to be contributing
to the tire cupping, require replacement.
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SPINDLES
SPINDLE INSPECTION \
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require replacement of broken
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.
Bent .................... B ............ Require replacement.
Broken .................. A ............ Require replacement.
Race seat area
undersized ............. B ............ Require replacement.
Scored .................. A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
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SPRINGS - COIL, LEAF AND TORSION BAR
When springs are replaced, it is suggested, but not required,
that both springs on an axle be replaced to maintain equal height from
side to side and to provide a balanced ride and proper handling.
When variable rate springs are installed in place of
conventional coil springs, they must be installed in axle sets to
ensure proper handling, uniform ride, and proper chassis height.
Erroneous height measurements may result from: improper tire
inflation, non-standard tire or wheel size, and heavy load in vehicle
or trunk.
SPRING (COIL, LEAF AND TORSION BAR) INSPECTION
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![MITSUBISHI MONTERO 1991 Service Manual \
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Condition Code](/img/19/57332/w960_57332-804.png "MITSUBISHI MONTERO 1991 Service Manual \
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Condition Code")
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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
corroded, affecting
structural integrity .. A .. Require replacement of corroded
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 (all springs
except secondary
leave(s) on multi-leaf
springs) .............. A ............. Require replacement.
Coil clash ............. .. .. (1) Require ride height check.
Coil spring insulator
deteriorated .......... 2 ........... Suggest replacement of
insulator.
Coil spring insulator
missing ............... 2 ........... Suggest replacement of
insulator.
Coil spring insulator
split ................. 2 ........... Suggest replacement of
insulator.
Coil spring plastic
coating deteriorated -
rust present .......... A ...... ( 2) Refer to manufacturer's
service requirements.
Composite spring
damaged ............... .. .......... ( 3) Further inspection
required.
Cracked (all springs
except composite leaf and
secondary leave(s) on
multi-leaf springs) ... A ............. Require replacement.
Installed incorrectly .. B .................. Require repair.
Leaf spring insulators
missing ............... 2 ........... Suggest replacement of
insulators.
Secondary leaf on multi-
leaf spring broken .... 1 .... Suggest repair or replacement
Secondary leaf on multi-
leaf spring cracked ... 1 .... Suggest repair or replacement
Torsion bar
Page 808 of 1333
replace steering damper.
Attaching hardware
corroded, affecting
structural integrity ... A . Require replacement of corroded
part, if available; otherwise,
replace steering damper.
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part, if available;
otherwise, replace steering
damper.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace steering
damper.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace steering damper.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace steering damper.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
steering damper.
Binding ................. A ............ Require replacement.
Damper body dented ...... A .......... (1) Further inspection
required.
Damper body punctured ... A ............ Require replacement.
Damping (none) .......... A ............ Require replacement.
Dust boot (bellows)
missing ................ 2 ......... ( 2) Suggest replacement
of boot.
Dust boot (bellows)
split .................. 2 ......... ( 2) Suggest replacement
of boot.
Dust shield broken ...... 2 ........ ( 2) Suggest replacement.
Dust shield missing ..... 2 ........ ( 2) Suggest replacement.
Leaking oil, enough for
fluid to be running
down the body .......... A ............ Require replacement.
Loose ................... A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Noise ................... 2 .......... ( 3) Further inspection
required.
Piston rod bent ......... A ............ Require replacement.
Piston rod broken ....... A ............ Require replacement.
Piston rod has surface
defect ................. 2 ............ Suggest replacement.
Piston rod threads
stripped (threads
missing) ............... A ............ Require replacement.
Piston rod threads
damaged ................ A .. Require repair or replacement.
Seized .................. A ............ Require replacement.
( 1) - Require replacement of units where dents restrict damper
Page 846 of 1333
Circuit Circuit
Application Terminals Terminals
Montero, Pickup 3.0L & Ram-50 3.0L ..... 2 & 4 ............. 1 & 3
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POWER STEERING OIL PRESSURE SWITCH
1) Power steering oil pressure switch is mounted on power
steering pump. Disconnect single wire connector at switch. Start
engine.
2) Connect ohmmeter between switch terminal and ground. If
continuity is present with steering wheel in straight-ahead position,
replace switch. If continuity is not present while turning steering
wheel, perform POWER STEERING IDLE-UP SYSTEM TEST. See IDLE-UP SYSTEMS
under IDLE CONTROL SYSTEM.
THROTTLE POSITION SENSOR
1) TPS is mounted to throttle body, at end of throttle shaft.
Disconnect TPS connector. See Fig. 6. Using ohmmeter, measure total
resistance between TPS connector terminals as specified in TPS
CONNECTOR TERMINAL IDENTIFICATION table. If resistance is not 3500-
6500 ohms, replace TPS.
2) Using an analog (needle-type) ohmmeter, measure variable
resistance between TPS connector terminals as specified in TPS
CONNECTOR TERMINAL IDENTIFICATION table.
3) Operate throttle valve from closed to wide open throttle.
If rate of resistance does not change smoothly within 3500-6500 ohms
throughout range of throttle valve movement, replace TPS.
Fig. 6: TPS Sensor Connector Terminal ID
Courtesy of Mitsubishi Motor Sales of America.
TPS CONNECTOR TERMINAL IDENTIFICATION TABLE
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remains on (light may flash) during vehicle operation, cause of
malfunction must be determined by using DIAGNOSTIC FAULT CHARTS (if
testing with voltmeter) or diagnostic CODE CHARTS (if testing with
DRB-II). If a sensor fails, ECU will use a substitute value in its
calculations to continue engine operation. In this condition, vehicle
is functional, but loss of good driveability may result.
INTERMITTENT FAILURES
Intermittent failures may cause CHECK ENGINE light to flicker
or illuminate and go out after the intermittent fault goes away.
However, the corresponding trouble code will be retained in ECU
memory. If related fault does not reoccur within a certain time frame,
related trouble code will be erased from ECU memory. Intermittent
failures may be caused by a sensor, connector or wiring related
problems. See INTERMITTENTS in H - TESTS W/O CODES article.
PRETEST INSPECTION
Before proceeding with diagnosis, the following precautions
must be followed:
* Vehicle must have a fully charged battery and functional
charging system.
* Visually inspect connectors and circuit wiring being worked
on.
* DO NOT disconnect battery or ECU. This will erase any fault
codes stored in ECU.
* DO NOT cause short circuits when performing electrical tests.
This will set additional fault codes, making diagnosis of original
problem more difficult.
* DO NOT use a test light in place of a voltmeter.
* When checking for spark, ensure coil wire is NO more than
1/4" from ground. If coil wire is more than 1/4" from ground,
damage to vehicle electronics and/or ECU may result.
* DO NOT prolong testing of fuel injectors. Engine may
hydrostatically (liquid) lock.
* When a vehicle has multiple fault codes, always repair lowest
number fault code first.
* If DRB-II is being used to diagnose system, always perform
verification test after repairs are made.
ENTERING ON-BOARD DIAGNOSTICS (USING VOLTMETER)
1) Before entering on-board diagnostics, refer to PRETEST
INSPECTION in this article. Turn ignition switch to OFF position.
Locate self-diagnostic connector. See SELF-DIAGNOSTIC TEST CONNECTOR
LOCATION table. Using an analog voltmeter, connect voltmeter positive
lead to self-diagnostic connector terminal No. 1 and negative lead to
terminal No. 12 (ground). See Fig. 6.
2) Turn ignition switch to ON position and disclosure of ECU
memory will begin. If 2 or more systems are non-functional, they are
indicated by order of increasing code number. Indication is made by
12-volt pulses of voltmeter pointer. A constant repetition of short
12-volt pulses indicates system is normal. If system is abnormal,
voltmeter will pulse between zero and 12 volts.
3) Signals will appear on voltmeter as long and short 12-volt
pulses. Long pulses represent tens; short pulses represent ones. For
example 4 long pulses and 3 short pulses indicates Code 43. See