service MITSUBISHI MONTERO 1998 Service Manual
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 1998, Model line: MONTERO, Model: MITSUBISHI MONTERO 1998Pages: 1501, PDF Size: 25.81 MB
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* STEERING UNIFORM INSPECTION GUIDELINES *
1998 Mitsubishi Montero
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
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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-
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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.
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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
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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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of part with damaged threads if
available; otherwise, replace
bushing.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads if
available; otherwise, replace
bushing.
Binding ................. A .. Require repair or replacement.
Deteriorated, affecting
performance ............ A .. Require repair or replacement.
Distorted, affecting
performance ............ A .. Require repair or replacement.
Leaking (fluid-filled
type) .................. A ............ Require replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .......... (1) Further inspection
required.
Rubber separating from
internal metal sleeve on
bonded bushing ......... A ............ Require replacement.
Seized .................. A ............ Require replacement.
Shifted (out of
position) .............. B .. Require repair or replacement.
Split ................... A ............ Require replacement.
Surface cracking (weather-
checked) ............... .. ........ No service suggested or
required.
( 1) - If noise isolated to bushing, suggest repair or
replacement.
CAUTION: Use only approved lubricant on rubber bushings.
Petroleum-based lubricants may damage rubber bushings.
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CENTER LINKS
CENTER LINK INSPECTION \
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Condition Code Procedure
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part, if available;
otherwise, replace center link.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace center link.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace center link.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace center link.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
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POWER STEERING HOSE INSPECTION \
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POWER STEERING HOSES
POWER STEERING HOSE INSPECTION \
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Condition Code Procedure
Blistered ............... B ........... Require replacement.
Blocked ................. A . Require repair or replacement.
Fitting threads damaged . A . Require repair or replacement.
Fitting threads stripped
(threads missing) ...... A ........... Require replacement.
Inner fabric
(webbing) cut .......... A ........... Require replacement.
Leaking ................. A . Require repair or replacement.
Missing ................. C ........... Require replacement.
Outer covering is cracked
to the extent that
the inner fabric of
hose is visible ........ B ........... Require replacement.
Restricted .............. A . Require repair or replacement.
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POWER STEERING (HYDRAULIC) PUMPS
If diagnosis has determined that complete disassembly is
necessary to determine the extent of the system failure, the
suggestion may be made to rebuild or replace the power steering pump.
Repair or replacement of the following components may be required if
performed as part of a power steering pump overhaul or rebuild service
to meet a minimum rebuild standard.
POWER STEERING (HYDRAULIC) PUMP INSPECTION
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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
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.
Belt alignment
incorrect .............. B .......... ( 1) Further inspection
required.
Belt cracked ............ 1 ............ Suggest replacement.
Belt frayed ............. 1 ............ Suggest replacement.
Belt missing ............ C ............ Require replacement.
Belt noisy .............. 2 .......... ( 2) Further inspection
required.
Belt plies separated .... A ............ Require replacement.
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Belt tension out of
specification .......... B ........... Require adjustment or
replacement.
Belt worn beyond
adjustment range ....... B ............ Require replacement.
Belt worn so it contacts
bottom of pulley ....... A ............ Require replacement.
Binding ................. A .. Require repair or replacement.
Fluid at or beyond
service interval ....... 3 ........... Suggest fluid change.
Fluid contaminated ...... B ........ (3) Require flushing and
refilling of the system.
Fluid level incorrect ... B ..... Require adjustment of fluid
level.
Inadequate assist ....... A .......... ( 4) Further inspection
required.
Leaking ................. A .. Require repair or replacement.
Noise ................... 2 .......... ( 5) Further inspection
required.
Pulley bent ............. A ... Require repair or replacement
of pulley.
Pulley missing .......... C .. Require replacement of pulley.
Remote reservoir
leaking ................ A .......... Require replacement of
reservoir,
Reservoir cap broken .... A ..... Require replacement of cap.
Reservoir cap missing ... C ..... Require replacement of cap.
Seized .................. A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped
(threads missing) ...... A ............ Require replacement.
( 1) - Determine cause of incorrect alignment and require repair.
( 2) - Determine cause of noise and suggest repair.
( 3) - Determine and correct source of contamination. OEM
specifications must be followed for fluid type.
( 4) - If pump is source of inadequate assist, require
repair or replacement.
( 5) - If noise is isolated to pump, suggest repair or
replacement.
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RADIUS ARMS
RADIUS ARM INSPECTION \
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require replacement of broken
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.
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(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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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