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Mitsubishi Montero (1991+). Manual - part 52

to the conditions that follow, you may suggest rebuilding or

replacement of the other wheel cylinder (on the same axle) for

preventive maintenance, for example, the part is close to the end of

its useful life.

Determine the need to rebuild or replace based upon the

individual wheel cylinder conditions that follow.

WHEEL CYLINDER INSPECTION

Condition Code Procedure

Attaching hardware bent . B ..... Require replacement of bent

parts.

Attaching hardware

broken ................. A ... Require repair or replacement

of hardware.

Attaching hardware

corroded, affecting

structural integrity ... A . Require replacement of corroded

parts.

Attaching hardware

loose .................. A .. Require repair or replacement.

Attaching hardware

missing ................ C .......... Require replacement of

hardware.

Attaching hardware not

functioning ............ A ... Require repair or replacement

of hardware.

Bleeder port damaged (if

non-repairable) ........ A ............ Require replacement.

Bleeder screw broken off

in wheel cylinder (if non-

repairable) ............ A ........ (1) Require replacement.

Bleeder screw plugged ... A ........... ( 1) Require repair or

replacement of bleeder screw.

Bleeder screw seized .... A ........ (2) Require replacement.

Bore corroded (pitted) .. B ............ Require replacement.

Bore grooved ............ A ............ Require replacement.

Bore oversized .......... B ............ Require replacement.

Dust boot missing ....... C ..... Require replacement of dust

boot.

Dust boot torn .......... A . (3) Require replacement of dust

boot.

Leaking ................. A ....... (4) Require rebuilding or

replacement.

Piston corroded, affecting

performance ............ B ... Require replacement of piston

and rebuilding or replacement

of wheel cylinder.

Piston finish worn off .. B ... Require replacement of piston

and rebuilding or replacement

of wheel cylinder.

Piston stuck in bore .... A .... Require replacement of wheel

cylinder.

Loose ................... B .. Require repair or replacement.

Threads damaged ......... A .. Require repair or replacement.

Threads stripped (threads

missing) ............... A ............ Require replacement.

(1) - Only required if the hydraulic system must be opened.

(2) - Seized is defined as bleeder screw that cannot be removed

after a practical attempt at removing. Only required if

the hydraulic system must be opened.

(3) - Inspect for conditions related to wheel cylinder.

(4) - Leaking is defined as a drop or more. Dampness is normal.

WIRING HARNESSES

NOTE: Copied from Electrical UIGs.

WIRING HARNESS INSPECTION

Condition Code Procedure

Application incorrect ... B .. Require repair or 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.

Connector broken ........ A .. Require repair or replacement.

Connector (Weatherpack

type) leaking .......... A .. Require repair or replacement.

Connector melted ........ A ........... ( 1) Require repair or

replacement.

Connector missing ....... C ............ Require replacement.

Insulation damaged,

conductors exposed ..... A .. Require repair or replacement.

Insulation damaged,

conductors not exposed . 1 ............ Suggest replacement.

Open .................... A .. Require repair or replacement.

Protective shield

(conduit) melted ....... 2 ........... ( 1) Suggest repair or

replacement.

Protective shield

(conduit) missing ...... 2 .. Suggest repair or replacement.

Resistance (voltage drop)

out of specification ... A .. Require repair or replacement.

Routed incorrectly ...... B ................. Require repair.

Secured incorrectly ..... B ................. Require repair.

Shorted ................. A .. Require repair or replacement.

Terminal broken ......... A .. Require repair or replacement.

Terminal burned, affecting

performance ............ A ........... ( 1) 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.

Voltage drop out of

specification .......... A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

BRAKE SYSTEM

1991 Mitsubishi Montero

1991 BRAKES

Disc & Drum

Chrysler Motors: Ram-50;

Mitsubishi: Montero, Pickup

DESCRIPTION

Brake system consists of a master cylinder, vacuum power

brake unit, proportioning valve and self-adjusting assembly. Pickup

and Ram-50 models have a Load-Sensing Proportioning Valve (LSPV). All

models are equipped with front disc brakes and rear drum brakes.

Parking brake assembly activates rear brakes.

BLEEDING BRAKE SYSTEM

BLEEDING PROCEDURES

Montero

Bleed brake system in following order: right rear, right

front and left front (one circuit handles both rear brakes).

Pickup & Ram-50

Bleed brake system in following order: right rear, left rear,

LSPV, right front and left front.

ADJUSTMENTS

BRAKE PEDAL HEIGHT & FREE PLAY

1) Separate connector from stoplight switch, and loosen lock

nut. Position switch so it does not contact brake pedal arm. Adjust

brake pedal height by rotating master cylinder push rod (yoke, if

equipped) until distance from top of brake pedal to floor board is

correct. See BRAKE PEDAL SPECIFICATIONS table.

2) DO NOT depress push rod. Tighten lock nut, and ensure

brake pedal height is within specification. Start engine to evacuate

brake booster chamber. Stop engine, and apply brake several times to

remove vacuum from brake booster.

3) Using hand pressure, depress brake pedal to measure free

play before resistance is felt. If distance is incorrect, bleed the

brake hydraulic system, and check for misadjusted brakes. Refer to the

BRAKE PEDAL SPECIFICATIONS table.

BRAKE PEDAL SPECIFICATIONS TABLE

Free Play Pedal Height

Application In. (mm) In. (mm)

Montero ............ .12-.31 (3-8) ... 7.5-7.7 (191-196)

Pickup & Ram-50 .... .12-.31 (3-8) ........... 6.5 (166)

LOAD-SENSING PROPORTIONING VALVE (LSPV) (Pickup & Ram-50)

Park vehicle on level surface. Remove all luggage and

passengers. Ensure lever is not against stopper bolt. Check spring

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