Mitsubishi Montero (1991+). Manual - part 49

         LATERAL ACCELERATION SWITCHES

         See ACCELEROMETERS.

         LEDS

         See BULBS AND LEDS.

         LENSES

LENSE INSPECTION

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.

         MASTER CYLINDERS

MASTER CYLINDER INSPECTION

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.

         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

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

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

                                                           parts.

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

Threads stripped (threads

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

(1) - Inoperative includes intermittent operation.

         PADS

         See FRICTION MATERIAL.

         PEDAL TRAVEL SWITCHES

         See SWITCHES.

         PEDALS

         See BRAKE PEDALS.

         POWERMASTER

         See HYDRO-BOOSTERS.

         PUMPS

         See ELECTRICAL PUMPS AND MOTORS.

         PRESSURE DIFFERENTIAL SWITCHES

         See SWITCHES.

         PRESSURE SWITCHES

         See SWITCHES.

         RELAYS

NOTE:    Copied from Electrical UIGs

RELAY INSPECTION

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.

Housing broken  ..........  A  ............  Require replacement.

Housing cracked  .........  2  ............  Suggest replacement.

Inoperative (1)  .........  A  ............  Require 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.

(1) - Inoperative includes intermittent operation or out of OEM

      specification.

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

      replacement of part.

         ROTORS

         Determine the need to recondition based upon individual rotor

conditions that follow. Friction material replacement does not require

rotor reconditioning unless other justifications exist.  DO NOT

recondition new rotors unless they are being pressed or bolted onto an

existing hub. It is not necessary to replace rotors in axle sets.

However, when replacing or reconditioning a rotor due to the

conditions that follow, you may suggest reconditioning of the other

rotor on the same axle to eliminate uneven braking behavior.

         Determine the need to replace based upon the individual rotor

conditions that follow. Reconditioning is defined as machining and

block sanding, or block sanding only. Block sanding is defined as

using 120-150 grit sandpaper with moderate to heavy force for 60

seconds per side. Always wash rotors after servicing or before

installing.

ROTOR INSPECTION

Condition                 Code                          Procedure

Corrosion affecting

 structural integrity  ...  A  ........  (1) Require replacement.

Cracked  .................  B  ............  Require replacement.

Hard spots  ..............  2  .......  Suggest reconditioning or

                                   replacement of rotor according

                                           to OEM specifications.

Lateral runout (wobble)

 exceeds OEM

 specifications  .........  B  ............  Require re-indexing,

                                   reconditioning, or replacement

                                     according to specifications.

Measured thickness is less

 than OEM discard

 specifications  .........  B  ............  Require replacement.

Rotor thickness is less

 than OEM "machine to"

 specifications but thicker

 than "discard at"

 specifications, and the

 rotor does not require

 reconditioning  .........  1  ........  (2) Suggest replacement.

Rotor thickness will be

 less than OEM "machine to"

 specifications after

 required