check engine light MITSUBISHI MONTERO 1998 User Guide

(62-73 kPa) of vacuum applied to the brake booster.
PARKING/EMERGENCY BRAKE
NOTE: Adjust service brakes before adjusting parking brake.
Start engine, and apply brake pedal. Pull parking brake lever
with a force of 44-45 lbs. (196-200 N). Parking brake lever should
move up 3-5 notches on Diamante, Stealth and 3000GT, 4-6 notches on
Montero, and 5-7 notches on all other models. If adjustment is
necessary, turn adjusting nut located under console or at end of cable
rod. See Fig. 6.
Fig. 6: Adjusting Parking/Emergency Brake (Typical)
Courtesy of Mitsubishi Motor Sales of America.
REAR BRAKE SHOES
Fully release parking brake and depress brake pedal several
times to center shoes and adjust brake shoe clearance. Adjust shoes so
brake shoes lightly contact brake drum. Adjust parking brake, and
check pedal travel. Rotate brake drum to verify free movement.
STOPLIGHT SWITCH
Loosen lock nut, and adjust switch-to-pedal arm clearance to
0.02-0.04" (0.5-1.0 mm). Tighten lock nut. DO NOT depress master
cylinder push rod during stoplight switch adjustment.
TESTING

POWER BRAKE BOOSTER
System Check
1) Run engine for 1-2 minutes. Shut engine off, and depress
brake pedal several times with normal pressure. If pedal height
gradually becomes higher with successive applications, power brake
booster is okay. If pedal height remains steady, power brake booster
is not operating properly, go to next step.
2) With engine stopped, depress brake pedal repeatedly until
pedal height no longer falls. Hold brake pedal down, and start engine.
If pedal moves downward slightly, power brake booster is okay. If
pedal height does not change, power brake booster is not operating
properly, go to next step.
3) With engine running, press and hold brake pedal. Shut off
engine. Hold brake pedal for 30 seconds. Brake pedal height should not
change. If pedal rises, power brake booster is not operating properly,
go to next step.
4) If brake booster operation is not as specified in each
step, disconnect vacuum hose at brake booster and check for sufficient
vacuum with engine running. Also check brake booster check valve
operation. Repair or replace as necessary.
Check Valve Inspection
Remove vacuum hose from power brake booster. Do not remove
check valve from hose. Check valve should hold vacuum in one direction
and allow air to pass in other direction.
LOAD-SENSING PROPORTIONING VALVE (LSPV)
Montero
1) Before diagnosing Load-Sensing Proportioning Valve (LSPV)\
,
ensure all other brake components are operating properly. When all
other brake system components are determined to be okay, ensure LSPV
spring length is within specification. See Fig. 1. See LOAD-SENSING
PROPORTIONING VALVE (LSPV) under ADJUSTMENTS.
2) After spring length is determined to be within
specification, connect pressure gauges to input and output ports of
LSPV. See Fig. 7. Bleed brake system. See BLEEDING BRAKE SYSTEM.
Fig. 7: Connecting Pressure Gauges To LSPV (Montero)
Courtesy of Mitsubishi Motor Sales of America.
3) With vehicle unloaded at correct ride height and LSPV
spring correctly adjusted to 8.9" (227 mm), slowly depress brake pedal\

specified, bleed system and inspect hydraulic and clutch components.
See CLUTCH PEDAL SPECIFICATIONS table.
CLUTCH PEDAL INTERLOCK SWITCH
1) Place transmission in Neutral and apply parking brake.
Turn ignition switch to START position with clutch pedal not
depressed. Engine should not crank. If engine cranks, adjust or
replace interlock switch.
2) Disconnect interlock switch connector. Interlock switch
connector is located at clutch pedal. Depress and release interlock
switch. Using ohmmeter, check continuity between interlock switch
terminals. If continuity exists with interlock switch depressed and
does not exist with switch released, switch is okay. Adjust or replace
as necessary.
REMOVAL & INSTALLATION
CLUTCH ASSEMBLY
Removal (2WD Models)
1) Disconnect negative battery cable. Remove shift knob, dust
cover retaining plate, gaskets, stopper plate and control lever
assembly. Raise and support vehicle.
2) Remove front exhaust pipe. Drain transmission fluid. Index
mark drive shaft flange and remove drive shaft.
3) Disconnect back-up light switch connector, speedometer
cable connection and exhaust pipe mounting bracket. Remove lower
bellhousing cover. Disconnect clutch cable from clutch lever.
4) Support transmission with jack. Remove rear engine mount
nuts and bolts from transmission. Remove crossmember with rear engine
mount. Remove remaining bellhousing bolts, move transmission toward
rear and lower from vehicle.
5) If reusing pressure plate, index mark pressure plate to
flywheel for installation reference. Install a clutch alignment tool
to prevent pressure plate and clutch disc from dropping. Loosen
pressure plate bolts gradually in a crisscross pattern to avoid
warping pressure plate flange during removal. Remove pressure plate
and clutch disc. See Fig. 3.
Inspection
1) Check release bearing and release fork for damage or wear.
DO NOT clean release bearing assembly in solvent.
2) Inspect pressure plate surface for wear, cracks, and/or
discoloration. Measure diaphragm spring ends for wear and uneven
height. Replace assembly if height difference between fingers exceeds
.02" (.5 mm).
3) Check facing of clutch disc for loose rivets, uneven
contact, deterioration, seizure or oil saturation. Measure distance
from clutch disc surface to head of rivet. Replace clutch disc if
distance is less than .012" (.30 mm). Replace worn or defective
components as necessary. See Fig. 4.
CAUTION: Install clutch disc with manufacturer's stamp mark (located
near hub of clutch disc) toward pressure plate.
Installation
1) Using a clutch alignment tool, install pressure plate and
clutch disc. If reusing pressure plate, ensure index marks are
aligned. Tighten bolts evenly in a crisscross pattern to
specification. See TORQUE SPECIFICATIONS . See Fig. 3.
2) Clean release bearing sliding surface. DO NOT clean

release bearing with solvent. Apply a light coat of multipurpose
grease to release bearing sliding surface. Apply a very light coating
of grease to input shaft splines. DO NOT allow grease or dirt on
clutch disc or pressure plate surfaces.
3) To install remaining components, reverse removal
procedure. Refill all fluids to proper levels. Adjust all control
cables, clutch pedal height and free play. See CLUTCH PEDAL HEIGHT and
CLUTCH PEDAL FREE PLAY under ADJUSTMENTS. See Fig. 1.
Removal (4WD Models)
1) Remove switch panel from rear console. Remove suspension
control switch or hole cover. Disconnect rear console harness
connector. Remove side panel. Remove rear console assembly. Remove
shift lever knob(s). Remove floor console harness connector. Remove
front console assembly.
2) Move transmission lever to Neutral position and transfer
lever to 4H (4WD high range) position. Remove control lever boot
retainer and boot. Remove transmission and transfer control lever
assemblies. Remove control lever bushing (transmission), gaskets and
stopper plates.
3) Raise and support vehicle. Remove skid plate and front
exhaust pipe. Drain transmission and transfer case fluid. Index mark
front and rear drive shaft flanges. Remove front and rear drive
shafts.
4) Remove drive shaft dust seals. Disconnect HI/LO and
2WD/4WD detection switch connectors. Disconnect back-up light switch
connector. Disconnect center differential lock detection switch
connector. Disconnect center differential lock operation switch
connector. Disconnect 4WD operation detection switch.
5) Disconnect speedometer cable. Remove clutch slave cylinder
heat shield. Remove clutch slave cylinder (without disconnecting
hydraulic line) and wire aside. Remove starter and starter cover.
Remove heat shield, both transmission stays and bellhousing lower
cover.
6) Support transmission with transmission jack. Remove
transfer case roll stopper and bracket. Remove crossmember and engine
mounting rear insulator. Remove transfer case protector bracket and
mass damper. Remove remaining bellhousing bolts. Pull toward rear of
vehicle to free transmission input shaft from clutch. Lower
transmission/transfer assembly from vehicle.
7) If reusing pressure plate, mark pressure plate to flywheel
for installation reference. Insert a clutch alignment tool to prevent
pressure plate and clutch disc from dropping. Loosen pressure plate
bolts gradually in a crisscross pattern to avoid warping pressure
plate flange during removal. Remove pressure plate and clutch disc.
See Fig. 3 .
Fig. 3: Removing & Installing Clutch On Flywheel (Typical)
Courtesy of Mitsubishi Motor Sales of America.
Inspection
1) Check release bearing and release fork for damage or wear.

coolant is 176-203F (80-95C). Turn engine off. Insert a paper clip
in engine speed detection connector. See Fig. 3. Connect a tachometer
to paper clip.
Fig. 3: Locating Engine Speed Detection Connector (3000GT - DOHC)
Courtesy of Mitsubishi Motor Sales of America
3) Install a timing light. Start engine and allow it to idle.
Using tachometer, read curb idle (RPM). Multiply RPM reading by 3 to
obtain actual curb idle speed. Ensure curb idle speed is 600-700 RPM.
Turn engine off. Curb idle speed is automatically controlled by Idle
Air Control (IAC) system. If curb idle speed is not as specified, see
DTC P0505 in G - TESTS W/CODES article.
4) Disconnect waterproof female connector from Brown ignition
timing check connector. See Fig. 4. Using a jumper wire, ground
ignition timing check terminal to read basic ignition timing. Using
timing light, read basic ignition timing value. See
IGNITION TIMING SPECIFICATIONS table. If basic ignition timing is
within specification, go to next step. If basic ignition timing is not
within specification, see DTC P0335 in G - TESTS W/CODES article.
5) Remove jumper wire to read actual ignition timing. Using
timing light, read actual ignition timing value. If actual ignition
timing is not within specification, see DTC P0335 in G - TESTS W/CODES
article.

Fig. 4: Locating Ignition Timing Check Connector
Courtesy of Mitsubishi Motor Sales of America
3000GT (SOHC)
1) Ignition timing is controlled by Powertrain Control Module
(PCM) and is not adjustable. Manufacturer provides procedure for
checking timing.
2) Start engine and warm engine until engine temperature
coolant is 176-203
F (80-95C). Turn engine off. Insert a paper clip
in noise filter connector. See Fig. 5. Connect a tachometer to paper
clip.
Fig. 5: Locating Noise Filter Connector
Courtesy of Mitsubishi Motor Sales of America
3) Install a timing light. Start engine and allow it to idle.
Using tachometer, read curb idle speed (RPM). Ensure curb idle speed

is 600-700 RPM. Turn engine off. Curb idle speed is automatically
controlled by Idle Air Control (IAC) system. If curb idle speed is not\
as specified, see DTC P0505 in G - TESTS W/CODES article.
4) Disconnect waterproof female connector from Brown ignition
timing check connector. See Fig. 4. Using a jumper wire, ground
ignition timing check terminal to read basic ignition timing. Using
timing light, read basic ignition timing value. See
IGNITION TIMING SPECIFICATIONS table. If basic ignition timing is
within specification, go to next step. If basic ignition timing is not
within specification, see DTC P0335 in G - TESTS W/CODES article.
5) Remove jumper wire to read actual ignition timing. Using
timing light, read actual ignition timing value. If actual ignition
timing is not within specification, see DTC P0335 in G - TESTS W/CODES
article.
All Other Models
1) Ignition timing is controlled by Powertrain Control Module
(PCM) and is not adjustable. Manufacturer provides procedure for
checking timing. On models with distributor, DO NOT attempt to adjust
ignition timing by rotating distributor.
2) Connect scan tool to Data Link Connector (DLC). DLC is
located below dash, near steering column. See Fig. 2. Install a timing
light. Start engine and allow it to idle.
3) Using scan tool, read curb idle speed (RPM). Ensure curb
idle speed is about 750 RPM. Turn engine off. Curb idle speed is
automatically controlled by Idle Air Control (IAC) system. If curb
idle speed is not as specified, see DTC P0505 in G - TESTS W/CODES
article.
CAUTION: MFI system actuator test must be cancelled or test will
continue to run for 27 minutes. Driving vehicle under this
condition may damage engine.
4) Using scan tool, select MFI SYSTEM ACTUATOR TEST, then
select item 17 (BASIC IGNITION TIMING). Read basic ignition timing
value. See IGNITION TIMING SPECIFICATIONS table. If basic ignition
timing is within specification, go to next step. If basic ignition
timing is not within specification, cancel MFI system actuator test.
See DTCS P0100 (except Mirage 1.5L), P0105, P0115 and P0335 in G -
TESTS W/CODES article.
5) Read actual ignition timing value. If actual ignition
timing is not within specification, cancel MFI system actuator test.
See DTCS P0100 (except Mirage 1.5L), P0105, P0115 and P0335 in G -
TESTS W/CODES article.
IDLE SPEED & MIXTURE
* PLEASE READ THIS FIRST *
NOTE: Perform adjustments with engine at normal operating
temperature, cooling fan and accessories off, transmission
in Park or Neutral, and front wheels in straight-ahead
position.
BASIC IDLE SPEED
NOTE: Basic idle speed adjustment information on Eclipse 2.0L
non-turbo engine is not available from manufacturer at time
of publication.
3000GT
1) Ensure vehicle is at normal operating temperature with all

lights, cooling fan and accessories off. Shift transmission into
Neutral or Park position.
2) If not using scan tool, go to next step. Connect scan tool
to Data Link Connector (DLC). DLC is located below dash, near steering\
column. See Fig. 2. Go to step 5).
3) On DOHC models, insert a paper clip in engine speed
detection connector. See Fig. 3. On SOHC models, insert paper clip in
noise filter connector. See Fig. 5. On all models, connect a
tachometer to paper clip.
4) Connect a jumper wire between ground and Data Link
Connector (DLC) terminal No. 1. See Fig. 2. Disconnect waterproof
female connector from Brown ignition timing check connector. See
Fig. 4 . Using a jumper wire, ground ignition timing check terminal.
5) Start engine and allow it to idle. Check basic idle speed.
See IDLE SPEED SPECIFICATIONS table. On DOHC models, multiply
tachometer reading by 3 to obtain actual basic idle speed. If idle
speed is not within specification, turn engine speed adjusting screw
until correct engine speed is obtained. See Fig. 6. Access to speed
adjusting screw is obtained by removing rubber plug on throttle body.
6) If idle speed cannot be lowered by turning engine speed
adjusting screw, determine if Throttle Position (TP) sensor has been
moved. Adjust TP sensor if necessary. See TP SENSOR ADJUSTMENT under
THROTTLE POSITION (TP) SENSOR. If TP sensor is okay, replace throttle
body.
Fig. 6: Adjusting Idle Speed (Typical)
Courtesy of Mitsubishi Motor Sales of America
IDLE SPEED SPECIFICATIONS TABLE









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Application Curb Idle Basic Idle
1.5L & 1.8L ............ 600-800 ............... 650-750
2.0L
Non-Turbo ............ 700-900 ................... (1)
Turbo ................ 650-850 ............... 700-800
2.4L ................... 650-850 ............... 700-800
3.0L & 3.5L ............ 600-800 ............... 650-750
( 1) - Information is not available from manufacturer at time
of publication.









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NOTE: Basic idle speed should only be adjusted after verifying
spark plugs, fuel injectors, idle air control motor and
engine compression are okay.
All Other Models
1) Ensure vehicle is at normal operating temperature with all
lights, cooling fan and accessories off. Shift transmission into
Neutral or Park position.
2) Basic idle speed can only be adjusted using a scan tool to
ground Data Link Connector (DLC). Connect scan tool to DLC. DLC is
located below dash, near steering column. See Fig. 2.
3) Start engine and allow it to idle. Using scan tool, select
MFI SYSTEM ACTUATOR TEST, then select item 30. Check basic idle speed.
See IDLE SPEED SPECIFICATIONS table.
CAUTION: MFI system actuator test must be cancelled or test will
continue to run for 27 minutes. Driving vehicle under this
condition may damage engine.
4) Cancel MFI system actuator test. If idle speed is not
within specification, turn engine speed adjusting screw until correct
engine speed is obtained. See Fig. 6. Access to speed adjusting screw
is obtained by removing rubber plug on throttle body.
5) If idle speed cannot be lowered by turning engine speed
adjusting screw, determine if fixed Speed Adjusting Screw (SAS). Fixed\
SAS is stop screw contacting throttle lever. See
FIXED SPEED ADJUSTING SCREW for procedure.
6) After all adjustments are verified to be correct, possible
cause of incorrect idle speed is deterioration of Idle Air Control
(IAC) circuit. See DTC P0505 in G - TESTS W/CODES article.
CURB (SLOW) IDLE SPEED
NOTE: Curb idle speed is controlled by Idle Air Control (IAC)
motor. Adjustment is usually not necessary. For curb idle
speed specifications, see IDLE SPEED SPECIFICATIONS table
under BASIC IDLE SPEED.
1) Check ignition timing and adjust if necessary. See
IGNITION TIMING . Run engine at 2000-3000 RPM for more than 5 seconds.
Allow engine to idle for 2 minutes. Check curb idle speed.
2) If curb idle speed is not within specification, check IAC
system. See DTC P0505 in G - TESTS W/CODES article. If IAC system is
okay, adjust basic idle speed. See BASIC IDLE SPEED.
FIXED SPEED ADJUSTING SCREW
NOTE: Fixed Speed Adjusting Screw (SAS) is preset by manufacturer
and usually does not require adjustment. Only adjust fixed
SAS if other adjustment procedures require it, or if

usage on specific models, see appropriate wiring diagram in
L - WIRING DIAGRAMS article. For theory and operation on each
output component, refer to system indicated after component.
Data Link Connector (DLC)
See SELF-DIAGNOSTIC SYSTEM .
EGR Control Solenoid Valve
See EXHAUST GAS RECIRCULATION (EGR) CONTROL under EMISSION
SYSTEMS.
Fuel Injectors
See FUEL CONTROL under FUEL SYSTEM.
Fuel Pressure Control Solenoid Valve (Turbo)
See FUEL DELIVERY under FUEL SYSTEM.
Fuel Pressure Regulator
See FUEL DELIVERY under FUEL SYSTEM.
Idle Air Control (IAC) Motor
See IDLE SPEED under FUEL SYSTEM.
Malfunction Indicator Light
See SELF-DIAGNOSTIC SYSTEM .
Power Transistor(s) & Ignition Coils
See IGNITION SYSTEMS .
Purge Control Solenoid Valve
See EVAPORATIVE CONTROL under EMISSION SYSTEMS.
Wastegate Control Solenoid Valve
See TURBOCHARGED ENGINES under AIR INDUCTION SYSTEM.
FUEL SYSTEM
FUEL DELIVERY
Electric fuel pump, located in gas tank, feeds fuel through
in-tank fuel filter, external fuel filter (located in engine
compartment) and fuel injector rail.
Fuel Pump
Fuel pump consists of a motor-driven impeller. Pump has an
internal check valve to maintain system pressure, and a relief valve
to protect fuel pressure circuit. Pump receives voltage supply from
MFI control relay.
Fuel Pressure Control Solenoid Valve (Turbo)
Valve prevents rough idle due to fuel percolation. On engine
restart, if engine coolant or intake air temperature reaches a preset
value, PCM applies voltage to fuel pressure control solenoid valve for
2 minutes after enginerestart. Valve will open, allowing atmospheric
pressure to be applied to fuel pressure regulator diaphragm. This
allows maximum available fuel pressure at injectors, enriching fuel
mixture and maintaining stable idle at high engine temperatures.
Fuel Pressure Regulator
Located on fuel injector rail, this diaphragm-operated relief
valve adjusts fuel pressure according to engine manifold vacuum.
As engine manifold vacuum increases (closed throttle), fuel