brake sensor MITSUBISHI MONTERO 1998 Workshop Manual

SUPER CHARGERS
SWITCHES
THERMAL VACUUM VALVES
THERMOSTATIC AIR DOOR ASSEMBLIES
THERMOSTATS AND HOUSINGS
THROTTLE BODIES
THROTTLE CABLES
THROTTLE LINKAGES AND CABLES
THROTTLE POSITION SENSORS
THROTTLE POSITION SWITCHES
TIMING BELT SPROCKETS
TIMING BELTS
TORQUE STRUTS
TRANSMISSION RANGE SWITCHES
TUBE CLAMPS
TUBE CONNECTORS
TUBE COUPLERS
TUBES
TURBO CHARGERS
VACUUM CONNECTIONS
VACUUM HOSES, TUBES AND CONNECTIONS (NON-METALLIC)
VACUUM REGULATOR SOLENOIDS
VACUUM TUBES
VEHICLE SPEED SENSORS
VOLUME AIR FLOW SENSORS
WASTE GATE CONTROL SOLENOIDS
WASTE GATES AND BOOST CONTROL MECHANISMS
WATER PUMPS (ELECTRIC)
WATER PUMPS (NON-ELECTRIC)
WIRING HARNESSES AND CONNECTORS
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
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

specified VSS connector terminal. See
VSS VOLTAGE FEED CIRCUIT IDENTIFICATION table. If voltage is not 4.5-
4.9 volts, replace PCM. If voltage is as specified, condition required
to set DTC is not present at this time. Go to next step.
VSS VOLTAGE FEED CIRCUIT IDENTIFICATION TABLE









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Application Terminal No.
Montero ................................................ 1
3000GT ................................................. 3









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9) Test is complete. Intermittent problem may exist. Road
test vehicle (if necessary) and attempt to duplicate conditions that
caused original complaint. Recheck for DTCs. If no DTCs are displayed,
go to INTERMITTENT DTCS .
DTC P0505: IDLE CONTROL SYSTEM FAILURE
NOTE: For terminal identification, see TERMINAL IDENTIFICATION. For
circuit and wire color identification, see
L - WIRING DIAGRAMS article.
1) Procedures are provided by manufacturer for component
testing using an engine analyzer with oscilloscope capability. Refer
to manufacturer's operation manual for instructions in use of
oscilloscope. If using engine analyzer, go to step 3). If using scan
tool, go to next step.
2) Using scan tool, read Idle Air Control (IAC) position
sensor step (item 45). See IAC POSITION SENSOR STEP SPECIFICATIONS
table. If scan tool does not read as specified, replace IAC position
sensor. If readings are as specified, go to step 5).
IAC POSITION SENSOR STEP SPECIFICATIONS TABLE









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A/C Switch Position Standard Step Value
Off ................................................. 2-25
Off To On ............................ Increase From 10-70
( 1) ................................... Increase From 5-50
( 1) - Brakes applied. A/C Off on Montero. A/C On on 3000GT.
Move gear selector lever to Drive position.









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NOTE: Check wave pattern when idle speed increases when A/C is
turned on. Wave pattern display lasts less than one second.
3) Disconnect IAC motor connector. Install Test Harness
(MB998463) between IAC motor and connector. Using engine analyzer with\
oscilloscope capability, connect special patterns probe in sequence to
test harness terminals No. 1 (Red clip), 3 (Blue clip), 4 (Black cl\
ip)
and 6 (Yellow clip) or PCM terminals No. 4, 5, 17 and 18 respectively.\
Start engine and allow it to idle. Turn A/C on. Compare oscilloscope
wave pattern with known-good wave pattern. See Fig. 44. Turn engine
off. If wave pattern is not normal, go to next step. If wave pattern
is normal, fault is intermittent. See INTERMITTENT DTCS.

WIRING DIAGRAM COMPONENT LOCATIONS
When trying to locate a component in a wiring diagram and you
don't know the specific system where it is located, use this handy
component locator to find the system wiring diagram in which the
component is located. Then, go to that system and locate the component
within the wiring diagram.
For example, if you don't know the specific system in which
the ignition switch is located, look up ignition switch in the wiring
diagram component location tables and go to the appropriate wiring
diagram(s) which contain either full or partial views of the ignition
switch. The full view of the ignition switch is located in Power
Distribution.
The first listing for the component will be the full or most
complete view of the component. Additional listings will be partial
views of the component. Not all components are used on all models.
All components will have a partial view in Ground
Distribution and Power Distribution. Data Link Connectors show
connecting circuits between modules. Alternate names for components
may be listed in wiring diagram component locations tables.
WIRING DIAGRAM COMPONENT LOCATIONS TABLE









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Component Wiring Diagram
ABS Electronic Control Unit ....................... Anti-Lock Brakes
Data Link Connectors
ABS Hydraulic Unit ................................ Anti-Lock Brakes
Acceleration Sensor ............................... Anti-Lock Brakes
Accessory Delay Relay ................................ Power Windows
A/C Compressor Clutch Relay ..................... Engine Performance
A/C Sensor ...................................... Engine Performance
A/C Pressure Switch ............................. Engine Performance
Adaptive Lamp Control Module ....................... Exterior Lights
Air Bag(s) ................................ Air Bag Restraint System\
Air Bag Module ............................ Air Bag Restraint System
Air Bag Sensor(s) ......................... Air Bag Restraint System\
Air Injection Pump Relay ........................ Engine Performance
Air Temperature Sensor ............................ Overhead Console
Alternator (Generator) ..................... Generators & Regulators\
Anti-Theft Control Module ........................ Anti-Theft System
Starters
Autolamp Control Relay ........................... Headlight Systems
Daytime Running Lights
Automatic Shutdown (ASD) Relay .................. Engine Performance\
Generators & Regulators
Autostick Switch ................................ Engine Performance
Auxiliary Battery Relay .................... Generators & Regulators
Back-Up Lights ...................................... Back-Up Lights
Exterior Lights
Barometric (BARO) Pressure Sensor ............... Engine Performance\
Battery ......................................... Power Distribution
Battery Temperature Sensor ...................... Engine Performance
Body Control Module .......................... Body Control Computer
Anti-Theft System
Daytime Running Lights
Engine Performance
Headlight Systems
Warning Systems
Boost Control Solenoid .......................... Engine Performance
Boost Sensor .................................... Engine Performance
Brake Fluid Level Switch .................. Analog Instrument Panels

Brake On/Off (BOO) Switch ................... Cruise Control Systems\
Engine Performance
Shift Interlock Systems
Buzzer Module ...................................... Warning Systems
Camshaft Position (CMP) Sensor .................. Engine Performance\
Central Control Module ........................... Anti-Theft System
Clockspring ............................... Air Bag Restraint System
Cruise Control Systems
Steering Column Switches
Clutch Pedal Position Switch .............................. Starters
Clutch Start Switch ....................................... Starters
Combination Meter ......................... Analog Instrument Panels
Constant Control Relay Module (CCRM) ............ Engine Performance\
Electric Cooling Fans
Convenience Center .............................. Power Distribution
Illumination/Interior Lights
Convertible Top Motor ........................ Power Convertible Top
Convertible Top Switch ....................... Power Convertible Top
Crankshaft Position (CKP) Sensor ................ Engine Performance\
Cruise Control Module ....................... Cruise Control Systems
Cruise Control Switch ....................... Cruise Control Systems
Condenser Fan Relay(s) ....................... Electric Cooling Fans\
Data Link Connector (DLC) ....................... Engine Performance\
Daytime Running Lights Module ............... Daytime Running Lights
Exterior Lights
Defogger Relay ................................ Rear Window Defogger
Diagnostic Energy Reserve Module (DERM) ... Air Bag Restraint System\
Discriminating Sensor (Air Bag) ........... Air Bag Restraint System\
Distributor ..................................... Engine Performance
Door Lock Actuators ............................... Power Door Locks
Remote Keyless Entry
Door Lock Relay(s) ................................ Power Door Locks\
Electrochromic Mirror ................................ Power Mirrors
Electronic Level Control (ELC)
Height Sensor .............................. Electronic Suspension
Electronic Level Control (ELC) Module ........ Electronic Suspension\
Engine Coolant Temperature (ECT)
Sending Unit ............................ Analog Instrument Panels
Engine Coolant Temperature (ECT) Sensor ......... Engine Performance\
Engine Control Module ........................... Engine Performance
Generators & Regulators
Starters
ETACS ECU .......................................... Warning Systems
Power Windows
Remote Keyless Entry
Evaporative (EVAP) Emissions Canister ........... Engine Performance\
EVAP Canister Purge Solenoid .................... Engine Performance
EVAP Canister Vent Solenoid ..................... Engine Performance
Exhaust Gas Recirculation (EGR) Valve ........... Engine Performance\
Fuel Tank Vacuum Sensor ......................... Engine Performance
Fog Lights ....................................... Headlight Systems
Daytime Running Lights
Fog Light Relay .................................. Headlight Systems
Daytime Running Lights
Fuel Door Release Solenoid ................. Power Fuel Door Release
Fuel Gauge Sending Unit ................... Analog Instrument Panels
Fuel Injectors .................................. Engine Performance
Fuel Pump ....................................... Engine Performance
Fuel Pump Relay ................................. Engine Performance
Power Distribution
Fuse/Relay Block ................................ Power Distribution
Fusible Links ................................... Power Distribution
Generators & Regulators

Parking Brake Switch ...................... Analog Instrument Panels
Park Lights ........................................ Exterior Lights
Park/Neutral Position Switch .............................. Starters
Engine Performance
Anti-Theft System
Body Control Module
Perimeter Lighting Control Relay ................... Exterior Lights
Power Amplifier ..................................... Power Antennas
Power Antenna Module ................................ Power Antennas
Power Antenna Motor ................................. Power Antennas
Power Distribution Center ....................... Power Distribution
Generators & Regulators
Starters
Power Door Lock Motors ............................ Power Door Locks
Power Mirror Motors .................................. Power Mirrors
Memory Systems
Power Sliding Door Controller .............. Power Sliding Side Door
Power Seat Motors ...................................... Power Seats
Memory Systems
Power Steering Pressure Switch .................. Engine Performance
Power Top Motor .............................. Power Convertible Top
Power Top Relay(s) ........................... Power Convertible Top\
Powertrain Control Module ....................... Engine Performance
Analog Instrument Panels
Cruise Control Systems
Data Link Connectors
Generators & Regulators
Starters
Power Window Motors .................................. Power Windows
Power Window Relay(s) ................................ Power Windows\
Radiator Fan Motor(s) ........................ Electric Cooling Fans\
Radiator Fan Relay(s) ........................... Engine Performance\
Electric Cooling Fans
Rainsense Module .............................. Wiper/Washer Systems
Raise Relay .................................. Power Convertible Top
Remote Anti-Theft Personality (RAP) Module ....... Anti-Theft System\
Starters
Warning Systems
Seat Belt Pretensioners ................... Air Bag Restraint System
Seat Belt Retractor Solenoid .................... Passive Restraints
Seat Belt Switch .......................... Air Bag Restraint System
Passive Restraints
Shift Interlock Solenoid ................... Shift Interlock Systems
Shift Lock Actuator ........................ Shift Interlock Systems
Side Marker Lights ................................. Exterior Lights
SIR Coil Assembly (Clockspring) ........... Air Bag Restraint System\
Slip Ring (Clockspring) ................... Air Bag Restraint System\
Steering Column Switches
SRS Control Module ........................ Air Bag Restraint System
Starter Motor ............................................. Starters
Starter Interrupt Relay ................................... Starters
Starter Solenoid .......................................... Starters
Starter Relay ............................................. Starters
Steering Wheel Position Sensor .................... Anti-Lock Brakes
Stoplights ......................................... Exterior Lights
Stoplight Switch ................................ Engine Performance
Cruise Control Systems
Anti-Lock Brakes
Sun Roof ECU ........................................ Power Sun Roof
Sun Roof Motor ...................................... Power Sun Roof
Sun Roof Position Sensor ............................ Power Sun Roof
Taillights ......................................... Exterior Lights
Throttle Position (TP) Sensor ................... Engine Performance\

Torque Converter Clutch Solenoid/Switch ......... Engine Performance
Traction Control Switch ........................... Anti-Lock Brakes
Trailer Tow Connector .............................. Exterior Lights
Trailer Tow Relay .................................. Exterior Lights
Transmission/Transaxle .......................... Engine Performance
Transmission Control Module (TCM) ............... Engine Performance\
Starters
Transmission Range Sensor ................................. Starters
Back-Up Lights
Engine Performance
Transmission Range Switch ........................... Back-Up Lights
Engine Performance
Anti-Theft System
Turn Signal Flasher ................................ Exterior Lights
Turn Signal Lights ................................. Exterior Lights
Twilight Sentinel Switch ......................... Headlight Systems
Daytime Running Lights
Vapor Canister Leak Detection Pump .............. Engine Performance
Vehicle Control Module (VCM) .................... Engine Performance\
Vehicle Dynamic Module ....................... Electronic Suspension
Vehicle Speed Control Servo ................. Cruise Control Systems
Vehicle Speed Sensor .......................... Data Link Connectors
Analog Instrument Panels
Cruise Control Systems
Electronic Suspension
Voltage Regulator .......................... Generators & Regulators
Water-In-Fuel Sensor ............................ Engine Performance
Analog Instrument Panels
Wheel Speed Sensors ............................... Anti-Lock Brakes
Window Timer Module .......................... Power Convertible Top
Windshield Intermittent Wiper Relay ........... Wiper/Washer Systems
Windshield Washer Motor ....................... Wiper/Washer Systems
Wiper Motor ................................... Wiper/Washer Systems









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1) Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELEASE.
Disconnect negative battery cable. Drain coolant. Remove air intake
hose. Remove throttle body and gasket with control cables and vacuum
hoses attached.
2) Remove EGR pipe (if equipped). Disconnect power brake
hose. Label and disconnect vacuum hoses and wiring harness connectors
as necessary. Remove intake plenum brackets and mounting bolts. Remove
intake plenum and gasket.
3) Disconnect high pressure fuel hose at fuel rail.
Disconnect fuel return hose. Disconnect vacuum hoses. Disconnect
injector electrical connectors. Remove fuel rail bolts, and lift fuel
rail and injectors from engine. Injectors may be removed after fuel
rail is removed from intake manifold.
Installation
To install, reverse removal procedure. Use NEW insulators and
"O" rings when installing injectors. Install injectors into fuel rail
with a twisting motion. Ensure injectors rotate smoothly when
installing. Refill cooling system.
Removal (Eclipse, Galant, Mirage & Montero Sport 3.0L)
1) Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELEASE.
Disconnect negative battery cable. Disconnect PCV hose and breather
hoses. Disconnect high pressure fuel hose at fuel rail. Disconnect
fuel return hose and vacuum hoses.
2) Disconnect injector electrical connectors. Remove fuel
rail bolts, and lift fuel rail and injectors from engine. Injectors
may be removed after fuel rail is removed from intake manifold.
Installation
To install, reverse removal procedure. Use NEW insulators and
"O" rings when installing injectors. Use lubricant on "O" rings.
Install injectors into fuel rail with a twisting motion. Ensure
injectors rotate smoothly when installing.
Removal (Montero)
1) Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELEASE.
Disconnect negative battery cable. Remove air intake hose. Remove
accelerator cable adjusting bolts. On A/T models, remove throttle
control cable. On all models, remove accelerator cable. Label and
disconnect all vacuum hoses from throttle body and upper intake
manifold (air intake plenum).
2) Remove EGR pipe and gasket. Remove ignition coil (if
necessary). Remove engine oil filler neck bracket. Disconnect PCV
hose. Remove throttle body, leaving coolant hoses connected. Remove
throttle body gasket. Remove front and rear intake plenum brackets.
Remove intake plenum mounting bolts. Remove intake plenum and gasket.
3) Disconnect high pressure fuel hose at fuel rail.
Disconnect fuel return hose. Disconnect vacuum hoses. Disconnect
injector electrical connectors. Remove fuel rail bolts, and lift fuel
rail and injectors from engine. Injectors may be removed after fuel
rail is removed from intake manifold.
Installation
To install, reverse removal procedure. Use NEW insulators and
"O" rings when installing injectors. Use lubricant on "O" rings.
Install injectors into fuel rail using a twisting motion. Ensure
injectors rotate smoothly when installing. Adjust throttle control and
accelerator cables (if necessary). Refill cooling system.
HEATED OXYGEN SENSOR (HO2S)
Removal & Installation

Removal
Raise and support vehicle. Remove wheel assembly. Remove hub
cap. Remove snap ring and shim. Remove drive flange. Remove brake
caliper and suspend with wire. On vehicles with ABS, remove ABS speed
sensor. On all models, remove lock washer. Remove lock nut using
Socket (MB990954). See Fig. 2. Remove front rotor and hub assembly.
Installation
To install, reverse removal procedure. Adjust wheel bearing
preload and check drive shaft endplay. See ADJUSTMENTS.
Fig. 2: Exploded View Of Hub Assembly (Montero Sport Shown, Montero
Similar)
Courtesy of Mitsubishi Motor Sales of America.
STEERING KNUCKLE
Removal
1) Raise and support vehicle. Remove wheel assembly. Remove
brake caliper. Remove axle hub assembly. See AXLE HUB ASSEMBLY under
REMOVAL & INSTALLATION . Remove brake dust cover from steering knuckle.
If equipped with ABS, remove ABS speed sensor.
2) On all models, disconnect tie rod end from steering
knuckle. Mark torsion bar adjusting nut for installation reference.
Loosen torsion bar anchor arm assembly adjusting nut. Loosen, but DO
NOT remove, ball joint-to-steering knuckle nuts.
3) Using Steering Linkage Puller (MB991406), separate ball
joints from steering knuckle. Detach upper and lower ball joints from
steering knuckle. Remove steering knuckle from axle shaft. Remove oil

FINAL ANCHOR ARM BOLT PROTRUSION








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Application/ Right Bolt Left Bolt
Model In. (mm) In. (mm\
)
Montero ................... 3.15 (80.0) .............. 3.15 (80.0\
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4) To complete installation, reverse removal procedure.
Tighten bolts to specification. See TORQUE SPECIFICATIONS. Check
riding height and front wheel alignment. See WHEEL ALIGNMENT
SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT section.
UPPER BALL JOINT
Removal
1) Raise and support vehicle. Remove wheel assembly. Mark
torsion bar adjusting nut for reassembly reference. Release torsion
bar tension. Loosen, but DO NOT remove, upper ball joint-to-steering
knuckle nut.
2) Using Steering Linkage Puller (MB991406), separate ball
joint from steering knuckle. Remove ball joint nut from steering
knuckle. Remove ball joint-to-upper control arm bolts. Remove ball
joint.
Installation
Lubricate ball joint. To complete installation, reverse
removal procedure. Tighten bolts to specification. See
TORQUE SPECIFICATIONS .
SHOCK ABSORBER & UPPER CONTROL ARM
Removal
1) Disconnect actuator on vehicles with Variable Shock
Absorbers. On all models, raise and support vehicle. Support lower
control arm using jackstand. Remove front wheels. Remove lower shock
absorber bolt. Remove nut from top of shock absorber and remove shock
assembly from vehicle.
2) Remove the bump stop from the bump stop bracket. Mark
anchor arm bolt for reassembly reference. Loosen anchor arm bolt to
release torsion bar tension. Disconnect and plug brake hose at frame
mount bracket.
3) Remove cotter pin from upper ball joint stud. Loosen, but
DO NOT remove, ball joint stud nut. Using Steering Linkage Puller
(MB991406), loosen ball joint from steering knuckle. Remove brake hose\
clip and rebound stopper. Remove rebound stopper and brake hose
support from control arm.
4) Remove ABS sensor bracket (if equipped) and rebound
stoppers. Remove upper control arm mounting bolts and shim(s). Note
direction of bolt installation and locations of camber adjustment
shims. Remove control arm. Remove upper ball joint from control arm.
Inspection
Inspect control arm for cracks and deformation. Check ball
joints. See BALL JOINT CHECKING under ADJUSTMENTS & INSPECTION.
Inspect ball joint dust cover for damage, and replace cover as
necessary.
Installation
1) To install, reverse removal procedure. Install control arm
bolts from outside of frame, with nuts against control arm. Install
the upper control with the marking "OUT" on shaft facing outside of
vehicle.

REAR SUSPENSION ASSEMBLY
NOTE: Procedures for Montero are for lateral rod, coil springs and
lower arms only. Procedures for Montero Sport are for leaf
springs only.
Removal (Montero)
1) Raise and support rear of vehicle. Place a jack under
center of rear axle housing. Remove parking brake cable attaching
bolts.
2) Remove rear speed sensor attaching bolt (if equipped).
Remove rear axle housing lock position harness attaching bolt and
lower shock bolts.
3) Remove lateral rod bolts and remove lateral rod. Remove
lower arm rear bolts. Remove lower arm front mounting nut and remove
lower arm. See Fig. 2.
Inspection
Check lateral rod for straightness and damage. Check rubber
bushings for deterioration, cracks and wear.
Installation
If lateral rod bushings need replacing, remove and install
using Lower Arm Bushing Arbor (MB990650). Apply a sufficient amount of\
liquid soap to bushings when installing them into lateral rod. If
lower arm rear bushings need replacing, remove and install rear
bushings using Rear Bushing Arbor (MB991293). To complete
installation, reverse removal procedure. Tighten all suspension
fasteners to specification with vehicle on ground and suspension
unloaded. See TORQUE SPECIFICATIONS .
Removal (Montero Sport)
1) Raise and support rear of vehicle. Place a jack under
center of rear axle housing.
2) Disconnect parking brake cable attaching bolts. Remove
rear speed sensor attaching bolt. Remove rear shock nuts and washers.
Remove rear shocks.
NOTE: The yellow shock mounts on left side and the pink one mounts
to the right side of vehicle.
3) Remove U-bolt nuts, U-bolt seat and U-bolts. Remove bump
stopper. Remove rear shackle plate nuts, shackle plate, bushings and
shackle assembly. Remove front shackle nuts and bolts. Remove leaf
spring. See Fig. 1.
Inspection
Check leaf springs for cracks and other damage. Inspect all
components and bushings for damage and wear. Replace components as
necessary.
Installation
To install, reverse removal procedure. Ensure shocks are
installed on proper side of vehicle. Tighten all suspension fasteners
to specification with vehicle on ground and suspension unloaded. See
TORQUE SPECIFICATIONS .
SHOCKS
Removal
1) Raise and support rear of vehicle. Place a jack under
center of rear axle housing. On Montero remove shock actuator (if
equipped).