light MITSUBISHI MONTERO 1998 Workshop Manual
Page 170 of 1501
35 Output Speed Ignition Off 0 Volts
Sensor Gnd
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35 Output Speed Ignition On 2.5 Volts
Sensor Gnd
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36 Input Speed Sensor Gnd Ignition Off 0 Volts
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36 Input Speed Sensor Gnd Ignition On 2.5 Volts
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37 Overdrive OFF Signal (
1) Steady Driving @ Battery
31 MPH (50 km/h)
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37 Overdrive OFF Signal (
1) Climbing Hill @ 0 - 1
31 MPH (50 km/h)
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38 Engine Ign. Signal Engine @ 3000 RPM .3 - 3.0
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39 Neutral Safety Switch In "D" Position Battery
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39 Neutral Safety Switch Except In "D" 0 Volts
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40 Neutral Safety Switch In "2" Position Battery
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40 Neutral Safety Switch Except In "2" 0 Volts
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41 HOLD Mode HOLD Mode Selected Battery
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41 HOLD Mode HOLD Mode Not Selected 0 Volts
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42 Overdrive Switch Overdrive ON 0 Volts
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42 Overdrive Switch Overdrive OFF Battery
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43 Output Speed Sensor Vehicle Stopped About 2.5
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43 Output Speed Sensor Vehicle Moving Other Than
2.5
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44 Input Speed Sensor Vehicle Stopped About 2.5
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44 Input Speed Sensor Vehicle Moving Other Than
2.5
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45 Coolant Temp Sensor Temp @ 86F (30C) 2.5
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45 Coolant Temp Sensor Temp @ 158F (70C) 0 Volts
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46 MIL Signal Ignition ON .5
4.5 Volts
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(
1) - Test circuit with shift lever in "D" position, mode selector
normal and cruise control on.
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REMOVAL & INSTALLATION
BRAKELIGHT SWITCH
Removal & Installation
1) Disconnect electrical connector. Remove lock nut, and
unscrew brakelight switch. To install, screw brakelight switch inward
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until brakelight plunger contacts brake pedal.
2) Loosen brakelight switch 1/2 to one turn. Install and
tighten lock nut on brakelight switch. Install electrical connector.
Ensure brakelights and cruise control operate properly.
INPUT SPEED SENSOR
Removal & Installation
Disconnect electrical connector. Remove bolt securing sensor
to transmission. Remove input speed sensor from transmission. See
Fig. 14 . To install, reverse removal procedure.
Fig. 14: Locating Input Speed Sensor
Courtesy of Mitsubishi Motor Sales of America.
OIL TEMPERATURE SENSOR
Removal & Installation
Sensor is located on transmission connected to cooler line,
near PNP switch. Disconnect electrical connector. Remove oil
temperature sensor from transmission. To install, reverse removal
procedure using NEW gasket.
OUTPUT SPEED SENSOR
Removal & Installation
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FR ............................................ Fill Pipe Restrictor
HO2S .......................................... Heated Oxygen Sensor
MIL .................................... Malfunction Indicator Light
PCV ................................. Positive Crankcase Ventilation
SFI ............................ Sequential Multiport Fuel Injection
SPK ................................................. Spark Controls
SPK-CC ..................................... SPK Computer Controlled
TWC .................................. Three-Way Catalytic Converter
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* BRAKE SYSTEM UNIFORM INSPECTION GUIDELINES *
1998 Mitsubishi Montero
GENERAL INFORMATION
Brake Systems - Motorist Assurance Program
Standards For Automotive Repair
All Makes & Models
CONTENTS
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS
ACCELEROMETERS (G SENSOR OR LATERAL)
ACCUMULATORS
ANCHOR PINS
ANTI-LOCK BRAKE SYSTEMS
BACKING PLATES
BRAKE FLUID
BRAKE FRICTION MATERIAL
BRAKE PADS
BRAKE PEDALS
BRAKE SHOES
BRAKE SHOE HARDWARE
BRAKE STOPLIGHT SWITCHES
BULB SOCKETS
BULBS AND LEDS
CALIPER HARDWARE
CALIPERS
CONTROLLERS
DIGITAL RATIO AXLE CONTROLLERS AND BUFFERS (DRAC AND DRAB)
DISABLE SWITCHES
DRUMS
ELECTRICAL PUMPS AND MOTORS
ELECTRONIC CONTROLLERS
FLUID
FLUID LEVEL SENSOR SWITCHES
FOUR WHEEL DRIVE SWITCHES
FRICTION MATERIAL
G SENSORS
HOSES
HYDRAULIC MODULATORS
HYDRO-BOOSTERS
HYDRO-ELECTRIC BOOSTERS (POWERMASTER)
IGNITION DISABLE SWITCHES
LATERAL ACCELERATION SWITCHES
LEDS
LENSES
MASTER CYLINDERS
MODULATORS
MOTORS
PARKING BRAKE SWITCHES
PARKING BRAKE SYSTEMS
PADS
PEDAL TRAVEL SWITCHES
PEDALS
POWERMASTER
PUMPS
PRESSURE DIFFERENTIAL SWITCHES
PRESSURE SWITCHES
RELAYS
ROTORS
SELF-ADJUSTING SYSTEMS
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SHOE HARDWARE
SHOES
SOCKETS
SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)
STEEL BRAKE LINES
STOPLIGHT SWITCHES
SWITCHES
TIRES
TOOTHED RINGS (TONE WHEEL)
VACUUM BOOSTERS
VACUUM HOSES
VALVES
WHEEL ATTACHING HARDWARE
WHEEL BEARINGS, RACES AND SEALS
WHEEL CYLINDERS
WIRING HARNESSES
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
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
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NOTE: Electro-magnetic interference (EMI) may be caused by
incorrect installation of accessories or components. EMI can
result in improper system operation.
BACKING PLATES
BACKING PLATE INSPECTION \
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Condition Code Procedure
Anchor pin bent ......... B .. Require repair or replacement.
Anchor pin broken ....... A ............ Require replacement.
Anchor pin worn, affecting
structural integrity ... B ............ Require replacement.
Backing plate bent ...... B .. Require repair or replacement.
Backing plate broken .... A ............ Require replacement.
Backing plate cracked ... B .. Require repair or replacement.
Corroded, affecting
structural integrity .... A ............ Require replacement.
Loose ................... B .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Shoe lands worn ......... A .. Require repair or replacement.
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BRAKE FLUID
CAUTION: Most manufacturers prohibit the use of DOT 5 brake fluid
in a system equipped with ABS.
DOT 3, DOT 4, and DOT 5.1 brake fluids are clear or light
amber in color. DOT 5 brake fluid is violet in color. Correct fluid
required for the brake system is stamped on the master cylinder cover.
BRAKE FLUID INSPECTION
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Condition Code Procedure
Beyond service interval . 3 .. Suggest flushing and refilling
with correct fluid.
Brake fluid type
incorrect .............. B .. Require flushing and refilling
with correct fluid.
Contaminated, for example,
fluid other than brake
fluid present .......... A or B ....... ( 1) Require service.
Hydraulic component ..... 3 .. Suggest flushing and refilling
overhaul or replacement with correct fluid.
Rubber master cylinder
cover gasket distorted
and gummy .............. A .......... ( 2) Require replacement
of gasket.
( 1) - If a fluid other than brake fluid is present in the brake
system which DOES affect the rubber parts, the required
service is to:
* Remove all components having rubber parts from the
system.
* Flush lines with denatured alcohol or brake cleaner
* Repair or replace all components having rubber parts
* Flush and fill with correct brake fluid. (Code A)
If a fluid other than brake fluid is present in the brake
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system which DOES NOT affect the rubber parts, the required
service is to flush and fill with the correct brake fluid.
(Code B)
( 2) - This condition may indicate contaminated brake fluid.
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BRAKE FRICTION MATERIAL
See FRICTION MATERIAL .
BRAKE PADS
See FRICTION MATERIAL .
BRAKE PEDALS
BRAKE PEDAL INSPECTION \
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Condition Code Procedure
Bent, affecting
performance ............ A .. Require repair or replacement.
Broken .................. A .. Require repair or replacement.
Pedal pad missing ....... C .... Require replacement of pedal
pad.
Pedal pad worn .......... 1 ............ Suggest replacement.
Pivot bushings worn,
affecting performance .. A .... Require replacement of pivot
bushings.
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BRAKE SHOES
See FRICTION MATERIAL .
BRAKE SHOE HARDWARE
See also SELF-ADJUSTING SYSTEMS .
BRAKE SHOE HARDWARE INSPECTION
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Condition Code Procedure
Broken .................. A ............ Require replacement.
Distorted ............... A ............ Require replacement.
Missing ................. C ............ Require replacement.
Surfaces rust-pitted .... 1 ............ Suggest replacement.
Worn, affecting
performance ............ A ............ Require replacement.
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BRAKE STOPLIGHT SWITCHES
BRAKE STOPLIGHT INSPECTION \
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Condition Code Procedure
Bent .................... B ............ Require replacement.
Broken .................. A ............ Require replacement.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
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Wear indicator device
(mechanical) contacts
rotor .................. .. ......... (6) Further inspection
required.
Worn close to minimum
specifications ......... 1 ........ ( 7) Suggest replacement.
Worn to, or below minimum
specifications ......... B ............ Require replacement.
( 1) - Identify and repair cause of contamination prior to
replacing friction material.
( 2) - When reconditioning or replacing drums or rotors,
replacement of friction material may be suggested
depending on the severity of the grooves or ridges.
( 3) - Some vehicles use pads that are tapered by design. Refer
to specific vehicle application. If not normal, require
replacement of pads and correction of cause.
( 4) - Uneven pad thickness is normal on some vehicles. Refer to
specific vehicle applications.
( 5) - The pad wear indicator light may come on due to other
electrical problems.
( 6) - Explain to the customer that the purpose of the wear
indicator is to alert him or her to check for friction
wear. Wear indicators may be bent or broken. Therefore,
the friction material must be measured. The need for
friction material replacement is determined based upon
the conditions stated in this section. Periodic inspection
is suggested.
( 7) - When the part appears to be close to the end of its useful
life, replacement may be suggested.
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G SENSORS
See ACCELEROMETERS .
HOSES
HOSE INSPECTION \
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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.
Blistered ............... B ............ Require replacement.
Fitting threads damaged . A .. Require repair or replacement.
Fitting threads stripped
(threads missing) ...... A ............ Require replacement.
Incorrectly secured ..... B ................. Require repair.
Inner fabric
(webbing) cut .......... B ............ Require replacement.
Leaking ................. A ............ Require replacement.
Missing ................. C ............ Require replacement.
Outer covering is cracked
to the extent that
inner fabric of hose
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specifications.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
(1) - If a sensor is not adjustable, further inspection is
required to identify and correct cause.
( 2) - Determine cause and correct prior to repair or
replacement of part.
( 3) - Determine source of contamination, such as metal
particles or water. Require repair or replacement.
( 4) - Inoperative includes intermittent operation or out of OEM
specification. Some components may be serviceable; check
for accepted cleaning procedure.
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STEEL BRAKE LINE INSPECTION \
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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.
Corroded, affecting
structural integrity ... A ............ Require replacement.
Fitting incorrect (for
example, compression
fitting) ............... B ............ Require replacement.
Flare type incorrect .... B .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Line material incorrect
(copper, etc.) ......... B ............ Require replacement.
Restricted .............. A ............ Require replacement.
Routed incorrectly ...... B ..... Require routing correction.
Rust-pitted ............. 1 ............ Suggest replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped
(threads missing) ...... A ............ Require replacement.
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STOPLIGHT SWITCHES
See BRAKE STOPLIGHT SWITCHES .
SWITCHES
NOTE: Copied from Electrical UIGs & added "float saturated" from
old fluid level sensor switches.
STEEL BRAKE LINE INSPECTION
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Condition Code Procedure
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
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BRAKE SYSTEM
1998 Mitsubishi Montero
1997-98 BRAKES
Mitsubishi - Disc & Drum
Diamante, Eclipse, Galant, Mirage, Montero, Montero Sport,
3000GT
INTRODUCTION
This article contains information on repair and service of
basic hydraulic brake system. If vehicle is equipped with anti-lock
brakes, also see appropriate ANTI-LOCK article.
DESCRIPTION
Brake system consists of a master cylinder, vacuum power
brake booster, proportioning valve and self-adjusting assembly.
Montero has a Load-Sensing Proportioning Valve (LSPV). All models are
equipped with front disc brakes and either rear disc or drum brakes.
Parking brake assembly activates rear brakes.
BLEEDING BRAKE SYSTEM
BLEEDING PROCEDURES
Bleed brakes whenever hydraulic lines are opened or pedal
feels spongy. Bleed system in appropriate sequence. See
BRAKE LINE BLEEDING SEQUENCE table. Use only DOT 3 or DOT 4 approved
fluid and DO NOT mix fluid types.
BRAKE LINE BLEEDING SEQUENCE
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Application Sequence
Diamante, Eclipse, Galant,
Mirage & 3000GT .................................... RR, LF, LR, RF
Montero ....................................... RR, LR, LSPV, RF, LF
Montero Sport ....................................... RR, LR, RF, LF
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ADJUSTMENTS
BRAKE PEDAL HEIGHT, FREE PLAY & CLEARANCE
1) To measure brake pedal height, pull up carpet under brake
pedal. Measure distance between floor board and middle of brake pedal
pad surface with brake pedal released. See BRAKE PEDAL HEIGHT
SPECIFICATIONS table.
2) To adjust pedal height, separate connector from stoplight
switch, and loosen switch lock nut. Back-off switch so it does not
contact brake pedal arm. Loosen master cylinder push rod lock nut.
Adjust brake pedal height by rotating master cylinder push rod until
brake pedal height is within specification.
BRAKE PEDAL HEIGHT SPECIFICATIONS
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Application Pedal Height: In. (mm)\