timing MITSUBISHI MONTERO 1998 Workshop Manual

(the whole presented as an assembly). A rebuilt or new
oil pump, or kit shall be supplied or fitted as
appropriate.
LONG BLOCK ASSEMBLY INSPECTION









\









\









\









\









\









\









\


Condition Code Procedure
Internal component failure
(any component) ........ A ........... (1) Require repair or
replacement of the long
block assembly.
( 1) - It is Required that all other failure related components
be inspected for cause and condition. Additional components
or assemblies may be Suggested for repair or replacement
such as a water pump on a short block (reason code 4,
technician's recommendation based on substantial and
informed experience).
Example:
If there is a failed head gasket with an external coolant
leak, in addition to Requiring replacement of the head
gasket, inspection of the following for cause and
condition is Required: Block, Cooling System, Cylinder
Head. It may be Suggested that additional inspections be
performed, such as the other head gasket on a V-type
engine.









\









\









\









\









\









\









\


SHORT BLOCK ASSEMBLIES
NOTE: A Short Block Assembly is a cylinder block and all those
components contained within the limits of the block deck
or decks, the pan rail, the block rear face and the
timing cover (where fitted), including the crankshaft.
SHORT BLOCK ASSEMBLY INSPECTION









\









\









\









\









\









\









\


Condition Code Procedure
Any internal component
failure ................ A ........... ( 1) Require repair or
replacement of the short
block assembly.
( 1) - It is Required that all other failure related components
be inspected for cause and condition. Additional
components or assemblies may be Suggested for repair or
replacement, such as a water pump on a short block
(reason code 4, technician's recommendation based on
substantial and informed experience).
Example:
If there is a failed head gasket with an external coolant
leak, in addition to Requiring replacement of the head
gasket, inspection of the following for cause and condition
is Required: Block, Cooling System, Cylinder Head. It may
be Suggested that additional inspections be performed,
such as the other head gasket on a V-type engine.









\









\









\









\









\









\









\

(1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Determine source of contamination, such as engine
coolant, fuel, metal particles, or water. Require
repair or replacement.
( 3) - Inoperative includes intermittent operation or out of
OEM specification. Some components may be serviceable;
check for accepted cleaning procedure.









\









\









\









\









\









\









\


ENGINE COOLING SYSTEMS
NOTE: Overheating, poor engine performance, and insufficient
cabin heat can be affected by, but are not limited to,
all of the components in the engine cooling system.
ENGINE COVERS (OIL PAN, VALVE COVER, TIMING COVER)
ENGINE COVER (OIL PAN, VALVE COVER, TIMING COVER) INSPECTION








\









\









\









\









\









\









\


Condition Code Procedure
Attaching hardware
incorrect .............. B ............ Require replacement.
Attaching hardware
loose .................. A .. Require repair or replacement.
Attaching hardware
missing ................ C ............ Require replacement.
Baffle loose ............ 2 .. Suggest repair or replacement.
Baffle missing .......... C ............ Require replacement.
Bent, affecting
performance ............ A .. Require repair or replacement.
Bent, not affecting
performance ............ .. ....... No service suggested or
required.
Cracked (not leaking) ... 2 .. Suggest repair or replacement.
Leaking externally ...... A .. Require repair or replacement.
Leaking internally,
causing fluid
contamination .......... A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Restricted passage ...... A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.









\









\









\









\









\









\









\


ENGINE OIL
ENGINE OIL INSPECTION








\









\









\









\









\









\









\


Condition Code Procedure
Contaminated ............ A .. ( 1) Require replacement of oil
and filter.
Level high .............. B ... Determine source of incorrect
level and require repair.
Level low ............... B ... Determine source of incorrect
level and require repair.
Maintenance intervals ... 3 ... Suggest replacement to comply
with vehicle's OEM recommended
service intervals.
( 1) - Determine source of contamination, such as engine coolant,
fuel, metal particles, or water when changing oil. Require

Threads stripped (threads
missing) ............... A ............ Require replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
(1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Inoperative includes intermittent operation or out of
OEM specification. Some components may be serviceable;
check for accepted cleaning procedure.









\









\









\









\









\









\









\


TIMING BELT SPROCKETS
TIMING BELT SPROCKET INSPECTION








\









\









\









\









\









\









\


Condition Code Procedure
Alignment incorrect ..... B ................. Require repair.
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.
Bent .................... A ............ Require replacement.
Cracked ................. A ............ Require replacement.
Key damaged ............. A ............ Require replacement.
Loose ................... A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Pulley damaged, affecting
belt life .............. A ............ Require replacement.
Sprocket damaged,
affecting belt life .... A .. Require repair or replacement.
Sprocket loose .......... B .. Require repair or replacement.
Sprocket-to-shaft
alignment incorrect ..... B .. Require repair or replacement.









\









\









\









\









\









\









\


TIMING BELTS
TIMING BELT INSPECTION








\









\









\









\









\









\









\


Condition Code Procedure
Adjustment incorrect .... 2 ......... ( 1) Suggest adjustment.
Alignment incorrect ..... B ........... ( 2) Further inspection
required.
Broken .................. A ............ Require replacement.
Cam timing out of
specification .......... B ................. Require repair.
Cracked ................. 1 ............ Suggest replacement.
Fluid-soaked ............ 1 ... Suggest replacement. Further
inspection required.
Frayed .................. 1 ............ Suggest replacement.
Maintenance intervals ... 3 ... Suggest replacement to comply
with vehicle OEM recommended

service intervals.
Missing ................. C ........ (3) Require replacement.
Noisy ................... 2 .......... ( 4) Further inspection
required.
See note below.
Plies separated ......... A ............ Require replacement.
Tension out of
specification .......... B ........... Require adjustment or
replacement.
Teeth missing ........... A ............ Require replacement.
( 1) - Inspect belt tensioners, pulleys, and cover.
( 2) - Determine cause of incorrect alignment and require repair.
( 3) - CAUTION: Internal engine damage may result from timing
belt damage/failure.
( 4) - Determine cause of noise and suggest repair.









\









\









\









\









\









\









\


TORQUE STRUTS
TORQUE STRUT 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.
Binding ................. A ............ Require replacement.
Body dented ............. A .......... ( 1) Further inspection
required.
Body punctured .......... A ............ Require replacement.
Bushing deteriorated,
affecting performance .. A ............ Require replacement.
Bushing deteriorated, not
affecting performance .. .. ........ No service suggested or
required.
Bushings missing ........ C ............ Require replacement.
Bushings separated from
mounting eye ........... 1 ............ Suggest replacement.
Damping (none) .......... A ............ Require replacement.
Leaking oil, enough for
fluid to be running down
the body ............... A ............ Require replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .......... ( 2) Further inspection
required.
Piston rod bent ......... A ............ Require replacement.
Piston rod broken ....... A ............ Require replacement.
Seized .................. A ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
( 1) - Require replacement of units where dents restrict strut
piston rod movement. If dents don't restrict movement, no
service is suggested or required.
( 2) - If noise is isolated to shock or strut, suggest replacement.

IDLE SPEED & IGNITION TIMING
Ensure idle speed and ignition timing are set to
specification. See IGNITION TIMING SPECIFICATIONS table. For
adjustment procedures, see D - ADJUSTMENTS article.
IGNITION TIMING SPECIFICATIONS (Degrees BTDC @ RPM) TABLE









\









\









\









\









\









\






Application ( 1) Base ( 2) ( 3) ( 4) Actual
1.5L ........... 2-78@ 650-750 ............ 10 @ 600-800
1.8L ........... 2-8 @ 600-800 ............. 5 @ 600-800
2.0L
Non-Turbo ......... ( 5) .......................... ( 5)
Turbo ........ 2-8 @ 650-850 ............. 8 @ 650-850
2.4L ........... 2-8 @ 650-850 ............ 10 @ 650-850
3.0L ........... 2-8 @ 600-800 ............ 15 @ 600-800
3.5L ........... 2-8 @ 600-800 ............ 15 @ 600-800
( 1) - With ignition timing adjustment connector grounded or
vacuum hose (farthest from distributor) disconnected.
( 2) - With ignition timing adjustment connector ungrounded
or vacuum hose (farthest from distributor) connected.
( 3) - If vehicle altitude is more than 2300 feet above sea
level, actual timing may be advanced (5 degrees).
( 4) - Actual ignition timing is approximate and may
fluctuate plus or minus 7 degrees.
( 5) - Ignition timing is NOT adjustable.









\









\









\









\









\









\






SUMMARY
If no faults were found while performing BASIC DIAGNOSTIC
PROCEDURES, proceed to G - TESTS W/CODES article. If no hard codes are
found in self-diagnostics, proceed to H - TESTS W/O CODES article for
diagnosis by symptom (i.e., ROUGH IDLE, NO START, etc.) or
intermittent diagnostic procedures.

DTC P0155
Heated Oxygen Sensor (HO2S) heater circuit failure (bank 2,
sensor 1). Possible causes are: connector or harness, or HO2S.
DTC P0156
Heated Oxygen Sensor (HO2S) circuit failure (bank 2, sensor
2). Possible causes are: connector or harness, or HO2S.
DTC P0161
Heated Oxygen Sensor (HO2S) heater circuit failure (bank 2,
sensor 2). Possible causes are: connector or harness, or HO2S.
DTC P0170
Fuel trim failure (bank 1). Possible causes are: intake air
leaks, cracked exhaust manifold, faulty VAF sensor frequency, HO2S,
injector, fuel pressure, ECT, IAT or BARO pressure sensor.
DTC P0173
Fuel trim failure (bank 2). Possible causes are: intake air
leaks, cracked exhaust manifold, faulty VAF sensor frequency, HO2S,
injector, fuel pressure, ECT, IAT or BARO pressure sensor.
DTC P0201
Cylinder No. 1 injector circuit failure. Possible causes are:
connector or harness, or faulty injector.
DTC P0202
Cylinder No. 2 injector circuit failure. Possible causes are:
connector or harness, or faulty injector.
DTC P0203
Cylinder No. 3 injector circuit failure. Possible causes are:
connector or harness, or faulty injector.
DTC P0204
Cylinder No. 4 injector circuit failure. Possible causes are:
connector or harness, or faulty injector.
DTC P0205
Cylinder No. 5 injector circuit failure. Possible causes are:
connector or harness, or faulty injector.
DTC P0206
Cylinder No. 6 injector circuit failure. Possible causes are:
connector or harness, or faulty injector.
DTC P0300
Random misfire detected. Possible causes are: connector or
harness, faulty ignition coil, ignition power transistor, spark plug,
ignition circuit, injector, HO2S, compression pressure, timing belt,
air intake system, fuel pressure, or CKP sensor.
DTC P0301
Cylinder No. 1 misfire detected. Possible causes are:
connector or harness, faulty ignition coil, ignition power transistor,
spark plug, ignition circuit, injector, HO2S, compression pressure,
timing belt, air intake system, fuel pressure, or CKP sensor.
DTC P0302
Cylinder No. 2 misfire detected. Possible causes are:
connector or harness, faulty ignition coil, ignition power transistor,
spark plug, ignition circuit, injector, HO2S, compression pressure,
timing belt, air intake system, fuel pressure, or CKP sensor.

DTC P0303
Cylinder No. 3 misfire detected. Possible causes are:
connector or harness, faulty ignition coil, ignition power transistor,
spark plug, ignition circuit, injector, HO2S, compression pressure,
timing belt, air intake system, fuel pressure, or CKP sensor.
DTC P0304
Cylinder No. 4 misfire detected. Possible causes are:
connector or harness, faulty ignition coil, ignition power transistor,
spark plug, ignition circuit, injector, HO2S, compression pressure,
timing belt, air intake system, fuel pressure, or CKP sensor.
DTC P0305
Cylinder No. 5 misfire detected. Possible causes are:
connector or harness, faulty ignition coil, ignition power transistor,
spark plug, ignition circuit, injector, HO2S, compression pressure,
timing belt, air intake system, fuel pressure, or CKP sensor.
DTC P0306
Cylinder No. 6 misfire detected. Possible causes are:
connector or harness, faulty ignition coil, ignition power transistor,
spark plug, ignition circuit, injector, HO2S, compression pressure,
timing belt, air intake system, fuel pressure, or CKP sensor.
DTC P0325
Knock Sensor (KS) circuit failure. Possible causes are:
connector or harness, or faulty KS.
DTC P0335
Crankshaft Position (CKP) sensor circuit failure. Possible
causes are: connector or harness, or faulty CKP sensor.
DTC P0340
Camshaft Position (CMP) sensor circuit failure. Possible
causes are: connector or harness, or faulty CMP sensor.
DTC P0400
Exhaust Gas Recirculation (EGR) flow failure. Possible causes\
are: connector or harness, faulty EGR valve, EGR solenoid, EGR valve
control vacuum, or manifold differential pressure sensor.
DTC P0403
Exhaust Gas Recirculation (EGR) solenoid failure. Possible
causes are: connector or harness, or faulty EGR solenoid.
DTC P0420
Catalyst efficiency below threshold. Possible causes are:
cracked exhaust manifold, or faulty catalytic converter.
DTC P0421
Warm-up catalyst efficiency below threshold (bank 1).
Possible causes are: faulty exhaust manifold. If exhaust manifold is
okay, replace catalytic converter.
DTC P0431
Warm-up catalyst efficiency below threshold (bank 2).
Possible causes are: faulty exhaust manifold. If exhaust manifold is
okay, replace catalytic converter.
DTC P0442
Evaporative (EVAP) emission control system leak detected.
Possible causes are: connector or harness, faulty EVAP purge solenoid,

L - WIRING DIAGRAMS article.
1) Specific self-diagnostic test is not available from
manufacturer at time of publication. Check ignition coil, power
transistor, spark plugs, fuel injectors, heated oxygen sensor,
crankshaft position sensor, and related connectors and harnesses.
2) Also check compression pressure, timing belt, fuel
pressure, and for intake air leaks. See F - BASIC TESTING article.
DTC P0325: KNOCK SENSOR (KS) NO. 1 CIRCUIT FAILURE
NOTE: This test applies to 3000GT equipped with DOHC engine only.
For terminal identification, see TERMINAL IDENTIFICATION. For
circuit and wire color identification, see
L - WIRING DIAGRAMS article.
1) Component or scan tool testing procedure not available
from manufacturer at time of publication. Turn ignition switch to OFF
position. Disconnect KS connector and PCM connector. Ground PCM
connector terminal No. 91. Go to next step.
2) Using DVOM, check for continuity between chassis ground
and KS connector terminal No. 1. If continuity does not exist, repair
wiring harness as necessary. If continuity exists, go to next step.
3) Remove jumper wire from PCM connector terminal No. 1.
Check for continuity between chassis ground and KS connector terminal
No. 2. If continuity does not exist, repair wiring harness as
necessary. If continuity exists, go to next step.
4) 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 P0335: CRANKSHAFT POSITION (CKP) SENSOR CIRCUIT FAILURE
NOTE: For terminal identification, see TERMINAL IDENTIFICATION. For
circuit and wire color identification, see
L - WIRING DIAGRAMS article.
NOTE: 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.
1) If using scan tool, go to step 3). Disconnect CKP sensor
connector. Install Test Harness (MB991348) between CKP sensor and
connector. Using engine analyzer with oscilloscope capability, connect
special patterns probe to CKP sensor connector terminal No. 2. Go to
next step.
2) Start engine. Compare oscilloscope wave pattern with
known-good wave pattern. See Fig. 38. Verify wavelength (time)
decreases as engine RPM increases. If wave pattern fluctuates to left
or right, check for loose timing belt or an abnormality in sensor
pick-up disc. If a rectangular wave pattern is generated even when
engine is not started, substitute known-good CKP sensor. Repeat test.
If wave pattern is still abnormal, go to step 6).
Fig. 38: Identifying Known-Good CKP Sensor Wave Pattern
Courtesy of Mitsubishi Motor Sales of America

3) Connect an engine tachometer. Crank engine. Ensure
ignition coil primary current toggles on and off. Using scan tool,
read engine cranking speed (item 22). Compare tachometer and scan tool\
RPM display. Go to next step.
4) If engine fails to start and tachometer reads zero RPM
when engine is cranked, check for broken timing belt or faulty CKP
sensor. If CKP sensor is suspected, substitute known-good CKP sensor.
Repeat test procedure. If engine fails to start, tachometer reads zero
RPM, and ignition coil primary current fails to toggle on and off,
check for faulty ignition coil, ignition circuit or power transistor.
If engine starts and readouts agree, go to next step.
5) Ensure A/C switch is in ON position to activate closed
throttle position switch. Allow engine to idle. Using scan tool, check
engine coolant temperature and read idle speed. See
IDLE RPM SPECIFICATIONS table. If RPM is not to specification, check
for faulty ECT sensor, basic idle speed adjustment, or idle air
control motor. If RPM is within specifications, go to next step.
IDLE RPM SPECIFICATIONS TABLE









\









\









\









\









\









\






Engine Coolant Temperature Engine RPM
-4
F (-20C)
Montero ...................................... 1300-1500
3000GT
Non-Turbo .................................. 1275-1475
Turbo ...................................... 1300-1500
32
F (0C)
Montero ...................................... 1300-1500
3000GT
Non-Turbo .................................. 1225-1425
Turbo ...................................... 1300-1500
68
F (20C)
Montero ...................................... 1300-1500
3000GT
Non-Turbo .................................. 1100-1300
Turbo ...................................... 1300-1500
104
F (40C)
Montero ...................................... 1040-1240
3000GT
Non-Turbo ................................... 950-1150
Turbo ...................................... 1050-1250
176
F (80C)
Montero & 3000GT ............................... 600-800









\









\









\









\









\









\






6) On 3000GT, go to next step. On Montero, disconnect CKP
sensor connector and MFI relay connector. Using DVOM, check for
continuity between CKP sensor connector terminal No. 3 and MFI relay
connector terminal No. 1. If continuity does not exist, repair wiring
harness as necessary. If continuity exists, go to next step.
7) With CKP sensor connector disconnected, check for
continuity between chassis ground and CKP sensor connector terminal
No. 1 on Montero or No. 2 on 3000GT. If continuity does not exist,
repair wiring harness as necessary. If continuity exists on 3000GT, go
to next step. On Montero, go to step 9).
8) Check for voltage between chassis ground and CKP sensor
connector terminal No. 3. If battery voltage does not exist, repair
wiring harness as necessary. If battery voltage exists, go to step
10).
9) Turn ignition switch to OFF position. With CKP sensor
connector disconnected, disconnect PCM connector. Check for continuity

between CKP sensor connector terminal No. 2 and PCM connector terminal
No. 43. If continuity does not exist, repair wiring harness as
necessary. If continuity exists, go to next step.
10) With ignition switch in ON position, check for voltage
between chassis ground and CKP sensor connector terminal No. 2. If 4.
8-5.2 volts do not exist, replace PCM. If voltage is to specification
and CKP sensor is suspected, go to next step.
11) 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 P0340: CAMSHAFT POSITION (CMP) SENSOR CIRCUIT FAILURE
NOTE: For terminal identification, see TERMINAL IDENTIFICATION. For
circuit and wire color identification, see
L - WIRING DIAGRAMS article.
NOTE: 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.
1) If using scan tool, go to step 3). Disconnect CMP sensor
connector. Install Test Harness (MB991348) between CMP sensor and
connector. Using engine analyzer with oscilloscope capability, connect
special patterns probe to CMP sensor connector terminal No. 2. Go to
next step.
2) Start engine. Compare oscilloscope wave pattern with
known-good wave pattern. See Fig. 39. Verify wavelength (time)
decreases as engine RPM increases. If wave pattern fluctuates to left
or right, check for loose timing belt or an abnormality in sensor
pick-up disc. If a rectangular wave pattern is generated even when
engine is not started, substitute known-good CMP sensor. Repeat test.
If wave pattern is still abnormal, go to next step.
Fig. 39: Identifying Known-Good CMP Sensor Wave Pattern
Courtesy of Mitsubishi Motor Sales of America
3) On Montero, go to next step. On 3000GT, disconnect CMP
sensor connector. Turn ignition switch to ON position. Check voltage
between chassis ground and CMP sensor connector terminal No. 3. If
battery voltage does not exist, repair wiring harness as necessary. If
battery voltage exists, go to step 5).
4) Disconnect CMP sensor connector and MFI relay connector.
Using DVOM, check for continuity between CMP sensor connector terminal
No. 3 and MFI relay connector terminal No. 1. If continuity does not
exist, repair wiring harness as necessary. If continuity exists, go to
next step.
5) Check for continuity between chassis ground and CMP sensor
connector terminal No. 4 on 3000GT equipped with DOHC engine or 1 on