MITSUBISHI MONTERO 1998 Service 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

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
satisfied with a repair transaction, the Motorist Assurance Program
offers mediation and arbitration through MAP/BBB-CARE and other non-
profit organizations. MAP conducted pilot programs in twelve states
before announcing the program nationally in October, 1998. During the
pilots, participating repair shops demonstrated their adherence to the
Pledge and Standards and agreed to follow the UICS in communicating
the results of their inspection to their customers. To put some
"teeth" in the program, an accreditation requirement for shops was
initiated. The requirements are stringent, and a self-policing method
has been incorporated which includes the "mystery shopping" of
outlets.
We welcome you to join us as we continue our outreach... with
your support, both the automotive repair industry and your customers
will reap the benefits. Please visit MAP at our Internet site www.
motorist.org or contact us at:
1444 I Street, NW Suite 700
Washington, DC 20005
Phone (202) 712-9042 Fax (202) 216-9646
January 1999
MAP UNIFORM INSPECTION GENERAL GUIDELINES
OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS
It is MAP policy that all exhaust, brake, steering,
suspension, wheel alignment, drive-line, engine performance and
maintenance, and heating, ventilation and air conditioning, and
electrical services be offered and performed under the standards and
procedures specified in these sections.
Before any service is performed on a vehicle, an inspection
of the appropriate system must be performed. The results of this
inspection must be explained to the customer and documented on an
inspection form. The condition of the vehicle and its components will
indicate what services/part replacements may be "Required" or
"Suggested". In addition, suggestions may be made to satisfy the
requests expressed by the customer.
When a component is suggested or required to be repaired or
replaced, the decision to repair or replace must be made in the
customer's best interest, and at his or her choice given the options
available.
This section lists the various parts and conditions that
indicate a required or suggested service or part replacement.
Although this list is extensive, it is not fully inclusive. In
addition to this list, a technician may make a suggestion. However,
any suggestions must be based on substantial and informed experience,
or the vehicle manufacturer's recommended service interval and must be
documented.
Some conditions indicate that service or part replacement is

required because the part in question is no longer providing the
function for which it is intended, does not meet a vehicle
manufacturer's design specification or is missing.
Example:
An exhaust pipe has corroded severely and has a hole
in it through which exhaust gases are leaking. Replacement
of the exhaust pipe in this case is required due to
functional failure.
Example:
A brake rotor has been worn to the point where it
measures less than the vehicle manufacturer's discard
specifications. Replacement of the rotor is required
because it does not meet design specifications.
Some conditions indicate that a service or part replacement
is suggested because the part is close to the end of its useful life
or addresses a customer's need, convenience or request. If a
customer's vehicle has one of these conditions, the procedure may be
only to suggest service.
Example:
An exhaust pipe is rusted, corroded or weak, but no leaks are
present. In this case, the exhaust pipe has not failed.
However, there is evidence that the pipe may need replacement
in the near future. Replacement of the pipe may be suggested
for the customer's convenience in avoiding a future problem.
Example:
The customer desires improved ride and/or handling,
but the vehicle's shocks or struts have not failed. In this
case, replacement may be suggested to satisfy the customer's
wishes. In this case, replacement of the shocks or struts may
not be sold as a requirement.
A customer, of course, has the choice of whether or not a
shop will service his or her vehicle. He or she may decide not to
follow some of your suggestions. When a repair is required, a MAP shop
must refuse partial service on that system if, in the judgment of the
service provider, proceeding with the work could create or continue an
unsafe condition. When a procedure states that required or suggested
repair or replacement is recommended, the customer must be informed of
the generally acceptable repair/replacement options whether or not
performed by the shop.
When presenting suggested repairs to the customer, you must
present the facts, allowing the customer to draw their own conclusions
and make an informed decision about how to proceed.
The following reasons may be used for required and suggested
services. These codes are shown in the "Code" column of the MAP
Uniform Inspection & Communications Standards that follow:
Reasons to Require Repair or Replacement
A - Part no longer performs intended purpose
B - Part does not meet a design specification (regardless of
performance)
C - Part is missing
NOTE: When a repair is required, the shop must refuse partial
service to the system in question, if the repair creates
or continues an unsafe condition.

Reasons to Suggest Repair or Replacement
1 - Part is close to the end of its useful life (just above
discard specifications, or weak; failure likely to occur
soon, etc.)
2 - To address a customer need, convenience, or request (to
stiffen ride, enhance performance, eliminate noise,
etc.)
3 - To comply with maintenance recommended by the vehicle's
Original Equipment Manufacturer (OEM)
4 - Technician's recommendation based on substantial and
informed experience
NOTE: Suggested services are always optional. When presenting
suggested repairs to the customer, you must present the
facts, allowing the customer to draw their own conclusions
and make an informed decision about how to proceed.
ENGINE ASSEMBLIES
SERVICE PROCEDURES REQUIRED AND SUGGESTED FOR PROPER VEHICLE
OPERATION
CYLINDER HEAD ASSEMBLIES
NOTE: A Cylinder Head Assembly is a cylinder head fitted with
valves, associated springs, retainers, and on overhead
camshaft cylinder heads (OHC), camshaft, camshaft
bearings, lash adjusters, tappets and rockers.
CYLINDER HEAD ASSEMBLY INSPECTION









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Condition Code Procedure
Adjustable valve lash is
out of specification ... B ................. Require repair.
Internal component failure
(any component) ........ A ........... ( 1) Require repair or
replacement of cylinder
head 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.









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LONG BLOCK ASSEMBLIES
NOTE: A Long Block Assembly is a short block assembly together
with a cylinder head assembly and all those components
fitted within the rocker or cam cover, and timing cover

(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









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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.









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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









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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.









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ENGINE COMPONENTS
ACCELERATOR PEDAL POSITION SENSORS
ACCELERATOR PEDAL POSITION SENSOR INSPECTION








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Condition Code Procedure
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of hardware.
Attaching hardware
threads stripped
(threads missing) ...... A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... ( 1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Inoperative ............. B ........... ( 2) Require repair or
replacement. Further
inspection required.
Missing ................. C ............ Require replacement.
Resistance out of
specification .......... B .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) 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.
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.









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ACCESSORY BELTS
ACCESSORY BELT INSPECTION

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Condition Code Procedure
Alignment incorrect ..... B .......... (1) Further inspection
required.
Cracked ................. 1 ............ Suggest replacement.
Frayed .................. 1 ............ Suggest replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .......... ( 2) Further inspection
required.
Plies separated ......... A ............ Require replacement.
Tension out of
specification .......... B ........... Require adjustment or
replacement.
Worn beyond adjustment
range .................. B ............ Require replacement.
Worn so it contacts
bottom of pulley ....... A ............ Require replacement.
( 1) - Determine cause of incorrect alignment and require repair.
( 2) - Determine cause of noise and suggest repair.









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ACCESSORY PULLEYS
ACCESSORY PULLEY INSPECTION








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Condition Code Procedure
Alignment incorrect ..... B .. Require repair or 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.
Bent .................... A ............ Require replacement.
Cracked ................. A ............ Require replacement.
Loose ................... A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Pulley damaged, affecting
belt life .............. A ............ Require replacement.









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ACTUATORS
See SENSORS AND ACTUATORS .
AIR CONDITIONING CYCLING SWITCHES
AIR CONDITIONING CYCLING SWITCH INSPECTION








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Condition Code Procedure
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of hardware.

Attaching hardware
threads stripped
(threads missing) ...... A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... (1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Contaminated ............ A ........... ( 2) Require repair or
replacement.
Inoperative ............. B ........... ( 3) Require repair or
replacement. Further
inspection required.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Resistance out of
specification ........... B .. Require repair or replacement.
Restricted, affecting
performance ............ A .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) 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.
Threads damaged ......... A .. Require repair or replacement.
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) - 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.









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AIR CONDITIONING PRESSURE SENSORS
AIR CONDITIONING PRESSURE SENSOR INSPECTION








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Condition Code Procedure
Attaching hardware
missing ................ C .......... Require replacement of
hardware.

Attaching hardware
threads damaged ........ A ... Require repair or replacement
of hardware.
Attaching hardware
threads stripped
(threads missing) ...... A ... Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A ........... (1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Contaminated ............ A ........... ( 2) Require repair or
replacement.
Inoperative ............. B ........... ( 3) Require repair or
replacement. Further
inspection required.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Resistance out of
specification .......... B .. Require repair or replacement.
Restricted, affecting
performance ............ A .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) 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.
Threads damaged ......... A .. Require repair or replacement.
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) - 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.









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AIR DUCTS AND TUBES
AIR DUCT AND TUBE 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.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Restricted, affecting
performance ............ A .. Require repair or replacement.









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AIR FILTER ELEMENTS
AIR FILTER ELEMENT INSPECTION








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Condition Code Procedure
Leaking ................. A ............ Require replacement.
Paper filter element
oil-soaked ............ A ........ ( 1) Require replacement.
Maintenance intervals ... 3 ... Suggest replacement to comply
with vehicle's OEM recommended
service intervals.
Melted .................. A ........... Required replacement.
Missing ................. C ............ Require replacement.
Restricted, affecting
performance ............ A ............ Require replacement.
Water-contaminated ...... A ........ ( 1) Require replacement.
( 1) - Further inspection required to determine cause.









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AIR FILTER GASKETS
See AIR FILTER HOUSINGS AND GASKETS .
AIR FILTER HOUSINGS AND GASKETS
AIR FILTER HOUSING AND GASKET 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.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.









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AIR FUEL RATIO SENSORS