MITSUBISHI MONTERO 1998 Service Manual

Manufacturer: MITSUBISHI, Model Year: 1998, Model line: MONTERO, Model: MITSUBISHI MONTERO 1998
Pages: 1501, PDF Size: 25.81 MB
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Page 671 of 1501

Application incorrect ... B ............ Require 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.
Connection leaking ...... A .. Require repair or replacement.
Corroded ................ 1 .. Suggest repair or replacement.
Fins damaged, affecting
performance ............ A .. Require repair or replacement.
Fins damaged, not
affecting performance .. 2 .. Suggest repair or replacement.
Internal oil cooler
leaking ................ A .. Require repair or replacement.
Internal restrictions,
affecting performance .. B .. Require repair or replacement.
Internal restrictions, not
affecting performance .. 2 .. Suggest repair or replacement.
Leaking ................. A .. Require repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A .. Require repair or replacement.
Tubes damaged, affecting
performance ............ A .. Require repair or replacement.
Tubes damaged, not
affecting performance .. .. ........ No service suggested or
required.
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ROLL OVER VALVES
ROLL OVER VALVE INSPECTION\
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Condition Code Procedure
Inoperative ............. A ....... ( 1) Require replacement.
Leaking ................. A ........... Require replacement.
Missing ................. C ........... Require replacement.
( 1) - Inoperative includes intermittent operation or out of
OEM specification.
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SEALING COMPOUNDS
SEALING COMPOUND INSPECTION\
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Condition Code Procedure
Leaking ................. A ........... ( 1) Require repair or
replacement.
( 1) - Require inspection of mating and sealing surface and
repair or replace as necessary.
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SEALS
SEAL INSPECTION

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Condition Code Procedure
Leaking ................. A ........... (1) Require repair or
replacement.
( 1) - Require inspection of mating and sealing surface and
repair or replace as necessary.
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SECONDARY AIR INJECTION SYSTEM MANAGEMENT DEVICES
SECONDARY AIR INJECTION SYSTEM MANAGEMENT DEVICE 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.

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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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SENSORS AND ACTUATORS
NOTE: Conditions pertaining to the sensors and actuators listed
in this section may be found under the name of the sensor
or actuator.
SENSOR ABBREVIATION TABLE
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Sensor Abbreviation
Accelerator Pedal Position Sensor ......................... APP
Air Conditioning Cycling Switch ............................ AC
Air Conditioning Pressure Sensor ........................... ..
Air Fuel Ratio Sensor ...................................... ..
Barometric Pressure Sensor ............................... BARO
Camshaft Position Sensor .................................. CMP
Clutch Pedal Position Switch .............................. CPP
Cooling Fan Motor Sensors and Switches ..................... ..
Crankshaft Position Sensor ................................ CKP
Electronic Transmission Feedback Devices ................... ..
Engine Coolant Temperature Sensor ......................... ECT
Evaporative Emission feedback devices ...................... ..
Exhaust Gas Recirculation feedback devices ................. ..
Fan Control Sensor ......................................... FC
Intake Air Temperature Sensor ............................. IAT
Knock Sensor ............................................... KS
Manifold Absolute Pressure Sensor ......................... MAP
Mass Air Flow Sensor ...................................... MAF
O2 Sensor ................................................. O2S
Park Neutral Position Switch .............................. PNP
Power Steering Pressure Sensor ............................ PSP
Thermal Vacuum Valve ...................................... TVV
Throttle Position Sensor ............................ TP Sensor
Throttle Position Switch ................................... ..
Transmission Range Switch ........................... TR Switch
Vehicle Speed Sensor ...................................... VSS
Volume Air Flow Sensor .................................... VAF
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ACTUATOR ABBREVIATION TABLE\
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Actuator Abbreviation
Air Injection Control Solenoid ............................. ..
Electronic Transmission control devices .................... ..
Evaporative Emission Canister ............................ EVAP
Purge Device ............................................... ..
Exhaust Gas Recirculation Device .......................... EGR
Fuel Injector .............................................. ..
Idle Air Control .......................................... IAC

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Idle Speed Control Actuator ............................... ISC
Mix Control Solenoid .............................. MC Solenoid
Secondary Air Injection System Management Device .... AIR, PAIR
Vacuum Regulator Solenoid .................................. ..
Waste Gate Control Solenoid ................................ ..
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SHROUDS, BAFFLES AND DEFLECTORS
SHROUD, BAFFLE AND DEFLECTOR INSPECTION\
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Condition Code Procedure
Application incorrect,
affecting cooling system
performance ............ A . 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, affecting cooling
system performance ..... A . Require repair or replacement.
Blocked, affecting cooling
system performance ..... A . Require repair or replacement.
Broken, affecting cooling
system performance ..... A . Require repair or replacement.
Cracked, affecting cooling
system performance ..... A . Require repair or replacement.
Loose, affecting cooling
system performance ..... A ................ Require repair.
Loose, not affecting
cooling system
performance ............ 2 ................ Suggest repair.
Missing, affecting cooling
system performance ..... C ........... Require replacement.
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SPARK PLUGS
NOTE: You are not required to replace spark plugs in sets.
However, you may suggest replacement of the other plugs
for preventive maintenance.
SPARK PLUG INSPECTION
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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Electrode eroded ........ 1 ............ Suggest replacement.
Fouled .................. A ........... ( 1) Require repair or
replacement.
Gap incorrect ........... B .. Require repair or replacement.
Insulation broken ....... A ............. Require replacement
Insulator cracked ....... A ............ Require replacement.
Leaking compression ..... A .. Require repair or replacement.
Maintenance interval .... 3 ............ Suggest replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads

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missing) ............... A ............ Require replacement.
(1) - Determine cause of fouling and suggest repair.
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SPRING LOCKS
SPRING LOCK INSPECTION\
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Condition Code Procedure
Leaking ................. A ........... ( 1) Require repair or
replacement.
( 1) - Require inspection of mating and sealing surface and
repair or replace as necessary.
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SUPER CHARGERS
SUPER CHARGER INSPECTION\
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Condition Code Procedure
Attaching hardware
damaged, affecting
operation or
performance ............ A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Bearing noisy ........... A ............ Require replacement.
Bearing worn ............ A ............ Require replacement.
Boost pressure
incorrect .............. A ........... ( 1) Require repair or
replacement.
Clearance out of
specification .......... B .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Noisy ................... 2 .. Suggest repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A .. Require repair or replacement.
( 1) - Boost pressure problems may be caused by other systems or
components.
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SWITCHES
SWITCH 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

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of hardware.
Binding, affecting
performance ............ A .. Require repair or replacement.
Binding, not affecting
performance ............ 2 .. Suggest repair or replacement.
Broken .................. A .. Require repair or replacement.
Burned, affecting
performance ............ A ........... (1) Require repair or
replacement.
Burned, not affecting
performance ............ 2 ........... ( 1) Suggest repair or
replacement.
Cracked, affecting
performance ............ A .. Require repair or replacement.
Cracked, not affecting
performance ............ 1 .. Suggest repair or replacement.
Leaking ................. A .. Require repair or replacement.
Malfunctioning .......... A ........... ( 2) Require repair or
replacement.
Melted, affecting
performance ............ A ........... ( 1) Require repair or
replacement.
Melted, not affecting
performance ............ 2 ........... ( 1) Suggest repair or
replacement.
Missing ................. C ............ Require replacement.
Out of adjustment ....... 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.
Won't return ............ A .. Require repair or replacement.
Worn .................... 1 ............ Suggest replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Includes inoperative, intermittent operation, or failure
to perform all functions.
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THERMAL VACUUM VALVES
THERMAL VACUUM VALVE INSPECTION\
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Condition Code Procedure
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

Page 677 of 1501

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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THERMOSTATIC AIR DOOR ASSEMBLIES
THERMOSTATIC AIR DOOR ASSEMBLY INSPECTION\
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Condition Code Procedure
Attaching hardware
damaged, affecting
operation or
performance ............ A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Binding ................. A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Seized .................. A .. Require repair or replacement.
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Page 678 of 1501

THERMOSTATS AND HOUSINGS
THERMOSTAT AND HOUSING INSPECTION\
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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
corroded ............... 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.
Housing corroded ........ 1 .. Suggest replacement of housing.
Inoperative ............. A ........ ( 1) Require replacement.
Installation incorrect .. B .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Thermostat missing ...... C .......... Require replacement of
thermostat.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A .. Require repair or replacement.
( 1) - Inoperative includes intermittent operation or out of
OEM specification.
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THROTTLE BODIES
THROTTLE BODY INSPECTION\
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Condition Code Procedure
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.
Leaking ................. A .. Require repair or replacement.
Restricted .............. A ............. ( 3) Require repair.
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.

Page 679 of 1501

Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A .. Require repair or replacement.
Throttle shaft binding,
affecting performance .. A .. Require repair or replacement.
Throttle shaft worn,
affecting performance .. A .. Require repair or replacement.
Throttle shaft worn, not
affecting performance .. 1 .. Suggest repair or 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) - Some components may be serviceable; check for accepted
cleaning procedure.
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THROTTLE CABLES
See THROTTLE LINKAGES AND CABLES .
THROTTLE LINKAGES AND CABLES
THROTTLE LINKAGE AND CABLE 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.
Bent .................... A .. Require repair or replacement.
Binding ................. A .. Require repair or replacement.
Bracket bent, affecting
performance ............ A .. Require repair or replacement.
Bracket bent, not
affecting performance .. .. ....... No service suggested or
required.
Bracket broken, affecting
performance ............ A Require replacement.
Bracket broken, not
affecting performance .. .. ....... No service suggested or
required.
Bracket corroded,
affecting performance .. A .. Require repair or replacement.
Bracket corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Bracket cracked, affecting
performance ............ A .. Require repair or replacement.
Bracket cracked, not
affecting performance .. 1 .. Suggest repair or replacement.

Page 680 of 1501

Bracket loose, affecting
performance ............ A .. Require repair or replacement.
Bracket loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Bracket missing ......... C ............ Require replacement.
Broken .................. A ............ Require replacement.
Cracked ................. A .. Require repair or replacement.
Disconnected ............ A .. Require repair or replacement.
Kinked .................. A .. Require repair or replacement.
Melted .................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .. Suggest repair or replacement.
Out of adjustment ....... B ........... (1) Require repair or
replacement.
Routed incorrectly ...... 2 ................. Suggest repair.
Seized .................. A .. Require repair or replacement.
( 1) - Follow OEM recommended adjustment procedures. Require
repair or replacement if out of specification.
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THROTTLE POSITION SENSORS
THROTTLE 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.
Contaminated ............ A ........... ( 2) Require repair or
replacement.
Inoperative ............. B ........... ( 3) 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

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