warning MITSUBISHI MONTERO 1998 Repair Manual

  * After repairs are completed, check AIR BAG 

 warning light to ensure system is functioning

 properly. 











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ISUZU (1990-98)
AIR BAG APPLICATION
AIR BAG APPLICATION TABLE - ISUZU (1990-98)








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Model Year (1) Location Inspection Table
Hombre ....... 1996-97 ........... DS .................. ISUZU-1
Impulse ...... 1990-92 ........... DS .................. ISUZU-5
Oasis ........ 1996-98 .......... D/P .................. ISUZU-2
Rodeo ........ 1996-98 .......... D/P .................. ISUZU-3
1995 1/2 ......... D/P .................. ISUZU-3
Stylus ....... 1991-93 ........... DS .................. ISUZU-5
Trooper ...... 1996-98 .......... D/P .................. ISUZU-3
1995 ............ D/P .................. ISUZU-4
( 1) - Location Definitions: D/P = Driver's & Passenger's Side,
DS = Driver's Side Only, SI = Side Impact.









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INSPECTION PROCEDURES
INSPECTION PROCEDURES TABLE - ISUZU-1







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Action  Component or System 










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Replace After 
* Air Bag Module(s) 

Deployment 
* Sensors In Area Of Accident Damage 










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Inspect & If 
* Instrument Panel Braces 

Damaged, Replace 
* Instrument Panel Steering Column 

Component  Reinforcement Plate 

(Even If Air 
* Seat Belts & Mounting Points 

Bag Did Not 
* Knee Bolster 

Deploy) 
* Sensors In Area Of Accident Damage 


* SRS Coil Assembly 










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Comments 
* Any sensor which the Diagnostic Energy 

 Reserve Module (DERM) indicates as bad must 

 be replaced. 


* If any components are damaged or bent, they 

 must be replaced. 


* SRS wiring can be repaired following 

 manufacturer's instructions. 











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INSPECTION PROCEDURES TABLE - ISUZU-2







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Action  Component or System 










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Replace After 
* Air Bag Module(s) 

Deployment 
* Seat Belt Tensioners (If Equipped) 


* SRS Control Unit 










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Inspect & If 
* Cable Reel 

Damaged, Replace 
* Dash Sensors (1991-94) 

 Component  * Seat Belts 

(Even If Air 
* SRS Control Unit 

Bag Did Not 
* Wiring Harness 

Deploy)  










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Comments 
* If any components are damaged or bent, they 

 must be replaced. 


* DO NOT attempt SRS wiring repairs. If SRS 

 wiring or harness connectors are faulty, 

 replace faulty wiring harness. 


* After vehicle is repaired, ensure AIR BAG 

 warning light is functioning properly. 











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INSPECTION PROCEDURES TABLE - ISUZU-3







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Action  Component or System 










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Replace After 
* Air Bag Module(s) 

Deployment 
* Sensing & Diagnostic Module (SDM) 










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Inspect & If 
* Instrument Panel Braces 

Damaged, Replace 
* Instrument Panel Steering Column 

Component  Reinforcement Plate 

(Even If Air 
* Seat Belts & Mounting Points 

Bag Did Not 
* Knee Bolsters & Mounting Points 

Deploy) 
* Steering Column 


* SRS Coil Assembly 


* Wiring Harnesses 










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Comments 
* If any components are damaged or bent, they 

 must be replaced. 


* DO NOT attempt wiring harness repairs. 

 Replace harness. 











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INSPECTION PROCEDURES TABLE - ISUZU-4







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Action  Component or System 










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Replace After 
* Air Bag Module(s) 

Deployment 
* All Sensors 










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Inspect & If 
* SRS Coil Assembly 

Damaged, Replace 
* Instrument Panel Steering Column 

Component  Reinforcement Panel 

(Even If Air 
* Instrument Panel Braces 

Bag Did Not 
* Knee Bolsters 

Deploy) 
* Seat Belts Mounting Points 


* Sensors In Area of Accident Damage 


* Steering Column 










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Comments 
* If any components are damaged or bent, they 

 must be replaced. 


* DO NOT attempt wiring harness repairs. 

 Replace harness. 











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INSPECTION PROCEDURES TABLE - ISUZU-5







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Action  Component or System 










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Replace After 
* Air Bag Module 

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Inspect & If 
* Arming Sensor 

Damaged, Replace 
* Coil Assembly 

Component 
* Diagnostic Energy Reserve Module (DERM) 

(Even If Air 
* Forward Sensor 

Bag Did Not 
* Instrument Panel-To-Steering Column 

Deploy)  Reinforcement 


* Knee Pad 


* Passenger Compartment Sensor 


* Steering Column 


* Wiring Harness & Brackets 










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Comments 
* If any components are damaged or bent, they 

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KIA (1995-98)
AIR BAG APPLICATION
AIR BAG APPLICATION TABLE - KIA (1995-98)








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Model Year (1) Location
Sephia .............. 1996-98 ...................... D/P
1995 1/2 ..................... D/P
Sportage ............ 1996-98 ...................... D/P
( 1) - Location Definitions: D/P = Driver's & Passenger's
Side, DS = Driver's Side Only, SI = Side Impact.









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INSPECTION PROCEDURES
INSPECTION PROCEDURES TABLE - KIA (1995-98)







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Action  Component or System 










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Replace After 
* Air Bag Module(s) 

Deployment  










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Inspect & If 
* Air Bag Diagnosis Control Unit 

Damaged, Replace 
* Clockspring 

Component 
* Impact Sensors Sensor Mountings ( 1) 

(Even If Air 
* Steering Column 

Bag Did Not 
* Steering Wheel 

Deploy) 
* Wiring Harness 










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Comments 
* After repairs a completed, ensure Warning 

 Light is functioning properly. 










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(
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LEXUS (1990-98)
AIR BAG APPLICATION
AIR BAG APPLICATION TABLE - LEXUS (1990-98)








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Comments 
* DO NOT attempt SRS wiring repairs. 


* If any components are damaged or bent, they 

 must be replaced. 










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(
1) - If Equipped. 

(
2) - 1998 Legacy, on side of deployment. 











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SUZUKI (1995-98)
AIR BAG APPLICATION
AIR BAG APPLICATION TABLE - SUZUKI (1995-98)








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Model Year (1) Location
Esteem .............. 1995-98 ...................... D/P
Sidekick ............ 1996-98 ...................... D/P
Swift ............... 1995-98 ...................... D/P
X90 ................. 1996-98 ...................... D/P
( 1) - Location Definitions: D/P = Driver's & Passenger's
Side, DS = Driver's Side Only, SI = Side Impact.









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INSPECTION PROCEDURES
INSPECTION PROCEDURES TABLE - SUZUKI (1995-98)







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Action  Component or System 










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Replace After 
* Air BagModule(s) 

Deployment 
* Sensing & Diagnostic Module (SDM) 










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Inspect & If 
* Air Bag Warning Light 

Damaged, Replace 
* Combination Switch Assembly 

Component 
* Contact Coil 

(Even If Air 
* Forward Discriminating Sensor ( 1) 

Bag Did Not 
* Instrument Panel Reinforcement 

Deploy) 
* Knee Bolsters 


* Seat Belts & Mounting Points 


* SDM Bracket 


* Steering Column Bracket 


* Steering Column & Shaft Joints 


* Steering Wheel 


* Wiring Harness 










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Comments 
* If any components are damaged or bent, they 

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TOYOTA (1990-98)

SCHEDULED SERVICES
1998 Mitsubishi Montero
1997-98 MAINTENANCE
Mitsubishi Maintenance & Service Intervals
Mitsubishi: Montero
* READ THIS FIRST *
Before preforming maintenance on vehicle, ensure that all
cautions and warnings have been observed to prevent vehicle damage or
personal injury. See CAUTIONS & WARNINGS in MAINTENANCE INFORMATION
article in this section.
Introduction
The frequency of scheduled inspection and maintenance
services in this article are based on "normal" vehicle usage. They DO
NOT take into account the following "severe" conditions:
* Driving In Dusty Conditions
* Trailer Towing, Police, Taxi, commercial Type Operation
* Extensive Idling, Driving In Stop-And-Go Traffic
* Short Trip Operation At Freezing Temperatures (Engine Not
Thoroughly Warmed Up)
* Driving In Sandy Areas
* Driving In Salty Areas
* More Than 50% Operation In Heavy City Traffic Or At Sustained
High Speeds During Hot Weather Above 90
F (32C)
* Driving On Off-Road
If any of these severe conditions exist, the "normal" service
schedule frequency for some service items is inadequate and must be
supplemented. See the following section for specific details,
SEVERE SERVICE CONDITIONS/ACTIONS .
SEVERE SERVICE CONDITIONS/ACTIONS
The following table identifies eight "severe" conditions that
cause faster-than-normal wear. Each condition lists affected service
item(s) and their revised (more frequent) service interval.
If any severe condition(s) is applicable, its revised service\
interval(s) supersede those found in the "normal" schedules. Depending\
on the specific mileage/time, the revised interval(s) may overlap a
normal schedule (in which case they can be done together). If not, it
must be performed outside of the normal schedule.
SEVERE SERVICE CONDITIONS/ACTIONS TABLE

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Condition  Action  Item  Perform Every (1) 
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Driving In Dusty  Replace  Engine Oil  3,000 Mile (4800 KM) 

Conditions    Or 3 Months 

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   Or 6 Months 

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  Filter  

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 Inspect  Disk Brake  6,000 Mile (9,600 KM) 

  Pads  Or 6 Months 

STEERING COLUMN SWITCHES
1998 Mitsubishi Montero
1998 ACCESSORIES & EQUIPMENT
Mitsubishi - Steering Column Switches
Diamante, Eclipse, Galant, Mirage, Montero, Montero Sport,
3000GT
* PLEASE READ THIS FIRST *
WARNING: Deactivate air bag system before performing any service
operation. See AIR BAG RESTRAINT SYSTEMS article. DO NOT
apply electrical power to any component on steering column
without first deactivating air bag system. Air bag may
deploy.
DESCRIPTION
Headlight and turn signal switch and wiper/washer switch are
part of combination switch. For information on cruise control switch
(right side of column), see appropriate CRUISE CONTROL SYSTEMS
article.
COMPONENT LOCATIONS
COMPONENT LOCATIONS TABLE








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Component Location
Headlight Relay .................... In Engine Compartment
Fuse/Relay Block
Foglight Relay
Except Montero & Montero Sport ... In Engine Compartment
Fuse/Relay Block
Taillight Relay
Except Montero Sport ............. In Engine Compartment
Fuse/Relay Block
Turn Signal/Hazard Flasher Unit
Diamante ............................ At Left Kick Panel
Eclipse .......................... Behind Center Of Dash
Except Diamante & Eclipse ..... Behind Left Side Of Dash
Wiper Relay
Front
Except Diamante & 3000GT .......... On Steering Column
Rear
Eclipse ........................ Behind Center Of Dash
Montero & Montero Sport .............. On Relay Block,
Behind Left Side Of Dash
3000GT ................ Behind Left Rear Quarter Panel









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COMPONENT TESTS
DIAMANTE
Turn Signal, Lighting & Dimmer/Passing Switch Tests
Disconnect steering column combination switch connector. See
Fig. 1 . Check continuity between specified terminals. See
STEERING COLUMN COMBINATION SWITCH CONTINUITY CHECK TABLE (DIAMANTE) .

Check continuity between specified terminals. See Figs. 31 and 33. If
continuity is not as specified, replace steering column combination
switch.
REMOVAL & INSTALLATION
* PLEASE READ THIS FIRST *
WARNING: Deactivate air bag system before performing any service
operation. See AIR BAG RESTRAINT SYSTEMS article. DO NOT
apply electrical power to any component on steering column
without first deactivating air bag system. Air bag may
deploy.
IGNITION SWITCH
Removal & Installation (Diamante)
Remove instrument panel lower cover. Remove upper and lower
steering column covers. See Fig. 1. Remove ignition switch. To
install, reverse removal procedure.
Removal & Installation (Eclipse)
1) Remove knee protector mount screw plugs. Remove knee
protector. Remove hood lock release handle. Remove upper and lower
steering column covers. See Fig. 6. Remove ignition key illumination
light.
2) Remove steering lock cylinder. Remove A/C-heater system
lap cooler and shower ducts. On A/T models, remove key interlock cable
and slide lever. On all models, remove ignition switch. To install,
reverse removal procedure.
Removal & Installation (Galant)
Remove knee protector. Remove upper and lower column covers.
See Fig. 11 . Remove ignition switch. To install, reverse removal
procedure.
Removal & Installation (Mirage)
Remove knee protector. Remove steering column cover. See
Fig. 15 . Remove clip and cover. On A/T models, remove key interlock
cable, spring and slide lever. On all models, remove ignition switch.
To install, reverse removal procedure.
Removal & Installation (Montero & Montero Sport)
Remove lower instrument panel cover. Remove upper and lower
column covers. See Fig. 19 or 25. Remove ignition switch. To install,
reverse removal procedure.
Removal & Installation (3000GT)
Remove knee protector. Remove upper and lower steering column
covers. See Fig. 31. Remove A/C-heater system lap cooler duct and foot
duct. Remove key reminder switch. Remove ignition switch. To install,
reverse removal procedure.
STEERING COLUMN SWITCH
CAUTION: DO NOT hammer on steering shaft. Collapsible steering column
mechanism may be damaged.
Removal & Installation (Diamante)
Remove air bag module. See AIR BAG RESTRAINT SYSTEMS article.
Remove steering wheel. Remove instrument panel lower cover. Remove
upper and lower steering column covers. See Fig. 1. Remove steering

STEERING COLUMN
1998 Mitsubishi Montero
1997-98 STEERING
Mitsubishi - Steering Columns - RWD & 4WD
Mitsubishi: Montero, Montero Sport
DESCRIPTION & OPERATION
WARNING: Vehicle is equipped with a Supplemental Restraint System
(SRS) that includes an air bag located in steering wheel.
Use caution when working around steering column. Ensure
battery is disconnected before attempting any repair. DO NOT
apply electrical power to any component on steering column
without disconnecting air bag module (air bag could deploy).
Steering column consists of a collapsible steering shaft with
lower joint assembly. Vehicle is equipped with a Supplemental
Restraint System (SRS) that includes an air bag and clockspring
located in steering column wheel.
NOTE: For information not covered in this article, air bag
DIAGNOSIS & TESTING or DISPOSAL PROCEDURES, see AIR BAG
RESTRAINT SYSTEM article.
DISABLING & ACTIVATING AIR BAG SYSTEM
WARNING: Wait at least 60 seconds after disconnecting negative
battery cable before servicing SRS. System reserve capacitor
maintains SRS voltage for about 60 seconds after battery is
disconnected. Servicing SRS before 60-second period may
cause accidental air bag deployment and possible personal
injury.
To disable system, turn ignition switch to OFF position.
Disconnect and isolate negative battery cable end. Wait at least 60
seconds. To activate system, reconnect negative battery cable.
AIR BAG SERVICE PRECAUTIONS
The following precautions should be observed when working
with SRS:
* Disable SRS before servicing any SRS or steering column
component. Failure to do this may result in accidental air
bag deployment and possible personal injury. See DISABLING &
ACTIVATING AIR BAG SYSTEM.
* Wait at least 60 SECONDS after disabling air bag system. SRS
system retains enough voltage, for a short time after system
is disabled, to deploy air bag.
* After repairs, always turn ignition on to ensure SRS warning
light is working properly and no system faults are indicated.
* Always wear safety glasses when servicing or handling an air
bag.
* DO NOT expose air bag module and clockspring to temperatures
more than 200
F (93C).
* When placing a live air bag on a bench or other surface,
always face air bag and trim cover up, away from surface.
This will reduce motion of module if air bag accidentally

deploys.
* After air bag deploys, air bag surface may contain deposits
of sodium hydroxide, which irritate skin. Always wear safety
glasses, rubber gloves and long-sleeved shirt during clean
up. Wash hands using mild soap and water. Follow correct
clean-up and disposal procedures.
* Because of critical system operating requirements, DO NOT
service any SRS components. Repairs are only made by
replacing defective part(s).
* DO NOT allow any electrical source near inflator on the back
of air bag module.
* When carrying live air bag module, trim cover should be
pointed away from body to minimize injury in case of
accidental air bag deployment.
* If SRS is not fully functional for any reason, DO NOT drive
vehicle until system is repaired and is fully functional. DO
NOT remove bulbs, modules, sensors or other components, or in
any way disable system from operating normally. If SRS is not
functional, park vehicle until repairs are made.
REMOVAL & INSTALLATION
STEERING WHEEL
WARNING: Wait at least 60 seconds after disconnecting negative
battery cable before servicing SRS. System reserve capacitor
maintains SRS voltage for about 60 seconds after battery is
disconnected. Servicing SRS before 60-second period may
cause accidental air bag deployment and possible personal
injury.
Removal
Disable air bag. See DISABLING & ACTIVATING AIR BAG SYSTEM .
Ensure steering wheel is straight ahead. Remove air bag. Place
reference mark on steering wheel and steering column shaft for
installation reference. Remove steering wheel nut and washer. Using
steering wheel puller, remove steering wheel.
CAUTION: DO NOT hammer on steering wheel during removal or
installation, as it may damage steering column.
Installation
To install, reverse removal procedure. Ensure reference marks
are aligned. Tighten fasteners to specification. See
TORQUE SPECIFICATIONS . Activate air bag. See DISABLING & ACTIVATING
AIR BAG SYSTEM.
COMBINATION SWITCH
CAUTION: When installing steering wheel, if rotating part of
clockspring is not properly centered with steering column
and front wheels, clockspring failure will result.
Removal & Installation
Remove lower instrument cover and lower heater duct. Remove
air bag and steering wheel. See STEERING WHEEL under
REMOVAL & INSTALLATION . Remove upper and lower steering column covers.
Disconnect clockspring electrical connector. Remove screws attaching
colckspring and remove clockspring. Disconnect combination switch
electrical connectors. Remove screws and combination switch. To
install, reverse removal procedure.

IGNITION SWITCH
Removal & Installation
1) Remove upper and lower steering column covers. Disconnect
harness connector from ignition switch. Using hacksaw, cut slots in
bolt heads of lock assembly. Using screwdriver, remove bolts and lock
assembly.
2) To install, reverse removal procedure. Tighten new bolts
until heads of bolts sheer off.
STEERING COLUMN
WARNING: Failure to follow air bag service precautions may result in
air bag deployment and personal injury. See AIR BAG SERVICE
PRECAUTIONS. Follow all service precautions before
attempting repairs. After component replacement, perform a
system operational check to ensure proper system operation.
CAUTION: Applying excessive pressure or causing impact to steering
shaft during service may cause column to collapse. Before
removing steering column, ensure wheels are in
straight-ahead position. Note steering wheel location for
installation reference.
Removal
1) Remove steering wheel. Remove combination switch and
ignition switch (if necessary). See STEERING WHEEL under
REMOVAL & INSTALLATION .
2) Remove lower instrument panel cover and air duct.
Disconnect all electrical connections. Disconnect brake pedal return
spring (if equipped). Disconnect gearshift control cable.
3) Remove bolts for dust cover at firewall. Remove bolt from
clamp at steering gear. Remove steering column bolts and remove
steering column.
Installation
To install, reverse removal procedure. Apply sealant (3M ATD
8663) to dust cover bolts before installing. Tighten bolts to
specification. See TORQUE SPECIFICATIONS .
OVERHAUL
STEERING COLUMN
WARNING: Failure to follow air bag service precautions may result in
air bag deployment and personal injury. See AIR BAG SERVICE
PRECAUTIONS. Follow all service precautions before
attempting repairs. After component replacement, perform a
system operational check to ensure proper system operation.
NOTE: Vehicle steering column is not repairable. See below for
joint assembly and steering lock removal and installation.
Disassembly
Remove steering column from vehicle. See STEERING COLUMN
under REMOVAL & INSTALLATION . Remove clamp bolt from joint assembly.
See Fig. 1 . Remove assembly. Remove lower boot, upper boot and dust
cover from joint assembly. To remove steering lock, use a hacksaw to
cut bolts at steering lock bracket side. Remove steering lock and
bracket.