body MITSUBISHI MONTERO 1998 Service Manual (1501 Pages)

Accessory Mount Stay Bolt (Montero)
8 mm Bolt .............................................. 17 (23)\
10 mm Bolt ............................................. 36 (49)\
Cooling Fan Bracket (Montero) ............................ 30 (41\
)
Engine Hanger (Montero) .................................. 13 (17\
)
Generator Bolt (Diamante) ................................ 15 (21\
)
Generator Bolt (Montero)
8 mm Bolt .............................................. 15 (21)\
10 mm Bolt ............................................. 38 (51)\
Generator Bracket (Diamante)
8 mm Bolt .............................................. 35 (48)\
10 mm Bolt ............................................. 17 (23)\
Generator Pivot Nut (Diamante) ........................... 32 (44\
)
Tensioner Pulley Nut ..................................... 37 (50)\
Tensioner Bracket Stay Bolt (Montero) .................... 18 (24\
)
Intake Manifold & Fuel
Bracket (Montero) ........................................ 18 (24\
)
ECT Sensor ............................................... 22 (30)\
Intake Manifold Nut ...................................... 15 (21)\
Thermostat Case .......................................... 14 (19)\
Water Inlet Fitting Bolt ................................. 14 (19)\
Water Outlet Fitting Bolt ................................ 14 (19)\
Water Passage (Montero) .................................. 14 (19\
)
Heater Pipe Bolt (Diamante) .............................. 13 (18\
)
Intake Plenum & Throttle Body
Air Intake Fitting Bolt & Nut (Montero) .................. 13 (18\
)
EGR Pipe Bolt ............................................ 13 (18)\
EGR Pipe Flair Nut ....................................... 44 (59)\
EGR Valve Bolt ........................................... 16 (22)\
Intake Manifold Plenum (Diamante) ........................ 13 (18\
)
Intake Manifold Plenum Stay Bolt
8 mm Bolt .............................................. 13 (18)\
10 mm Bolt ............................................. 27 (36)\
Water Outlet Fitting Bracket Bolt ........................ 14 (19)\
Bracket (Diamante) ....................................... 18 (24\
)
Motor Mount Brackets
Bracket
8 mm Bolt .............................................. 16 (22)\
10 mm Bolt ............................................. 30 (41)\
12 mm Bolt ............................................. 55 (75)\
Oil Pan & Oil Pump
Drain Plug ............................................... 30 (40)\
Oil Cooler By-Pass Valve (Montero) ....................... 41 (55\
)
Oil Filter Bolt (Montero) ................................ 15 (21\
)
Oil Filter Bracket
8 mm Bolt .............................................. 18 (24)\
10 mm Bolt ............................................. 30 (40)\
Oil Screen
8 mm Bolt ............................................... 14 (19)\
Plug .................................................... 33 (45)\
Piston & Connection Rod
Connecting Rod Cap Nut ................................... 38 (52)\
Rocker Arms & Camshafts
Distributor Adapter Bolt (Diamante) ...................... 17 (23\
)
Rocker Arm Shaft Bolt .................................... 23 (31)\
Spark Plug ................................................. 18 (25)\
Timing Belt
Auto Tensioner Bolt ...................................... 18 (24)\
Camshaft Sprocket Bolt ................................... 65 (88)\
Idler Pulley Bolt ........................................ 32 (44)\
Tensioner Arm Bolt ....................................... 32 (44)\
Tensioner Pulley Bolt .................................... 36 (49)\
Water Pump Bolt (Montero) ................................ 18 (24\
)

Water Pump Bolt (Diamante)
8 mm Bolt .............................................. 18 (24)\
10 mm Bolt ............................................. 30 (41)\
INCH Lbs. (N.m)
Crankshaft & Drive Plate
Bell Housing ............................................ 79.7 (9)\
Oil Seal Case .......................................... 97.3 (11)\
Rear Plate (Montero) ................................... 97.3 (11\
)
Exhaust Manifold
Heat Shield ........................................... 123.9 (14)\
Oil Level Gauge Guide Bolt ............................ 123.9 (14)\
Generator & Drive Belt
Cooling Fan Bolt (Montero) ............................. 97.3 (11\
)
Cooling Fan Nut (Montero) .............................. 97.3 (11\
)
Timing Indicator Bolt (Montero) ........................ 97.3 (11\
)
Intake Manifold & Fuel
ECT Gauge Sender ....................................... 97.4 (11)\
Fuel Pressure Regulator Bolt ............................ 79.6 (9)\
Fuel Pipe Banjo Bolt .................................... 79.6 (9)\
Injector & Fuel Rail Bolt ............................. 106.2 (12)\
Water Outlet Pipe ..................................... 123.9 (14)\
Intake Plenum & Throttle Body
Ignition Coil Bolt (Montero) ............................ 115 (13\
)
Manifold Differential Pressure (MDP) Sensor ............. 44 (4.9\
)
Throttle Body Bolt ...................................... 106 (12)\
Vacuum Hose Assembly (Diamante) ......................... 88 (9.8\
)
Oil Pan & Oil Pump
Baffle Plate (Montero) ................................. 97.3 (11\
)
Baffle Plate (Diamante) ................................ 97.3 (11\
)
6 mm Bolt ............................................... 53.1 (6)\
8 mm Bolt ............................................... 79.6 (9)\
Oil Pump Cover Bolt (Diamante) ......................... 88.5 (10\
)
Oil Pump Cover Bolt (Montero)
6 mm x 10 mm Bolt .................................... 97.3 (11)\
6 mm x 18 mm Bolt ..................................... 53.1 (6)\
Oil Pressure Gauge Sender .............................. 88.5 (10)\
Oil Pan (Upper) ......................................... 53.1 (6\
)
Oil Pan (Lower) ........................................ 97.3 (11\
)
Oil Pump Case ......................................... 123.9 (14)\
Oil Screen (Montero)
6 mm Bolt ............................................. 53.1 (9)\
Rocker Arms & Camshafts
Rocker Cover Bolt ....................................... 31 (3.5)\
Thrust Case Bolt ...................................... 115.1 (13)\
Timing Belt
Camshaft Position (CMP) Sensor (Montero) ................ 79.6 (\
9)
Crankshaft Position (CKP) Sensor ........................ 79.6 (9\
)
( 1) - Tighten cylinder head bolts in 2 or 3 steps with engine cold.
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ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS\
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Application Specification
Displacement .................................. 213.4 Cu. In. (3.5L)\
Bore ............................................... 3.6614" (93 mm)\

A - INTRODUCTION
1998 Mitsubishi Montero
1998 ENGINE PERFORMANCE
Mitsubishi - Introduction
Diamante, Eclipse, Eclipse Spyder, Galant, Mirage, Montero,
Montero Sport, 3000GT
1997-98 MODEL COVERAGE
ENGINE/VIN IDENTIFICATION
ENGINE/VIN IDENTIFICATION TABLE\
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BODY ENGINE FUEL IGNITION

MODEL CODE (1) ENGINE (2) ID (3)SYSTEM SYSTEM (5)

\b\
\b\
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\b\b\
\b\
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Diamante 7 3.5L V6 (6G74) SOHC P SFI Hall Effect

(
4) ( 6)

\b\
\b\
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\b\b\
\b\
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Eclipse 4 2.0L 4-Cyl. (420A) Y SFI DIS (
7)

DOHC (
4)

\
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\b\
\b\b\
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2.0L 4-Cyl. (4G63) F SFI DIS (
7)

DOHC Turbo (
4)

\b\
\b\
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\b\b\
\b\
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Eclipse 5 2.0L 4-Cyl. (4G63) F SFI DIS (
7)

Spyder DOHC Turbo (
4)

\
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\b\
\b\b\
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2.4L 4-Cyl. (4G64) G SFI DIS (
7)

SOHC (
4)

\b\
\b\
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\b\b\
\b\
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Galant 6 2.4L 4-Cyl. (4G64) G SFI Hall Effect

SOHC (
4) ( 6)

\b\
\b\
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\b\b\
\b\
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Mirage 1, 6 1.5L 4-Cyl. (4G15) A SFI Hall Effect

SOHC (
4) ( 6)

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\b\
\b\b\
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1.8L 4-Cyl. (4G93) C SFI DIS (
7)

SOHC (
4)

\b\
\b\
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\b\b\
\b\
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Montero 1 3.5L V6 (6G74) SOHC M SFI DIS (
7)

(
4)

\b\
\b\
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\b\b\
\b\
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Montero 1 2.4L 4-Cyl. (4G64) G SFI Hall Effect

Sport SOHC (
4) ( 6)

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\b\
\b\b\
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3.0L V6 (6G72) SOHC P SFI DIS (
7)

(
4)

\b\
\b\
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\b\b\
\b\
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3000GT 4, 5 3.0L V6 (6G72) SOHC H SFI Hall Effect

(
4) ( 6)

\
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\b\
\b\b\
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3.0L V6 (6G72) DOHC J SFI DIS (
7)

(
4)

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\b\
\b\b\
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3.0L V6 (6G72) DOHC K SFI DIS (
7)

Turbo (
4)

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(
1) - Body code is seventh character of Vehicle Identification

Number (VIN). VIN is located on upper left corner of

instrument panel.

(
2) - See Figs. 1 and 2.

(
3) - Engine ID is eighth character of VIN.

(
4) - Fuel system is a Sequential Fuel Injection (SFI) system.

(
5) - Ignition timing is computer-controlled.

(
6) - This system may also be referred to as distributor ignition.

(
7) - This system may also be referred to as distributorless

ignition.

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VIN DEFINITION
J A 3 A Y 3 6 A 1 W U 0 0 0 0 0 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
1 - Indicates Nation of Origin.
2 - Indicates Manufacturer.
3 - Indicates Vehicle Type.
4 - Indicates Restraint System. ( 1)
5 - Indicates Model.
6 - Indicates Vehicle Series.
7 - Indicates Body Type.
8 - Indicates Engine Type and Make.
9 - Indicates Check Digit.
10 - Indicates Model Year.
11 - Indicates Assembly Plant.
12-17 - Indicates Serial Number.
( 1) - On Montero & Montero Sport, fourth character of VIN indicates
GVWR.
VIN CODE/YEAR APPLICATIONS
VIN CODE/YEAR APPLICATION TABLE\
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VIN Code Model Year
T ................................................... 1996
V ................................................... 1997
W ................................................... 1998
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ENGINE CODE LOCATIONS
Fig. 1: Engine Code Locations (Diamante)
Courtesy of Chrysler Corp.

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ABBREVIATION DEFINITION

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B/P Backpressure

BAC By-Pass Air Control

BAP Barometric Absolute Pressure Sensor

BARO Barometric

BBDC Before Bottom Dead Center

BCM Body Control Module

BDC Bottom Dead Center

BHP Brake Horsepower

BLK Black

BLU Blue

BMAP Barometric & Manifold Absolute Pressure Sensor

BOO Brake On-Off Switch

BP Barometric Pressure sensor

BPS Barometric Pressure Sensor

BPT Backpressure Transducer

BRN Brown

BTDC Before Top Dead Center

BTU British Thermal Unit

BVSV Bimetallic Vacuum Switching Valve

Baro. Barometric

Batt. Battery

Bbl. Barrel (Example: 4-Bbl.)

Blst. Ballast

Blwr. Blower

Brkr. Breaker

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"C" ABBREVIATION TABLE
"C" ABBREVIATION TABLE\
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ABBREVIATION DEFINITION

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C Celsius (Degrees)

C(3) I Computer Controlled Coil Ignition

C(4) Computer Controlled Catalytic Converter

CANP Canister Purge solenoid

CARB California Air Resources Board

CAT Catalytic Converter

CB Circuit Breaker

CBD Closed Bowl Distributor

CBVV Carburetor Bowl Vent Valve

cc Cubic Centimeter

CCC Computer Command Control

CCD Computer Controlled Dwell

CCM Central Control Module

CCO Converter Clutch Override

CCOT Cycling Clutch Orifice Tube

CCW Counterclockwise

CDI Capacitor Discharge Ignition

CEC Computerized Engine Control

CFI Central Fuel Injection

CID Cubic Inch Displacement

CID Cylinder Identification sensor

CIS Continuous Injection System

CIS-E Continuous Injection System-Electronic

CKT Circuit

CLR Clear

CNG Compressed Natural Gas

RVB Rear Vacuum Break

RWAL Rear Wheel Anti-Lock Brake

RWD Rear Wheel Drive

Recirc. Recirculate or Recirculation

Reg. Regulator

Rly. Relay

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"S" ABBREVIATION TABLE
"S" ABBREVIATION TABLE\
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ABBREVIATION DEFINITION

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SAW Spark Angle Word

SBC Single Bed Converter

SBEC Single Board Engine Controller

SC Super Charged

SCC Spark Control Computer

SCS Air Suction Control Solenoid

SDM Supplemental Restraint System Diagnostic Module

SDU SRS Diagnostic Unit

SEN Sensor

SES Service Engine Soon

SFI Sequential (Port) Fuel Injection

SIG RTN Signal Return circuit

SIL Shift Indicator Light

SIR Supplemental Inflatable Restraint

SMEC Single Module Engine Controller

SOHC Single Overhead Cam

SOL or Sol. Solenoid

SPFI Sequential Port Fuel Injection

SPK Spark Control

SPOUT Spark Output Signal

SRS Supplemental Restraint System (Air Bag)

SS 3/4-4/3 Shift Solenoid circuit

SSI Solid State Ignition

STAR Self-Test Automatic Readout

STI Self Test Input circuit

STO Self-Test Output

SUB-O2 Sub Oxygen Sensor

Sen. or Sens. Sensor

Sol. Solenoid

Sprchg. Supercharger

Strg. Steering

Susp. Suspension

Sw. Switch

Sys. System

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"T" ABBREVIATION TABLE
"T" ABBREVIATION TABLE\
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ABBREVIATION DEFINITION

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T.V. Throttle Valve

TAB Thermactor Air By-Pass

TAC Thermostatic Air Cleaner

TAD Thermactor Air Diverter

TAN Tan

TBI Throttle Body Injection

SHAFT SEAL
CAUTION: Secure rear housing to compressor body using a vise before
removing front housing through-bolts. Compressor rear housing
may separate from compressor body, spilling refrigerant oil.
Removal
1) Remove clutch coil. See CLUTCH COIL. See Fig. 1 or 2.
Position compressor in a vise so compressor rear housing is secured to
compressor body. Remove front housing through-bolts and front housing.
2) Using a flat-blade screwdriver, remove felt retainer and
felt from front housing. Remove shaft seal snap ring. Using a flat-
blade screwdriver, remove shaft seal and "O" ring. See Fig. 1 or 2.
Installation
1) Inspect compressor shaft and front housing bore for damage
and/or excessive wear. Ensure "O" ring and shaft seal seat are clean.
Apply NEW refrigerant oil to compressor side of front housing bore.
Lubricate "O" ring and shaft seal with NEW refrigerant oil. Using a
21-mm socket, install shaft seal with "O" ring side facing away from
compressor. Install shaft seal snap ring. See Fig. 1 or 2.
2) Install felt into felt retainer. Using a 14-mm deep
socket, install felt and felt retainer. Lubricate compressor shaft.
Install front housing using care not damage shaft seal lip. See Fig. 1
or 2.
3) Alternately tighten front housing through-bolts to 19 ft.
lbs. (26 N.m). Install clutch plate center bolt. Using an INCH-lb.
torque wrench, ensure compressor breakaway torque is 43 INCH lbs. (4.9
N.m) or less. To complete installation, reverse removal procedures.
Ensure air gap between clutch plate and pulley is correct. See
CLUTCH COIL .
Fig. 1: Exploded View Of Compressor (Nippondenso 10PA17C 10-Cyl.)
Courtesy of Toyota Motor Sales, U.S.A., Inc.

component. Failure to do this may result in accidental air
bag deployment and possible personal injury. Refer to
DISABLING & ACTIVATING AIR BAG SYSTEM .
* For about 60 seconds after air bag system is disabled, it
retains enough voltage to deploy air bags. After disabling
system, wait at least 60 seconds before servicing.
* After servicing, always turn ignition on from passenger-side
of vehicle in case of accidental air bag deployment.
* After servicing, check SRS warning light to verify system
operation. See SYSTEM OPERATION CHECK.
* Always wear safety glasses when servicing or handling an
air bag.
* The SRS-ECU must be stored in its original special container
until used for service. It must be stored in a clean, dry
place, away from sources of extreme heat, sparks and high
electrical energy.
* DO NOT expose air bag module and clockspring to temperatures
greater than 200
F (93C).
* When placing a live air bag module on a bench or other
surface, always face air bag module 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 irritates 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. Refer to
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 a live (undeployed) air bag module, trim cover
must be pointed away from body to minimize injury in case of
accidental air bag deployment.
* DO NOT probe wire harness connector terminals. Instead, use
SRS Check Harness (MB991530).
* DO NOT probe a wire through insulator, as this will damage
it and eventually cause failure due to corrosion.
* When performing electrical tests, prevent accidental
shorting of terminals. Such shorts can damage fuses or
components and may cause a second fault code to set, making
diagnosis of original problem more difficult.
* Never use an analog volt/ohm meter or test light in place of
a Digital Volt/Ohm Meter (DVOM). Use only a DVOM with a
maximum test current of 2 mA (milliamps) at minimum range of
resistance measurement. Also see SPECIAL TOOLS.
* 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.
SPECIAL TOOLS
To avoid air bag deployment when working on SRS, DO NOT use
electrical test equipment such as test lights, battery or A/C-powered
volt/ohmmeter, or any type of electrical equipment other than those
specified by manufacturer. See SRS RECOMMENDED TOOLS table.
SRS RECOMMENDED TOOLS TABLE
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Symptom Inspection Procedure
Communication With All Systems Not Possible ............ 1
Communication With SRS Only Not Possible ............... 2
Ignition Switch On (Engine Stopped)
SRS Warning Light Does Not Come On ............... DTC 43
SRS Warning Light Stays On After 7 Seconds ...... DTC 43
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INSPECTION PROCEDURE 1
The cause is probably in power supply system (including
ground circuit of diagnostic line). Check connectors and harness, and
repair if necessary.
INSPECTION PROCEDURE 2
NOTE: Refer to WIRING DIAGRAMS for connector identification.
1) Before proceeding, see SERVICE PRECAUTIONS. Deactivate
SRS. See DISABLING & ACTIVATING AIR BAG SYSTEM .
2) Measure SRS Check Harness (MB991613) connector No. 5.
Disconnect SRS-ECU connector C-122 and connect SRS check harness
connector No. 3 to C-122. Check continuity between terminal No. 20, 21
and ground. If there is no continuity, go to next step. If there is
continuity, go to step 4).
3) Check connector C-122, and repair if necessary. If
connector is okay, check for trouble symptoms. If fault exists, check
harness between SRS-ECU and ground, and repair if necessary.
4) Measure SRS check harness connector No. 5. Disconnect SRS-
ECU connector C-122 and connect SRS harness check connector No. 3 to
C-122. Connect negative battery cable. Measure voltage between
terminal No. 13 and 14, and body ground. If voltage at terminals is 9
volts or more, check harness wire between SRS-ECU and Data Link
Connector (DLC), and repair if necessary. If harness wire is okay,
replace SRS-ECU. See SRS AIR BAG CONTROL UNIT (ECU) under REMOVAL &
INSTALLATION. If voltage is not as specified, check connector C-80, C-
93, C-101, and C-132, and repair if necessary. If connectors are okay,
check for trouble symptoms. If fault exists, check harness between
SRS-ECU and IG1 A or B (ignition switch), and repair if necessary.
Fig. 10: Identifying SRS Check Harness (MB991613) Connectors
Courtesy of Mitsubishi Motor Sales of America.
DTC 11, 12 & 13: FRONT IMPACT SENSOR SYSTEM

cause accidental air bag deployment and personal injury.
NOTE: Refer to WIRING DIAGRAMS for connector identification.
1) Before proceeding, see SERVICE PRECAUTIONS. Deactivate
SRS. See DISABLING & ACTIVATING AIR BAG SYSTEM .
2) Disconnect passenger-side air bag connector C-107. Connect
SRS Check Harness (MB991613) connector No. 1 to passenger-side air bag\
connector. Erase DTC memory and check if DTCs 24, 25, or 64 are set.
If any of these DTCs are output, go to next step. If DTCs are not
output, replace passenger-side air bag module. See
PASSENGER-SIDE AIR BAG MODULE under REMOVAL & INSTALLATION.
3) Check connectors C-107 and C-122, and repair if necessary.
If connectors are okay, check trouble symptoms. If fault is still
present, check harness wire between passenger-side air bag module and
SRS-ECU, and repair if necessary. If harness wire is okay, replace
SRS-ECU. See SRS AIR BAG CONTROL UNIT (ECU) under REMOVAL &
INSTALLATION.
DTC 31 & 32: SRS-ECU CAPACITOR SYSTEM
Before proceeding, see SERVICE PRECAUTIONS. Replace SRS-ECU.
See SRS AIR BAG CONTROL UNIT (ECU) under REMOVAL & INSTALLATION.
DTC 34: CONNECTOR LOCK SYSTEM
NOTE: If vehicle condition returns to normal, DTC will be erased
and SRS warning light will return to normal.
NOTE: Refer to WIRING DIAGRAMS for connector identification.
Before proceeding, see SERVICE PRECAUTIONS. Check connector
C-122 and repair if necessary. If connector is okay, check for trouble
symptom. If fault exists, replace SRS-ECU. See
SRS AIR BAG CONTROL UNIT (ECU) under REMOVAL & INSTALLATION.
DTC 35: SRS-ECU SYSTEM (AFTER AIR BAG DEPLOYMENT)
Before proceeding, see SERVICE PRECAUTIONS. Replace SRS-ECU.
See SRS AIR BAG CONTROL UNIT (ECU) under REMOVAL & INSTALLATION.
DTC 41: IG1 (A) POWER CIRCUIT SYSTEM
NOTE: If vehicle condition returns to normal, DTC will be erased
and SRS warning light will return to normal.
NOTE: Refer to WIRING DIAGRAMS for connector identification.
1) Before proceeding, see SERVICE PRECAUTIONS. Deactivate
SRS. See DISABLING & ACTIVATING AIR BAG SYSTEM .
2) Measure SRS Check Harness (MB991613) connector No. 5.
Disconnect SRS-ECU connector C-122 and connect SRS check harness
connector No. 3 to C-122. Check terminal No. 20 and 21 for continuity
to ground. If there is no continuity, go to next step. If there is
continuity, go to step 4).
3) Check connector C-122 and repair if necessary. If
connector is okay, check for trouble symptom. If fault exists, check
harness wire between SRS-ECU and ground, and repair if necessary.
4) Measure SRS check harness connector No. 5. Disconnect SRS-
ECU connector C-122 and connect SRS harness check connector No. 3 to
C-122. Connect negative battery cable and turn ignition switch to ON
position. If voltage between terminal No. 14 and body ground is 9

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