height MITSUBISHI MONTERO 1998 Service Manual (1501 Pages)

Stroke ........................................... 3.3779" (85.8 mm)\
Compression Ratio ............................................ 9.0:1
Fuel System .................................................... MFI
Horsepower @ RPM ........................................ 200 @ 5000
Torque Ft. Lbs. @ RPM ................................... 228 @ 3500
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ROCKER ARMS & CAMSHAFT
ROCKER ARMS & CAMSHAFT\
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Application In. (mm)\
Camshaft Lobe Height
Montero
Intake
Standard ..................................... 1.4846 (37.710)\
Limit ........................................ 1.4650 (37.210)\
Exhaust
Standard ..................................... 1.4622 (37.140)\
Limit ........................................ 1.4425 (36.640)\
Diamante
Intake
Standard ..................................... 1.4795 (37.580)\
Limit ........................................ 1.4598 (37.080)\
Exhaust
Standard ..................................... 1.4547 (36.950)\
Limit ........................................ 1.4350 (36.450)\
Camshaft Journal Diameter .......................... 1.7689 (44.930)\
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CYLINDER HEAD & VALVES
CYLINDER HEAD & VALVES\
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Application Specification
Head Warpage
Standard ........................................ .0012" (.030 mm)\
Limit ........................................... .0079" (.200 mm)\
Maximum Resurface ................................. .0079" (.200 mm)\
Overall Height ................................ 4.7244" (120.000 mm)\
Valve Margin
Intake
Standard ..................................... .0394" (1.000 mm)\
Limit ......................................... .0197" (.500 mm)\
Exhaust
Standard ..................................... .0472" (1.200 mm)\
Limit ......................................... .0276" (.700 mm)\
Valve Height (Montero)
Intake
Standard .................................. 4.4213" (112.300 mm)\
Limit ..................................... 4.4016" (111.800 mm)\
Exhaust
Standard .................................. 4.4924" (114.110 mm)\
Limit ..................................... 4.4728" (113.610 mm)\
Stem Diameter
Intake ......................................... .2362" (6.000 mm)\
Exhaust ........................................ .2362" (6.000 mm)\
Stem to Guide Clearance
Intake
Standard ........................... .0008-.0020" (.020-.050 mm)\
Limit ......................................... .0039" (.100 mm)\

Exhaust
Standard ........................... .0016-.0028" (.040-.070 mm)\
Limit ......................................... .0059" (.150 mm)\
Valve Stem Projection (Montero)
Standard ..................................... 1.9409" (49.300 mm)\
Limit ........................................ 1.9606" (49.800 mm)\
Valve Face Angle ......................................... 45
-45.5Valve Spring
Free Height
Standard ................................... 2.0079" (51.000 mm)\
Limit ...................................... 1.9685" (50.000 mm)\
Out of Square
Standard ............................................ 2
Or Less
Limit ....................................................... 4Valve Seat Width ...................... .0354-.0512" (.900-1.300 mm)\
Valve Guide
Inner Diameter ................................. .2362" (6.000 mm)\
Outer Diameter ................................. .433" (11.000 mm)\
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PISTON & CONNECTING ROD
PISTON & CONNECTING ROD\
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Application In. (mm)\
Piston Diameter .................................... 3.6614 (93.000)\
Piston to Block Clearance (Diamante) ....... .0008-.0016 (.020-.040\
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Piston to Block Clearance (Montero) ........ .0012-.0020 (.030-.050\
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Piston Ring
No. 1
Ring to Groove Clearance
Standard ............................. .0012-.0028 (.030-.070)\
Limit ........................................... .0039 (.100)\
End Gap
Standard ............................. .0118-.0177 (.300-.450)\
Limit ........................................... .0315 (.800)\
No. 2
Ring to Groove Clearance
Standard ............................. .0008-.0024 (.020-.060)\
Limit ........................................... .0039 (.100)\
End Gap
Standard ............................. .0177-.0236 (.450-.600)\
Limit ........................................... .0315 (.800)\
Oil Control Ring
End Gap (Diamante)
Standard ............................. .0079-.0236 (.200-.600)\
Limit .......................................... .0394 (1.000)\
End Gap (Montero)
Standard ............................. .0039-.0138 (.100-.350)\
Limit .......................................... .0394 (1.000)\
Piston Pin
Outer Diameter
Standard ........................................ .8661 (22.000)\
Limit ............................................. .0039 (.100)\
Connecting Rod
Big End Side Clearance
Standard ............................... .0039-.0098 (.100-.250)\
Limit ............................................... .0157 (.4)\
Oil Clearance .......................... .0008-.0020 (.020-.050)\
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CRANKSHAFT

CRANKSHAFT\
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Application Specification
End Play
Standard ................................. .0020-.0098 (.050-.250)\
Limit ................................................. .0118 (.3)\
Journal Diameter
Diamante
Main Bearing ................................... 2.3622 (60.000)\
Rod Bearing .................................... 1.9685 (50.000)\
Montero
Main Bearing ................................... 2.5197 (64.000)\
Rod Bearing ................................................ (1)
Oil Clearance
Standard ................................. .0008-.0016 (.020-.040)\
Limit ................................................. .0039 (.1)\
Max. Out Of Round ..................................... .0002 (.005)\
Max. Taper ............................................ .0002 (.005)\
( 1) - See CRANKSHAFT PIN & CONNECTING ROD BEARING IDENTIFICATION
(MONTERO) table under REMOVAL & INSTALLATION.
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CYLINDER BLOCK
CYLINDER BLOCK\
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Application In. (mm)\
Warpage
Standard ............................................ .0020 (.050)\
Limit ............................................... .0039 (.100)\
Overall Height ..................... 8.2834-8.2913 (210.400-210.600)\
Cylinder Bore Diameter
Diamante ......................................... 3.6614 (93.000)\
Montero .......................................... 3.5866 (91.100)\
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g grams

GND or GRND Ground

GRN Green

GRY Gray

Ga. Gauge

Gals. gallons

Gov. Governor

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"H" ABBREVIATION TABLE
"H" ABBREVIATION TABLE\
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ABBREVIATION DEFINITION

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H/D Heavy Duty

HAC High Altitude Compensation

HC Hydrocarbons

HEDF High Speed Electro Drive Fan relay or circuit

HEGO Heated Exhaust Gas Oxygen Sensor

HEGOG HEGO Ground circuit

HEI High Energy Ignition

HLDT Headlight

HO High Output

HP High Performance

HSC High Swirl Combustion

HSO High Specific Output

HTR Heater

HVAC Heating

Headlt. Headlight

Hg Mercury

Hgt. Height

Htr. Heater

Hz Hertz (Cycles Per Second)

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"I" ABBREVIATION TABLE
"I" ABBREVIATION TABLE\
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ABBREVIATION DEFINITION

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I.D. Inside Diameter

IAC Idle Air Control

IACV Idle Air Control Valve

IC Integrated Circuit

ID Identification

IDM Ignition Diagnostic Monitor

IGN Ignition system or circuit

ILC Idle Load Compensator

In. Hg Inches of Mercury

INCH Lbs. Inch Pounds

INFL REST Inflatable Restraint

INJ Injector or Injection

IP Instrument Panel

IPC Instrument Panel Cluster

ISA Idle Speed Actuator

ISC Idle Speed Control

ISS Idle Stop Solenoid

ITS Idle Tracking Switch

IVSV Idle Vacuum Switching Valve

ADJUSTMENTS
* PLEASE READ FIRST *
NOTE: For adjustment information on brake pedal height, free play,
parking brake and stoplight switch, see BRAKE SYSTEM article.
WHEEL SPEED SENSOR (WSS)
NOTE: Rear WSS gap adjustment information is not available from
manufacturer.
Front WSS-To-Rotor Gap Adjustment
1) Raise and support vehicle. Remove wheel(s). Inspect senso\
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pole piece for damage. Repair if necessary. If sensor pole piece is
okay, check WSS-to-rotor gap.
2) Using a feeler gauge, check clearance between sensor pole
and rotor tooth surface. See Fig. 1. Front WSS sensor clearance should
be .008-.390" (0.2-1.0 mm). If clearance is not as specified, loosen
sensor mounting bolt. Adjust sensor position until clearance is within
specification. Tighten sensor mounting bolt to specification. See
TORQUE SPECIFICATIONS .
Fig. 1: Checking Front WSS-To-Rotor Gap
Courtesy of Mitsubishi Motor Sales of America.
TROUBLE SHOOTING
ANTI-LOCK WARNING LIGHT
1) Turn ignition on. ANTI-LOCK warning light should come on

BRAKE SYSTEM
1998 Mitsubishi Montero
1997-98 BRAKES
Mitsubishi - Disc & Drum
Diamante, Eclipse, Galant, Mirage, Montero, Montero Sport,
3000GT
INTRODUCTION
This article contains information on repair and service of
basic hydraulic brake system. If vehicle is equipped with anti-lock
brakes, also see appropriate ANTI-LOCK article.
DESCRIPTION
Brake system consists of a master cylinder, vacuum power
brake booster, proportioning valve and self-adjusting assembly.
Montero has a Load-Sensing Proportioning Valve (LSPV). All models are
equipped with front disc brakes and either rear disc or drum brakes.
Parking brake assembly activates rear brakes.
BLEEDING BRAKE SYSTEM
BLEEDING PROCEDURES
Bleed brakes whenever hydraulic lines are opened or pedal
feels spongy. Bleed system in appropriate sequence. See
BRAKE LINE BLEEDING SEQUENCE table. Use only DOT 3 or DOT 4 approved
fluid and DO NOT mix fluid types.
BRAKE LINE BLEEDING SEQUENCE
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Application Sequence
Diamante, Eclipse, Galant,
Mirage & 3000GT .................................... RR, LF, LR, RF
Montero ....................................... RR, LR, LSPV, RF, LF
Montero Sport ....................................... RR, LR, RF, LF
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ADJUSTMENTS
BRAKE PEDAL HEIGHT, FREE PLAY & CLEARANCE
1) To measure brake pedal height, pull up carpet under brake
pedal. Measure distance between floor board and middle of brake pedal
pad surface with brake pedal released. See BRAKE PEDAL HEIGHT
SPECIFICATIONS table.
2) To adjust pedal height, separate connector from stoplight
switch, and loosen switch lock nut. Back-off switch so it does not
contact brake pedal arm. Loosen master cylinder push rod lock nut.
Adjust brake pedal height by rotating master cylinder push rod until
brake pedal height is within specification.
BRAKE PEDAL HEIGHT SPECIFICATIONS
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Application Pedal Height: In. (mm)\

Diamante, Eclipse,
Montero Sport & Galant .......................... 6.9-7.1 (175-181)\
Mirage ........................................... 6.4-6.6 (164-167)\
Montero .......................................... 7.3-7.5 (186-191)\
3000GT ........................................... 7.0-7.2 (177-182)\
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3) Tighten lock nut, and ensure brake pedal height is within
specification. Start engine to evacuate brake booster chamber. Stop
engine, and apply brake several times to remove vacuum from brake
booster.
4) Using hand pressure, depress brake pedal to measure free
play before resistance is felt. Free play distance for all models is
0.10-0.31" (3-8 mm). If distance is not within specification, it is
probably caused by excessive play between the brake pedal arm and the
clevis pin. Check and replace as necessary.
5) Start engine and apply 110 lbs. (490 N) of pressure to
brake pedal. With the carpet pulled back, measure the distance between
the brake pedal and the floorboard. If the distance is not 3.1-3.5"
(80-90 mm) check for air in brake hydraulic system, brake adjustment
or defective parking brake component or adjustment. Adjust or repair
as necessary.
LOAD-SENSING PROPORTIONING VALVE (LSPV)
Montero
1) Park vehicle on level surface. Remove excess weight from
vehicle. Make sure the lever is all the way towards the valve side.
Measure length of entire spring. See Fig. 1.
If spring length is not within specification, adjust spring
support until correct length is obtained. See LSPV SPRING LENGTH
table.
Fig. 1: Adjusting Load-Sensing Proportioning Valve Spring (Montero)
Courtesy of Mitsubishi Motor Sales of America.
BRAKE BOOSTER PUSH ROD

POWER BRAKE BOOSTER
System Check
1) Run engine for 1-2 minutes. Shut engine off, and depress
brake pedal several times with normal pressure. If pedal height
gradually becomes higher with successive applications, power brake
booster is okay. If pedal height remains steady, power brake booster
is not operating properly, go to next step.
2) With engine stopped, depress brake pedal repeatedly until
pedal height no longer falls. Hold brake pedal down, and start engine.
If pedal moves downward slightly, power brake booster is okay. If
pedal height does not change, power brake booster is not operating
properly, go to next step.
3) With engine running, press and hold brake pedal. Shut off
engine. Hold brake pedal for 30 seconds. Brake pedal height should not
change. If pedal rises, power brake booster is not operating properly,
go to next step.
4) If brake booster operation is not as specified in each
step, disconnect vacuum hose at brake booster and check for sufficient
vacuum with engine running. Also check brake booster check valve
operation. Repair or replace as necessary.
Check Valve Inspection
Remove vacuum hose from power brake booster. Do not remove
check valve from hose. Check valve should hold vacuum in one direction
and allow air to pass in other direction.
LOAD-SENSING PROPORTIONING VALVE (LSPV)
Montero
1) Before diagnosing Load-Sensing Proportioning Valve (LSPV)\
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ensure all other brake components are operating properly. When all
other brake system components are determined to be okay, ensure LSPV
spring length is within specification. See Fig. 1. See LOAD-SENSING
PROPORTIONING VALVE (LSPV) under ADJUSTMENTS.
2) After spring length is determined to be within
specification, connect pressure gauges to input and output ports of
LSPV. See Fig. 7. Bleed brake system. See BLEEDING BRAKE SYSTEM.
Fig. 7: Connecting Pressure Gauges To LSPV (Montero)
Courtesy of Mitsubishi Motor Sales of America.
3) With vehicle unloaded at correct ride height and LSPV
spring correctly adjusted to 8.9" (227 mm), slowly depress brake pedal\

WHEEL CYLINDERS
Removal & Installation
Raise and support vehicle. Remove rear brake drum and shoes.
See REAR BRAKE DRUM & SHOES . Remove wheel cylinder and seal assembly.
To install, reverse removal procedure. Bleed brakes. See
BLEEDING BRAKE SYSTEM .
MASTER CYLINDER
Removal
Drain brake fluid from master cylinder. Remove sensor
connector (if equipped). Disconnect brake lines from master cylinder,
and install plugs to prevent brake fluid spillage. Remove master
cylinder from booster and separate reservoirs from housing (if
necessary).
Installation
To install, reverse removal procedure. Before installation,
check and adjust clearance between back of master cylinder piston and
power brake push rod. See MASTER CYLINDER PUSH ROD under ADJUSTMENTS.
After installation, adjust pedal height. See BRAKE PEDAL HEIGHT & FREE
PLAY under ADJUSTMENTS. Bleed brake system.
POWER BRAKE BOOSTER
Removal
Remove brake master cylinder. See MASTER CYLINDER. Disconnect
vacuum hose from power brake booster. Disconnect clevis pin attaching
brake pedal to power brake booster push rod. From inside vehicle,
remove 4 nuts attaching power brake booster to firewall. Remove power
brake booster.
Installation
To install, reverse removal procedure. Install master
cylinder. Bleed brake system if necessary.
POWER BRAKE BOOSTER CHECK VALVE
NOTE: To test check valve before removal, see POWER BRAKE BOOSTER
under TESTING.
Removal & Installation
Remove vacuum hose with check valve from power brake booster.
Loosen hose clamp(s) and remove check valve from hose on Mirage and
Summit. On all models, coat end(s) of check valve with sealant before
installation. Install valve with arrow (identification mark) pointing
toward intake manifold. Install and secure hose clamp(s).
REAR AXLE BEARINGS & OIL SEAL
Removal (Montero & Montero Sport)
1) With disc or drum removed, disconnect brake line from
caliper or wheel cylinder. Disconnect parking brake cable end, and
remove cable attaching bolts. Remove brake backing plate, bearing case
and axle shaft as an assembly. If axle shaft binds, use slide hammer
and puller to remove.
2) Remove shims, "O" ring and snap ring. Retain shims for
installation. Secure axle shaft assembly in a vise, and remove one
retainer bolt from backing plate. Push bearing case completely to side
of dust cover. Place adhesive tape around edge of bearing case at

CLUTCH
1998 Mitsubishi Montero
1997-98 CLUTCHES
Mitsubishi RWD
Montero, Montero Sport
DESCRIPTION
Clutch system uses diaphragm spring, single-disc type
clutches. Clutch is hydraulically operated.
ADJUSTMENTS
CLUTCH PEDAL FREE PLAY
1) Depress clutch pedal by hand until resistance is felt.
Measure clutch pedal free play. See CLUTCH PEDAL SPECIFICATIONS table.
See Fig. 1 .
2) If pedal free play needs to be adjusted, loosen lock nut
on clutch master cylinder push rod and rotate push rod to obtain
correct free play. Tighten lock nut. See Fig. 1. If depressed free
play cannot be adjusted, bleed system and inspect hydraulic and clutch
components.
CLUTCH PEDAL HEIGHT
1) Measure distance between face of clutch pedal and floor
board. See CLUTCH PEDAL SPECIFICATIONS table. See Fig. 1. To adjust
pedal height, disconnect clutch switch connector (if equipped).
2) Loosen master cylinder push rod lock nut. Rotate stopper,
clutch switch or clutch master cylinder push rod until correct pedal
height is obtained.
CLUTCH PEDAL SPECIFICATIONS
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Application In. (mm)\
Montero
Free Play ......................................... .24-.51 (6-13)\
Pedal Height
Pedal Depressed ( 1) ................................... 1.4 (35)
Pedal Released ............................... 7.3-7.5 (185-190)\
Montero Sport
Free Play ......................................... .24-.51 (6-13)\
Pedal Height
Pedal Depressed ( 1) ................................... 2.2 (56)
Pedal Released ....................................... 7.0 (178)\
( 1) - Specification given is minimum distance.
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