oil MITSUBISHI MONTERO 1998 Service Manual
Page 7 of 1501
Fig. 7: Cylinder Head Tightening Sequence
Courtesy of Mitsubishi Motor Sales of America.
Fig. 8: Oil Pan Tightening Sequence
Courtesy of Mitsubishi Motor Sales of America.
Page 13 of 1501
Fig. 16: Connecting Rod Identification Location (Montero)
Courtesy of Mitsubishi Motor Sales of America.
ENGINE OILING
OIL PUMP SPECIFICATIONS\
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Application Specification
Gear Side Clearance ..................... .0016-.0039" (.040-.10 mm)\
Gear-To-Front Cover Clearance
Standard .............................. .0039-.0071" (.10-.180 mm)\
Limit ........................................... .0138" (.350 mm)\
Tip to Tip Clearance ................... .0024-.0071" (.060-.180 mm)\
Minimum Warm Oil Pressure at Idle ............. 11.4 psi (.8 kg/cm
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TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS\
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Application Ft. Lbs. (N.m)\
Crankshaft Drive Plate ..................................... 55 (74)\
Crankshaft Main Bearing Cap Bolt
Diamante ................................................. 69 (93)\
Montero .................................................. 55 (74)\
Crankshaft Pulley Bolt ................................... 134 (182)\
Cylinder Head Bolt ( 1) .................................... 80 (108)
Distributor Lock Nut (Diamante) ............................ 17 (23\
)
Exhaust Manifold Nut ....................................... 21 (29)\
Generator & Drive Belt
Accessory Mount Bolt (Montero) ........................... 32 (44\
)
Page 14 of 1501
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\
)
Page 15 of 1501
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)\
Page 17 of 1501
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\
)
Piston to Block Clearance (Montero) ........ .0012-.0020 (.030-.050\
)
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
Page 18 of 1501
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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Page 26 of 1501
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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
Page 36 of 1501
A/C COMPRESSOR REFRIGERANT OIL CHECKING
1998 Mitsubishi Montero
1998 A/C SYSTEM GENERAL SERVICING
Mitsubishi - Compressor Refrigerant Oil Checking
Diamante, Eclipse, Galant, Mirage, Montero, Montero Sport &
3000GT
* PLEASE READ THIS FIRST *
NOTE: Always refer to underhood A/C specification label in engine
compartment or A/C compressor label while servicing A/C
system. If engine compartment/compressor label specifications
differ from specifications in this article, use
underhood/compressor label specifications.
A/C COMPRESSOR APPLICATIONS
A/C COMPRESSOR APPLICATION TABLE \
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Application Compressor
Diamante ......................... Sanden MSC105CVS Scroll
Eclipse
2.0L Non-Turbo ............. Nippondenso 10PA17C 10-Cyl.
2.0L Turbo & 2.4L .............. Sanden MSC105CVS Scroll
Galant ............................ Sanden MSC90C12 Scroll
Mirage ............................... Sanden MSC90 Scroll
Montero ....................... Nippondenso 10PA15 10-Cyl.
Montero Sport ...................... Sanden MSC105C Scroll
3000GT .............................. Sanden MSC105 Scroll
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REFRIGERANT OIL & REFRIGERANT CAPACITY SPECIFICATIONS
NOTE: DO NOT exceed A/C system refrigerant oil capacity when
servicing system.
REFRIGERANT OIL & R-134a REFRIGERANT CAPACITY TABLE
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Application ( 1) Oil Refrigerant
Ounces Ounces
Diamante .................... 5.7-6.4 ........ 22.9-24.3
Eclipse
2.0L Non-Turbo ............ 2.7-4.1 ........ 24.7-26.1
2.0L Turbo & 2.4L ......... 5.7-6.4 ........ 24.7-26.1
Galant ...................... 4.1-5.1 ........ 22.9-24.3
Mirage ...................... 4.1-5.1 ........ 19.6-21.0
Montero ..................... ( 2) 4.1 ........ 21.2-22.9
Montero Sport ............... ( 2) 5.7 ........ 22.9-24.0
3000GT ...................... 4.7-6.1 ........ 26.1-27.9
( 1) - Total system capacity, unless otherwise noted.
( 2) - Compressor refrigerant oil capacity.
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REFRIGERANT OIL
Page 37 of 1501
Only NEW, moisture-free refrigerant oil should be used in the
air conditioning system. This oil is highly refined and dehydrated so
moisture content is less than 10 parts per million. The oil container
must be tightly closed at all times when not in use, or moisture from
the air will be absorbed into the refrigerant oil.
SERVICING PRECAUTIONS
DISCHARGING SYSTEM
Discharge A/C system, using approved refrigerant
recovery/recycling equipment that meets SAE J2210 requirements. Always
follow recovery/recycling equipment manufacturer's instructions. After
refrigerant recovery process is completed, replace any refrigerant oil
removed with the same amount of NEW refrigerant oil.
DISCONNECTING LINES & FITTINGS
After system is discharged, carefully clean area around all
fittings to be opened. Always use 2 wrenches when tightening or
loosening fittings. Some refrigerant lines are connected with a
coupling. Special tools may be required to disconnect lines. Cap or
plug all openings as soon as lines are removed. DO NOT remove shipping
caps from replacement components until ready to install.
CONNECTING LINES & FITTINGS
NOTE: Ensure all replacement component connections match
connections of system being worked on.
Always use a NEW gasket or "O" ring when connecting lines or
fittings. Coat "O" ring with NEW refrigerant oil and ensure it is not
twisted during installation. Always use two wrenches to prevent damage
to lines and fittings.
PLACING SYSTEM IN OPERATION
After component service or replacement has been completed and
all connections have been made, thoroughly evacuate system with a
vacuum pump. Charge system with proper amount of refrigerant and
perform leak test. See REFRIGERANT OIL & REFRIGERANT SPECIFICATIONS
table for system capacities. Ensure there are no leaks at any fitting
that has been opened. After system has been leak tested, check system
performance.
NIPPONDENSO 10-CYL.
Eclipse 2.0L Non-Turbo & Montero
Replacement compressor is shipped with NEW refrigerant oil.
Drain, measure and discard refrigerant oil from old compressor. Drain
NEW refrigerant oil from replacement compressor equal to difference
between amount drained from old compressor and amount shipped in
replacement compressor. If any other components are replaced, add NEW
refrigerant oil as specified. See COMPONENT REFRIGERANT OIL CAPACITIES
(MITSUBISHI - NIPPONDENSO 10-CYL.) table.
COMPONENT REFRIGERANT OIL CAPACITIES TABLE (NIPPONDENSO)
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Component Ounces
Compressor ( 1)
Page 38 of 1501
Eclipse 2.0L Non-Turbo ............................. 3.4
Montero ............................................ 4.1
Condenser ............................................ 1.4
Evaporator ........................................... 1.4
Receiver-Drier ....................................... 0.3
Suction Hose ......................................... 0.3
(1) - If replacement compressor is shipped without
refrigerant oil, add same amount of NEW refrigerant
oil to replacement compressor that was drained from
old compressor.
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SANDEN SCROLL
Diamante, Eclipse 2.0L Turbo & 2.4L, Galant, Mirage, Montero
Sport and 3000GT
Replacement compressor is shipped with NEW refrigerant oil.
Drain, measure and discard refrigerant oil from old compressor. Drain
NEW refrigerant oil from replacement compressor equal to difference
between amount drained from old compressor and amount shipped in
replacement compressor. If any other components are replaced, add NEW
refrigerant oil as specified. See COMPONENT REFRIGERANT OIL CAPACITIES
(SANDEN SCROLL) table.
COMPONENT REFRIGERANT OIL CAPACITIES TABLE (SANDEN SCROLL)
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Component Ounces
Compressor ( 1)
Diamante, Eclipse 2.0L Turbo & 2.4L & Galant ... 5.7-6.4
Mirage ............................................. 4.4
3000GT ............................................. 5.4
Condenser
Diamante, Eclipse 2.0L Turbo & 2.4L,
Galant, Mirage & 3000GT ............................ 0.5
Evaporator
Diamante, Eclipse 2.0L Turbo & 2.4L,
Galant, Mirage & 3000GT ............................ 2.0
Receiver-Drier
Diamante, Eclipse 2.0L Turbo & 2.4L,
Galant, Mirage & 3000GT ............................ 0.3
Refrigerant Lines
Diamante, Eclipse 2.0L Turbo & 2.4L,
Galant, Mirage & 3000GT ............................ 0.3
( 1) - If replacement compressor is shipped without
refrigerant oil, add same amount of NEW refrigerant
oil to replacement compressor that was drained from
old compressor.
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