open MITSUBISHI MONTERO 1998 Service Manual
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 1998, Model line: MONTERO, Model: MITSUBISHI MONTERO 1998Pages: 1501, PDF Size: 25.81 MB
Page 777 of 1501
GENERAL COOLING SYSTEM SERVICING
1998 Mitsubishi Montero
GENERAL INFORMATION
General Cooling System Servicing
* PLEASE READ THIS FIRST *
The following article is for general information only.
Information may not apply to all years, makes and models. See specific
article in the ENGINE COOLING section.
DESCRIPTION
The basic liquid cooling system consists of a radiator, water
pump, thermostat, electric or belt-driven cooling fan, pressure cap,
heater, and various connecting hoses and cooling passages in the block
and cylinder head.
MAINTENANCE
DRAINING
Remove radiator cap and open heater control valve to maximum
heat position. Open drain cocks or remove plugs in bottom of radiator
and engine block. In-line engines usually have one plug or drain cock,
while "V" type engines will have 2, one in each bank of cylinders.
CLEANING
A good cleaning compound removes most rust and scale. Follow
manufacturer's instructions in the use of cleaner. If considerable
rust and scale has to be removed, cooling system should be flushed.
Clean radiator air passages with compressed air.
FLUSHING
CAUTION: Some manufacturers use an aluminum and plastic radiator.
Flushing solution must be compatible with aluminum.
Back Flushing
Back flushing is an effective means of removing cooling
system rust and scale. The radiator, engine and heater core should be
flushed separately.
Radiator
To flush radiator, connect flushing gun to water outlet of
radiator and disconnect water inlet hose. To prevent flooding engine,
use a hose connected to radiator inlet. Use air in short bursts to
prevent damage to radiator. Continue flushing until water runs clear.
Engine
To flush engine, remove thermostat and replace housing.
Connect flushing gun to water outlet of engine. Flush using short air
bursts until water runs clean.
Heater Core
Flush heater core as described for radiator. Ensure heater
control valve is set to maximum heat position before flushing heater.
Page 778 of 1501
REFILLING
To prevent air from being trapped in engine block, engine
should be running when refilling cooling system. After system is full,
continue running engine until thermostat is open, then recheck fill
level. Do not overfill system.
TESTING
THERMOSTAT
1) Visually inspect thermostat for corrosion and proper
sealing of valve and seat. If okay, suspend thermostat and thermometer
in a 50/50 mixture of coolant and water. See Fig. 1. Do not allow
thermostat or thermometer to touch bottom of container. Heat water
until thermostat just begins to open.
2) Read temperature on thermometer. This is the initial
opening temperature and should be within specification. Continue
heating water until thermostat is fully open and note temperature.
This is the fully opened temperature. If either reading is not to
specification, replace thermostat.
Fig. 1: Testing Thermostat in Anti-Freeze/Water Solution
PRESSURE TESTING
A pressure tester is used to check both radiator cap and
Page 782 of 1501
GENERATOR OUTPUT TEST
NOTE: A slightly discharged battery should be used, as a fully
charged battery may not allow full generator output.
1) Turn ignition off. Disconnect negative battery cable.
Disconnect generator output wire from terminal "B". Connect positive
lead of 100-amp ammeter to terminal "B" and negative lead to
disconnected output lead.
CAUTION: Tighten each connection securely, as heavy current flow will
exist. DO NOT use clips on ammeter. An inductive-type
ammeter is recommended.
2) Connect positive voltmeter lead (0-20 volts) to generator\
terminal "B" and negative lead to ground. Install a tachometer and
reconnect negative battery cable.
3) Ensure voltmeter indicates battery voltage. If voltage is
not present, check for open circuit in wire between generator terminal
"B" and positive battery terminal. Check grounds and fusible link.
4) Start engine and turn headlights on. Set headlights at
high beam and heater blower switch on HIGH. Increase engine speed to
2500 RPM and note generator output current on ammeter. Minimum output
should be within specification. See
GENERATOR MINIMUM OUTPUT SPECIFICATIONS table.
NOTE: Output voltage changes with electrical load and temperature.
Ensure proper electrical load is applied while checking
output. Nominal output may not be obtained if generator or
ambient temperature is excessive. Allow generator or
temperature to cool, and recheck output. Generator output is
stamped on metal plate attached to generator case.
5) If minimum output is not obtained and generator wiring is
okay, repair generator. Operate engine at idle speed after the test.
GENERATOR MINIMUM OUTPUT SPECIFICATIONS TABLE
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Application Amps
Diamante ............................................. 110
Eclipse
2.0L Non-Turbo ...................................... 90
2.0L Turbo .......................................... 75
2.4L ................................................ 90
Galant ................................................ 90
Mirage ................................................ 80
Montero .............................................. 100
Montero Sport
2.4L ................................................ 60
3.0L ................................................ 85
3000GT
DOHC ............................................... 110
SOHC ................................................ 90
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REGULATED VOLTAGE TEST
NOTE: Ensure battery is fully charged and proper drive belt
tension exists.
1) Turn ignition switch off. Disconnect negative battery
cable. Connect positive voltmeter lead to terminal "S" of generator.
Page 783 of 1501
See Fig. 1 . Connect negative voltmeter lead to ground.
2) Disconnect generator output wire from terminal "B".
Install a 100-amp ammeter in series with terminal "B" and disconnected
output lead. Connect positive lead of ammeter to terminal "B" and
negative lead to disconnected output wire. Install a tachometer, and
reconnect negative battery cable.
3) Turn ignition switch on and ensure voltmeter indicates
battery voltage. If voltage is not present, check for open in wire
between generator terminal "S" and positive battery terminal. Check
for blown fusible link.
4) Start engine. Ensure all lights and accessories are off.
Operate engine at 2500 RPM and read voltmeter when generator output
current drops to 10 amps or less. Voltage regulator is okay if voltage
output is within specification. See REGULATOR VOLTAGE SPECIFICATIONS
table.
REGULATOR VOLTAGE SPECIFICATIONS TABLE
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Ambient Temperature Voltage
-4
F (-20C) ................................... 14.2-15.4
68F (20C) .................................... 13.9-14.9
140F (60C) ................................... 13.4-14.6
176F (80C) ................................... 13.1-14.5 \
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GENERATOR RELAY TEST
NOTE: Information for all other models is not available from
manufacturer at time of publication.
Diamante & Mirage
Remove generator relay. On Diamante, relay is located in
relay box in engine compartment near battery. On Mirage, relay is
located in relay box in engine compartment between battery and strut
tower. On both models, connect positive lead of ohmmeter to relay
terminal No. 4. See WIRING DIAGRAMS. Connect negative lead of ohmmeter
to relay terminal No. 2. Continuity should be present. Switch ohmmeter
lead locations. Continuity should not be present. Replace generator
relay if continuity is not as specified.
BENCH TESTING
RECTIFIER ASSEMBLY
1) Using ohmmeter, check for continuity between diodes and
stator coil lead connection. See Fig. 2. Reverse leads. If continuity
is present in both directions, diode is shorted. Replace rectifier
assembly.
2) To check entire diode assembly, use an ohmmeter to check
for continuity between both ends of each diode. See Fig. 2. Switch
ohmmeter leads. Continuity should be present in one direction only. If
continuity is not as specified, diode is defective. Replace rectifier
assembly.
Page 800 of 1501
This lever is used to select source of airflow. With lever at
fresh air setting, outside air is allowed to enter and/or pass through
heater. With lever at recirculated air setting, air is recirculated
inside passenger compartment.
FRONT BLOWER SWITCH
Front blower switch controls fan speeds to regulate amount of
airflow. Fan speed increases as switch is turned/moved to far right.
COOL AIR BY-PASS KNOB
With heater in floor, defrost/floor or defrost mode, turning
knob to far left allows cool air to enter passenger compartment
through center vent.
FRONT MODE SELECTOR KNOB/LEVER
Depending on position selected, airflow can be directed to
different areas of passenger compartment. Airflow selection
capabilities include individual areas or a combination of windshield,
upper body, knee and/or foot area.
TEMPERATURE CONTROL
Temperature control is adjusted by moving control lever or
turning control knob to left or right. Temperature control cable opens
and closes heater control valve, which determines heat output. Highest
heat setting is attained when lever/knob at far right position. With
temperature lever/knob at cool setting, ambient air is used for
ventilating.
ADJUSTMENTS
FRONT FRESH/RECIRCULATED AIR SELECTOR CABLE
Place air selector lever at recirculated air setting. Press
damper lever inward, in direction of arrow. See Fig. 2. Connect inner
wire of fresh/recirculated air selector cable to damper lever. Secure
outer wire of selector cable with clip.
Fig. 2: Adjusting Front Fresh/Recirculated Air Selector Cable
Courtesy of Mitsubishi Motor Sales of America.
FRONT MODE SELECTOR CABLE
Page 817 of 1501
I - SYSTEM/COMPONENT TESTS
1998 Mitsubishi Montero
1998 ENGINE PERFORMANCE
Mitsubishi - System & Component Testing
Diamante, Eclipse, Galant, Mirage, Montero, Montero Sport,
3000GT
INTRODUCTION
NOTE: Testing individual components does not isolate shorts or
opens. Perform all voltage tests using a Digital
Volt-Ohmmeter (DVOM) with minimum 10-megohm input impedance,
unless stated otherwise in test procedure. Use ohmmeter to
isolate wiring harness shorts or opens. Testing procedures
not covered in this article require a scan tool. See
G - TESTS W/CODES article.
Before testing separate components or systems, perform basic
diagnostic procedures in F - BASIC TESTING article. Since many
computer-controlled and monitored components set a diagnostic trouble
code if they malfunction, also perform self-diagnostics in G - TESTS
W/CODES article.
AIR INDUCTION SYSTEMS
TURBOCHARGER
Turbocharger Pressure Check
1) Disconnect Black turbocharger pressure control hose at
wastegate solenoid valve, and plug valve nipple. Attach pressure gauge
to hose. Drive vehicle and accelerate engine, in 2nd gear, to 3500 RPM
or more. Check turbocharger pressure when pressure gauge stabilizes.
See TURBOCHARGER PRESSURE SPECIFICATIONS table.
2) If pressure gauge reading is more than specified, check
wastegate actuator. See DTCs P1103 and P1104 in G - TESTS W/CODES
article. Replace wastegate actuator as required. If pressure gauge
reading is less than specified, check for malfunctioning wastegate
valve, turbocharger pressure leaks and faulty turbocharger.
TURBOCHARGER PRESSURE SPECIFICATIONS TABLE
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Application Pressure psi (kg/cm)
Eclipse ................................ 6.4-14.7 (.4-1.0)
3000GT ................................... 2.9-8.7 (.2-.6)
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Air By-Pass Valve
Remove air by-pass valve. Valve is mounted to intake air duct
between air-to-air intercooler and intake plenum. Apply vacuum to
diaphragm of vacuum valve. Valve should begin opening at approximately
16 in. Hg. Observe operation of valve through by-pass opening.
Wastegate Actuator Test
Actuator is mounted on turbocharger. For testing procedures,
see DTCs P1103 and P1104 in G - TESTS W/CODES article.
Wastegate Control Solenoid Valve Test
On Eclipse, valve is mounted to top back section of air
cleaner. On 3000GT, valve is mounted to firewall, beside EGR solenoid.
Page 818 of 1501
For testing procedures, see DTCs P1103 and P1104 in G - TESTS W/CODES
article.
COMPUTERIZED ENGINE CONTROLS
CONTROL UNIT
NOTE: For Powertrain Control Module (PCM) location, see
POWERTRAIN CONTROL MODULE (PCM) LOCATION table. To identify
PCM power and ground terminals, see appropriate pin voltage
chart in J - PIN VOLTAGE CHARTS article. To identify PCM
power and ground circuits, see appropriate wiring diagram in
L - WIRING DIAGRAMS article.
Ground Circuits
1) Turn ignition off. Using an ohmmeter, check continuity
between chassis ground and PCM ground terminal(s). See Figs. 1-5.
Ohmmeter should indicate zero ohms. If reading is not as specified,
check and repair open circuit between PCM connector and chassis
ground. If reading is as specified, go to next step.
2) Connect voltmeter negative lead to chassis ground. Connect
positive lead to PCM ground terminal(s). With engine running,
voltmeter should indicate less than one volt. If reading is more than
one volt, check for open, corrosion or loose connection in ground
circuit.
Power Circuits
Turn ignition on. Check for battery voltage on both PCM power
terminals. See Figs. 1-5. If battery voltage is not present, check
operation of MFI relay. See RELAYS under MOTORS, RELAYS & SOLENOIDS.
POWERTRAIN CONTROL MODULE (PCM) LOCATION TABLE
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Application Location
Eclipse 2.0L Non-Turbo .................. In Front Of Left
Front Strut Tower
Mirage & Montero Sport .............. Behind Right Side Of
Instrument Panel (Glove Box)
Montero ........................... Right Front Kick Panel
All Other Models ................... Behind Center Console
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Fig. 1: Identifying PCM Terminals (Diamante)
Courtesy of Mitsubishi Motor Sales of America
Fig. 2: Identifying PCM Terminals (Eclipse 2.0L Non-Turbo)
Courtesy of Mitsubishi Motor Sales of America
Page 874 of 1501
J - PIN VOLTAGE CHARTS
1998 Mitsubishi Montero
1998 ENGINE PERFORMANCE
Mitsubishi - Pin Voltage Charts
Diamante, Eclipse, Galant, Mirage, Montero, Montero Sport,
3000GT
INTRODUCTION
NOTE: Unless stated otherwise in testing procedures, perform all
voltage tests using a Digital Volt-Ohmmeter (DVOM) with a
minimum 10-megohm input impedance. Voltage readings may vary
slightly due to battery condition or charging rate.
Pin voltage charts are supplied to reduce diagnostic time.
Checking pin voltages at the PCM connector determines whether it is
receiving and transmitting proper voltage signals. Diagnostic charts
may also help determine if PCM harness is shorted or open.
TEST PROCEDURE
CAUTION: Shorting positive DVOM lead between connector terminal and
ground could damage vehicle wiring, sensor and PCM.
1) If necessary, remove Powertrain Control Module (PCM) to
access harness connector. For PCM location, see PCM LOCATION table.
Leave PCM connectors connected.
2) Using DVOM, backprobe terminals. Connect positive DVOM
lead to appropriate PCM terminal. Connect negative DVOM lead to PCM
ground terminal. For PCM terminal identification, see appropriate
chart. See Figs. 1-24.
3) All measurements are applicable to vehicle at normal
operating temperature at sea level. Unless otherwise noted, engine is
idling when specification requires engine running. Ensure transmission
shift selector is in Neutral or Park (as applicable). If DVOM displays\
measurement that is not within specification, see G - TESTS W/CODES
article.
PCM LOCATION TABLE
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Application Location
Eclipse 2.0L Non-Turbo ............ In Front of Left Front
Strut Tower
Mirage & Montero Sport .............. Behind Right Side Of
Instrument Panel (Glove Box)
Montero ........................... Right Front Kick Panel
All Others ......................... Behind Center Console
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Fig. 1: Identifying PCM Terminals (Diamante)
Courtesy of Mitsubishi Motor Sales of America
Page 898 of 1501
Fig. 4: IAT Sensor Terminals (All Other Models)
Courtesy of Mitsubishi Motor Sales of America
Throttle Position (TP) Sensor
Measure total and variable resistance between specified TP
sensor terminals. See Fig. 5 or 6. See
TP SENSOR TEST TERMINAL IDENTIFICATION table. Total resistance should
be 3500-6500 ohms. Variable resistance should change smoothly between
3500 and 6500 ohms as throttle valve is moved from closed to wide open
throttle.
TP SENSOR TEST TERMINAL IDENTIFICATION TABLE
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Application Terminals No.
Total Resistance
Eclipse 2.0L Non-Turbo ........................... 1 & 3
All Other Models ................................. 1 & 4
Variable Resistance
Eclipse 2.0L Non-Turbo ........................... 2 & 3
Diamante, Montero & Montero Sport 3.0L ........... 1 & 3
All Other Models ................................. 2 & 4
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Fig. 5: Identifying TP Sensor Terminals (Eclipse 2.0L Non-Turbo)
Courtesy of Mitsubishi Motor Sales of America
Page 968 of 1501
allowing metal objects to contact the battery posts and the
vehicle at the same time.
CAUTION: Never disconnect the battery while the engine is running;
doing so could damage the car's electrical components.
REPLACING BLOWN FUSES
Before replacing a blown fuse, remove ignition key, turn off
all lights and accessories to avoid damaging the electrical system. Be
sure to use fuse with the correct indicated amperage rating. The use
of an incorrect amperage rating fuse may result in a dangerous
electrical system overload.
BRAKE PAD WEAR INDICATOR
Indicator will cause a squealing or scraping noise, warning
that brake pads need replacement.
BRAKE FLUID
WARNING: DO NOT use reclaimed fluid or fluid that has been stored
in old or open containers. It is essential that foreign
particles and other liquids are kept out of the brake fluid
reservoir.
CATALYTIC CONVERTER
Continued operation of vehicle with a severe malfunction
could cause converter to overheat, resulting in possible damage to
converter and vehicle.
ENGINE COOLANT SERVICE
WARNING: To avoid the danger of being scalded never change the coolant
when the engine is hot.
WARNING: Never remove the radiator cap when the engine is hot Serious
burns could be caused by high pressure fluid escaping from
the radiator.
CAUTION: When adding or replacing engine coolant, use a high quality
ethylene glycol antifreeze diluted with 50% distilled water.
When putting the cap on the reserve tank, line up the arrow
on the cap and the arrow on the tank, or coolant can leak out
ENGINE DRIVE BELT SERVICE
WARNING: Be sure the ignition key is OFF. The engine could rotate
unexpectedly.
ENGINE OIL
WARNING: The engine oil may be high enough to burn your fingers
when the drain plug is loosened. Wait until the drain plug
is cool enough to touch with you bare hands.
WARNING: Continuous contact with used engine oil has been found to
cause skin cancer in laboratory animals. Brief contact with
used engine oil may irritate skin. To minimize your exposure
to used oil, wear a long sleeve shirt and moisture-proof
gloves when changing oil. If oil contacts your skin, wash