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 1228 of 1501
SUN ROOF R & I
Removal & Installation (Eclipse & Galant)
1) Remove side trim covers by lightly pulling panels straight
down. Unbolt and remove roof glass panel with adjust plates. See
Fig. 1 . Operate sun roof drive cable assembly to fully open position.
Remove deflector. Remove guide rail cover. Operate sun roof drive
cable assembly to fully closed position and remove rear drip channel.
2) Remove overhead switch assembly. Remove rear seat. Push
down on rear seat cushion and pull seat release lever. Unbolt and
remove seat back. Remove front and rear door scuff plate.
3) Remove center pillar lower and upper trim. Remove roof
rail and sun roof trim strips. Remove front and rear pillar trim.
Remove assist handle. Remove headliner. Disconnect motor harness
connector. Remove motor mounting bolts and remove motor.
4) Attach protective tape around roof opening. Pull sliding
roof assembly forward through roof opening. Disconnect drain hoses. If
drain hoses need replacement, attach cord to exterior end of drain
hose. Pull drain hose from interior end. Remove housing assembly and
set brackets.
5) To install components, reverse removal procedure. Sun roof
drive cables must be properly indexed to drive motor drive gear.
Remove drive motor cam gear cover. Using manual closure wrench
(included in tool pouch), rotate motor to correct position. See
Fig. 12 . Install motor. Install remaining components. To adjust roof
glass panel, see SUN ROOF GLASS FIT under ADJUSTMENTS.
Removal & Installation (Montero)
1) Remove trim covers. Unbolt roof glass panel from sliding
assembly and remove. Remove sun roof switch assembly and drive motor.
Remove front and rear door scuff plate.
2) Remove center pillar lower and upper trim. Remove roof
rail and sun roof trim strips. Remove front and rear pillar trim.
Remove assist handle. Remove headliner. Remove rear set bracket.
Remove sun roof assembly. Disconnect drain hoses.
3) If drain hoses need replacement, attach cord to exterior
end of drain hose. Pull drain hose from interior end. To install
components, reverse removal procedure. See DRIVE MOTOR R & I for
installation procedures.
Removal & Installation (Montero Sport & 3000GT)
Remove sun roof switch and dome light assembly. Remove
bracket behind dome light. Remove headliner. Remove drain hose
retaining clips and remove drain hose. Remove sun roof assembly. To
install, reverse removal procedure.
WIRING DIAGRAMS
Page 1255 of 1501
![MITSUBISHI MONTERO 1998 Service Manual \
\
\
\
\
\
\
AIR RIDE SUSPENSION - WARNING LAMPS
AIR RIDE SU](/img/19/57333/w960_57333-1254.png "MITSUBISHI MONTERO 1998 Service Manual \
\
\
\
\
\
\
AIR RIDE SUSPENSION - WARNING LAMPS
AIR RIDE SU")
\
\
\
\
\
\
\
AIR RIDE SUSPENSION - WARNING LAMPS
AIR RIDE SUSPENSION - WARNING LAMP INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Bulb burned out ......... A ............ Require replacement.
Warning light does
not come on during
bulb check ............. .. . Further inspection required to
determine cause.
Warning light flashes ... .. . Further inspection required to
determine cause.
Warning light is
intermittent ........... .. . Further inspection required to
determine cause.
Warning light stays
on after initial
bulb check ............. .. . Further inspection required to
determine cause.
\
\
\
\
\
\
\
AIR RIDE SUSPENSION - WIRING HARNESSES
AIR RIDE SUSPENSION - WIRING HARNESS INSPECTION \
\
\
\
\
\
\
Condition Code Procedure
Connector bent .......... A .. Require repair or replacement.
Connector broken ........ A .. Require repair or replacement.
Connector loose ......... A .. Require repair or replacement.
Damaged (cut, burned, or
chafed) ................ A .. Require repair or replacement.
Excessive resistance .... B .. Require repair or replacement.
Fuse blown .............. A ............ Require replacement.
Fusible link blown ...... A ............ Require replacement.
Open .................... A .. Require repair or replacement.
Poor ground ............. A .. Require repair or replacement.
Routed incorrectly ...... B .. Require rerouting according to
vehicle manufacturer's
specifications.
Shorted ................. A .. Require repair or replacement.
Terminal bent ........... A .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal corroded ....... A .. Require repair or replacement.
Terminal loose .......... A .. Require repair or replacement.
\
\
\
\
\
\
\
BALL JOINTS
Before requiring or suggesting ball joint replacement, the
approved OEM procedure must be used to measure ball joint wear. The
measurement(s) obtained, along with the vehicle manufacturer's
specifications, must be noted on the inspection report. Some states
require that these measurements also appear on the invoice.
NOTE: The term "perceptible movement," defined as any visible
movement in any direction, has been the industry standard
for determining the need for replacement of follower ball
joints. Some vehicle manufacturers are now publishing
specifications for follower ball joints that were
Page 1370 of 1501
![MITSUBISHI MONTERO 1998 Service Manual \
OK NOT OK
\b](/img/19/57333/w960_57333-1369.png "MITSUBISHI MONTERO 1998 Service Manual \
OK NOT OK
\b")
\
OK NOT OK
\b \b
\
\
\
\
\
\
* Check Pick-Up coil for * Adjust or replace as
correct resistance value. necessary.
\
\
\
\b
\
\
\
\b
\
\
\
\
NOT OK OK
\b \b
\
\
\
\
\
\
* Replace Pick-Up coil if * Check control module for
not to specification. good ground connections.
\
\
\
\b
\
\
\
\b
OK
\b
\
\
\
\
\
* If vehicle fails to run at this point, go to
the appropriate article in the ENGINE
PERFORMANCE section.
\
\
\
\
\
\b
\
\
\
\b
\
\
\
\
\
OK NOT OK
\b \b
\
\
\
\
\
\
* Check wires from the battery/ * Replace ballast resistor
ignition switch to the coil. if the measured resistance
Also check the coil primary value is not within
and secondary resistance. specification.
\
\
\
\b
\
\
\
\b
STARTER TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
BASIC STARTER TROUBLE SHOOTING CHART
\
\
\
\
\
\
\
CONDITION POSSIBLE CAUSE CORRECTION \
\
\
\
\
\
\
Starter Fails Dead battery or bad Check battery charge
to Operate connections between and all wires and
starter and battery connections to starter
Ignition switch faulty Adjust or replace
or misadjusted ignition switch
Open circuit between Check and repair wires
starter switch ignition and connections as
terminal on starter relay necessary
Starter relay or starter See Testing in STARTER
defective article
Page 1371 of 1501
![MITSUBISHI MONTERO 1998 Service Manual Open solenoid pull-in See Testing in STARTER
wire article
\
\
\](/img/19/57333/w960_57333-1370.png "MITSUBISHI MONTERO 1998 Service Manual Open solenoid pull-in See Testing in STARTER
wire article
\
\
\")
Open solenoid pull-in See Testing in STARTER
wire article
\
\
\
\
\
\
\
Starter Does Not Weak battery or dead Charge or replace
Operate and cell battery as necessary
Headlights Dim
Loose or corroded battery Check that battery
connections connections are clean
and tight
Internal ground in See Testing in STARTER
starter windings article
Grounded starter fields See Testing in STARTERS
Armature rubbing on pole See STARTER article
shoes
\
\
\
\
\
\
\
Starter Turns Starter clutch slipping See STARTER article
but Engine
Does Not Rotate
Broken clutch housing See STARTER article
Pinion shaft rusted or See STARTER article
dry
Engine basic timing See Ignition Timing in
incorrect TUNE-UP article
Broken teeth on engine Replace flywheel and
flywheel check for starter pinion
gear damage
\
\
\
\
\
\
\
Starter Will Not Faulty overrunning See STARTER article
Crank Engine clutch
Broken clutch housing See STARTER article
Broken flywheel teeth Replace flywheel and
check for starter pinion
gear damage
Armature shaft sheared See STARTER article
or reduction gear teeth
stripped
Weak battery Charge or replace
battery as necessary
Faulty solenoid See On-Vehicle Tests in
STARTER article
Poor grounds Check all ground
connections for
tight and clean
connections
Ignition switch faulty Adjust or replace
or misadjusted ignition switch as
necessary
\
\
\
\
\
\
\
Starter Cranks Battery weak or Charge or replace
Engine Slowly defective battery as necessary
Page 1373 of 1501
![MITSUBISHI MONTERO 1998 Service Manual \
\
\
\
\
\
\
Starter Drive Starter motor loose on](/img/19/57333/w960_57333-1372.png "MITSUBISHI MONTERO 1998 Service Manual \
\
\
\
\
\
\
Starter Drive Starter motor loose on")
\
\
\
\
\
\
\
Starter Drive Starter motor loose on Tighten starter
Will Not mountings attach bolts
Disengage
Worn drive end bushing See STARTER article
Damaged engine flywheel Replace flywheel and
teeth starter pinion gear for
damage
Drive yolk return spring Replace return spring
broken or missing
Faulty ignition switch Replace ignition switch
Insufficient clearance Replace starter
between winding leads to solenoid
solenoid terminal and main
contact in solenoid
Starter clutch not Replace starter clutch
disengaging
Ignition starter switch Replace ignition switch
contacts sticking
\
\
\
\
\
\
\
Starter Relay Faulty solenoid switch, Check all wiring
Operates but switch connections or between relay and
Solenoid Does Not solenoid or replace
relay or solenoid as
necessary
Broken lead or loose Repair wire or wire
soldered connections connections as
necessary
\
\
\
\
\
\
\
Solenoid Plunger Weak battery Charge or replace
Vibrates When battery as necessary
Switch is Engaged
Solenoid contacts Clean contacts or
corroded replace solenoid
Faulty wiring Check all wiring
leading to solenoid
Broken connections inside Repair connections or
switch cover replace solenoid
Open hold-in wire Replace solenoid
\
\
\
\
\
\
\
Low Current Draw Worn brushes or weak Replace brushes or
brush springs as
necessary
\
\
\
\
\
\
\
High Pitched Whine Distance too great Align starter or check
During Cranking between starter that correct starter
Before Engine pinion and flywheel and flywheel are being
Fires but Engine used
Fires and Cranks
Normally
\
\
\
\
\
\
\
High Pitched Distance too small between
Whine After Engine starter pinion and flywheel
Page 1374 of 1501
![MITSUBISHI MONTERO 1998 Service Manual Fires With Key Flywheel runout contributes
released. Engine to the intermittent nature
Fires and Cranks
Normally
\
\
\
\](/img/19/57333/w960_57333-1373.png "MITSUBISHI MONTERO 1998 Service Manual Fires With Key Flywheel runout contributes
released. Engine to the intermittent nature
Fires and Cranks
Normally
\
\
\
\")
Fires With Key Flywheel runout contributes
released. Engine to the intermittent nature
Fires and Cranks
Normally
\
\
\
\
\
\
\
AIR CONDITIONING & HEAT
AIR CONDITIONING TROUBLE SHOOTING
WARNING: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
BASIC AIR CONDITIONING TROUBLE SHOOTING CHART
\
\
\
\
\
\
\
CONDITION POSSIBLE CAUSE \
\
\
\
\
\
\
Compressor Not Working
Compressor clutch circuit open.
Compressor clutch coil inoperative.
Poor clutch ground connection.
Fan belts loose.
Thermostatic switch inoperative.
Thermostatic switch not adjusted.
Ambient temperature switch open.
Superheat fuse blown. \
\
\
\
\
\
\
Excessive Noise or Vibration
Missing or loose mounting bolts.
Bad idler pulley bearings.
Fan belts not tightened correctly.
Compressor clutch contacting body.
Excessive system pressure.
Compressor oil level low.
Damaged clutch bearings.
Damaged reed valves.
Damaged compressor. \
\
\
\
\
\
\
Insufficient or No Cooling;
Compressor Working
Expansion valve inoperative.
Heater control valve stuck open.
Low system pressure.
Blocked condenser fins.
Blocked evaporator fins.
Vacuum system leak.
Vacuum motors inoperative.
Control cables improperly adjusted.
Restricted air inlet.
Mode doors binding.
Blower motor inoperative.
Temperature above system capacity. \
\
\
\
\
\
\
HEATER SYSTEM TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
Page 1375 of 1501
problem symptoms. For model-specific Trouble Shooting,
refer to DIAGNOSTIC, or TESTING articles available in the
section(s) you are accessing.
BASIC HEATER SYSTEM TROUBLE SHOOTING CHART
\
\
\
\
\
\
\
CONDITION POSSIBLE CAUSE \
\
\
\
\
\
\
Insufficient, Erratic,
or No Heat
Low Coolant Level
Incorrect thermostat.
Restricted coolant flow through
heater core.
Heater hoses plugged.
Misadjusted control cable.
Sticking heater control valve.
Vacuum hose leaking.
Vacuum hose blocked.
Vacuum motors inoperative.
Blocked air inlet.
Inoperative heater blower motor.
Oil residue on heater core fins.
Dirt on heater core fins. \
\
\
\
\
\
\
Too Much Heat
Improperly adjusted cables.
Sticking heater control valve.
No vacuum to heater control valve.
Temperature door stuck open. \
\
\
\
\
\
\
Air Flow Changes During
Acceleration
Vacuum system leak.
Bad check valve or reservoir. \
\
\
\
\
\
\
Air From Defroster At All
Times
Vacuum system leak.
Improperly adjusted control cables.
Inoperative vacuum motor. \
\
\
\
\
\
\
Blower Does Not Operate
Correctly
Blown fuse.
Blower motor windings open.
Resistors burned out.
Motor ground connection loose.
Wiring harness connections loose.
Blower motor switch inoperative.
Blower relay inoperative.
Fan binding or foreign object
in housing.
Fan blades broken or bent. \
\
\
\
\
\
\
BRAKES
BRAKE SYSTEM TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
Page 1389 of 1501
Air in fuel system Bleed air from system
Incorrect or contaminated Replace fuel
fuel
Injector nozzle malfunction Check nozzles, see
FUEL SYSTEMS
\
\
\
\
\
\
\
Engines Starts Injection pump timing Reset pump timing, see
and Idles Rough incorrect FUEL SYSTEMS
W/out Smoke or Engine not fully broken in Put more miles on
Noise, But Clears engine
After Warm-Up Air in system Bleed air from system
Injector nozzle malfunction Check nozzles, see
FUEL SYSTEMS
\
\
\
\
\
\
\
Engine Idles Blocked fuel filter Replace fuel filter
Correctly, Injection pump timing Reset pump timing, see
Misfires Above incorrect FUEL SYSTEMS
Idle Incorrect or contaminated Replace fuel
fuel
\
\
\
\
\
\
\
Engine Won't Fast idle adjustment Reset fast idle, see
Return To Idle incorrect TUNE-UP
Internal injection pump Replace injection pump,
malfunction see FUEL SYSTEMS
External linkage binding Check linkage and
remove binding
\
\
\
\
\
\
\
Fuel Leaks On Loose or broken fuel line Check lines and
Ground connections
Internal injection pump Replace injection pump,
seal leak see FUEL SYSTEMS
\
\
\
\
\
\
\
Cylinder Injector nozzles sticking Test injectors, see
Knocking Noise open FUEL SYSTEMS
Very low nozzle opening Test injectors and/or
pressure replace
\
\
\
\
\
\
\
Loss of Engine Restricted air intake Remove restriction
Power EGR valve malfunction Replace EGR valve
Blocked or damaged exhaust Remove restriction
system and/or replace
components
Blocked fuel tank filter Replace filter
Restricted fuel filter Remove restriction
and/or replace filter
Block vent in gas cap Remove restriction
and/or replace cap
Tank-to-injection pump fuel Check fuel lines and
supply blocked connections
Blocked fuel return system Remove restriction
Incorrect or contaminated Replace fuel
fuel
Blocked injector nozzles Check nozzle for
blockage, see FUEL
SYSTEMS
Low compression Check valves, rings,
pistons, see ENGINES
\
\
\
\
\
\
\
Loud Engine Basic timing incorrect Reset timing, see
Noise With Black FUEL SYSTEMS
Smoke EGR valve malfunction Replace EGR valve
Internal injection pump Replace injection pump,
malfunction see FUEL SYSTEMS
Page 1391 of 1501
Low fuel pressure Test pressure regul-
ator and fuel pump,
check for restricted
lines and filters
No distributor reference Repair ignition
pulses system as necessary
Open coolant temperature Test sensor and
sensor circuit wiring
Shorted W.O.T. switch in Disconnect W.O.T.
T.P.S. switch, engine
should start
Defective ECM Replace ECM
Fuel tank residual pressure Test for fuel
valve leaks pressure drop after
shut down
\
\
\
\
\
\
\
Hard Starting Disconnected hot air tube Reconnect tube and
to air cleaner test control valve
Defective Idle Air Control Test valve operation
(IAC) valve and circuit
Shorted, open or misadjusted Test and adjust or
T.P.S. replace T.P.S.
EGR valve open Test EGR valve and
control circuit
Poor Oxygen sensor signal Test for shorted or
circuit
Incorrect mixture from PCV Test PCV for flow,
system check sealing of oil
filter cap
\
\
\
\
\
\
\
Poor High Speed Low fuel pump volume Faulty pump or
Operation restricted fuel
lines or filters
Poor MAP sensor signal Test MAP sensor,
vacuum hose and
wiring
Poor Oxygen sensor signal Test for shorted or
open sensor or
circuit
Open coolant temperature Test sensor and
sensor circuit wiring
Faulty ignition operation Check wires for
cracks or poor con-
nections, test
secondary voltage
with oscilloscope
Contaminated fuel Test fuel for water
Page 1392 of 1501
or alcohol
Intermittent ECM ground Test ECM ground
connection for
resistance
Restricted air cleaner Replace air cleaner
Restricted exhaust system Test for exhaust
manifold back
pressure
Poor MAF sensor signal Check leakage
between sensor and
manifold
Poor VSS signal If tester for ALCL
hook-up is available
check that VSS
reading matches
speedometer
\
\
\
\
\
\
\
Ping or Knock on Poor Knock sensor signal Test for shorted or
Acceleration open sensor or
circuit
Poor Baro sensor signal Test for shorted or
open sensor or
circuit
Improper ignition timing See VEHICLE EMISSION
CONTROL LABEL (where
applicable)
Check for engine Low coolant, loose
overheating problems belts or electric
cooling fan
inoperative
\
\
\
\
\
\
\
NOTE: For additional electronic fuel injection trouble shooting
information, see the appropriate article in the ENGINE
PERFORMANCE section (not all vehicles have Computer Engine
Control articles). Information is provided there for
diagnosing fuel system problems on vehicles with electronic
fuel injection.
IGNITION SYSTEM TROUBLE SHOOTING
NOTE: This is GENERAL information. This article is not intended
to be specific to any unique situation or individual vehicle
configuration. The purpose of this Trouble Shooting
information is to provide a list of common causes to
problem symptoms. For model-specific Trouble Shooting,
refer to SUBJECT, DIAGNOSTIC, or TESTING articles available
in the section(s) you are accessing.
Ignition Secondary Trouble Shooting Chart
\
\
\
\
\
\
START: Visually inspect Spark Plug Wires, Coil Wires,
Plug Wire Boots, Rotor, and Distributor Cap for
signs of damage.