brake MITSUBISHI MONTERO 1998 User Guide

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\
r
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

for one second, and then go out. Turn ignition switch to START
position. Warning light should come on and stay on.
2) When ignition switch is turned from START to ON position,
warning light should come on for one second, and then go out. If
warning light functions as specified, go to step 3). If warning light
does not function as specified, see appropriate trouble shooting test:
* IGNITION SWITCH IN ON POSITION (ENGINE NOT RUNNING),
ANTI-LOCK WARNING LIGHT INOPERATIVE
* AFTER ENGINE STARTS, ANTI-LOCK WARNING LIGHT REMAINS ON
* IGNITION SWITCH IN START POSITION, ANTI-LOCK WARNING LIGHT
INOPERATIVE
* IGNITION SWITCH IN ON POSITION, ANTI-LOCK WARNING LIGHT
BLINKS TWICE. IN START POSITION, LIGHT STAYS ON. WHEN
IGNITION SWITCH IS CYCLED FROM START TO ON POSITION, LIGHT
BLINKS ONCE, THEN TURNS OFF
3) Test drive vehicle. If ANTI-LOCK warning light does not
come on at low speed, go to next step. If light comes on at low speed,
motor relay, solenoid valve or Wheel Speed Sensor (WSS) malfunction is\
indicated. Go to step 6). If insufficient braking force or ABS
malfunction exists, go to next step. If none of listed symptoms exist,
go to step 6).
4) Check conventional brake system components for proper
operation. Check for mechanical lock of hydraulic unit solenoid valve.
Check for plugged hydraulic line in hydraulic unit. Repair or replace
as necessary. If hydraulic unit is okay, go to next step.
5) Ensure WSS rotor gap is correct. See WHEEL SPEED SENSOR
(WSS) under ADJUSTMENTS. Check for faulty wheel speed sensor. See
WHEEL SPEED SENSOR (WSS) under COMPONENT TESTS. Replace sensor as
necessary. See WHEEL SPEED SENSOR (WSS) under REMOVAL & INSTALLATION.
Inspect ECU connectors and related wiring harness. See WIRING DIAGRAMS
. If testing indicates no mechanical or electrical failures,
substitute ECU with known-good unit and retest.
6) Enter ABS self-diagnostics and retrieve Diagnostic Trouble
Codes (DTCs). See RETRIEVING DTCs under SELF-DIAGNOSTIC SYSTEM. If no
DTCs are displayed, fault may be intermittent. Attempt to make
malfunction reoccur. If no diagnostic output exists, check and repair
wiring harness between ECU and data link connector. See
WIRING DIAGRAMS .
NOTE: Trouble shoot ANTI-LOCK warning light in following sequence:
instrument cluster circuit, ECU and valve relay.
Ignition Switch In ON position (Engine Not Running),
ANTI-LOCK Warning Light Inoperative
1) If all other warning lights come on with ignition on, go
to step 3). If other warning lights do not come on, check fuse No. 11
in main fuse panel. If fuse is blown, correct cause of blown fuse, and
replace fuse. If fuse is okay, go to next step.
2) Remove instrument cluster. Turn ignition on. Using DVOM,
check voltage between vehicle ground and instrument cluster ANTI-LOCK
warning light terminal No. 28. See Fig. 2. If light does not come on,
go to next step. If light comes on, check and repair connectors and
related wiring harness between instrument cluster, ABS valve relay and
ECU. See WIRING DIAGRAMS .
3) Turn ignition off. Check for faulty warning light bulb.
Replace bulb as necessary. If bulb is okay, check and repair
connectors and related wiring harness between instrument cluster and
ECU. See WIRING DIAGRAMS . If connectors and wiring are okay, replace
instrument cluster.

NOTE: DTC is set if ECU detects stoplight switch stays on for 15
minutes or more, or an open circuit in stoplight switch
system.
1) Check if stoplights are functioning correctly. If
stoplights function correctly, go to next step. If stoplights do not
function correctly, check and repair stoplight circuit. See
WIRING DIAGRAMS.
2) Turn ignition off. Disconnect ECU 22-pin connector. Using
DVOM, measure voltage between ECU 22-pin connector terminal No. 34 and
ground while depressing brake pedal. See Figs. 5-6. If battery voltage
is present, go to next step. If battery voltage is not present, check
and repair connectors and related wiring harness between stoplight
switch and ECU. See WIRING DIAGRAMS.
3) Check and repair ECU 22-pin connector. If connector is
okay, replace ECU.
DTC 41, 42 OR 43: SOLENOID VALVE CIRCUIT
NOTE: DTC sets if ECU senses that solenoid is on with no power
supplied, or off with power supplied.
1) Disconnect hydraulic unit connectors. Using ohmmeter,
check resistance between hydraulic unit connectors terminals No. 4 and
12, 5 and 12, and 6 and 12. See Fig. 11. Resistance should be 4.04-4.
54 ohms. If resistance is as specified, go to next step. If resistance
is not as specified, replace faulty hydraulic unit. See HYDRAULIC UNIT
under REMOVAL & INSTALLATION .
2) Check resistance between hydraulic unit connectors
terminals No. 1 and 12, 2 and 12, and 3 and 12. Resistance should be
8.04-8.59 ohms. If resistance is as specified, go to next step. If
resistance is not as specified, replace faulty hydraulic unit. See
HYDRAULIC UNIT under REMOVAL & INSTALLATION .
3) Turn ignition off. Disconnect ECU connectors. Check
continuity of each circuit between ECU connectors and hydraulic unit
connectors. See WIRING DIAGRAMS. If continuity exists, go to next
step. If continuity does not exist, check and repair connectors and
related wiring harness between ECU and hydraulic unit. See
WIRING DIAGRAMS .
4) Check continuity between hydraulic unit connector terminal
No. 12 and ABS relay box terminal No. 1. See Figs. 4 and 11. If
continuity exists, go to next step. If continuity does not exist,
check and repair connectors and related wiring harness between
hydraulic unit and ABS relay box. See WIRING DIAGRAMS.
5) Check and repair ECU connectors. If connectors are okay,
replace ECU.
Fig. 11: Identifying Hydraulic Unit Connector Terminals
Courtesy of Mitsubishi Motor Sales of America.
DTC 51: VALVE RELAY

Fig. 16: Locating Electronic Control Unit (ECU)
Courtesy of Mitsubishi Motor Sales of America.
"G" SENSOR
CAUTION: DO NOT turn "G" sensor upside-down or lay unit on its side.
DO NOT drop "G" sensor. DO NOT disassemble unit. Replace "G"
sensor as an assembly.
Removal & Installation
Sensor is located under center console, near shifter. See
Fig. 10 . Remove center console assembly. Disconnect sensor wiring
harnes s connector. Remove sensor. To install, reverse removal
procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS.
HYDRAULIC UNIT
Removal
Remove brakelines from hydraulic unit. Remove ABS relay box
cover. See Fig. 3. Disconnect ground wire and wiring harness
connectors from hydraulic unit. Remove hydraulic unit retaining nuts.
Carefully remove hydraulic unit.
Installation
To install, reverse removal procedure. Install hydraulic unit
brakelines. Ensure brakelines are installed in correct location. See
Fig. 17. Bleed brake system. See BLEEDING BRAKE SYSTEM.

Fig. 17: Identifying Hydraulic Unit Brakeline Connections
Courtesy of Mitsubishi Motor Sales of America.
WHEEL SPEED SENSOR (WSS)

Removal & Installation
Disconnect WSS connector. Remove WSS bolts. Remove WSS from
vehicle. To install, reverse removal procedure. Sensors are not
interchangeable. Adjust wheel WSS-to-rotor gap. See WHEEL SPEED SENSOR
(WSS) under ADJUSTMENTS. To complete installation, reverse removal
procedure. Tighten WSS bolts to specification. See
TORQUE SPECIFICATIONS .
WHEEL SENSOR ROTOR
Removal & Installation
Remove brake disc. Remove disc assembly. Remove wheel
bearings. Remove axle hub. Remove bolts attaching sensor rotor to hub
assembly. To install, reverse removal procedure.
OVERHAUL
HYDRAULIC UNIT
DO NOT attempt to overhaul or disassemble hydraulic unit. If
hydraulic unit is defective, replace entire assembly.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application INCH Lbs. (N.m)\
"G" Sensor Mounting Bolt ................................. 80 (9.0)\
Wheel Speed Sensor (WSS) Bolt .................... 84-120 (9.5-14.6\
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WIRING DIAGRAMS

Fig. 18: Anti-Lock Brake System (ABS) Wiring Diagram (1997 Montero)\

Fig. 19: Anti-Lock Brake System (ABS) Wiring Diagram (1998 Montero)\

AUTO TRANS DIAGNOSIS - R4AW3 & V4AW3
1998 Mitsubishi Montero
1997-98 AUTOMATIC TRANSMISSIONS
Mitsubishi R4AW3 & V4AW3 Electronic Controls
Montero, Montero Sport
APPLICATION
TRANSMISSION APPLICATION








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Vehicle Transmission Model
Montero Sport 2WD ............................................ R4AW3
Montero & Montero Sport 4WD .................................. V4AW3









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CAUTION: Vehicle is equipped with Supplemental Restraint System (SRS).
When servicing vehicle, use care to avoid accidental air bag
deployment. SRS-related components are located in steering
column, center console, instrument panel and lower panel on
instrument panel. DO NOT use electrical test equipment on
these circuits. If necessary, deactivate SRS before servicing
components. See AIR BAG SERVICING article in APPLICATIONS &
IDENTIFICATION.
DESCRIPTION
Automatic transmission is a 4-speed electronically controlled
transmission. Solenoids that control shift changes are located in
valve body. Solenoids are controlled by a Transmission Control Module
(TCM). TCM receives information from various input devices and uses
this information to control shift solenoids for transmission shifting
and lock-up solenoid for torque converter lock-up.
An Overdrive (OD) switch is mounted on the shift lever. When
OD switch is depressed to ON position, transmission will shift into
4th gear when shift lever is in "D" position, and OD OFF light on
instrument panel will go off. When OD switch is released to OFF
position, transmission will shift into 3rd gear, and OD OFF light on
instrument panel will illuminate.
A pattern select switch is located near shift lever on center
console. Pattern select switch contains a NORMAL and a HOLD operating
position. When pattern select switch is depressed (HOLD position) with\
shift lever in Drive position, transmission starts in 2nd gear.
Upshifts and downshifts will occur at a higher vehicle speed than with
switch in NORMAL position. See MITSUBISHI R4AW3 & V4AW3 OVERHAUL
article. Indicator light on instrument panel indicates pattern select
switch is in HOLD position.
Transmission is equipped with a shift lock and key interlock
system. Shift lock system prevents shift lever from being moved from
Park unless brake pedal is depressed. Key interlock system prevents
ignition key from being moved from ACC to LOCK position on ignition
switch unless shift lever is in Park. See MITSUBISHI SHIFT LOCK
SYSTEMS article.
OPERATION
TCM
TCM receives information from various input devices and uses

this information to control solenoids on transmission valve body. TCM
controls transmission shifting and torque converter lock-up.
TCM contains a self-diagnostic system, which will store
Diagnostic Trouble Codes (DTC) if failure or problem exists in
electronic control system. DTC can be retrieved to determine problem
area. See SELF-DIAGNOSTIC SYSTEM. TCM is located under left side of
instrument panel, left of steering column. See Fig. 1.
TCM INPUT DEVICES
Brakelight Switch Signal
Brakelight switch delivers input signal to TCM, indicating
vehicle braking. Brakelight switch is located on brake pedal support.
Cruise Control Electronic Control Unit (ECU)
Cruise control ECU delivers an input signal to control
overdrive operation in accordance with vehicle speed when cruise
control is operating. When in overdrive with cruise control on, if
vehicle speed drops 2 MPH less than the set speed, overdrive is
released to prevent reduction in vehicle speed. Once vehicle speed is
more than the set speed, overdrive function is resumed. If coolant
temperature is low, transmission will not shift into overdrive. Cruise
control ECU is located below center A/C vent, behind temperature
control panel on Montero. On Montero Sport, cruise control ECU is
located behind driver's kick panel.
Engine Coolant Temperature Sensor (ECT) Signal
Engine coolant temperature sensor delivers input signal to
TCM, indicating engine coolant temperature. Coolant temperature sensor
is located on engine.
Input & Output Shaft Speed Sensors
Sensors are magnetic pick-ups that monitor input and output
shaft speeds. AC waveforms are input to TCM by sensors. Sensors are
located on front and rear side of transmission case.
OD Switch Signal
The OD switch provides an input signal to TCM to indicate
when overdrive is selected by operator. When OD switch is depressed to
ON position, transmission will shift into 4th gear when shift lever is
in "D" position, and OD OFF light on instrument panel will go off.
When OD switch is released to OFF position, transmission will shift
into 3rd gear, and OD OFF light on instrument panel will come on. The
OD switch is mounted on shift lever.
Oil Temperature Sensor Signal
Oil temperature sensor provides TCM with ATF temperature
values. TCM uses this information to control shift points for maximum
performance. If transmission oil temperature exceeds standard values,
instrument panel ATF - TEMP light will come on. Sensor is mounted to
cooler line at transmission.
Park/Neutral Position (PNP) Switch Signal
PNP switch delivers an input signal to TCM indicating shift
lever position. Switch is located on side of transmission.
Throttle Position (TP) Sensor Signal
TP sensor delivers closed throttle and variable throttle
position input signals to TCM. TP sensor is located on side of
throttle body.
4WD Low Range Detection Switch
4WD low range detection switch provides information to TCM