ad blue MITSUBISHI MONTERO 1998 Owner's Manual

the old insert and machining an oversize insert bore. Replacement
oversize insert is usually chilled and the cylinder head is sometimes
warmed. Valve seat is pressed into the head. This operation requires
specialized machine shop equipment.
Valve Seat Concentricity
Using dial gauge, install gauge pilot in valve guide.
Position gauge arm on the valve seat. Adjust dial indicator to zero.
Rotate arm 360 degrees and note reading. Runout should not exceed
specification.
To check valve-to-valve seat concentricity, coat valve face
lightly with Prussian Blue dye. Install valve and rotate it on valve
seat. If pattern is even and entire seat is coated at valve contact
point, valve is concentric with the seat.
REASSEMBLY
Valve Stem Installed Height
Valve stem installed height must be checked when new valves
are installed or when valves or valve seats have been ground. Install
valve in valve guide. Measure distance from tip of valve stem to
spring seat. See Fig. 11. Distance must be within specifications.
Fig. 11: Measuring Valve Stem Installed Height - Typical
This Graphic For General Information Only
Remove valve and grind valve stem tip if height exceeds
specification. Valve tips are surface hardened. DO NOT remove more

Application Wire Color Location
Diamante .................. Black/Blue ............ (1)
Eclipse (Turbo & 2.4L) .... Black/Blue ............. ( 2)
Galant .................... Black/Blue ............ ( 3)
Mirage .................... Black/Blue ............ ( 1)
Montero ...................... White .............. ( 4)
3000GT .................... Black/Blue ............ ( 6)
( 1) - On firewall, above brake master cylinder.
( 2) - On firewall behind battery.
( 3) - On main wiring harness, near center of firewall.
( 4) - On main wiring harness, near right center of firewall.
( 5) - Near left rear corner of engine compartment, below
cruise control actuator (if equipped).
( 6) - On main wiring harness, near wiper motor on firewall,
behind battery.









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3) Start engine and allow it to idle. Measure fuel pressure
with vacuum hose connected to fuel pressure regulator. Record fuel
pressure reading. See FUEL PUMP PERFORMANCE table. Disconnect and plug
vacuum hose from fuel pressure regulator. Record fuel pressure
reading.
4) Check for fuel pressure in fuel return hose by gently
pinching hose while increasing engine speed. If fuel volume is low,
fuel pressure in return hose will not be felt. Increase engine speed
to 2500-3000 RPM, 2-3 times. Return engine to idle. Fuel pressure
should not drop when engine is returned to idle.
5) Turn ignition off. Ensure fuel pressure reading does not
decrease within 2 minutes. If a decrease is noted, monitor speed of
decrease.
6) If fuel pressure is lower than specification, fuel
pressure drops at idle after increasing engine speed to 2500-3000 RPM,
or no fuel pressure in fuel return hose can be felt, check for clogged
fuel filter, or faulty fuel pressure regulator or fuel pump.
7) If fuel pressure is greater than specification, check for
a faulty fuel pressure regulator or plugged fuel return line. If fuel
pressure does not change when vacuum hose to regulator is connected or
disconnected, check for a leaking or clogged vacuum hose to fuel
pressure regulator or faulty fuel pressure regulator.
8) If fuel pressure decreases suddenly after engine is
stopped, check valve in fuel pump is not seated. Replace fuel pump. If
fuel pressure drops slowly, fuel injector is leaking or fuel pressure
regulator valve seat is leaking. Check for faulty fuel injector or
fuel pressure regulator. Repair as necessary.
9) When fuel pressure test is complete, repeat fuel pressure
release procedure before disconnecting fuel pressure gauge. Install
NEW "O" ring at end of high pressure fuel inlet line. Check for fuel
leaks.
FUEL PUMP PERFORMANCE TABLE









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At Idle w/Vacuum At Idle w/o Vacuum
Application psi (kg/cm) psi (kg/cm)
Eclipse 2.0L
Non-Turbo ........... ( 1) ............ 47-50 (3.3-3.5)
Turbo ............. 33 (2.3) ......... 42-45 (3.0-3.5)
3000GT Turbo ........ 34 (2.4) ......... 43-45 (3.0-3.1)
All Other Models .... 38 (2.7) ......... 47-50 (3.3-3.5)
( 1) - Information is not available from manufacturer at time

specified VSS connector terminal. See
VSS VOLTAGE FEED CIRCUIT IDENTIFICATION table. If voltage is not 4.5-
4.9 volts, replace PCM. If voltage is as specified, condition required
to set DTC is not present at this time. Go to next step.
VSS VOLTAGE FEED CIRCUIT IDENTIFICATION TABLE









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Application Terminal No.
Montero ................................................ 1
3000GT ................................................. 3









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9) Test is complete. Intermittent problem may exist. Road
test vehicle (if necessary) and attempt to duplicate conditions that
caused original complaint. Recheck for DTCs. If no DTCs are displayed,
go to INTERMITTENT DTCS .
DTC P0505: IDLE CONTROL SYSTEM FAILURE
NOTE: For terminal identification, see TERMINAL IDENTIFICATION. For
circuit and wire color identification, see
L - WIRING DIAGRAMS article.
1) Procedures are provided by manufacturer for component
testing using an engine analyzer with oscilloscope capability. Refer
to manufacturer's operation manual for instructions in use of
oscilloscope. If using engine analyzer, go to step 3). If using scan
tool, go to next step.
2) Using scan tool, read Idle Air Control (IAC) position
sensor step (item 45). See IAC POSITION SENSOR STEP SPECIFICATIONS
table. If scan tool does not read as specified, replace IAC position
sensor. If readings are as specified, go to step 5).
IAC POSITION SENSOR STEP SPECIFICATIONS TABLE









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A/C Switch Position Standard Step Value
Off ................................................. 2-25
Off To On ............................ Increase From 10-70
( 1) ................................... Increase From 5-50
( 1) - Brakes applied. A/C Off on Montero. A/C On on 3000GT.
Move gear selector lever to Drive position.









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NOTE: Check wave pattern when idle speed increases when A/C is
turned on. Wave pattern display lasts less than one second.
3) Disconnect IAC motor connector. Install Test Harness
(MB998463) between IAC motor and connector. Using engine analyzer with\
oscilloscope capability, connect special patterns probe in sequence to
test harness terminals No. 1 (Red clip), 3 (Blue clip), 4 (Black cl\
ip)
and 6 (Yellow clip) or PCM terminals No. 4, 5, 17 and 18 respectively.\
Start engine and allow it to idle. Turn A/C on. Compare oscilloscope
wave pattern with known-good wave pattern. See Fig. 44. Turn engine
off. If wave pattern is not normal, go to next step. If wave pattern
is normal, fault is intermittent. See INTERMITTENT DTCS.

Fig. 44: Identifying Know-Good IAC Motor Wave Pattern
Courtesy of Mitsubishi Motor Sales of America
4) Disconnect IAC motor connector. Leave test harness
connected to IAC motor. Using DVOM, check resistance between test
harness terminals No. 2 (White clip) and either 1 (Red clip) or 3
(Blue clip), and between test harness terminals No. 5 (Green clip) a\
nd
either 4 (Black clip) or 6 (Yellow clip). Resistance should be 28-33\
ohms at 68
F (20C). If resistance is as specified, go to next step.
If resistance is not as specified, replace IAC motor. Go to step 10).
5) On 3000GT, go to step 7). On Montero, disconnect IAC motor\
connector and MFI relay connector. Check for continuity between IAC
motor connector terminal No. 2 and MFI relay connector terminal No. 1.
If continuity does not exist, repair wiring harness as necessary. If
continuity exists, go to next step.
6) Check for continuity between IAC motor connector terminal
No. 5 and MFI relay connector terminal No. 1. If continuity does not
exist, repair wiring harness as necessary. If continuity exists, go to
next step.
7) Disconnect IAC motor connector. Turn ignition switch to ON
position. Check voltage between chassis ground and IAC motor connector
terminals No. 2 and 5. If battery voltage does not exist on either
circuit, repair wiring harness as necessary. If battery voltage exists
on both circuits, go to next step.
8) Turn ignition switch to OFF position. Disconnect PCM
connector and IAC motor connector. Ground specified PCM connector
terminal and using DVOM, check continuity between chassis ground and
specified IAC motor connector terminal. See
PCM-TO-IAC MOTOR HARNESS CIRCUIT IDENTIFICATION table. If continuity
does not exist, repair wiring harness as necessary. If continuity
exists, go to next step.
PCM-TO-IAC MOTOR HARNESS CIRCUIT IDENTIFICATION TABLE









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PCM Terminal No. IAC Motor Terminal No.
14 ..................................................... 1
15 ..................................................... 4
28 ..................................................... 3
29 ..................................................... 6









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HOW TO USE SYSTEM WIRING DIAGRAMS
1998 Mitsubishi Montero
GENERAL INFORMATION
Using Wiring Diagrams
All Models
INTRODUCTION
This cd obtains wiring diagrams and technical service
bulletins, containing wiring diagram changes from the domestic and
import manufacturers. These are checked for accuracy and are all
redrawn into a consistent format for easy use.
In the past, when cars were simpler, diagrams were simpler.
All components were connected by wires and diagrams seldom exceeded 4
pages in length. Today, some wiring diagrams require more than 16
pages. It would be impractical to expect a service technician to trace
a wire from page 1 across every page to page 16.
Removing some of the wiring maze reduces eyestrain and time
wasted searching across several pages. Today the majority of
these

diagrams follow a much improved format, which permits space for
internal switch details.
Wiring diagrams are drawn in a "top-down" format. The
diagrams are drawn with the power source at the top of the diagram and
the ground point at the bottom of the diagram. Components locations
are identified on the wiring diagrams. Any wires that don't connect
directly to a component are identified on the diagram to indicate
where they go.
COLOR ABBREVIATIONS
COLOR ABBREVIATIONS TABLE








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Color Normal Optional
Black ................ BLK .......................... BK
Blue ................. BLU .......................... BU
Brown ................ BRN .......................... BN
Clear ................ CLR .......................... CR
Dark Blue .......... DK BLU ...................... DK BU
Dark Green ......... DK GRN ...................... DK GN
Green ................ GRN .......................... GN
Gray ................. GRY .......................... GY
Light Blue ......... LT BLU ...................... LT BU
Light Green ........ LT GRN ...................... LT GN
Orange ............... ORG .......................... OG
Pink ................. PNK .......................... PK
Purple ............... PPL .......................... PL
Red .................. RED .......................... RD
Tan .................. TAN .......................... TN
Violet ............... VIO .......................... VI
White ................ WHT .......................... WT
Yellow ............... YEL .......................... YL









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IDENTIFYING WIRING DIAGRAM ABBREVIATIONS
NOTE: Abbreviations used on these diagrams are normally
self-explanatory. If necessary see ABBREVIATIONS

Fig. 3: Passenger Compartment Fuse Box
Courtesy of Mitsubishi Motor Sales of America.
1 - 15 Amp (Light Blue)
Cigarette Lighter

2 - 10 Amp (Red)
Radio
3 - 10 Amp (Red)
Heater Relay
4 - 10 Amp (Red)
4A/T
5 - 20 Amp (Yellow)
Front & Rear Air Conditioner
6 - 10 Amp (Red)
Turn Signals
7 - 10 Amp (Red)
Meters
8 - 10 Amp (Red)
Horn
9 - 15 Amp (Light Blue)
Wiper
10 - 10 Amp (Red)
Power Window Control
11 - 10 Amp (Red)
Four Wheel Drive System, Overdrive Control (Vehicles With
Automatic Transmission Only)
12 - 15 Amp (Light Blue)
Power Door Locks
13 - 10 Amp (Red)
Doom Light, Clock
14 - 15 Amp (Light Blue)
Backup Lights
15 - 15 Amp (Light Blue)
Stoplights
16 - 25 Amp
Heater
17 - 15 Amp (Light Blue)
Accessory Socket
18 - 10 Amp (Red)
Rear Heater
19 - Spare Fuse
ENGINE COMPARTMENT
Fig. 4: Engine Compartment Fusible Links
Courtesy of Mitsubishi Motor Sales of America.

COMPONENT TESTS
DRIVE MOTOR
Eclipse & Montero Sport
Remove drive motor. See DRIVE MOTOR R & I under REMOVAL &
INSTALLATION. Using 12-volt power supply, apply voltage to 2-terminal
connector. Reverse power supply leads to reverse motor direction.
Replace motor as necessary.
Galant
Remove drive motor. See DRIVE MOTOR R & I under REMOVAL &
INSTALLATION. Using 12-volt power supply, apply voltage to terminals
No. 1 (Blue wire) and No. 4 (Blue/White wire) of 6-terminal drive
motor connector. Reverse power supply leads to reverse motor
direction. Replace motor as necessary.
Montero
Remove drive motor. See DRIVE MOTOR R & I under REMOVAL &
INSTALLATION. Using 12-volt power supply, apply voltage to terminals
No. 1 (Green wire) and No. 3 (Green/Red wire and Black wire) of 4-
terminal drive motor connector. Reverse power supply leads to reverse
motor direction. Replace motor as necessary.
3000GT
Remove drive motor. See DRIVE MOTOR R & I under REMOVAL &
INSTALLATION. Using 12-volt power supply, apply voltage to terminals
No. 1 (Red/Blue wire) and No. 2 (Red/Yellow wire) of 8-terminal driv\
e
motor connector. Reverse power supply leads to reverse motor
direction. Replace motor as necessary.
DRIVE MOTOR LIMIT SWITCH
Eclipse & Montero Sport
1) Remove sun roof ECU. Look into viewing windows while
turning rotating wheel. See Fig. 2. Turn rotating wheel until White
marks appear. When White marks appear in viewing windows at same time,
stop turning rotating wheel.
2) Close sun roof fully. Install timed sun roof control unit.
Ensure wiring connector is properly inserted into control unit. Insert
a flat-blade screwdriver, place on tab and press to right, being
careful not to pinch wiring. See Fig. 3.
Fig. 2: Timing Sun Roof ECU (Eclipse & Montero Sport)
Courtesy of Mitsubishi Motor Sales of America

Fig. 3: Installing Sun Roof ECU (Eclipse & Montero Sport)
Courtesy of Mitsubishi Motor Sales of America
Galant
Remove limit switches from drive motor. Using ohmmeter, check
continuity of each switch. Continuity should exist between terminals
No. 3 (Blue/Red wire) and No. 5 (Black wire) for switch No. 1, and
terminals No. 5 (Black wire) and No. 6 (Blue/Black wire) for switch
No. 2. Replace switches as necessary. See Fig. 4.
Fig. 4: Identifying Sun Roof Motor Connector (Galant)
Courtesy of Mitsubishi Motor Sales of America
Montero
Using ohmmeter, check continuity of limit switch. When