body MITSUBISHI MONTERO 1998 Workshop Manual
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 1998, Model line: MONTERO, Model: MITSUBISHI MONTERO 1998Pages: 1501, PDF Size: 25.81 MB
Page 997 of 1501
1) Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELEASE.
Disconnect negative battery cable. Drain coolant. Remove air intake
hose. Remove throttle body and gasket with control cables and vacuum
hoses attached.
2) Remove EGR pipe (if equipped). Disconnect power brake
hose. Label and disconnect vacuum hoses and wiring harness connectors
as necessary. Remove intake plenum brackets and mounting bolts. Remove
intake plenum and gasket.
3) Disconnect high pressure fuel hose at fuel rail.
Disconnect fuel return hose. Disconnect vacuum hoses. Disconnect
injector electrical connectors. Remove fuel rail bolts, and lift fuel
rail and injectors from engine. Injectors may be removed after fuel
rail is removed from intake manifold.
Installation
To install, reverse removal procedure. Use NEW insulators and
"O" rings when installing injectors. Install injectors into fuel rail
with a twisting motion. Ensure injectors rotate smoothly when
installing. Refill cooling system.
Removal (Eclipse, Galant, Mirage & Montero Sport 3.0L)
1) Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELEASE.
Disconnect negative battery cable. Disconnect PCV hose and breather
hoses. Disconnect high pressure fuel hose at fuel rail. Disconnect
fuel return hose and vacuum hoses.
2) Disconnect injector electrical connectors. Remove fuel
rail bolts, and lift fuel rail and injectors from engine. Injectors
may be removed after fuel rail is removed from intake manifold.
Installation
To install, reverse removal procedure. Use NEW insulators and
"O" rings when installing injectors. Use lubricant on "O" rings.
Install injectors into fuel rail with a twisting motion. Ensure
injectors rotate smoothly when installing.
Removal (Montero)
1) Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELEASE.
Disconnect negative battery cable. Remove air intake hose. Remove
accelerator cable adjusting bolts. On A/T models, remove throttle
control cable. On all models, remove accelerator cable. Label and
disconnect all vacuum hoses from throttle body and upper intake
manifold (air intake plenum).
2) Remove EGR pipe and gasket. Remove ignition coil (if
necessary). Remove engine oil filler neck bracket. Disconnect PCV
hose. Remove throttle body, leaving coolant hoses connected. Remove
throttle body gasket. Remove front and rear intake plenum brackets.
Remove intake plenum mounting bolts. Remove intake plenum and gasket.
3) Disconnect high pressure fuel hose at fuel rail.
Disconnect fuel return hose. Disconnect vacuum hoses. Disconnect
injector electrical connectors. Remove fuel rail bolts, and lift fuel
rail and injectors from engine. Injectors may be removed after fuel
rail is removed from intake manifold.
Installation
To install, reverse removal procedure. Use NEW insulators and
"O" rings when installing injectors. Use lubricant on "O" rings.
Install injectors into fuel rail using a twisting motion. Ensure
injectors rotate smoothly when installing. Adjust throttle control and
accelerator cables (if necessary). Refill cooling system.
HEATED OXYGEN SENSOR (HO2S)
Removal & Installation
Page 998 of 1501
1) Front HO2S is mounted in exhaust pipe below exhaust
header. Rear HO2S is mounted behind catalytic converter. HO2S is
equipped with a permanent pigtail which must be protected from damage
when HO2S is removed. Ensure HO2S is free of contaminants. Avoid using
cleaning solvents of any type.
2) HO2S may be difficult to remove when engine temperature is
less than 120
F (48 C). If using original sensor, always use anti-
seize compound on threads before installation. New sensor threads are
precoated with anti-seize. Tighten HO2S to specification. See
TORQUE SPECIFICATIONS .
THROTTLE BODY
Removal
1) Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELEASE.
Drain enough coolant to ensure coolant level is below throttle body.
Disconnect air intake hose.
2) Remove accelerator, cruise control and A/T throttle valve
cables (if equipped). Disconnect fuel vapor hose, electrical harness
connector, vacuum hose and coolant hoses. Remove throttle body
retaining bolts.
Disassembly
Remove throttle position sensor. Remove idle air control
motor. Remove throttle bracket and connector bracket (if equipped).
Remove idle position switch and adjusting nut (if equipped).
CAUTION: DO NOT remove throttle valve. DO NOT use cleaning solvents
on throttle position sensor, idle air control motor or idle
position switch.
Cleaning
1) Clean all parts except throttle position sensor, idle air
control motor and idle position switch in solvent.
WARNING: Safety glasses MUST be worn whenever compressed air is used
for parts cleaning.
2) Check vacuum port and passage for clogging. Clean vacuum,
vapor and fuel passages using compressed air.
Reassembly
To reassemble, reverse disassembly procedure.
Installation
To install, reverse removal procedure.
THROTTLE POSITION (TP) SENSOR
Removal & Installation
Throttle Position (TP) sensor is located on throttle body.
Disconnect TP sensor electrical connector. Remove TP sensor screws and
TP sensor. To install, reverse removal procedure. Tighten TP sensor
screws to specification. See TORQUE SPECIFICATIONS. For TP sensor
adjustment procedure, see D - ADJUSTMENTS article.
TURBOCHARGERS
Removal (Eclipse)
1) Disconnect negative battery cable. Drain engine coolant
and oil. On models equipped with A/C, remove condenser fan motor
assembly. Remove front heated oxygen sensor. Remove oil dipstick guide
and "O" ring.
Page 1000 of 1501
Heated Oxygen Sensor
Front .................................... 29-33 (39-44)
Rear ..................................... 15-29 (20-39)
Heat Protector Bolts .................. 8.8-11 (12.0-15.0)
Intake Manifold Plenum Bolt/Nut .................. 13 (18)
Knock Sensor ............................... 15-18 (20-24)
Oil Return Pipe-To-Engine .................. 10-14 (14-19)
Oil Supply Pipe-To-Engine Nut .................... 14 (19)
Oil Supply Pipe-To-Turbocharger Nut .............. 14 (19)
Plenum-To-Intake Manifold Bolts ............ 11-15 (15-20)
Throttle Body .................................... 14 (19)
Turbocharger-To-Exhaust Manifold Bolt/Nut
Step 1 ......................................... 21 (29)
Step 2 ........................ Additional 60-70 Degrees
Water Pipe-To-Turbocharger
Eclipse .................................. 25-36 (34-49)
3000GT ......................................... 22 (30)
INCH Lbs. (N.m)
Camshaft Position Sensor .......................... 80 (9)
Crankshaft Position Sensor ........................ 80 (9)
Distributor Hold-Down Bolt ...................... 106 (12)
Engine Cover ............................. 22-40 (2.5-4.5)
Fuel Pressure Regulator ........................... 80 (9)
Fuel Pump Nuts .................................. 22 (2.5)
Fuel Rail Bolts ....................... 80-106 (9.0-12.0)
TP Sensor Screws ......................... 13-22 (1.5-2.5)
Wastegate Actuator Bolts ............... 80-106 (9.0-12.0)
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Page 1003 of 1501
Normal Maximum Time-Out
Component Draw Draw (Minutes)
Anti-Theft System ................ 0.4 .... 1.0 ....... ...
Auto Door Lock ................... 1.0 .... 1.0 ....... ...
Body Control Module .............. 3.6 ... 12.4 ........ 20
Central Processing System ........ 1.6 .... 2.7 ........ 20
Electronic Control Module ........ 5.6 ... 10.0 ....... ...
Electronic Level Control ......... 2.0 .... 3.3 ........ 20
Heated Windshield Module ......... 0.3 .... 0.4 ....... ...
HVAC Power Module ................ 1.0 .... 1.0 ....... ...
Illuminated Entry ................ 1.0 .... 1.0 ......... 1
Light Control Module ............. 0.5 .... 1.0 ....... ...
Oil Level Module ................. 0.1 .... 0.1 ....... ...
Multi-Function Chime ............. 1.0 .... 1.0 ....... ...
Pass Key Decoder Module ......... 0.75 .... 1.0 ....... ...
Power Control Module ............. 5.0 .... 7.0 ....... ...
Retained Accessory Power ......... 3.8 .... 3.8 ....... ...
Radio ............................ 7.0 .... 8.0 ........ 15
Twilight Sentinel Module ......... 1.0 .... 1.0 ....... ...
Voltage Regulator ................ 1.4 .... 2.0 ....... ...
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INTERMITTENT PARASITIC LOAD PROBLEMS
Intermittent parasitic lad can occur because of a memory
device that does not power down with ignition off. With an
intermittent parasitic load, battery draw can be greater than 1.0 amp.
To find and intermittent problem requires that an ammeter and
Disconnect Tool (J-38758) test switch be connected and left in the
circuit. See Fig. 1. Road test vehicle. After road test, turn ignition
off and remove key.
Monitor the milliamps scale for 15-20 minutes after ignition
is turned off. This allows monitoring memory devices to determine if
they time out and stop drawing memory current. The test switch is
needed to protect ammeter when the vehicles is started.
DIODE CHECK & SOLENOID TEST (GENERAL MOTORS)
Page 1083 of 1501
Eclipse
Without Theft Alarm ........................ Behind Center Of Dash
With Theft Alarm .... Under Left Of Instrument Panel, On Relay Box
Galant ................................... Inside Right Front Fender
Mirage .......................... In Left Underhood Fuse/Relay Block
Montero ...................................... Behind Center Of Dash
Montero Sport ................... In Left Underhood Fuse/Relay Block
3000GT ......................... In Right Underhood Fuse/Relay Block
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Fig. 1: Identifying Starter Relay Connector Terminals (3000GT)
Courtesy of Chrysler Corp.
BENCH TESTING
* PLEASE READ THIS FIRST *
CAUTION: Perform tests in less than 10 seconds to prevent damage to
coil.
NO-LOAD TEST
1) Install starter in soft-jawed vise. Connect starter in
series with a fully-charged 12-volt battery. Connect a 100-amp ammeter
and carbon pile rheostat in series with positive battery post and
starter motor terminal. See Fig. 2.
2) Install voltmeter across starter motor. Adjust carbon pile
rheostat to full resistance. Connect cable from starter motor body to
negative battery terminal. Adjust carbon pile rheostat to proper test
voltage. Ensure maximum amperage is as specified and starter rotates
Page 1151 of 1501
deploys.
* After air bag deploys, air bag surface may contain deposits
of sodium hydroxide, which irritate skin. Always wear safety
glasses, rubber gloves and long-sleeved shirt during clean
up. Wash hands using mild soap and water. Follow correct
clean-up and disposal procedures.
* Because of critical system operating requirements, DO NOT
service any SRS components. Repairs are only made by
replacing defective part(s).
* DO NOT allow any electrical source near inflator on the back
of air bag module.
* When carrying live air bag module, trim cover should be
pointed away from body to minimize injury in case of
accidental air bag deployment.
* If SRS is not fully functional for any reason, DO NOT drive
vehicle until system is repaired and is fully functional. DO
NOT remove bulbs, modules, sensors or other components, or in
any way disable system from operating normally. If SRS is not
functional, park vehicle until repairs are made.
REMOVAL & INSTALLATION
STEERING WHEEL
WARNING: Wait at least 60 seconds after disconnecting negative
battery cable before servicing SRS. System reserve capacitor
maintains SRS voltage for about 60 seconds after battery is
disconnected. Servicing SRS before 60-second period may
cause accidental air bag deployment and possible personal
injury.
Removal
Disable air bag. See DISABLING & ACTIVATING AIR BAG SYSTEM .
Ensure steering wheel is straight ahead. Remove air bag. Place
reference mark on steering wheel and steering column shaft for
installation reference. Remove steering wheel nut and washer. Using
steering wheel puller, remove steering wheel.
CAUTION: DO NOT hammer on steering wheel during removal or
installation, as it may damage steering column.
Installation
To install, reverse removal procedure. Ensure reference marks
are aligned. Tighten fasteners to specification. See
TORQUE SPECIFICATIONS . Activate air bag. See DISABLING & ACTIVATING
AIR BAG SYSTEM.
COMBINATION SWITCH
CAUTION: When installing steering wheel, if rotating part of
clockspring is not properly centered with steering column
and front wheels, clockspring failure will result.
Removal & Installation
Remove lower instrument cover and lower heater duct. Remove
air bag and steering wheel. See STEERING WHEEL under
REMOVAL & INSTALLATION . Remove upper and lower steering column covers.
Disconnect clockspring electrical connector. Remove screws attaching
colckspring and remove clockspring. Disconnect combination switch
electrical connectors. Remove screws and combination switch. To
install, reverse removal procedure.
Page 1162 of 1501
cross shaft and rack piston for wear and damage. Check contact part of
adjusting bolt for uneven wear. Check dust seal, oil seal and "O"
rings for wear and damage.
Reassembly
1) Install NEW cross shaft lower "U" packing (if removed).
Press lower cross shaft oil seal into gearbox housing. See Fig. 3.
Press bearing and oil seal into top cover. Install bearing race and
"O" ring.
2) Apply transmission fluid to seal ring contact areas on
mainshaft, and install seal rings firmly into valve grooves. Wrap
serrated part of mainshaft with vinyl tape. Mount valve body to valve
housing. Install cage and align hole in cage with channel in
mainshaft. Install bearing race and insert balls.
3) Install mainshaft into valve housing while pressing on
bearing race to prevent balls from falling out. Using spanner wrench,
install lock nut and tighten until it contacts bearing race.
4) Tighten lock nut while measuring mainshaft endplay using
dial indicator. When mainshaft endplay is .001" (.003 mm), use a punch\
to crimp circumference of lock nut. Ensure mainshaft rotates freely.
5) Apply transmission fluid to "O" ring and piston seal ring,
and install into gearbox housing. Install rack piston until it
contacts edge of mainshaft. Rotate mainshaft to align ball raceway
with insertion hole. Install 19 balls.
NOTE: Insert balls so no clearance exists between balls.
6) Place remaining 7 balls in circulator and install
circulator to rack piston. Install circulator holder. Install NEW
cross shaft upper "U" packing (if removed). Install upper cross shaft
"O" ring. Apply transmission fluid to rack piston seal ring and insert
valve housing. Rotate mainshaft until rack piston is centered (neutral
position).
7) Install adjusting plate so beveled part is facing upward.
Using a feeler gauge, measure clearance between adjusting bolt and
cross shaft. If clearance is greater than .002" (.05 mm), replace with\
appropriate adjusting plate.
8) Apply multipurpose grease to seal surface of "U" packing.
Apply transmission fluid to cross shaft teeth and side cover "O" ring.
Install cross shaft to side cover, and temporarily tighten adjusting
bolt lock nut.
CAUTION: DO NOT rotate side cover during installation, or damage to
cross shaft oil seal may result.
9) Apply transmission fluid to rack piston teeth and shaft
areas. Apply multipurpose grease to oil seal lip. Install side cover
assembly (with cross shaft) to gearbox.
10) Position mainshaft in straight-ahead position. While
turning adjusting bolt, measure mainshaft combined starting torque
using Preload Socket (MB990228-01) and an INCH-lb. torque wrench.
Combined starting torque should be 4-11 INCH lbs. (.5-1.3 N.m). Center\
reading should be 2 INCH lbs. (.2 N.m) higher than reading at either
end.
11) Tighten adjusting bolt lock nut to specification. See
TORQUE SPECIFICATIONS . Install pitman arm with mating marks aligned.
POWER STEERING PUMP
Disassembly
1) Remove suction connector bolts. Mount pump in a soft-jawed
vise. Remove pump cover bolts and cover. Using a plastic mallet, tap
pulley assembly shaft from pump housing. See Fig. 4.
Page 1164 of 1501
damage. Inspect groove of rotor vane and cam surface for stepped wear.
Check vane for damage. Install vane into rotor groove. Measure
clearance between vane and rotor groove. If clearance exceeds .0024"
(.061 mm), replace entire assembly.
2) Check ring and rotor sides for damage. Replace entire
assembly if any damage is present. Check sliding surfaces of control
valve for obstructions. Replace parts as required. If control valve is
replaced, always use valve with same identification mark as one being
replaced. Check power steering fluid pressure.
Reassembly
1) Lubricate "O" rings and internal pump components with ATF
before reassembly. Install flow control valve spring and control valve
in housing.
2) Install and tighten pressure connector. Depress control
valve to check for smooth operation. Apply grease to lip of oil seal.
Install oil seal into pump body. Install pulley assembly into pump
body.
3) Install rotor to pulley assembly with punch mark at pump
cover side. Install snap ring. Lift rotor to ensure that snap ring is
in countersunk part of shaft. Align cam ring dowel holes and install
cam ring with punch mark on pump body side.
4) Apply transmission fluid to vanes, and install vanes onto
rotor with rounded edges outward. Install "O" ring, cam case and pump
cover. Install and tighten suction connector.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS \
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Application Ft. Lbs. (N.m)\
Adjusting Bolt Lock Nut .................................... 27 (37)\
Idler Arm Bracket-To-Frame Bolt & Nut
Montero ............................................ 40-47 (54-64)\
Montero Sport ............................................ 43 (59)\
Idler Arm-To-Bracket Lock Nut ............................. 101 (44)\
Oil Pump Cover Bolts ....................................... 15 (20)\
Pitman Arm-To-Cross Shaft Nut
Montero ........................................ 108-123 (146-176)\
Montero Sport .................................. 108-123 (147-167)\
Pressure Hose In-Line Fitting
Montero .................................................. 25 (34)\
Montero Sport ............................................ 16 (22)\
Relay Rod-To-Idler Arm Nut ................................. 33 (44)\
Relay Rod-To-Pitman Arm Nut ................................ 33 (44)\
Side Cover Bolts
Montero .................................................. 36 (49)\
Montero Sport ...................................... 41-47 (50-64)\
Steering Gear Hose Fittings ................................ 11 (15)\
Steering Gear-To-Frame Bolts ......................... 40-47 (54-64)\
Tie Rod Adjusting Sleeve Lock Nuts ......................... 69 (93)\
Tie Rod End Castle Nuts .................................... 33 (44)\
Valve Housing Bolts
Montero .................................................. 36 (49)\
Montero Sport ...................................... 41-47 (56-64)\
Valve Housing Lock Nut ......................................... ( 1)
( 1) - Tighten lock nut until it contacts bearing race.
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Page 1190 of 1501
Condition Code Procedure
Attaching hardware bent . B ... Require repair or replacement
of bent part, if available;
otherwise, replace shock or
strut.
Attaching hardware
broken ................. A ... Require replacement of broken
part, if available; otherwise,
replace shock or strut.
Attaching hardware
corroded, affecting
structural integrity ... A . Require replacement of corroded
part, if available; otherwise,
replace shock or strut.
Attaching hardware
incorrect .............. A .......... Require replacement of
incorrect part, if available;
otherwise, replace shock or
strut.
Attaching hardware
loose .................. A ... Require repair or replacement
of loose part, if available;
otherwise, replace shock or
strut.
Attaching hardware
missing ................ C .. Require replacement of missing
part, if available; otherwise,
replace shock or strut.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of part with damaged threads,
if available; otherwise,
replace shock or strut.
Attaching hardware
threads stripped
(threads missing) ...... A ..... Require replacement of part
with stripped threads, if
available; otherwise, replace
shock or strut.
Binding ................. A ............ Require replacement.
Body dented ............. A .......... (1) Further inspection
required.
Body punctured .......... A ............ Require replacement.
Brake hose bracket
bent ................... B .. Require repair or replacement.
Brake hose bracket
missing ................ C ............ Require replacement.
Brake hose bracket
threads damaged ........ A .. Require repair or replacement.
Brake hose bracket
threads stripped
(threads missing) ...... C ............ Require replacement.
Compression bumper
missing ................ C .......... Require replacement of
compression bumper.
Compression bumper
split .................. 1 .......... Suggest replacement of
compression bumper.
Damping (none) .......... A ............ Require replacement.
Dust boot (bellows)
split .................. 2 ......... ( 2) Suggest replacement
of boot.
Page 1191 of 1501
Dust boot (bellows)
missing ................ 2 ......... (2) Suggest replacement
of boot.
Dust boot (bellows)
torn ................... 2 ......... ( 2) Suggest replacement
of boot.
Dust shield broken ...... 2 ........ ( 2) Suggest replacement.
Dust shield missing ..... 2 ........ ( 2) Suggest replacement.
Gland nut (strut housing
cap) is not removable
using appropriate tool . A .. ( 3) Require replacement of nut
and/or housing.
Gland nut (strut housing
cap) threads damaged ... A ... Require repair or replacement
of nut.
Gland nut (strut housing
cap) threads stripped
(threads missing) ...... A ..... Require replacement of nut.
Housing dented .......... A .......... ( 1) Further inspection
required.
Housing punctured ....... A ............ Require replacement.
Jounce bumper missing ... C ... Require replacement of jounce
bumper.
Jounce bumper split ..... 1 ... Suggest replacement of jounce
bumper.
Leaking oil, enough for
fluid to be running down
the body ............... A ........ ( 4) Require replacement.
Noise ................... 2 .......... ( 5) Further inspection
required.
Piston rod bent ......... A ............ Require replacement.
Piston rod broken ....... A ............ Require replacement.
Piston rod has surface
defect ................. 2 ............ Suggest replacement.
Piston rod threads
damaged ................ A .. Require repair or replacement.
Piston rod threads
stripped (threads
missing) ............... A ............ Require replacement.
Seized .................. A ............ Require replacement.
Shock missing ........... C ............ Require replacement.
Strut housing bent ...... A ............ Require replacement.
Strut housing cap (gland
nut) is not removable
using appropriate tool . A ......... ( 3) Require replacement
of nut and/or housing.
Strut housing cap (gland
nut) threads damaged ... A ... Require repair or replacement
of nut.
Strut housing cap (gland
nut) threads stripped
(threads missing) ...... A ..... Require replacement of nut.
Strut housing severely
corroded, affecting
structural integrity ... A ............ Require replacement.
Strut housing threads
damaged ................ A .. Require repair or replacement.
Strut housing threads
stripped (threads
missing) ............... A ............ Require replacement.
Tire cupping ............ A .......... ( 6) Further inspection
required.