clutch MITSUBISHI MONTERO 1998 Repair Manual

NOTE: Locking clutch overhaul procedure is not available from
manufacturer. Use illustration for exploded view of locking
clutch. See Fig. 2.
Fig. 2: Exploded View Of Locking Clutch
Courtesy of Mitsubishi Motor Sales of America.
TORQUE SPECIFICATIONS









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Engine Oil Ambient Temperature Less Than  SAE 5W-30 

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1)  0\bF (-18\bC) To 100\bF (38\bC)  












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Ambient Temperature Above 0\bF  SAE 10W-30 

 (-18\bC) To Over 100\bF (38\bC)  











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Power  All Automatic Transmission 

Steering   Fluid DEXRON II 

Fluid   











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Engine  All  50/50 Mixture Of 

Coolant   Distilled Water & 

  Ethylene Glycol 











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Transfer Case All API Classification GL-4

  SAE 75W-85W Or 75W-90 











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Front Axle  All API Classification GL-5

  Or Higher (
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Clutch Fluid  All  DOT 3 Or DOT 4 











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Hook Lock  All  Multipurpose Grease 

Catch, Door   NLGI Grade 2 

Lock Strikers  

Seat Adjust-   

ers, Backdoor  

Lock, Parking  

Brake Cable   

Mechanism   











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Front Wheel  All  Multipurpose Grease 

Bearings   NLGI Grade 2 Or 

  Equivalent 











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Door Hinges, All  Engine Oil 

Back Door   

Hinges   











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A/C  All  HFC-134a 

Refrigerant   











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Manual  All API Classification GL-4

Transmission   SAE 75W-85W Or 75W-90 











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Automatic  All  "ATF DEXRON II" Or 

Transmission   Equivalent 











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Brake Fluid  All  DOT 3 Or DOT 4 











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Rear Axle  All API Classification GL-5

  Or Higher (
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(
1) - SAE 5W-30 engine oil is preferred. SAE 10W-30 may be used if 

the Ambient Temperature is above 0\b F (-18\b C). 

(
2) - SAE90, 85W-90, 80W-90 may be used in temperatures above 

-10\b F (-23\b C). SAE 80W, 80W-90 may be used in temperatures 

from -30\b F (-34\b C) to -10\b F (-23\b C). SAE 75W may be used 

in temperatures below -30\b F (-34\b C). 










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2) Disconnect air intake hose and vacuum hoses. Remove air
hose and air outlet housing. Remove heat protectors. Disconnect
exhaust pipe. Remove power steering oil pump and bracket. Remove
engine hanger bracket. Disconnect oil inlet pipe.
3) Disconnect engine coolant hoses and tubes from
turbocharger. Remove exhaust manifold nuts and bolts. Remove exhaust
manifold and gaskets. Disconnect oil pressure and return pipes. Remove
turbocharger and exhaust manifold assembly. Separate turbocharger from
exhaust manifold.
Removal (3000GT - Front)
1) Disconnect negative battery cable. Drain engine oil and
coolant. Remove radiator. Disconnect exhaust pipe. Remove air intake
hose, air hoses and air pipe. Remove generator and belt. Remove oil
dipstick guide.
2) Remove heat protector. Disconnect front heated oxygen
sensor connector. Remove oil return pipe. Remove turbocharger support
bracket, and remove turbocharger from exhaust manifold.
Removal (3000GT - Rear)
1) Disconnect battery cables, and remove battery. Drain
engine oil and cooling system. Remove accelerator cable. Remove air
hose, air pipe and heat protectors. Disconnect clutch booster vacuum
hose. Remove air intake hoses and EGR pipe. Disconnect heated oxygen
sensor connectors.
2) Remove oil pipe and EGR valve. Disconnect exhaust fitting,
and remove rear heat protector. Remove oil return pipe. Remove
turbocharger assembly.
Inspection (All Models)
Check turbine and compressor wheels for cracking and other
damage. Ensure turbine and compressor wheels turn smoothly. Check for
oil leakage from turbocharger assembly. Check for proper wastegate
valve operation. See I - SYSTEM/COMPONENT TESTS article.
CAUTION: Apply light coat of oil to inner surface of flared area on
water pipe (flare nut fitting) before connecting to engine.
Installation (All Models)
1) To install, reverse removal procedure. Before oil pipe
flare nut (above turbocharger) is installed, pour clean engine oil
into turbocharger oil pipe installation hole. Ensure oil and air hoses
are properly installed and securely clamped.
2) Use NEW gaskets. Adjust accelerator cable (if necessary).\
Refill engine oil and coolant. Check for oil and coolant leaks.
Tighten all bolts to specification. See TORQUE SPECIFICATIONS.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLE








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Applications Ft. Lbs. (N.m)
Coolant Pipe-To-Turbocharger Banjo Bolt .......... 31 (42)
EGR Valve ........................................ 16 (22)
Engine Coolant Temperature Sensor ................ 22 (30)
Exhaust Manifold-To-Engine Nuts ............ 18-21 (24-29)
Exhaust Manifold-To-Turbocharger Bolts ..... 40-47 (54-64)
Exhaust Pipe Bolts ......................... 21-36 (29-49)
Fuel Filter Line ................................. 27 (36)
Fuel Tank Drain Plug ....................... 11-18 (15-24)
Fuel Tank Nuts ............................. 15-21 (20-29)

 Item  Condition  Specification (1) 
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Engine Oil  Oil Pan  4.5 Qts. (4.3L) 

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 Oil Filter  0.32 Qts. (0.3L) 

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 Oil Cooler  0.32 Qts. (0.3L) 
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Engine  Drained; With Reserve Tank  10 Qts. (9.5L) 

Coolant   
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Automatic  Drained  8.9 Qts. (8.5L) 

Transmission   
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Manual  Drained  3.3 Qts. (3.2L) 

Transmission   
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Rear Axle  Drained  3.3 Qts. (3.2L) 
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Transfer Case Drained  2.6 Qts. (2.5L) 
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1) - Capacities are recommended or calculated levels. Always use 

dipstick to measure level. 
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LUBRICATION SPECIFICATIONS
LUBRICATION SPECIFICATIONS TABLE
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Material  Condition  Specification 
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Engine Oil Ambient Temperature Less Than  SAE 5W-30 

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1)  0F (-18C) To 100F (38C)  

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Ambient Temperature Above 0F  SAE 10W-30 

 (-18C) To Over 100F (38C)  
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Power  All Automatic Transmission 

Steering   Fluid DEXRON II 

Fluid   
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Engine  All  50/50 Mixture Of 

Coolant   Distilled Water & 

  Ethylene Glycol 
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Transfer Case All API Classification GL-4

  SAE 75W-85W Or 75W-90 
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Front Axle  All API Classification GL-5

  Or Higher (
2) 
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Clutch Fluid  All  DOT 3 Or DOT 4 
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Hook Lock  All  Multipurpose Grease 

Catch, Door   NLGI Grade 2 

Lock Strikers  

Seat Adjust-   

ers, Backdoor  

Lock, Parking  

Brake Cable   

Mechanism   
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STARTER
1998 Mitsubishi Montero
1998 STARTING & CHARGING SYSTEMS
Mitsubishi - Starters
Diamante, Eclipse, Galant, Mirage, Montero, Montero Sport,
3000GT
DESCRIPTION & OPERATION
Starter is a conventional 12-volt, 4-pole brush-type motor,
with direct or gear reduction drive. Starter-mounted solenoid shifts
overrunning clutch and pinion into flywheel when starter is energized.
TROUBLE SHOOTING
NOTE: See TROUBLE SHOOTING article in the GENERAL INFORMATION
section.
ON-VEHICLE TESTING
TROUBLE SHOOTING
1) If starter motor does not operate at all:
* Check starter coil.
* Check electrical connections.
* Check clutch pedal position switch (M/T).
* Check starter relay (M/T).
* Check park/neutral position switch (A/T).
2) If starter motor does not stop, check starter magnetic
switch solenoid.
STARTER RELAY
Diamante, Galant & Montero
1) Remove starter relay. See STARTER RELAY LOCATIONS table.
With no power supplied to any relay, continuity should exist between
relay terminals No. 1 and 2. See WIRING DIAGRAMS.
2) Connect a jumper wire from positive battery terminal to
relay terminal No. 1 and another jumper wire from negative battery
terminal to relay terminal No. 2. Continuity should exist between
relay terminals No. 3 and 4. Replace relay as necessary.
Eclipse (A/T With Theft Alarm)
1) Remove starter relay. See STARTER RELAY LOCATIONS table.
With no power supplied to any relay, continuity should exist between
relay terminals No. 1 and 2. See WIRING DIAGRAMS.
2) Connect a jumper wire from positive battery terminal to
relay terminal No. 1 and another jumper wire from negative battery
terminal to relay terminal No. 2. Continuity should exist between
relay terminals No. 3 and 4. Replace relay as necessary.
Eclipse (A/T Without Theft Alarm)
1) Remove starter relay. See STARTER RELAY LOCATIONS table.
With no power supplied to any relay, continuity should exist between
relay terminals No. 1 and 3. See WIRING DIAGRAMS.
2) Connect a jumper wire from positive battery terminal to
relay terminal No. 1 and another jumper wire from negative battery

SUN ROOF GLASS FIT
1) Fully close sun roof. Ensure roof glass panel is parallel
with roof opening. Sun roof glass panel parallelism should be within .
04" (1 mm), above and below roof surface. If parallelism is not as
specified, adjust glass panel by loosening sun roof glass panel
attaching screws and repositioning glass panel. Tighten screws. See
Fig. 1 .
2) If adjustment cannot be made by loosening mounting screws,
check if sun roof glass or motor is in fully closed position. Readjust
as necessary.
Fig. 1: Exploded View Of Sun Roof Assembly (Typical)
Courtesy of Mitsubishi Motor Sales of America
SUN ROOF MOTOR CLUTCH CHECK

Except Eclipse & Montero Sport
1) Remove sun roof motor. See DRIVE MOTOR R & I under REMOVAL
& INSTALLATION. Using crank handle stored in tool pouch, place crank
handle into drive motor shaft.
2) Place spring scale on crank handle about 3.92" (100 mm)
from drive motor shaft. Ensure spring scale is at right angle to crank
handle. On Galant, connect battery source to sun roof motor connector
terminals No. 1 and 4 to rotate motor. See Fig. 4. On Montero, connect
battery source to sun roof motor connector terminals No. 1 and 3 to
rotate motor. See Fig. 5. On 3000GT, connect battery source to sun
roof motor connector terminals No. 1 and 2 to rotate motor. See Fig. 6
.
3) On Galant, spring scale should read 30-38 INCH lbs. (3.4-
4.3 N.m). On Montero and 3000GT, spring scale should read 35-43 INCH
lbs. (3.9-4.9 N.m). If clutch sliding force is not as specified, on
Galant and Montero, adjust motor adjusting nut to left or right. On
3000GT, replace sun roof motor.
TROUBLE SHOOTING
Check following items listed below symptom to aid in
diagnosis and repair of sun roof assembly.
SUN ROOF INOPERATIVE
* Fusible link or multipurpose fuse.
* Sun roof switch.
* Drive motor.
ROOF GLASS PANEL DOES NOT OPERATE CORRECTLY
* Foreign matter lodged in guide rail.
* Drive motor drive gear not correctly indexed with drive
cables.
* Decrease in clutch slipping force of drive motor.
* Misaligned roof glass panel causing binding.
NOISY MOTOR OPERATION
* Drive motor drive gear not correctly indexed with drive
cables.
* Worn or damaged drive motor pinion bearing.
* Worn or deformed drive cable.
NOISY ROOF PANEL OPERATION
* Foreign matter lodged in guide rail.
* Loose guide rail and lid.
WATER LEAKS
* Dust accumulation in housing assembly.
* Clogged drain hose.
* Broken or disconnected drain hose.
* Worn roof lid weatherstrip.
* Excessive roof panel-to-roof opening clearance and/or
incorrectly fitted weatherstrip.
WIND NOISE
* Loose or deformed deflector.

Fig. 10: Manual Transmission & Clutch

Open solenoid pull-in See Testing in STARTER
wire article









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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









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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









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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
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Starter Cranks Battery weak or Charge or replace
Engine Slowly defective battery as necessary

Engine overheated See ENGINE COOLING
SYSTEM article
Engine oil too heavy Check that proper
viscosity oil
is used
Poor battery-to-starter Check that all
connections between
battery and starter are
clean and tight
Current draw too low or See Bench Tests in
too high STARTER article
Bent armature, loose pole See STARTER article
shoes screws or worn
bearings
Burned solenoid contacts Replace solenoid
Faulty starter Replace starter









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Starter Engages Engine timing too far See Ignition Timing in
Engine Only advanced TUNE-UP article
Momentarily
Overrunning clutch not Replace overrunning
engaging properly clutch. See STARTER
article
Broken starter clutch See STARTER article
Broken teeth on engine Replace flywheel and
flywheel check starter pinion
gear for damage
Weak drive assembly See STARTER article
thrust spring
Weak hold-in coil See Bench Tests in
STARTER article









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Starter Drive Defective point assembly See Testing in STARTER
Will Not Engage article
Poor point assembly ground See Testing in STARTER
article
Defective pull-in coil Replace starter
solenoid









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Starter Relay Dead battery Charge or replace
Does Not Close battery as necessary
Faulty wiring Check all wiring and
connections leading to
relay
Neutral safety switch Replace neutral safety
faulty switch
Starter relay faulty Replace starter relay