light MITSUBISHI MONTERO 1998 Manual PDF

Fig. 4: Locating Ignition Timing Check Connector
Courtesy of Mitsubishi Motor Sales of America
3000GT (SOHC)
1) Ignition timing is controlled by Powertrain Control Module
(PCM) and is not adjustable. Manufacturer provides procedure for
checking timing.
2) Start engine and warm engine until engine temperature
coolant is 176-203
F (80-95C). Turn engine off. Insert a paper clip
in noise filter connector. See Fig. 5. Connect a tachometer to paper
clip.
Fig. 5: Locating Noise Filter Connector
Courtesy of Mitsubishi Motor Sales of America
3) Install a timing light. Start engine and allow it to idle.
Using tachometer, read curb idle speed (RPM). Ensure curb idle speed

is 600-700 RPM. Turn engine off. Curb idle speed is automatically
controlled by Idle Air Control (IAC) system. If curb idle speed is not\
as specified, see DTC P0505 in G - TESTS W/CODES article.
4) Disconnect waterproof female connector from Brown ignition
timing check connector. See Fig. 4. Using a jumper wire, ground
ignition timing check terminal to read basic ignition timing. Using
timing light, read basic ignition timing value. See
IGNITION TIMING SPECIFICATIONS table. If basic ignition timing is
within specification, go to next step. If basic ignition timing is not
within specification, see DTC P0335 in G - TESTS W/CODES article.
5) Remove jumper wire to read actual ignition timing. Using
timing light, read actual ignition timing value. If actual ignition
timing is not within specification, see DTC P0335 in G - TESTS W/CODES
article.
All Other Models
1) Ignition timing is controlled by Powertrain Control Module
(PCM) and is not adjustable. Manufacturer provides procedure for
checking timing. On models with distributor, DO NOT attempt to adjust
ignition timing by rotating distributor.
2) Connect scan tool to Data Link Connector (DLC). DLC is
located below dash, near steering column. See Fig. 2. Install a timing
light. Start engine and allow it to idle.
3) Using scan tool, read curb idle speed (RPM). Ensure curb
idle speed is about 750 RPM. Turn engine off. Curb idle speed is
automatically controlled by Idle Air Control (IAC) system. If curb
idle speed is not as specified, see DTC P0505 in G - TESTS W/CODES
article.
CAUTION: MFI system actuator test must be cancelled or test will
continue to run for 27 minutes. Driving vehicle under this
condition may damage engine.
4) Using scan tool, select MFI SYSTEM ACTUATOR TEST, then
select item 17 (BASIC IGNITION TIMING). Read basic ignition timing
value. See IGNITION TIMING SPECIFICATIONS table. If basic ignition
timing is within specification, go to next step. If basic ignition
timing is not within specification, cancel MFI system actuator test.
See DTCS P0100 (except Mirage 1.5L), P0105, P0115 and P0335 in G -
TESTS W/CODES article.
5) Read actual ignition timing value. If actual ignition
timing is not within specification, cancel MFI system actuator test.
See DTCS P0100 (except Mirage 1.5L), P0105, P0115 and P0335 in G -
TESTS W/CODES article.
IDLE SPEED & MIXTURE
* PLEASE READ THIS FIRST *
NOTE: Perform adjustments with engine at normal operating
temperature, cooling fan and accessories off, transmission
in Park or Neutral, and front wheels in straight-ahead
position.
BASIC IDLE SPEED
NOTE: Basic idle speed adjustment information on Eclipse 2.0L
non-turbo engine is not available from manufacturer at time
of publication.
3000GT
1) Ensure vehicle is at normal operating temperature with all

lights, cooling fan and accessories off. Shift transmission into
Neutral or Park position.
2) If not using scan tool, go to next step. Connect scan tool
to Data Link Connector (DLC). DLC is located below dash, near steering\
column. See Fig. 2. Go to step 5).
3) On DOHC models, insert a paper clip in engine speed
detection connector. See Fig. 3. On SOHC models, insert paper clip in
noise filter connector. See Fig. 5. On all models, connect a
tachometer to paper clip.
4) Connect a jumper wire between ground and Data Link
Connector (DLC) terminal No. 1. See Fig. 2. Disconnect waterproof
female connector from Brown ignition timing check connector. See
Fig. 4 . Using a jumper wire, ground ignition timing check terminal.
5) Start engine and allow it to idle. Check basic idle speed.
See IDLE SPEED SPECIFICATIONS table. On DOHC models, multiply
tachometer reading by 3 to obtain actual basic idle speed. If idle
speed is not within specification, turn engine speed adjusting screw
until correct engine speed is obtained. See Fig. 6. Access to speed
adjusting screw is obtained by removing rubber plug on throttle body.
6) If idle speed cannot be lowered by turning engine speed
adjusting screw, determine if Throttle Position (TP) sensor has been
moved. Adjust TP sensor if necessary. See TP SENSOR ADJUSTMENT under
THROTTLE POSITION (TP) SENSOR. If TP sensor is okay, replace throttle
body.
Fig. 6: Adjusting Idle Speed (Typical)
Courtesy of Mitsubishi Motor Sales of America
IDLE SPEED SPECIFICATIONS TABLE









\









\









\









\









\









\







Application Curb Idle Basic Idle
1.5L & 1.8L ............ 600-800 ............... 650-750
2.0L
Non-Turbo ............ 700-900 ................... (1)
Turbo ................ 650-850 ............... 700-800
2.4L ................... 650-850 ............... 700-800
3.0L & 3.5L ............ 600-800 ............... 650-750
( 1) - Information is not available from manufacturer at time
of publication.









\









\









\









\









\









\







NOTE: Basic idle speed should only be adjusted after verifying
spark plugs, fuel injectors, idle air control motor and
engine compression are okay.
All Other Models
1) Ensure vehicle is at normal operating temperature with all
lights, cooling fan and accessories off. Shift transmission into
Neutral or Park position.
2) Basic idle speed can only be adjusted using a scan tool to
ground Data Link Connector (DLC). Connect scan tool to DLC. DLC is
located below dash, near steering column. See Fig. 2.
3) Start engine and allow it to idle. Using scan tool, select
MFI SYSTEM ACTUATOR TEST, then select item 30. Check basic idle speed.
See IDLE SPEED SPECIFICATIONS table.
CAUTION: MFI system actuator test must be cancelled or test will
continue to run for 27 minutes. Driving vehicle under this
condition may damage engine.
4) Cancel MFI system actuator test. If idle speed is not
within specification, turn engine speed adjusting screw until correct
engine speed is obtained. See Fig. 6. Access to speed adjusting screw
is obtained by removing rubber plug on throttle body.
5) If idle speed cannot be lowered by turning engine speed
adjusting screw, determine if fixed Speed Adjusting Screw (SAS). Fixed\
SAS is stop screw contacting throttle lever. See
FIXED SPEED ADJUSTING SCREW for procedure.
6) After all adjustments are verified to be correct, possible
cause of incorrect idle speed is deterioration of Idle Air Control
(IAC) circuit. See DTC P0505 in G - TESTS W/CODES article.
CURB (SLOW) IDLE SPEED
NOTE: Curb idle speed is controlled by Idle Air Control (IAC)
motor. Adjustment is usually not necessary. For curb idle
speed specifications, see IDLE SPEED SPECIFICATIONS table
under BASIC IDLE SPEED.
1) Check ignition timing and adjust if necessary. See
IGNITION TIMING . Run engine at 2000-3000 RPM for more than 5 seconds.
Allow engine to idle for 2 minutes. Check curb idle speed.
2) If curb idle speed is not within specification, check IAC
system. See DTC P0505 in G - TESTS W/CODES article. If IAC system is
okay, adjust basic idle speed. See BASIC IDLE SPEED.
FIXED SPEED ADJUSTING SCREW
NOTE: Fixed Speed Adjusting Screw (SAS) is preset by manufacturer
and usually does not require adjustment. Only adjust fixed
SAS if other adjustment procedures require it, or if

DEFOGGER - REAR WINDOW
1998 Mitsubishi Montero
1998 ACCESSORIES & EQUIPMENT
Mitsubishi - Rear Window Defoggers
Diamante, Eclipse, Galant, Mirage, Montero, Montero Sport,
3000GT
DESCRIPTION & OPERATION
Rear window defogger is a heating filament grid bonded to
inside of window. Rear window defogger is controlled by defogger
switch on instrument panel and a defogger relay.
On Montero, a timer relay controls defogger operation for 9-
11 minutes, then turns defogger off. On Eclipse and Galant, defogger
timer circuit is integral with Electronic Timer Alarm Control System
(ETACS) ECU. Timer will operate defogger for 11 minutes then turn off,\
even with defogger switch in ON position and indicator light
illuminated. On Diamante, timer will operate defogger for 20 minutes,
then turn off.
COMPONENT LOCATIONS
COMPONENT LOCATIONS TABLE








\









\









\









\









\









\






Component Location
A/C ECU
Diamante ......................... Behind Center Of Dash
Data Link Connector (DLC) ....... Under Left Side Of Dash,
Near Steering Column
Defogger Relay
Montero Sport ....................... Under Left Side Of
Glove Compartment
Except Montero Sport ................... On Relay Block,
Behind Left Side Of Dash
Defogger Timer
Diamante ......................... Integral With A/C ECU
Eclipse & Galant ............... Integral With ETACS-ECU
Montero ...................... Behind Left Side Of Dash,
Behind Speaker
ETACS-ECU ......................... Above Left Kick Panel,
On Junction Block









\









\









\









\









\









\






TROUBLE SHOOTING
* PLEASE READ THIS FIRST *
NOTE: For additional trouble shooting information on Eclipse and
Galant, see SYMPTOM TESTS.
DEFOGGER DOES NOT WORK
Check for blown fuse, poor contact, defective defogger
switch, poor connection or open wire.
DEFOGGER TIMER INOPERATIVE

Check defogger switch or defogger timer. See COMPONENT TESTS.
INDICATOR LIGHT DOES NOT WORK
Check for burned out bulb, open circuit or poor connection.
INDICATOR LIGHT IS DIM
Check rheostat or indicator bulb.
SYMPTOM TESTS
INPUT SIGNAL INSPECTION
NOTE: The following information only applies to Eclipse and Galant.
NOTE: Perform input signal inspection before proceeding with
SYSTEM TESTS .
Eclipse & Galant
1) Input signal inspection can be performed using scan tool
or an analog voltmeter. To perform inspection using scan tool, go to
next step. To perform inspection using an analog voltmeter, go to step
3).
2) Turn ignition off. Connect scan tool to Data Link
Connector (DLC). Turn ignition on and then off. If buzzer on scan tool\
sounds when ignition was turned on, ECU input signal is normal. If
buzzer did not sound, go to SYSTEM TESTS.
3) Turn ignition off. Connect DTC Check Harness (MB991529) t\
o
DLC terminals No. 4 or 5 (ground) and terminal No. 9. See Fig. 1.
Connect voltmeter leads to check harness leads. Turn ignition switch
on, then off. If voltmeter deflects once when ignition was turned on,
ECU input signal is normal. If voltmeter did not deflect, go to
SYSTEM TESTS .
Fig. 1: Identifying Data Link Connector (DLC) Terminals
Courtesy of Mitsubishi Motor Sales of America
SYSTEM TESTS

Fig. 6: Identifying Defogger Switch Terminals (3000GT)
Courtesy of Mitsubishi Motor Sales of America
DEFOGGER TIMER TEST
Montero
Remove defogger timer from interior relay block. Connect test
battery and test light to timer. See Fig. 7. Ensure test light
illuminates for about 11 seconds when battery voltage is applied to
terminal No. 3. Reapply battery voltage to terminal No. 3 and observe
test light. Test light should go off. If timer does not test as
specified, replace timer.
Fig. 7: Identifying Defogger Timer Terminals (Montero)
Courtesy of Mitsubishi Motor Sales of America
GRID TEST

Removal
1) Raise and support vehicle. Drain gear oil. Support
differential carrier. Remove axle shafts and inner shaft. See
AXLE SHAFTS R & I and
INNER SHAFT & BEARING . Place alignment mark on drive shaft and pinion
companion flange for reassembly reference.
2) Remove drive shaft. Remove differential mounting brackets
at differential and frame. See Fig. 1. Disconnect front crossmember
from frame. Remove differential carrier assembly and front
crossmember. Remove differential carrier from front crossmember.
Installation
To install, reverse removal procedure. Align marks on drive
shaft and pinion companion flange.
INNER SHAFT & BEARING
Removal
Remove right axle shaft. See AXLE SHAFTS R & I. Using slide
hammer, remove inner shaft from differential carrier. See Fig. 1. If
dust seal replacement is required, pry dust seal from housing tube
assembly using a screwdriver. To remove bearing, bend outer area of
dust cover inward on inner shaft. Press shaft out of bearing. Remove
dust cover from shaft.
Inspection
Inspect inner shaft for damaged splines or threads. Inspect
bearing for roughness or damage.
Installation
1) Install housing tube. Using Seal Installer (MB990955) and\
Handle (C-4171), install NEW dust seal in housing tube. Dust seal must\
be even with housing tube. Coat seal lip with grease.
2) Using a pipe with O.D. of 2.00" (75.0 mm), wall thickness\
of .16" (4.0 mm) and overall length of 2.00" (50.0 mm), install dust\
cover on shaft. Coat inside of dust cover with grease. Press bearing
on shaft. Install new circlip on inner shaft. Carefully drive inner
shaft into differential. DO NOT damage oil seal. To complete
installation, reverse removal procedure.
OVERHAUL
AXLE SHAFTS & BEARINGS
NOTE: References to BJ and DOJ refer to Birfield Joint and Double
Offset Joint, respectively.
Disassembly
1) Remove boot bands. Remove circlip from DOJ outer race.
Separate axle shaft from DOJ outer race. Remove balls from DOJ cage.
Remove DOJ cage from DOJ inner race in direction of BJ. See Fig. 2.
2) Remove snap ring from axle shaft shaft. Remove DOJ inner
race from shaft. Remove circlip from shaft. Wrap tape around splines
of shaft to prevent boot damage during removal. Remove DOJ boot. Note
size of boot. Remove dust cover from shaft. Move boot protector toward
BJ side of shaft and remove. Remove BJ boot.
CAUTION: Axle shaft and BJ are serviced as a unit. DO NOT attempt to
disassemble BJ and axle shaft.
Reassembly
1) Coat shaft with light coat of grease. Wrap splines with

spacer, pinion front shim(s) and front pinion bearing. DO NOT install
oil seal at this time. Install pinion companion flange, washer and
retaining nut. Tighten nut to 137 ft. lbs. (190 N.m).
2) Using INCH-lb. torque wrench, check pinion rotating torque
without pinion oil seal. See PINION ROTATING TORQUE SPECIFICATIONS
table. Adjust rotating torque by replacing drive pinion front shims or
spacer. Once correct rotating torque is obtained, install oil seal.
Coat seal lip with grease.
3) Install pinion flange so alignment marks are correct.
Apply light coat of grease to flange washer contact area. Install NEW
retaining nut. Check pinion rotating torque with pinion oil seal
installed. Rotating torque must be within specification. See
PINION ROTATING TORQUE SPECIFICATIONS table.
Side Bearing Installation
1) Using Bearing Installer (MB990802-01), install bearings o\
n
differential case. Select 2 side bearing adjusting shims thinner than
those removed. Shims must be equal in thickness on both sides. Install
shims on each side of case assembly. Install case assembly in
differential carrier housing.
2) Push case assembly fully to one side of carrier. Using 2
feeler gauges (feeler gauges 180 degrees opposed), measure clearance
between carrier and side bearing. Remove shims from one side of
differential carrier.
3) Measure thickness of shims removed. Add .002" (.05 mm) to\
50% of measured clearance and then add thickness measurement of
removed shim. This is thickness of new shim that should be installed
on each side of case. Install equal thickness shims on each side of
case assembly.
NOTE: Ensure zero clearance exists between gear carrier and
adjusting shim.
4) Install side bearing shims and differential case assembly
in differential carrier. Using brass drift, tap shims to fit them to
side bearing outer race. Install bearing caps. Tighten bolts to
specification. See TORQUE SPECIFICATIONS . Check ring gear backlash.
Ring Gear Backlash
1) Lock drive pinion in place. Using dial indicator, check
ring gear backlash at heel of ring gear tooth. Measure at 4 locations
of ring gear. Gear backlash should be .004-.006" (.10-.15 mm).
2) If backlash is not within specification, change side
bearing adjusting shims and recheck backlash. See
GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION. Check gear
tooth contact using Prussian Blue.
CAUTION: When changing shims, total thickness of all shims must
remain constant to ensure correct bearing preload.
Ring Gear Runout
Using dial indicator, measure runout at back side of ring
gear. Runout should not exceed .002" (.05 mm). If runout is excessive,\
change ring gear-to-differential case mounting position. Ensure ring
gear mounting bolts are tightened to correct specification. Recheck
runout. Install cover and gasket.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








\









\









\









\









\









\









\







Application Ft. Lbs. (N.m)\

(.05-.20 mm). If clearance is not within specification, change thrust
washer to obtain correct clearance.
10) Apply gear oil and friction modifier to all components.
Install components in differential case. Ensure assembly order and
direction of clutch components are correct. See Fig. 16.
Fig. 16: Limited Slip Differential Assembly
Courtesy of Mitsubishi Motor Sales of America.
11) Install differential case cover with reference marks
aligned. Tighten screws to specification in several steps. See
TORQUE SPECIFICATIONS . Ensure cases contact each other completely when
fully assembled. Check for incorrect clutch assembly if gap exists.
12) Using Clutch Plate Preload Tool (MB990988), Shaft
(MB990989) and torque wrench, measure starting torque. See Fig. 17.
Rotate unit slightly before measuring starting torque.