ESP MITSUBISHI MONTERO 1998 Service Manual

HEATER HOSES
HIGH PRESSURE RELIEF VALVES (HPRV)
IDLERS
IN-LINE FILTERS
METAL FITTINGS
METAL LINES
MIX AND AIR CONTROL DOORS (BLEND DOORS)
O-RINGS
ORIFICE TUBES
PILOT-OPERATED ABSOLUTES (POAS)
PLENUMS
PRESSURE CONTROL VALVES
PRESSURE SENSORS
PULLEYS
RADIATORS
RECEIVER-DRIERS
REFRIGERANT
REFRIGERANT OIL
RELAYS
SEALS
SERVICE PORTS
SPRING LOCK COUPLINGS
SUCTION THROTTLING VALVES (STVS)
SWITCHES (ELECTRICAL)
TENSIONERS
THERMISTORS AND PRESSURE SENSORS
THERMOSTATS AND HOUSINGS
VACUUM HOSES AND TUBES
VACUUM RESERVOIRS
VACUUM TUBES
VALVES IN RECEIVER (VIRS)
WATER PUMPS (ELECTRIC AUXILIARY)
WIRING HARNESSES AND CONNECTORS
MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt
(1) a Pledge of Assurance to their Customers and (2) the Motorist
Assurance Program Standards of Service. All participating service
providers have agreed to subscribe to this Pledge and to adhere to the
promulgated Standards of Service demonstrating to their customers that
they are serious about customer satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection communication standards

Switch Continuity Between
Position Terminal No.
OFF .................................................. (1)
Low ......................................... 1 & 8; 3 & 5
Medium-Low .................................. 1 & 8; 5 & 6
Medium-High .............................. 1, 4 & 8; 2 & 5
High ..................................... 1, 4 & 8; 5 & 7
( 1) - Continuity should not exist between any terminals.









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DUAL-PRESSURE SWITCH
Disconnect dual-pressure connector, and connect a jumper wire
across harness connector terminals. Connect manifold gauge set to
system, and check operating pressures. Dual-pressure switch will allow
compressor operation when system pressure is within specification.
When high or low pressure side of dual-pressure switch is at operation
pressure (ON), condition is normal if there is continuity between the
respective terminals. If continuity is not present when switch is ON,
replace dual-pressure switch. See PRESSURE SWITCH SPECIFICATIONS
table.
PRESSURE SWITCH SPECIFICATIONS TABLE ( 1)









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Application ON Pressure OFF Pressure
psi (kg/cm) psi (kg/cm)
High Pressure ......... 455 (32) .............. 541 (38)
Low Pressure .......... 32 (2.2) .............. 28 (2.0)
( 1) - With ambient temperature at 80
F (27C).








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COMPRESSOR CLUTCH
Disconnect wiring to compressor clutch. Connect battery
voltage directly to A/C compressor clutch wiring harness terminals. If
click is heard, clutch engagement is okay. If click is not heard,
pulley and armature are not making contact. Repair or replace as
necessary.
RELAYS
4-Terminal Relay
1) Remove relay from relay box located in engine compartment.
Using an ohmmeter, check continuity between relay terminals.
Continuity should exist between terminals No. 2 and 4, but not between
terminals No. 1 and 3. See Fig. 6.
2) Connect battery voltage to terminal No. 2, and ground
terminal No. 4. Ensure continuity now exists between terminals No. 1
and 3. If continuity is not as specified, replace relay.

SHOE HARDWARE
SHOES
SOCKETS
SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)
STEEL BRAKE LINES
STOPLIGHT SWITCHES
SWITCHES
TIRES
TOOTHED RINGS (TONE WHEEL)
VACUUM BOOSTERS
VACUUM HOSES
VALVES
WHEEL ATTACHING HARDWARE
WHEEL BEARINGS, RACES AND SEALS
WHEEL CYLINDERS
WIRING HARNESSES
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt:\
1) a Pledge of Assurance to their Customers and
2) the Motorist Assurance Program Standards of Service.
All participating service providers have agreed to subscribe
to this Pledge and to adhere to the promulgated Standards of Service
demonstrating to their customers that they are serious about customer
satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection communication standards
are continually re-published. In addition to these, standards for
Drive Train and Transmissions have recently been promulgated.
Participating shops utilize these Uniform Inspection & Communication
Standards as part of the inspection process and for communicating
their findings to their customers.
The Motorist Assurance Program continues to work
cooperatively and proactively with government agencies and consumer
groups toward solutions that both benefit the customer and are
mutually acceptable to both regulators and industry. We maintain the
belief that industry must retain control over how we conduct our
business, and we must be viewed as part of the solution and not part
of the problem. Meetings with state and other government officials
(and their representatives), concerned with auto repair and/or
consumer protection, are conducted. Feedback from these sessions is
brought back to the association, and the program adjusted as needed.
To assure auto repair customers recourse if they were not

* Place transmission in Neutral position.
* Ensure emergency brake has been set and all accessories
are turned off.
* Start engine and bring to normal operating temperature.
* Allow vehicle to idle in Neutral for one minute.
* Initial relearn is complete: process will be completed during
normal driving.
Some manufacturers identify a specific relearn procedure
which will help establish suitable driveability during relearn stage.
These procedures are especially important if vehicle is equipped with
and electronically controlled automatic transmission or transaxle.
Always complete procedure before returning vehicle to customer.

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

Scan Tool Method (3000GT)
Turn ignition off. Connect scan tool to DLC. Follow scan tool
manufacturer's instructions. Turn ignition on. Perform ON/OFF
operation of each door lock or power window switch. If scan tool
buzzer sounds once, ECU input signal to corresponding switch circuit
is normal.
Voltmeter Method (3000GT)
Using Diagnostic Trouble Code Check Harness (MB991529),
connect harness to DLC terminals No. 4 and 5. Connect voltmeter to
harness. Turn ignition on. Perform ON/OFF operation of each door lock
or power window switch. If voltmeter pointer moves once, ECU input
signal from corresponding switch circuit is normal.
COMPONENT TESTS
* PLEASE READ THIS FIRST *
NOTE: If after all testing procedures are completed, system is not
functioning properly, substitute with a known-good ETACS-ECU
and retest.
DOOR LOCK ACTUATOR
Left Front Door (Montero & 3000GT)
1) Access left front door lock actuator. See
DOOR LOCK ACTUATOR R & I under REMOVAL & INSTALLATION. Disconnect
harness connector. Set actuator in LOCK position. Connect positive
lead of 12-volt power source to actuator terminal No. 1 (Blue/Red
wire) on Montero or terminal No. 3 (Blue/Red wire) on 3000GT. See
WIRING DIAGRAMS . Actuator should move to UNLOCK position when terminal
No. 3 (White/Black wire) on Montero or terminal No. 1 (Blue/Black
wire) on 3000GT is connected to ground.
2) With actuator set in UNLOCK position, connect positive
lead of 12-volt power source to actuator terminal No. 3 (White/Black
wire) on Montero or terminal No. 1 (Blue/Black wire) on 3000GT. See
WIRING DIAGRAMS . Actuator should move to LOCK position when terminal
No. 1 (Blue/Red wire) on Montero or terminal No. 3 (Blue/Red wire) o\
n
3000GT is connected to ground.
3) On 3000GT, check for continuity between actuator terminals
No. 2 (Brown/Yellow wire) and No. 4 (Black wire). See WIRING DIAGRAMS.
Continuity should be present with actuator set in UNLOCK position.
Continuity should not be present with actuator set to LOCK position.
Right Front Door (Montero & 3000GT)
1) Access right front door lock actuator. See
DOOR LOCK ACTUATOR R & I under REMOVAL & INSTALLATION. Disconnect
harness connector. Set actuator in LOCK position. Connect positive
lead of 12-volt power source to actuator terminal No. 3 (Blue/Red
wire) on Montero or terminal No. 1 (Blue/Red wire) on 3000GT. See
WIRING DIAGRAMS . Actuator should move to UNLOCK position when terminal
No. 1 (White/Black wire) on Montero or terminal No. 3 (Blue/Black
wire) on 3000GT is connected to ground.
2) With actuator set in UNLOCK position, connect positive
lead of 12-volt power source to actuator terminal No. 1 (White/Black
wire) on Montero or terminal No. 3 (Blue/Black wire) on 3000GT. See
WIRING DIAGRAMS . Actuator should move to LOCK position when terminal
No. 3 (Blue/Red wire) on Montero or terminal No. 1 (Blue/Red wire) o\
n
3000GT is connected to ground.
3) On 3000GT, check for continuity between actuator terminals
No. 2 (Brown wire) and No. 4 (Black wire). See WIRING DIAGRAMS.
Continuity should be present with actuator set in UNLOCK position.

VEHICLE SPEED SENSORS
VENTS
VIBRATION DAMPERS
WHEEL ATTACHMENT HARDWARE
WHEEL SPEED SENSORS
WIRING HARNESSES AND CONNECTORS
YOKES AND SLIP YOKES
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt
(1) a Pledge of Assurance to their Customers and (2) the Motorist
Assurance Program Standards of Service. All participating service
providers have agreed to subscribe to this Pledge and to adhere to the
promulgated Standards of Service demonstrating to their customers that
they are serious about customer satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection were recently published.
Further, revisions to all of these inspection communication standards
are continually republished. In addition to these, standards for Drive
Train and Transmissions have recently been promulgated. Participating
shops utilize these Uniform Inspection & Communication Standards as
part of the inspection process and for communicating their findings to
their customers.
The Motorist Assurance Program continues to work
cooperatively and proactively with government agencies and consumer
groups toward solutions that both benefit the customer and are
mutually acceptable to both regulators and industry. We maintain the
belief that industry must retain control over how we conduct our
business, and we must be viewed as part of the solution and not part
of the problem. Meetings with state and other government officials
(and their representatives), concerned with auto repair and/or
consumer protection, are conducted. Feedback from these sessions is
brought back to the association, and the program adjusted as needed.
To assure auto repair customers recourse if they were not
satisfied with a repair transaction, the Motorist Assurance Program
offers mediation and arbitration through MAP/BBB-CARE and other non-
profit organizations. MAP conducted pilot programs in twelve states
before announcing the program nationally in October, 1998. During the
pilots, participating repair shops demonstrated their adherence to the
Pledge and Standards and agreed to follow the UICS in communicating
the results of their inspection to their customers. To put some
"teeth" in the program, an accreditation requirement for shops was
initiated. The requirements are stringent, and a self-policing method

IGNITION SWITCHES
INDICATOR LIGHTS
KEYLESS ENTRY KEYPADS AND TRANSMITTERS
KEYLESS ENTRY TRANSMITTERS
LEDS
LENSES
MICROPHONES
MIRRORS (ELECTROCHROMATIC AND HEATED)
MOTORS
NEUTRAL SAFETY SWITCHES
ODOMETERS
ODOMETERS, SPEEDOMETERS AND TACHOMETERS (CABLE-DRIVEN)
PULLEYS
RECEIVERS, AMPLIFIERS, EQUALIZERS AND SUB-WOOFER VOLUME CONTROLS
RELAY BOXES
RELAYS
SEALED BEAMS
SEAT HEATERS
SECURITY ALARM SENSORS
SIRENS
SOLENOIDS
SPEAKERS AND MICROPHONES
SPEEDOMETER AND TACHOMETER LINKAGES AND CABLES
SPEEDOMETER CABLES
SPEEDOMETERS
STARTERS
SUB-WOOFER VOLUME CONTROLS
SWITCHES
TACHOMETER CABLES
TACHOMETERS
TAPE PLAYERS AND CD PLAYERS
TENSIONERS
TIMERS
TIRE PRESSURE SENSORS
TRANSCEIVERS
TRANSDUCERS
VACUUM ACCUMULATORS (RESERVOIRS)
VACUUM RESERVOIRS
VOLTAGE REGULATORS
WASHER FLUID LEVEL SENDERS
WASHER PUMPS
WIPER ARMS AND BLADES
WIPER BLADES
WIPER HOSES AND NOZZLES
WIPER LINKAGES
WIPER NOZZLES
WIPER PUMP RESERVOIRS
WIRING HARNESSES AND CONNECTORS
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,

NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
REMOVAL
Remove intake and exhaust manifolds and valve cover. Cylinder
head and camshaft carrier bolts (if equipped), should be removed only
when the engine is cold. On many aluminum cylinder heads, removal
while hot will cause cylinder head warpage. Mark rocker arm or
overhead cam components for location.
Remove rocker arm components or overhead cam components.
Components must be installed in original location. Individual design
rocker arms may utilize shafts, ball-type pedestal mounts or no rocker
arms. For all design types, wire components together and identify
according to the corresponding valve. Remove cylinder head bolts.
Note length and location. Some applications require cylinder head
bolts be removed in proper sequence to prevent cylinder head damage.
See Fig. 1 . Remove cylinder head.
Fig. 1: Typical Cylinder Head Tightening or Loosening Sequence
This Graphic For General Information Only
INSTALLATION
Ensure all surfaces and head bolts are clean. Check that head
bolt holes of cylinder block are clean and dry to prevent block damage
when bolts are tightened. Clean threads with tap to ensure accurate
bolt torque.
Install head gasket on cylinder block. Some manufacturer's
may recommend sealant be applied to head gasket prior to installation.
Note that all holes are aligned. Some gasket applications may be
marked so certain area faces upward. Install cylinder head using care
not to damage head gasket. Ensure cylinder head is fully seated on
cylinder block.
Some applications require head bolts be coated with sealant
prior to installation. This is done if head bolts are exposed to water
passages. Some applications require head bolts be coated with light
coat of engine oil.

Ensure cylinder is checked for taper, out-of-round and
properly honed prior to checking piston and cylinder bore fit. See
CYLINDER BLOCK in this article. Using dial bore gauge, measure
cylinder bore. Measure piston at right angle to piston pin in center
of piston skirt area. Subtract piston diameter from cylinder bore
diameter. The difference is piston-to-cylinder clearance. Clearance
must be within specification. Mark piston for proper cylinder
location.
ASSEMBLING PISTON & CONNECTING ROD
Install proper fitted piston on connecting rod for proper
cylinder. Ensure piston marking on top of piston marked is in
correspondence with connecting rod and cap number. See Fig. 14.
Fig. 14: Piston Pin Installation - Typical
This Graphic For General Information Only
Lubricate piston pin and install in connecting rod. Ensure
piston pin retainers are fully seated (if equipped). On pressed type
piston pins, follow manufacturer's recommended procedure to avoid
distortion or breakage.
CHECKING PISTON RING CLEARANCES