change time MITSUBISHI MONTERO 1998 Service Manual
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 1998, Model line: MONTERO, Model: MITSUBISHI MONTERO 1998Pages: 1501, PDF Size: 25.81 MB
Page 225 of 1501
POWER BRAKE BOOSTER
System Check
1) Run engine for 1-2 minutes. Shut engine off, and depress
brake pedal several times with normal pressure. If pedal height
gradually becomes higher with successive applications, power brake
booster is okay. If pedal height remains steady, power brake booster
is not operating properly, go to next step.
2) With engine stopped, depress brake pedal repeatedly until
pedal height no longer falls. Hold brake pedal down, and start engine.
If pedal moves downward slightly, power brake booster is okay. If
pedal height does not change, power brake booster is not operating
properly, go to next step.
3) With engine running, press and hold brake pedal. Shut off
engine. Hold brake pedal for 30 seconds. Brake pedal height should not
change. If pedal rises, power brake booster is not operating properly,
go to next step.
4) If brake booster operation is not as specified in each
step, disconnect vacuum hose at brake booster and check for sufficient
vacuum with engine running. Also check brake booster check valve
operation. Repair or replace as necessary.
Check Valve Inspection
Remove vacuum hose from power brake booster. Do not remove
check valve from hose. Check valve should hold vacuum in one direction
and allow air to pass in other direction.
LOAD-SENSING PROPORTIONING VALVE (LSPV)
Montero
1) Before diagnosing Load-Sensing Proportioning Valve (LSPV)\
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ensure all other brake components are operating properly. When all
other brake system components are determined to be okay, ensure LSPV
spring length is within specification. See Fig. 1. See LOAD-SENSING
PROPORTIONING VALVE (LSPV) under ADJUSTMENTS.
2) After spring length is determined to be within
specification, connect pressure gauges to input and output ports of
LSPV. See Fig. 7. Bleed brake system. See BLEEDING BRAKE SYSTEM.
Fig. 7: Connecting Pressure Gauges To LSPV (Montero)
Courtesy of Mitsubishi Motor Sales of America.
3) With vehicle unloaded at correct ride height and LSPV
spring correctly adjusted to 8.9" (227 mm), slowly depress brake pedal\
Page 367 of 1501
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\
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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 \
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Application Ft. Lbs. (N.m)\
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during manufacture, some new type valves cannot be reground.
Resurface valve on proper angle specification using valve
grinding machine. Follow manufacturer's instructions for valve
grinding machine. Specifications may indicate a different valve face
angle than seat angle.
Measure valve margin after grinding. Replace valve if not
within specification. Valve stem tip can be refinished using valve
grinding machine.
Valve Lapping
During valve lapping of recent designed valves, be sure to
follow manufacturers recommendations. Surface hardening and materials
used with some valves do not permit lapping. Lapping process will
remove excessive amounts of the hardened surface.
Valve lapping is done to ensure adequate sealing between
valve face and seat. Use either a hand drill or lapping stick with
suction cup attached.
Moisten and attach suction cup to valve. Lubricate valve stem
and guide. Apply a thin coat of fine valve grinding compound between
valve and seat. Rotate lapping tool between the palms or with hand
drill.
Lift valve upward off the seat and change position often.
This is done to prevent grooving of valve seat. Lap valve until a
smooth polished seat is obtained. Thoroughly clean grinding compound
from components. Valve to valve seat concentricity should be checked.
See VALVE SEAT CONCENTRICITY.
CAUTION: Valve guides must be in good condition and free of carbon
deposits prior to valve seat grinding. Some engines contain
an induction hardened valve seat. Excessive material removal
will damage valve seats.
Valve Seat Grinding
Select coarse stone of correct size and angle for seat to be
ground. Ensure stone is true and has a smooth surface. Select correct
size pilot for valve guide dimension. Install pilot in valve guide.
Lightly lubricate pilot shaft. Install stone on pilot. Move stone off
and on the seat approximately 2 times per second during grinding
operation.
Select a fine stone to finish grinding operation. Grinding
stones with 30 and 60 degree angles are used to center and narrow the
valve seat as required. See Fig. 10.
Fig. 10: Adjusting Valve Seat Width - Typical
This Graphic For General Information Only
Valve Seat Replacement
Replacement of valve seat inserts is done by cutting out
Page 564 of 1501
interchangeable. Inspect all components for wear. Note amount of wear
in lifter body-to-camshaft contact area. Surface must have smooth and
convex contact face. If wear is apparent, carefully inspect cam lobe.
Inspect push rod contact area and lifter body for scoring
or signs of wear. If body is scored, inspect lifter bore for damage
and lack of lubrication. On roller type lifters, inspect roller for
flaking, pitting, loss of needle bearings and roughness during
rotation.
Measure lifter body O.D. in several areas. Measure lifter
bore I.D. of cylinder block. Some models offer oversized lifters.
Replace lifter if damaged.
If lifter check valve is not operating, obstructions may be
preventing it from closing or valve spring may be broken. Clean or
replace components as necessary.
Check plunger operation. Plunger should drop to bottom of the
body by its own weight when assembled dry. If plunger is not free,
soak lifter in solvent to dissolve deposits.
Lifter leak-down test can be performed on lifter. Lifter
must be filled with special test oil. New lifters contain special test
oil. Using lifter leak-down tester, perform leak-down test following
manufacturer's instructions. If leak-down time is not within
specifications, replace lifter assembly.
Lifters should be soaked in clean engine oil several hours
prior to installation. Coat lifter base, roller (if equipped) and
lifter body with ample amount of Molykote or camshaft lubricant. See
Fig. 13. Install lifter in original location. Install remaining
components. Valve lash adjustment is not required on most hydraulic
lifters. Preload of hydraulic lifter is automatic. Some models may
require adjustment.
Mechanical Lifters
Lifter assemblies must be installed in original locations.
Remove rocker arm assembly and push rod. Mark components for location.
Some applications require intake manifold or lifter cover removal.
Remove lifter retainer plate (if used). To remove lifters, use lifter
remover or magnet.
Inspect push rod contact area and lifter body for scoring or
signs of wear. If body is scored, inspect lifter bore for damage and
lack of lubrication. Note amount of wear in lifter body-to-camshaft
contact area. Surface must have smooth and convex contact face. If
wear is apparent, carefully inspect cam lobe.
Coat lifter base, roller (if equipped) and lifter body with
ample amount of Molykote or camshaft lubricant. Install lifter in
original location. Install remaining components. Tighten bolts to
specification. Adjust valves. See VALVE ADJUSTMENT in this article.
PISTONS, CONNECTING RODS & BEARINGS
* PLEASE READ THIS FIRST *
NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
RIDGE REMOVAL
Ridge in cylinder wall must be removed prior to piston
removal. Failure to remove ridge prior to removing pistons will cause
piston damage in piston ring locations.
With the piston at bottom dead center, place a rag in the
bore to trap metal chips. Install ridge reamer in cylinder bore.
Adjust ridge reamer using manufacturer's instructions. Remove ridge
Page 705 of 1501
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
Page 749 of 1501
wiring harness as necessary. If continuity exists, go to next step.
5) Reconnect PCM connector. Turn ignition switch to ON
position. Check voltage between chassis ground and ECT sensor
connector terminal No. 1. 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.
6) 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 P0120: THROTTLE POSITION (TP) SENSOR CIRCUIT FAILURE
NOTE: For terminal identification, see TERMINAL IDENTIFICATION. For
circuit and wire color identification, see
L - WIRING DIAGRAMS article.
1) If using scan tool, go to step 3). Disconnect TP sensor
connector. Using DVOM, check resistance between TP sensor terminals
No. 1 and No. 4. If resistance is not 3500-6500 ohms, replace TP
sensor. If resistance is as specified, go to next step.
2) Check resistance between TP sensor terminals No. 1 and 3
on Montero or No. 2 and 4 on 3000GT. While monitoring DVOM, slowly
open throttle from idle to fully open position. If resistance does not
change smoothly, replace TP sensor. If resistance changes smoothly, go
to step 4).
3) Turn ignition switch to ON position. Using scan tool, read
TP sensor voltage value (item 14). With throttle at idle, value should\
read 300-1000 mV. Value should increase while slowly opening throttle.
At wide open throttle, value should read 4500-5500 mV. If value is not
as specified, replace TP sensor. If value is as specified, go to next
step.
4) Disconnect TP sensor connector. Using DVOM, check
continuity between chassis ground and TP sensor connector terminal No.
1. If continuity does not exist, repair wiring harness as necessary.
If continuity exists on 3000GT, go to next step. On Montero, go to
step 6).
5) Check continuity between chassis ground and TP sensor
connector terminal No. 4. If continuity does not exist, repair wiring
harness as necessary. If continuity exists, go to next step.
6) Turn ignition switch to OFF position. Disconnect PCM
connector. Ground specified PCM connector terminal. See
TP SENSOR-TO-PCM WIRING HARNESS TERMINAL IDENTIFICATION table. Check
for continuity between chassis ground and specified TP sensor
connector terminal. If continuity does not exist, repair wiring
harness as necessary. If continuity exists on 3000GT, go to step 8).
On Montero, go to next step.
TP SENSOR-TO-PCM WIRING HARNESS TERMINAL IDENTIFICATION TABLE
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Application TP Sensor Terminal No. PCM Terminal No.
Montero ................. 3 ......................... 78
4 ......................... 42
3000GT .................. 2 ......................... 78
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7) Reconnect PCM connector. Turn ignition switch to ON
position. Check voltage between chassis ground and TP sensor connector
terminal No. 4 on Montero or No. 1 on 3000GT. If voltage is not 4.8-5.
2 volts, replace PCM. If voltage is as specified, condition required
to set DTC is not present at this time. Go to next step.
8) Test is complete. Intermittent problem may exist. Road
Page 754 of 1501
3) Using scan tool, read FUEL INJECTOR DRIVE TIME (item 41)
while cranking engine. See INJECTOR CRANKING DRIVE TIME SPECIFICATIONS
table. Go to next step.
INJECTOR CRANKING DRIVE TIME SPECIFICATIONS TABLE
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Coolant Temperature Drive Time (ms)
32
F (0C)
Montero ...................................... 11.0-17.0
3000GT
DOHC
Non-Turbo ................................ 12.9-19.3
Turbo ..................................... 8.4-12.6
SOHC ....................................... 13.8-16.8
68
F (20C)
Montero ...................................... 28.0-42.0
3000GT
DOHC
Non-Turbo ................................ 36.1-54.1
Turbo .................................... 23.3-34.9
SOHC ....................................... 40.0-48.8
176
F (80C)
Montero ....................................... 7.4-11.2
3000GT
DOHC
Non-Turbo ................................. 8.2-12.4
Turbo ...................................... 5.4-8.2
SOHC ........................................ 8.6-10.6
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4) Ensure engine coolant temperature is at 176-205F (80-
95C), all accessories are off and A/T is in Park or M/T is in
Neutral. Using scan tool, read FUEL INJECTOR DRIVE TIME (item 41)
under specified engine conditions. See
INJECTOR OPERATING DRIVE TIME SPECIFICATIONS table. Go to next step.
INJECTOR OPERATING DRIVE TIME SPECIFICATIONS TABLE
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Engine Speed Drive Time (ms)
700 RPM
Montero ........................................ 2.1-3.3
3000GT
DOHC
Non-Turbo .................................. 2.5-3.7
Turbo ...................................... 1.7-2.9
SOHC ......................................... 2.3-3.5
2000-2500 RPM
Montero ........................................ 1.9-3.1
3000GT
DOHC
Non-Turbo .................................. 2.2-3.4
Turbo ...................................... 1.5-2.7
SOHC ......................................... 2.1-3.3
Suddenly Accelerated
Montero & 3000GT ................................... ( 1)
( 1) - Drive time should increase.
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5) Allow engine to idle after warm up. Using scan tool, shut
off fuel injectors in sequence. Idle should change when good fuel
Page 755 of 1501
injectors are shut off. If idle state does not change, check fuel
injector connection, spark plug and cable, and cylinder compression.
If conditions are not as specified in preceding steps, go to next
step.
6) On 3000GT, go to next step. On Montero, disconnect MFI
relay connector and fuel injector connector at faulty fuel injector.
Using DVOM, check for continuity between MFI relay connector terminal
No. 1 fuel injector intermediate connector terminal No. 8. If
continuity does not exist, repair wiring harness as necessary. If
continuity exists, go to step 9).
7) Disconnect fuel injector connector. Using DVOM, check
voltage between chassis ground and fuel injector connector terminal
No. 1. If battery voltage does not exist, repair wiring harness as
necessary. If battery voltage exists, go to next step.
8) Ground specified PCM connector terminal for appropriate
fuel injector. See INJECTOR-TO-PCM CIRCUIT IDENTIFICATION (3000GT)
table. Using DVOM, check for continuity between chassis ground and
terminal No. 2 of each fuel injector connector. If continuity does not
exist, repair appropriate circuit as necessary. If continuity exists,
condition required to set DTC is not present at this time. Go to step
10).
INJECTOR-TO-PCM CIRCUIT IDENTIFICATION (3000GT) TABLE
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Injector No. PCM Terminal No.
1 ...................................................... 1
2 ..................................................... 14
3 ...................................................... 2
4 ..................................................... 15
5 ...................................................... 3
6 ..................................................... 16
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9) Ground specified PCM connector terminal. See
INJECTOR-TO-PCM CIRCUIT IDENTIFICATION (MONTERO) table. Using DVOM,
check for continuity between chassis ground and specified fuel
injector connector terminal. If continuity does not exist, repair
appropriate circuit as necessary. If continuity exists, condition
required to set DTC is not present at this time. Go to next step.
INJECTOR-TO-PCM CIRCUIT IDENTIFICATION (MONTERO) TABLE
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Injector Injector Connector PCM
No. Terminal No. Terminal No.
1 ......................... 3 ........................ 1
2 ......................... 2 ....................... 14
3 ......................... 1 ........................ 2
4 ......................... 7 ....................... 15
5 ......................... 6 ........................ 3
6 ......................... 5 ....................... 16
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10) 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 P0300-P0306: CYLINDER MISFIRE DETECTED
NOTE: For terminal identification, see TERMINAL IDENTIFICATION. For
circuit and wire color identification, see
Page 772 of 1501
![MITSUBISHI MONTERO 1998 Service Manual 2) Disconnect pressure hose from oil pump. See Fig. 45.
Install Adapter (MB990993) on oil pump. Install Adapter (MB990994) o\
n
disconnected hose. Connect Pressure Gauge (MB990662) and shutof](/img/19/57333/w960_57333-771.png "MITSUBISHI MONTERO 1998 Service Manual 2) Disconnect pressure hose from oil pump. See Fig. 45.
Install Adapter (MB990993) on oil pump. Install Adapter (MB990994) o\
n
disconnected hose. Connect Pressure Gauge (MB990662) and shutof")
2) Disconnect pressure hose from oil pump. See Fig. 45.
Install Adapter (MB990993) on oil pump. Install Adapter (MB990994) o\
n
disconnected hose. Connect Pressure Gauge (MB990662) and shutoff valve\
between adapters. Open shutoff valve. Bleed steering hydraulic system.
See HYDRAULIC SYSTEM BLEEDING in STEERING SYSTEM article.
Fig. 45: Testing PSP Sensor Circuit
Courtesy of Mitsubishi Motor Sales of America
3) Install a thermometer in fluid reservoir. Start engine and
allow it to idle. Turn steering wheel several times until fluid
temperature reaches 122-140
F (50-60C). Disconnect PSP switch
connector. Install a DVOM between ground and PSP switch terminal. See
Fig. 45 . Note continuity reading on DVOM. Go to next step.
4) With engine idling, gradually close shutoff valve to
increase power steering system pressure. Check pressure when PSP
switch is actuated by watching for a change in continuity. PSP switch
Page 810 of 1501
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