check engine 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 20 of 1501
instrument panel.
(
2) - See Figs. 1 and 2.
(
3) - Engine ID is eighth character of VIN.
(
4) - Fuel system is a Sequential Fuel Injection (SFI) system.
(
5) - Ignition timing is computer-controlled.
(
6) - This system may also be referred to as distributor ignition.
(
7) - This system may also be referred to as distributorless
ignition.
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VIN DEFINITION
J A 3 A Y 3 6 A 1 W U 0 0 0 0 0 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
1 - Indicates Nation of Origin.
2 - Indicates Manufacturer.
3 - Indicates Vehicle Type.
4 - Indicates Restraint System. ( 1)
5 - Indicates Model.
6 - Indicates Vehicle Series.
7 - Indicates Body Type.
8 - Indicates Engine Type and Make.
9 - Indicates Check Digit.
10 - Indicates Model Year.
11 - Indicates Assembly Plant.
12-17 - Indicates Serial Number.
( 1) - On Montero & Montero Sport, fourth character of VIN indicates
GVWR.
VIN CODE/YEAR APPLICATIONS
VIN CODE/YEAR APPLICATION TABLE\
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VIN Code Model Year
T ................................................... 1996
V ................................................... 1997
W ................................................... 1998
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ENGINE CODE LOCATIONS
Fig. 1: Engine Code Locations (Diamante)
Courtesy of Chrysler Corp.
Page 36 of 1501
A/C COMPRESSOR REFRIGERANT OIL CHECKING
1998 Mitsubishi Montero
1998 A/C SYSTEM GENERAL SERVICING
Mitsubishi - Compressor Refrigerant Oil Checking
Diamante, Eclipse, Galant, Mirage, Montero, Montero Sport &
3000GT
* PLEASE READ THIS FIRST *
NOTE: Always refer to underhood A/C specification label in engine
compartment or A/C compressor label while servicing A/C
system. If engine compartment/compressor label specifications
differ from specifications in this article, use
underhood/compressor label specifications.
A/C COMPRESSOR APPLICATIONS
A/C COMPRESSOR APPLICATION TABLE \
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Application Compressor
Diamante ......................... Sanden MSC105CVS Scroll
Eclipse
2.0L Non-Turbo ............. Nippondenso 10PA17C 10-Cyl.
2.0L Turbo & 2.4L .............. Sanden MSC105CVS Scroll
Galant ............................ Sanden MSC90C12 Scroll
Mirage ............................... Sanden MSC90 Scroll
Montero ....................... Nippondenso 10PA15 10-Cyl.
Montero Sport ...................... Sanden MSC105C Scroll
3000GT .............................. Sanden MSC105 Scroll
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REFRIGERANT OIL & REFRIGERANT CAPACITY SPECIFICATIONS
NOTE: DO NOT exceed A/C system refrigerant oil capacity when
servicing system.
REFRIGERANT OIL & R-134a REFRIGERANT CAPACITY TABLE
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Application ( 1) Oil Refrigerant
Ounces Ounces
Diamante .................... 5.7-6.4 ........ 22.9-24.3
Eclipse
2.0L Non-Turbo ............ 2.7-4.1 ........ 24.7-26.1
2.0L Turbo & 2.4L ......... 5.7-6.4 ........ 24.7-26.1
Galant ...................... 4.1-5.1 ........ 22.9-24.3
Mirage ...................... 4.1-5.1 ........ 19.6-21.0
Montero ..................... ( 2) 4.1 ........ 21.2-22.9
Montero Sport ............... ( 2) 5.7 ........ 22.9-24.0
3000GT ...................... 4.7-6.1 ........ 26.1-27.9
( 1) - Total system capacity, unless otherwise noted.
( 2) - Compressor refrigerant oil capacity.
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REFRIGERANT OIL
Page 63 of 1501
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. Require repair or replacement.
(1) - Refer to manufacturer's diagnostic trouble code
procedure and require repair or replacement of
affected component(s).
( 2) - Determine cause and correct prior to repair or
replacement of part.
( 3) - Determine source of contamination, such as engine coolant,
fuel, metal particles, or water. Require repair or
replacement. Check for accepted cleaning procedure.
( 4) - Inoperative includes intermittent operation or out of
OEM specification. Some components may be serviceable.
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COOLANT
COOLANT INSPECTION \
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Condition Code Procedure
Acidity (pH) incorrect .. 1 ........... Suggest correction or
replacement.
Contaminated ............ B ...... ( 1) Require replacement or
recycling. Further
inspection required.
Level incorrect ......... B .......... ( 2) Require filling to
proper level.
Maintenance intervals ... 3 ........ ( 3) Suggest replacement.
Mixture incorrect ....... B ........... Require correction or
replacement.
Type incorrect .......... B ............ Require replacement.
( 1) - Determine source of contamination and require correction
prior to coolant replacement.
( 2) - Determine source of incorrect level and suggest repair.
( 3) - The system should be drained and/or flushed and
refilled with correct coolant according to OEM
recommended service interval and procedures.
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COOLING FAN BLADES
COOLING FAN BLADE INSPECTION \
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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Attaching hardware
broken ................. A ... Require repair or replacement
of hardware.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware not
functioning ............ A ... Require repair or replacement
of hardware.
Page 86 of 1501
ADJUSTMENTS
NOTE: For adjustment procedures, see HEATER SYSTEM article.
TROUBLE SHOOTING
NO COOLING
1) Ensure compressor clutch is operating. If compressor
clutch is operating, go to next step. If compressor clutch is not
operating, check fuses and A/C switch. Check dual-pressure switch.
Check air inlet sensor and air thermosensor. Check A/C compressor
relay. Check A/C compressor clutch coil. Check A/C control unit.
2) Ensure system is properly charged with correct amount of
refrigerant. Evacuate and charge system as necessary. Ensure receiver-
drier is not clogged. Check compressor belt for proper tension. Check
for clogged expansion valve. Check compressor operation. Repair or
replace components as necessary.
INSUFFICIENT AIRFLOW
Check for air leakage at air duct joint. Check for frost on
evaporator. Ensure blower motor is operating properly. Check for
obstructed air intake.
INSUFFICIENT COOLING
Ensure system is properly charged with correct amount of
refrigerant and free of air and moisture. Evacuate and charge system
as necessary. Ensure receiver-drier is not clogged. Ensure sufficient
airflow through condenser exists. Check compressor belt for proper
tension. Check compressor operation. Repair or replace compressor as
necessary. Check for clogged expansion valve. Replace expansion valve
as necessary. Check A/C compressor clutch coil.
INTERMITTENT COOL AIR
Check for air or moisture in system. Evacuate and charge
system as necessary. Check for expansion valve malfunction. Replace
expansion valve if necessary. Check compressor belt for proper
tension.
TESTING
* PLEASE READ THIS FIRST *
WARNING: To avoid injury from accidental air bag deployment, read and
carefully follow all SERVICE PRECAUTIONS and DISABLING &
ACTIVATING AIR BAG SYSTEM procedures in AIR BAG RESTRAINT
SYSTEM article.
NOTE: For testing procedures not covered in this article, see
HEATER SYSTEM article.
A/C SYSTEM PERFORMANCE
1) Park vehicle out of direct sunlight. Install A/C gauge
set. Start engine and allow it to idle at 1000 RPM. Turn A/C on. Set
A/C controls to recirculated air, panel (vent) mode and full cold
Page 91 of 1501
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.
Page 93 of 1501
A/C SWITCH
Removal & Installation
Lower glove box. Remove instrument cover. Remove lap cooler
and foot shower ducts. Remove center panel and A/C-heater control
panel. Remove bezel and knob. Disconnect A/C switch connector, and
remove A/C switch. To install, reverse removal procedure.
A/C ENGINE COOLANT TEMPERATURE SWITCH
Removal & Installation
Drain coolant below level of thermostat housing. See Fig. 8.
Remove A/C engine coolant temperature switch wiring harness connector,
and unscrew A/C engine coolant temperature switch from thermostat
housing. To install, reverse removal procedure. Tighten A/C engine
coolant temperature switch to specification. See TORQUE SPECIFICATIONS
. Add coolant and check for leaks.
Fig. 8: Locating A/C Engine Coolant Temperature Switch
Courtesy of Mitsubishi Motor Sales of America.
BLOWER MOTOR & RESISTOR
Removal & Installation
Remove right side foot shower duct. Disconnect blower and/or
resistor. Remove blower motor and/or resistor. See Fig. 9. To install,
reverse removal procedure.
Page 119 of 1501
Symptom Inspection Procedure
Communication With All Systems Not Possible ............ 1
Communication With SRS Only Not Possible ............... 2
Ignition Switch On (Engine Stopped)
SRS Warning Light Does Not Come On ............... DTC 43
SRS Warning Light Stays On After 7 Seconds ...... DTC 43
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INSPECTION PROCEDURE 1
The cause is probably in power supply system (including
ground circuit of diagnostic line). Check connectors and harness, and
repair if necessary.
INSPECTION PROCEDURE 2
NOTE: Refer to WIRING DIAGRAMS for connector identification.
1) Before proceeding, see SERVICE PRECAUTIONS. Deactivate
SRS. See DISABLING & ACTIVATING AIR BAG SYSTEM .
2) Measure SRS Check Harness (MB991613) connector No. 5.
Disconnect SRS-ECU connector C-122 and connect SRS check harness
connector No. 3 to C-122. Check continuity between terminal No. 20, 21
and ground. If there is no continuity, go to next step. If there is
continuity, go to step 4).
3) Check connector C-122, and repair if necessary. If
connector is okay, check for trouble symptoms. If fault exists, check
harness between SRS-ECU and ground, and repair if necessary.
4) Measure SRS check harness connector No. 5. Disconnect SRS-
ECU connector C-122 and connect SRS harness check connector No. 3 to
C-122. Connect negative battery cable. Measure voltage between
terminal No. 13 and 14, and body ground. If voltage at terminals is 9
volts or more, check harness wire between SRS-ECU and Data Link
Connector (DLC), and repair if necessary. If harness wire is okay,
replace SRS-ECU. See SRS AIR BAG CONTROL UNIT (ECU) under REMOVAL &
INSTALLATION. If voltage is not as specified, check connector C-80, C-
93, C-101, and C-132, and repair if necessary. If connectors are okay,
check for trouble symptoms. If fault exists, check harness between
SRS-ECU and IG1 A or B (ignition switch), and repair if necessary.
Fig. 10: Identifying SRS Check Harness (MB991613) Connectors
Courtesy of Mitsubishi Motor Sales of America.
DTC 11, 12 & 13: FRONT IMPACT SENSOR SYSTEM
Page 128 of 1501
ANTI-LOCK BRAKE SYSTEM
1998 Mitsubishi Montero
1997-98 BRAKES
Mitsubishi - Anti-Lock
Montero
DESCRIPTION
CAUTION: See ANTI-LOCK BRAKE SAFETY PRECAUTIONS article in GENERAL
INFORMATION.
NOTE: For more information on brake system, see BRAKE SYSTEM
article.
The Anti-Lock Brake System (ABS) is designed to prevent wheel\
lock-up during heavy braking. This allows operator to maintain
steering control while stopping vehicle in shortest distance possible.
Major components are a hydraulic unit, wheel speed sensors, "G"
sensor, ABS Electronic Control Unit (ECU) and ANTI-LOCK warning light.\
ABS has a self-diagnostic system to indicate a system malfunction and
for use in system trouble shooting.
OPERATION
Each wheel sensor sends an AC electrical signal to the ECU.
The ECU reads this information as wheel speed. When any decelerating
wheel speed rate is determined to be excessive in comparison to other
monitored wheels, the hydraulic unit cycles hydraulic brake pressure
to each wheel to equalize speed of all wheels. ABS turns itself off
when vehicle drops to 4 MPH. Minor lock-up may occur at this point.
With engine running and vehicle speed greater than 4 MPH,
pump motor will operate for a short period of time and may be heard
inside vehicle. During pump motor operation, ABS system is completing
a self-check. During ABS system operation, a pulsing brake pedal and
vibration in steering wheel and vehicle body may be experienced. These
conditions are normal.
BLEEDING BRAKE SYSTEM
BLEEDING PROCEDURES
CAUTION: When adding brake fluid, ensure filter is properly fitted on
reservoir tank.
ABS system is bled using conventional method. With engine
running, manually bleed system using an assistant. For bleeding order,
see BRAKE LINE BLEEDING SEQUENCE table. Ensure Load Sensing
Proportioning Valve (LSPV) is bled in sequence. Remove all air from
brake system. Refill brake fluid reservoir after bleeding procedure is
complete.
BRAKE LINE BLEEDING SEQUENCE
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Application Sequence
Montero ....................................... RR, LR, LSPV, RF, LF
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Page 130 of 1501
for one second, and then go out. Turn ignition switch to START
position. Warning light should come on and stay on.
2) When ignition switch is turned from START to ON position,
warning light should come on for one second, and then go out. If
warning light functions as specified, go to step 3). If warning light
does not function as specified, see appropriate trouble shooting test:
* IGNITION SWITCH IN ON POSITION (ENGINE NOT RUNNING),
ANTI-LOCK WARNING LIGHT INOPERATIVE
* AFTER ENGINE STARTS, ANTI-LOCK WARNING LIGHT REMAINS ON
* IGNITION SWITCH IN START POSITION, ANTI-LOCK WARNING LIGHT
INOPERATIVE
* IGNITION SWITCH IN ON POSITION, ANTI-LOCK WARNING LIGHT
BLINKS TWICE. IN START POSITION, LIGHT STAYS ON. WHEN
IGNITION SWITCH IS CYCLED FROM START TO ON POSITION, LIGHT
BLINKS ONCE, THEN TURNS OFF
3) Test drive vehicle. If ANTI-LOCK warning light does not
come on at low speed, go to next step. If light comes on at low speed,
motor relay, solenoid valve or Wheel Speed Sensor (WSS) malfunction is\
indicated. Go to step 6). If insufficient braking force or ABS
malfunction exists, go to next step. If none of listed symptoms exist,
go to step 6).
4) Check conventional brake system components for proper
operation. Check for mechanical lock of hydraulic unit solenoid valve.
Check for plugged hydraulic line in hydraulic unit. Repair or replace
as necessary. If hydraulic unit is okay, go to next step.
5) Ensure WSS rotor gap is correct. See WHEEL SPEED SENSOR
(WSS) under ADJUSTMENTS. Check for faulty wheel speed sensor. See
WHEEL SPEED SENSOR (WSS) under COMPONENT TESTS. Replace sensor as
necessary. See WHEEL SPEED SENSOR (WSS) under REMOVAL & INSTALLATION.
Inspect ECU connectors and related wiring harness. See WIRING DIAGRAMS
. If testing indicates no mechanical or electrical failures,
substitute ECU with known-good unit and retest.
6) Enter ABS self-diagnostics and retrieve Diagnostic Trouble
Codes (DTCs). See RETRIEVING DTCs under SELF-DIAGNOSTIC SYSTEM. If no
DTCs are displayed, fault may be intermittent. Attempt to make
malfunction reoccur. If no diagnostic output exists, check and repair
wiring harness between ECU and data link connector. See
WIRING DIAGRAMS .
NOTE: Trouble shoot ANTI-LOCK warning light in following sequence:
instrument cluster circuit, ECU and valve relay.
Ignition Switch In ON position (Engine Not Running),
ANTI-LOCK Warning Light Inoperative
1) If all other warning lights come on with ignition on, go
to step 3). If other warning lights do not come on, check fuse No. 11
in main fuse panel. If fuse is blown, correct cause of blown fuse, and
replace fuse. If fuse is okay, go to next step.
2) Remove instrument cluster. Turn ignition on. Using DVOM,
check voltage between vehicle ground and instrument cluster ANTI-LOCK
warning light terminal No. 28. See Fig. 2. If light does not come on,
go to next step. If light comes on, check and repair connectors and
related wiring harness between instrument cluster, ABS valve relay and
ECU. See WIRING DIAGRAMS .
3) Turn ignition off. Check for faulty warning light bulb.
Replace bulb as necessary. If bulb is okay, check and repair
connectors and related wiring harness between instrument cluster and
ECU. See WIRING DIAGRAMS . If connectors and wiring are okay, replace
instrument cluster.
Page 131 of 1501
Fig. 2: Identifying Instrument Cluster Connector Terminals
Courtesy of Mitsubishi Motor Sales of America.
After Engine Starts, ANTI-LOCK Warning Light Remains On
1) With ignition on, disconnect instrument cluster
connectors. If warning light remains on, replace instrument cluster.
If warning light goes off, go to next step.
2) Disconnect ECU 22-pin connector and ABS relay box 8-pin
connector. See Fig. 3. If warning light goes off, replace ECU. If
warning light stays on, check and repair connectors and related wiring
harness between ECU, instrument cluster, and ABS valve relay. See
WIRING DIAGRAMS .
Fig. 3: Exploded View Of Hydraulic Unit & Components
Courtesy of Mitsubishi Motor Sales of America.
Ignition Switch In START Position, ANTI-LOCK Warning Light
Inoperative