seat 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 17 of 1501
![MITSUBISHI MONTERO 1998 Service Manual Exhaust
Standard ........................... .0016-.0028" (.040-.070 mm)\
Limit ......................................... .0059" (.150 mm)\
Valve Stem Projection (Montero)
Standard](/img/19/57333/w960_57333-16.png "MITSUBISHI MONTERO 1998 Service Manual Exhaust
Standard ........................... .0016-.0028\" (.040-.070 mm)\
Limit ......................................... .0059\" (.150 mm)\
Valve Stem Projection (Montero)
Standard")
Exhaust
Standard ........................... .0016-.0028" (.040-.070 mm)\
Limit ......................................... .0059" (.150 mm)\
Valve Stem Projection (Montero)
Standard ..................................... 1.9409" (49.300 mm)\
Limit ........................................ 1.9606" (49.800 mm)\
Valve Face Angle ......................................... 45
-45.5Valve Spring
Free Height
Standard ................................... 2.0079" (51.000 mm)\
Limit ...................................... 1.9685" (50.000 mm)\
Out of Square
Standard ............................................ 2
Or Less
Limit ....................................................... 4Valve Seat Width ...................... .0354-.0512" (.900-1.300 mm)\
Valve Guide
Inner Diameter ................................. .2362" (6.000 mm)\
Outer Diameter ................................. .433" (11.000 mm)\
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PISTON & CONNECTING ROD
PISTON & CONNECTING ROD\
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Application In. (mm)\
Piston Diameter .................................... 3.6614 (93.000)\
Piston to Block Clearance (Diamante) ....... .0008-.0016 (.020-.040\
)
Piston to Block Clearance (Montero) ........ .0012-.0020 (.030-.050\
)
Piston Ring
No. 1
Ring to Groove Clearance
Standard ............................. .0012-.0028 (.030-.070)\
Limit ........................................... .0039 (.100)\
End Gap
Standard ............................. .0118-.0177 (.300-.450)\
Limit ........................................... .0315 (.800)\
No. 2
Ring to Groove Clearance
Standard ............................. .0008-.0024 (.020-.060)\
Limit ........................................... .0039 (.100)\
End Gap
Standard ............................. .0177-.0236 (.450-.600)\
Limit ........................................... .0315 (.800)\
Oil Control Ring
End Gap (Diamante)
Standard ............................. .0079-.0236 (.200-.600)\
Limit .......................................... .0394 (1.000)\
End Gap (Montero)
Standard ............................. .0039-.0138 (.100-.350)\
Limit .......................................... .0394 (1.000)\
Piston Pin
Outer Diameter
Standard ........................................ .8661 (22.000)\
Limit ............................................. .0039 (.100)\
Connecting Rod
Big End Side Clearance
Standard ............................... .0039-.0098 (.100-.250)\
Limit ............................................... .0157 (.4)\
Oil Clearance .......................... .0008-.0020 (.020-.050)\
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CRANKSHAFT
Page 40 of 1501
SHAFT SEAL
CAUTION: Secure rear housing to compressor body using a vise before
removing front housing through-bolts. Compressor rear housing
may separate from compressor body, spilling refrigerant oil.
Removal
1) Remove clutch coil. See CLUTCH COIL. See Fig. 1 or 2.
Position compressor in a vise so compressor rear housing is secured to
compressor body. Remove front housing through-bolts and front housing.
2) Using a flat-blade screwdriver, remove felt retainer and
felt from front housing. Remove shaft seal snap ring. Using a flat-
blade screwdriver, remove shaft seal and "O" ring. See Fig. 1 or 2.
Installation
1) Inspect compressor shaft and front housing bore for damage
and/or excessive wear. Ensure "O" ring and shaft seal seat are clean.
Apply NEW refrigerant oil to compressor side of front housing bore.
Lubricate "O" ring and shaft seal with NEW refrigerant oil. Using a
21-mm socket, install shaft seal with "O" ring side facing away from
compressor. Install shaft seal snap ring. See Fig. 1 or 2.
2) Install felt into felt retainer. Using a 14-mm deep
socket, install felt and felt retainer. Lubricate compressor shaft.
Install front housing using care not damage shaft seal lip. See Fig. 1
or 2.
3) Alternately tighten front housing through-bolts to 19 ft.
lbs. (26 N.m). Install clutch plate center bolt. Using an INCH-lb.
torque wrench, ensure compressor breakaway torque is 43 INCH lbs. (4.9
N.m) or less. To complete installation, reverse removal procedures.
Ensure air gap between clutch plate and pulley is correct. See
CLUTCH COIL .
Fig. 1: Exploded View Of Compressor (Nippondenso 10PA17C 10-Cyl.)
Courtesy of Toyota Motor Sales, U.S.A., Inc.
Page 145 of 1501
All switches are mounted to transfer case. See Fig. 9.
Switches use single harness lead and ground to transfer case. See 4WD
INDICATOR SWITCH CONTINUITY CHECK table. Ensure all appropriate
grounding straps are connected to vehicle body or frame.
4WD INDICATOR SWITCH CONTINUITY CHECK
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Switch Transfer Control Lever Position Specification
Center Differential Lock
Detection Switch .............. 4H ................. No Continuity
Detection Switch ............. 4HLc ................... Continuity
Center Differential Lock
Operation Detection Switch .. 4H .................. No Continuity
" ........................... 4HLc .................... Continuity
4WD Operation
Detection Switch .............. 2H ................. No Continuity
Detection Switch .............. 4H .................... Continuity
HI/LO Detection Switch ...... 4HLc .................... Continuity
" ............................. N .................. No Continuity
" ........................... 4LLc .................... Continuity
2WD/4WD
Detection Switch ............ 2H .................... Continuity
" ........................... 4H ................. No Continuity
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REAR DIFFERENTIAL CONTROL UNIT
Remove rear seat and remove rear differential control unit.
Do not disconnect control unit harness connector. Backprobe harness
connector. Check voltage between each individual terminal and ground
terminal No. 6 (Black wire). See Figs. 14 and 15. If after all tests
have been completed system is not operating properly, substitute rear
differential control unit with known good-unit and retest.
Fig. 14: Identifying Rear Differential Control Unit Connector
Courtesy of Mitsubishi Motor Sales of America.
Page 366 of 1501
![MITSUBISHI MONTERO 1998 Service Manual races are fully seated. Install Pinion Height Gauge (MB990901-01) with\
pinion bearings. See Fig. 6. DO NOT install oil seal.
2) Using INCH-lb. torque wrench, measure pinion rotating
torque.](/img/19/57333/w960_57333-365.png "MITSUBISHI MONTERO 1998 Service Manual races are fully seated. Install Pinion Height Gauge (MB990901-01) with\
pinion bearings. See Fig. 6. DO NOT install oil seal.
2) Using INCH-lb. torque wrench, measure pinion rotating
torque.")
races are fully seated. Install Pinion Height Gauge (MB990901-01) with\
pinion bearings. See Fig. 6. DO NOT install oil seal.
2) Using INCH-lb. torque wrench, measure pinion rotating
torque. Gradually tighten pinion height gauge to increase rotating
torque to proper specification. See
PINION ROTATING TORQUE SPECIFICATIONS table. Install Cylinder Gauge
(MB990903-01). Ensure flat areas are aligned and that gauge contacts
carrier bearing bores firmly. See Fig. 6.
3) Select adjusting shim with same thickness as gap between
cylinder gauge and pinion height gauge. Use minimum amount of
adjusting shims. Install selected adjusting shims between drive pinion
gear and rear drive pinion bearing. Using Bearing Installer (MB990802-
01), install rear pinion bearing.
PINION ROTATING TORQUE SPECIFICATIONS
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Application INCH Lbs. (N.m)\
Oil Seal Not Installed
With Lubrication ............................... 1.3-2.2 (.15-.25)\
Without Lubrication ............................ 2.6-4.3 (.30-.50)\
Oil Seal Installed
With Lubrication ............................... 3.1-3.9 (.35-.45)\
Without Lubrication ............................ 4.3-6.1 (.50-.70)\
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Fig. 6: Setting Drive Pinion Depth
Courtesy of Mitsubishi Motor Sales of America.
Drive Pinion Preload
1) Install drive pinion in differential carrier. Install
Page 371 of 1501
Connect air pressure gauge in-line to air hose from air pump.
Air pump is located in right storage area, under rear seat. Connect
battery voltage to air pump (positive lead to Red wire). The air pump
is operating correctly when the following sequences occur;
* Pump should operate for no more than 5 seconds.
* Pressure should be 4-6 psi (.28-.41 kg/cm
) within 10-20
seconds after pump has stopped.
* After air pump has stopped operating, it should not restart
operating for 5 minutes.
Center Differential Lock Operation Switch
See ANTI-LOCK BRAKE SYSTEM article in BRAKES.
Differential Lock Switch
Remove switch from center console. To test switch operation,
see Fig. 2 . Replace switch as needed.
Differential Lock Control Unit
See ANTI-LOCK BRAKE SYSTEM article in BRAKES.
Lock Detection Switch
1) Raise and support vehicle. Disconnect air hose connection
near rear differential. Connect air source with pressure regulator and
pressure gauge. Apply 4 psi (.28 kg/cm
) pressure. Disconnect lock
detection switch harness connector.
2) Using ohmmeter, check if continuity exists with air
pressure applied. Continuity should exist with air pressure applied.
If continuity exists, ensure axle is locked by attempting to turn rear
wheels separately of each other.
3) If continuity does not exist, go to step 4). If continuity\
does exist but axles are not locked, see CARRIER ASSEMBLY under
REMOVAL & INSTALLATION and inspect locking assembly.
4) Remove detection switch from housing. Using ohmmeter,
check continuity of switch. Continuity should exist with switch
plunger extended. With plunger in neutral position, continuity should
not exist. Replace switch as needed.
Fig. 2: Checking Differential Lock Switch Continuity
Courtesy of Mitsubishi Motor Sales of America.
REMOVAL & INSTALLATION
Page 385 of 1501
Fig. 17: Checking Differential Starting Torque
Courtesy of Mitsubishi Motor Sales of America.
13) Ensure starting torque is within specification. See
STARTING TORQUE table. Ensure adhesive is removed from ring gear
mounting bolts and gear mounting surface. Clean internal threads with
tap.
14) Ensure alignment marks on differential case and ring gear
align. Apply Loctite 271 to bolts, and install ring gear on
differential case. Tighten bolts in diagonal sequence to
specification. See TORQUE SPECIFICATIONS .
STARTING TORQUE
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Application Ft. Lbs. (N.m)\
Used Clutch Plates ................................... 29-54 (40-75)\
New Clutch Plates .................................... 18-54 (25-75)\
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Carrier Assembly & Drive Pinion Installation
1) Install pinion bearing races in differential housing.
Ensure races are fully seated. Install Pinion Height Gauge (MB990901)
and pinion bearings. See Fig. 18. DO NOT install oil seal.
Page 387 of 1501
![MITSUBISHI MONTERO 1998 Service Manual PINION ROTATING TORQUE SPECIFICATIONS table.
PINION ROTATING TORQUE SPECIFICATIONS
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\](/img/19/57333/w960_57333-386.png "MITSUBISHI MONTERO 1998 Service Manual PINION ROTATING TORQUE SPECIFICATIONS table.
PINION ROTATING TORQUE SPECIFICATIONS
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PINION ROTATING TORQUE SPECIFICATIONS table.
PINION ROTATING TORQUE SPECIFICATIONS
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Application INCH Lbs. (N.m)\
Oil Seal Not Installed
With Lubrication ................................. 3.5-4.3 (.4-.5)\
Without Lubrication .............................. 5.2-7.8 (.6-.9)\
Oil Seal Installed
With Lubrication ............................... 5.6-6.5 (.65-.75)\
Without Lubrication .......................... 7.4-10.0 (.85-1.15)\
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3) Install cylinder gauge in side bearing seats. Ensure flat
areas align, and gauge contacts side bearing seat firmly. Select
adjusting shim with same thickness as gap between cylinder gauge and
pinion height gauge.
4) Use minimum amount of adjusting shims. Install selected
adjusting shims between drive pinion gear and rear pinion bearing.
Using bearing installer and press, install rear pinion bearing.
5) Install drive pinion in differential housing. Install
spacer, pinion front shim(s) and front pinion bearing. DO NOT install
oil seal. Install pinion companion flange, washer and retaining nut.
Tighten nut to specification. See TORQUE SPECIFICATIONS.
6) Check pinion rotating torque. 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.
Install pinion companion flange so alignment marks are correct. Apply
light coat of grease to contact area of pinion flange washer.
7) Install NEW retaining nut. Recheck pinion rotating torque.
Ensure rotating torque is within specification. Press side bearings
onto differential case. Install outer races. Install differential
carrier into differential housing. Align bearing cap index marks, and
snug carrier cap bolts. Ensure outer races and bearing caps are
installed in original location.
8) Install side bearing nuts. Tighten bearing cap bolts to
specification. See TORQUE SPECIFICATIONS . Tighten bearing nuts until
bearing outer races are seated against bearings. Adjust ring gear
backlash.
Ring Gear Backlash
1) Secure drive pinion in place. Using dial indicator, check
ring gear backlash at heel of ring gear tooth. See Fig. 6. Measure at
4 locations of ring gear. Gear backlash must be within specification.
Backlash should be .005-.007" (.13-.18 mm).
2) If backlash is less than specification, loosen side
bearing nut at back of ring gear, and tighten side bearing nut on
tooth side of ring gear by same amount. If backlash exceeds
specification, loosen side bearing nut at tooth side of ring gear, and
tighten side bearing nut at back of ring gear by same amount.
3) After adjusting backlash, tighten both side bearing nuts
half the distance between 2 adjacent holes on side bearing nut.
Recheck backlash. Ensure bearing cap bolts are tightened to
specification. See TORQUE SPECIFICATIONS .
4) Lock plates are of 2 designs for hole location of side
bearing nuts. Install proper type lock plate. Tighten lock plate bolt
to specification. See TORQUE SPECIFICATIONS. Check gear tooth contact
pattern. See GEAR TOOTH CONTACT PATTERNS article in GENERAL
INFORMATION.
Ring Gear Runout
Page 389 of 1501
DIFFERENTIAL LOCK - REAR
1998 Mitsubishi Montero
1997-98 DRIVE AXLES
Mitsubishi Rear Differential Lock
Montero, Montero Sport
DESCRIPTION & OPERATION
The rear differential lock system is designed to be used only
when low-speed wheel spin occurs in a ditch, or on a slippery or
uneven surface. The indicator light will blink when switch is turned
on as system completes locking operation. After the differential is
locked, the light will stop blinking and remain on.
The rear differential lock system will not lock with vehicle
in 4H or 2H position, and if vehicle speed is greater than 7 MPH.
Vehicle speed should be maintained at less than 12 MPH during rear
differential lock operation.
NOTE: The Anti-lock Brake System (ABS) does not operate when the
rear differential is locked. It is normal for the ABS
warning light to be on at this time.
COMPONENT LOCATIONS
Rear Differential Lock Air Pump
Air pump is located under left side of rear seat.
Rear Differential Lock Control Unit
Control unit is located under left side lower quarter trim
panel in rear compartment.
Rear Differential Lock Switch
Lock switch is located on lower center of instrument panel,
below radio.
Rear Differential Lock Detection Switch
Lock detection switch is located on rear differential
carrier.
TROUBLE SHOOTING
INDICATOR LIGHT FLASHES WHEN LOCK SWITCH IS TURNED ON
If vehicle speed is greater than 7 MPH, reduce speed to less
than 3 MPH. If vehicle speed is less than 7 MPH, rotate steering wheel
to right and left to reset light.
INDICATOR LIGHT FLASHES WHEN LOCK SWITCH IS TURNED OFF
If indicator flashes after lock switch is turned off, depress
and release accelerator several times while driving straight ahead to
reset light.
TESTING
REAR DIFFERENTIAL LOCK AIR PUMP
Page 393 of 1501
1) Using ohmmeter, check for continuity between specified
rear differential lock switch terminals with switch in specified
positions. See WIRING DIAGRAMS.
2) With lock switch in ON position, continuity should exist
between terminals No. 2 and 5. With lock switch in OFF position,
continuity should exist between terminals No. 2 and 3.
3) Continuity should also exist between terminals No. 1 and 6
with lock switch in ON or OFF position. If continuity is not as
specified, replace lock switch.
REAR DIFFERENTIAL LOCK SYSTEM AIR LEAKAGE CHECK
NOTE: DO NOT apply more pressure than required to bring pressure
gauge reading to about 5 psi (.35 kg/cm ).
1) Remove rear differential lock air pump and remove air hose
from air pump. Connect a pressure gauge and air regulator (for
adjusting compressed air pressure) to air hose. Using air regulator,
adjust compressed air pressure until pressure gauge indicates about 5
psi (.35 kg/cm
).
2) Shut off air valve. Wait about 10 minutes and check if air
pressure has dropped. If air pressure has dropped, air hose is not
leaking.
REMOVAL & INSTALLATION
REAR DIFFERENTIAL LOCK AIR PUMP
Removal & Installation
Remove rear seat. Remove bracket from rear differential lock
air pump and remove air pump. Disconnect air hoses from air pump.
Disconnect electrical connector from air pump. To install, reverse
removal procedure.
REAR DIFFERENTIAL LOCK CONTROL UNIT
Removal & Installation
Remove left side lower quarter trim panel in rear
compartment. Remove rear differential lock control unit. Disconnect
electrical connector from control unit. To install, reverse removal
procedure.
WIRING DIAGRAMS
Page 469 of 1501
Junction Block Behind left side of dash.
Passenger Compartment Relay Box Behind left side of dash.
Power Seat Relay Box Under driver's seat.
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CONTROL UNITS
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Component Component Location \
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ABS Control Unit Mounted on top of right rear
wheelwell, under metal plate.
A/C Control Unit On top of evaporator case.
Antenna Motor ECU Behind center console.
Auto-Cruise Control ECU Behind center of dash.