1998 MITSUBISHI MONTERO Service Manual

Schrader valve is similar in construction and operation to a
tire valve. When a test gauge hose with built-in valve core depressor
is attached, Schrader stem is pushed inward to the open position and
allows system pressure to reach gauge.
If test hose does not have a built-in core depressor, an
adapter must be used. Never attach hose or adapter to Schrader valve
unless it is first connected to manifold gauge set.
Refrigerant R-12 Schrader-type valve cores have TV5 thread
size. Refrigerant R-134a Schrader-type valve cores use M6 (Metric)
threads. See Fig. 1.
SERVICE VALVE LOCATIONS
SERVICE VALVE LOCATIONS TABLE








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Vehicle High Low
Diamante ...................... ( 1) ................ ( 2)
Eclipse ....................... ( 1) ................ ( 2)
Galant ........................ ( 1) ................ ( 2)
Mirage ........................ ( 1) ................ ( 2)
Montero ....................... ( 3) ................ ( 3)
Montero Sport ................. ( 1) ................ ( 2)
3000GT ........................ ( 4) ................ ( 2)
( 1) - On high pressure line, between accumulator/receiver-
drier and evaporator.
( 2) - On low pressure line, between evaporator and
compressor.
( 3) - On top of accumulator/receiver-drier.
( 4) - On high pressure line, near receiver-drier.









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REFRIGERANT RECOVERY/RECYCLING
Refrigerant recovery/recycling equipment is used to remove
refrigerant from vehicle's A/C system without polluting atmosphere. To
remove and recycle refrigerant, connect the recovery/recycling
equipment and following the equipment manufacturer's instructions.
Removed refrigerant is filtered, dried and stored in a tank
within the recovery/recycling equipment until it is ready to be pumped
back into vehicle A/C system. With refrigerant stored in the
recovery/recycling equipment, A/C system can be opened without
polluting atmosphere.
NOTE: Separate sets of hoses, gauges and refrigerant
recovery/recycling equipment MUST be used for R-12 and
R-134a based systems. DO NOT mix R-12 and R-134a
refrigerants, as their refrigerant oils and desiccants are
not compatible. It is NOT possible to clean equipment
thoroughly enough to prevent cross-contamination of A/C
systems. On systems with R-134a refrigerant, use
Polyalkylene Glycol (PAG) wax-free refrigerant oil.

A/C SYSTEM SPECIFICATIONS
1998 Mitsubishi Montero
1998 AIR CONDITIONING & HEAT
Mitsubishi - A/C System Specifications
Montero
A/C SYSTEM SPECIFICATIONS
A/C SYSTEM SPECIFICATIONS TABLE








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Application Specification
Compressor Type ............... Nippondenso 10PA15 10-Cyl.
Compressor Belt Deflection ( 1)
New .......................... 13/64-15/64" (5.1-6.0 mm)
Used ......................... 17/64-19/64" (6.6-7.5 mm)
Compressor Oil Capacity ..................... ( 2) 2.7 ozs.
Refrigerant (R-134a) Capacity ................. 21-23 ozs.
System Operating Pressures ( 4)
High Side ............... 149-213 psi (10.5-15.0 kg/cm
)
Low Side .................... 14-33 psi (1.0-2.3 kg/cm)
( 1) - With 22 lbs. (100 N.m) force applied midway on longest
span of belt.
( 2) - Use ND 8-OIL refrigerant oil.
( 3) - Use SUN PAG 56 refrigerant oil.
( 4) - With ambient temperature at about 80
F (27C).








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AIR BAG RESTRAINT SYSTEM
1998 Mitsubishi Montero
1998 AIR BAG RESTRAINT SYSTEMS
Mitsubishi
Montero
DESCRIPTION & OPERATION
WARNING: To avoid injury from accidental air bag deployment, read and
carefully follow all WARNINGS and SERVICE PRECAUTIONS.
Supplemental Restraint System (SRS) consists of an SRS
warning light, driver-side and passenger-side air bag module,
clockspring, right and left front impact sensors, and SRS Air Bag
Control Unit (ECU). The SRS-ECU contains an analog and a safing impact\
sensor. See Fig. 1.
Air bags are designed to deploy in a frontal or near frontal
impact of moderate to severe force. For air bags to deploy, ignition
must be on and safing impact sensor and at least one front impact
sensor must activate simultaneously.
Fig. 1: Locating SRS Components
Courtesy of Mitsubishi Motor Sales of America.
SRS WARNING LIGHT

When ignition switch is turned to ON or START position, SRS
warning light on instrument panel should come on for about 7 seconds
and then go off. This indicates SRS-ECU has determined SRS is
functioning properly. If SRS warning light flashes, stays on all the
time, or does not come on, a fault exists in SRS. See
DIAGNOSIS & TESTING.
FRONT IMPACT SENSORS
Sensors are inertia switches that verify direction and
severity of impact. If impact is great enough, switch contacts close,
completing an electrical circuit. Front impact sensors are located
under front fenders. See Fig. 1.
AIR BAG MODULE(S)
An inflator assembly in the air bag module produces nitrogen
gas to fill air bag. See Fig. 1. When a small amount of current from
SRS-ECU is applied, ignitor starts a thermal reaction, which spreads
to a pellet-filled canister that produces nitrogen gas. Gas pressure
builds and discharges from inflator through a diffuser and screen
assembly, forcing trim cover to burst along its seams until air bag is
fully inflated. When air bag is fully inflated, gas escapes through
vents on sides of air bag.
SRS AIR BAG CONTROL UNIT (ECU)
SRS-ECU (with integral safing and analog impact sensor) is
located behind front floor console assembly. See Fig. 1. If a system
fault occurs, SRS-ECU memory stores a diagnostic trouble code (DTC).
DATA LINK CONNECTOR (DLC)
DLC is located under left side of dash. See Fig. 1. DLC is
used to access SRS self-diagnostics through Mitsubishi Multi-Use
Tester II (MUT-II) (MB991502).
CLOCKSPRING
Clockspring connects driver-side air bag module to steering
column wiring, forming SRS circuit. See Fig. 1. Clockspring is a flat,
ribbon-like cable that winds and unwinds when steering wheel is
turned. Because of clockspring's constant movement, it is the most
fragile part in the system.
SYSTEM OPERATION CHECK
WARNING: After servicing, always turn ignition on from passenger-side
of vehicle in case of accidental air bag deployment.
Turn ignition switch to ON position. SRS warning light on
instrument panel should come on for about 7 seconds and then turn off.
This indicates SRS is functioning properly. If SRS warning light does
not come on, stays on, or comes on while driving, SRS is
malfunctioning and needs repair. See DIAGNOSIS & TESTING.
SERVICE PRECAUTIONS
Observe the following precautions when working with SRS:
* Disable SRS before servicing any SRS or steering column

component. Failure to do this may result in accidental air
bag deployment and possible personal injury. Refer to
DISABLING & ACTIVATING AIR BAG SYSTEM .
* For about 60 seconds after air bag system is disabled, it
retains enough voltage to deploy air bags. After disabling
system, wait at least 60 seconds before servicing.
* After servicing, always turn ignition on from passenger-side
of vehicle in case of accidental air bag deployment.
* After servicing, check SRS warning light to verify system
operation. See SYSTEM OPERATION CHECK.
* Always wear safety glasses when servicing or handling an
air bag.
* The SRS-ECU must be stored in its original special container
until used for service. It must be stored in a clean, dry
place, away from sources of extreme heat, sparks and high
electrical energy.
* DO NOT expose air bag module and clockspring to temperatures
greater than 200
F (93C).
* When placing a live air bag module on a bench or other
surface, always face air bag module and trim cover up, away
from surface. This will reduce motion of module if air bag
accidentally deploys.
* After air bag deploys, air bag surface may contain deposits
of sodium hydroxide, which irritates skin. Always wear
safety glasses, rubber gloves and long-sleeved shirt during
clean-up. Wash hands using mild soap and water. Follow
correct clean-up and disposal procedures. Refer to
DISPOSAL PROCEDURES .
* Because of critical system operating requirements, DO NOT
service any SRS components. Repairs are only made by
replacing defective part(s).
* DO NOT allow any electrical source near inflator on the back
of air bag module.
* When carrying a live (undeployed) air bag module, trim cover
must be pointed away from body to minimize injury in case of
accidental air bag deployment.
* DO NOT probe wire harness connector terminals. Instead, use
SRS Check Harness (MB991530).
* DO NOT probe a wire through insulator, as this will damage
it and eventually cause failure due to corrosion.
* When performing electrical tests, prevent accidental
shorting of terminals. Such shorts can damage fuses or
components and may cause a second fault code to set, making
diagnosis of original problem more difficult.
* Never use an analog volt/ohm meter or test light in place of
a Digital Volt/Ohm Meter (DVOM). Use only a DVOM with a
maximum test current of 2 mA (milliamps) at minimum range of
resistance measurement. Also see SPECIAL TOOLS.
* If SRS is not fully functional for any reason, DO NOT drive
vehicle until system is repaired and is fully functional. DO
NOT remove bulbs, modules, sensors or other components, or
in any way disable system from operating normally. If SRS is
not functional, park vehicle until repairs are made.
SPECIAL TOOLS
To avoid air bag deployment when working on SRS, DO NOT use
electrical test equipment such as test lights, battery or A/C-powered
volt/ohmmeter, or any type of electrical equipment other than those
specified by manufacturer. See SRS RECOMMENDED TOOLS table.
SRS RECOMMENDED TOOLS TABLE









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Tool Name Tool Number
For Component Replacement
Steering Wheel Puller ......................... MB990803
For Testing SRS
Digital Volt-Ohm Meter (DVOM) ...................... (1)
Multi-Use Tester II ........................... MB991502
ROM Pack ........................................... ( 2)
SRS Check Harness ............................. MB991613
For Deploying Air Bags
SRS Air Bag Adapter Harness "A" ( 3) ........... MB686560
SRS Air Bag Adapter Harness "B" ( 4) ........... MB628919
( 1) - Maximum current output of DVOM must not exceed 2 mA
(milliamps) when set on minimum range of resistance
measurement.
( 2) - ROM pack is used with multi-use tester.
( 3) - For on-vehicle deployment of driver-side air bag. For
on-vehicle or off-vehicle deployment of passenger-side
air bag.
( 4) - For off-vehicle deployment of driver-side air bag.









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DISABLING & ACTIVATING AIR BAG SYSTEM
WARNING: SRS system voltage is maintained for about 60 seconds after
battery cable is disconnected. After disconnecting battery
cable, wait at least 60 seconds before servicing SRS.
Failure to wait may cause accidental air bag deployment and
possible personal injury.
To disable system, turn ignition switch to LOCK position.
Disconnect negative battery cable. Shield cable end. Wait at least 60
seconds before servicing. To activate system, reconnect negative
battery cable.
DISPOSAL PROCEDURES
WARNING: Undeployed air bag must be deployed before disposal.
Disposing of an undeployed air bag may violate federal,
state and/or local laws. This also applies to vehicles that
are to be scrapped. Never sell a used air bag module.
UNDEPLOYED AIR BAG
WARNING: Deploy air bag outdoors and away from people. Air bag
deployment makes a loud noise. NEVER deploy air bag module
with trim cover face down.
NOTE: If replacing a deployed air bag, both front impact sensors
and SRS-ECU must also be replaced. If vehicle is to be
scrapped, perform PROCEDURE 1 (ON-VEHICLE DEPLOYMENT) below.
If vehicle will continue to be operated, perform PROCEDURE 2
(OFF-VEHICLE DEPLOYMENT) below.
Procedure 1 (On-Vehicle Deployment)
1) Before proceeding, follow air bag service precautions. See
SERVICE PRECAUTIONS . Open all doors and windows. Move vehicle to an
isolated area. Disconnect negative battery cable and wrap tape around
cable terminal.
2) Disconnect positive battery cable. Remove battery. Wait at

least 60 seconds before continuing. Remove steering column lower
cover. Disconnect clockspring 2-pin Red connector.
3) Make a harness with two 20-foot (or longer) wires. Connec\
t
wires at one end of this harness to SRS Air Bag Adapter Harness "A"
(MB686560). Wrap connections with insulating tape. See Fig. 2.
4) Temporarily connect other end of harness wires together to
prevent unexpected air bag deployment. Connect SRS air bag adapter
harness "A" to clockspring 2-pin Red connector. Run 20-foot wires
outside of vehicle as far away as possible from vehicle.
5) Ensure there are no loose parts in passenger compartment
and no one is within 20 feet of vehicle.
6) Deploy air bag by connecting ends of 20-foot wires to
terminals of a 12-volt battery. If air bags fail to deploy, go to
PROCEDURE 2 below. After deployment, allow air bag modules to cool and
dust to settle for at least 30 minutes before approaching vehicle.
Fig. 2: Connecting Wires To Air Bag Adapter Harness
Courtesy of Mitsubishi Motor Sales of America.
Procedure 2 (Off-Vehicle Deployment)
1) Before proceeding, follow air bag service precautions. See

SERVICE PRECAUTIONS. Turn ignition switch to LOCK position. Disconnect
negative battery cable. Shield cable end. Disconnect positive battery
cable. Remove battery. Wait at least 60 seconds before continuing.
2) Remove air bag module. Place air bag module on ground at
least 20 feet away from people or objects. Air bag module face (trim
cover) must face upward to prevent movement of air bag module when it
is deployed.
3) Make a harness with two 20-foot (or longer) wires. Connec\
t
wires at one end of this harness to stripped wires of SRS Air Bag
Adapter Harness "B" (MB628919) for driver-side air bag, or SRS Air Bag\
Adapter Harness "A" (MB686560) for passenger-side air bag. See Fig. 2.
4) Wrap connections with insulating tape. Temporarily connect
other end of harness wires together to prevent unexpected air bag
deployment. Connect appropriate adapter harness to air bag module
connector. Place a tire without a rim over the air bag module so rim
hole surrounds air bag module. Stack 3 more tires on top of first
tire. Connect ends of 20-foot wires to terminals of a 12-volt battery.
5) After air bag module deploys, let it cool off and allow
dust to settle for at least 30 minutes before approaching. Tightly
seal deployed air bag module in a strong vinyl bag and dispose of air
bag as you would any other part.
DEPLOYED AIR BAG CLEAN-UP
WARNING: Vehicle interior will contain sodium hydroxide powder, a
by-product of air bag deployment. Since this powder can
irritate skin, eyes, nose and throat, wear safety glasses,
rubber gloves and long-sleeved shirt during clean-up.
1) Avoid breathing powder from air bag deployment. Begin
clean-up by putting tape over air bag exhaust vent to prevent
additional powder from escaping into vehicle interior. Use a vacuum
cleaner to remove any residual powder from A/C-heater outlets and
vehicle interior.
2) Turn blower motor to low for a few minutes and exit
vehicle. Turn blower motor off. Vacuum any other powder expelled from
plenum. Vacuum interior a second time to recover all powder. Avoid
kneeling or sitting on unclean areas. Wrap deployed air bag in heavy
vinyl plastic and dispose of it as you would any other part.
POST-COLLISION INSPECTION
When a vehicle has been involved in a collision, certain
components of the passive restraint system must be inspected or
replaced. See PASSIVE RESTRAINT SYSTEM INSPECTION article in the
GENERAL INFORMATION section for post-collision inspection information.
REMOVAL & INSTALLATION
WARNING: Follow air bag service precautions to prevent accidental air
bag deployment and personal injury. See SERVICE PRECAUTIONS.
Replace faulty SRS components; DO NOT repair or disassemble.
Handle all SRS components carefully.
DRIVER-SIDE AIR BAG MODULE & CLOCKSPRING
Removal
1) Before proceeding, see SERVICE PRECAUTIONS. Reactivate
SRS. See DISABLING & ACTIVATING AIR BAG SYSTEM .
2) Ensure front wheels are in straight-ahead position. Remove
lower covers from air bag module. Remove air bag module mounting nut