1998 MITSUBISHI MONTERO catalytic converter

loose .................. A ... Require repair or replacement
of injection tube or
replacement of catalytic
converter.
Air injection tube
restricted ............. A ... Require repair or replacement
of injection tube or
replacement of catalytic
converter.
Air injection tube
threads damaged ........ A ... Require repair or replacement
of injection tube or
replacement of catalytic
converter.
Air injection tube
threads stripped
(threads missing) ...... A ... Require repair or replacement
of injection tube or
replacement of catalytic
converter.
Body cracked ............ B .. Require repair or replacement.
Converter empty ......... A .. Require repair or replacement.
Converter fill plug
missing ................ C .. Require repair or replacement.
Converter missing ....... C ............ Require replacement.
Exhaust gases leaking ... A .. Require repair or replacement.
Flanges leaking ......... A ... Require repair or replacement
of flanges.
Inlet pipes cracked ..... B .. Require repair or replacement.
Internal rattle (except
pellet-type) ........... 2 .......... (1) Further inspection
required.
Mounting brackets that
are part of converter
broken ................. A .. Require repair or replacement.
Obvious overheating ..... .. ......... ( 2) Require testing of
converter.
Outlet pipes cracked .... B .. Require repair or replacement.
Pieces of catalyst
material found
downstream ............. 1 ............ Suggest replacement.
Plugged ................. A ........ ( 3) Require replacement.
Testing has determined
that existing converter
has been lead-poisoned,
contaminated, or failed
testing ................ A .. Require repair or replacement.
( 1) - If the converter is breaking up, suggest converter
replacement. If an object has fallen into the converter,
remove the object.
( 2) - Overheating is caused by something other than the
converter. Further diagnosis is required to determine
the cause of the overheating.
( 3) - Determine cause and correct to ensure that new converter
will not become plugged.









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EXHAUST AND TAIL PIPES
NOTE: For pipes with resonators, also see MUFFLERS AND RESONATORS.
EXHAUST AND TAIL PIPE INSPECTION

2.0L
(VIN F) ........................................ 8.5:1
(VIN Y) ........................................ 9.6:1
2.4L (VIN G) ..................................... 9.5:1
3.0L
(VIN H) ........................................ 8.9:1
(VIN J) ....................................... 10.0:1
(VIN K) ........................................ 8.0:1
(VIN P) ........................................ 9.0:1
3.5L (VIN M & P) ................................. 9.0:1
Compression Pressure
1.5L (VIN A) ..................... 192 psi (13.4 kg/cm
)
1.8L (VIN C) ..................... 199 psi (13.9 kg/cm)
2.0L (VIN F) ..................... 178 psi (12.5 kg/cm)
2.0L (VIN Y) ............ 170-225 psi (11.7-15.5 kg/cm)
2.4L (VIN G) ..................... 192 psi (13.4 kg/cm)
3.0L
(VIN H & P) .................... 171 psi (12.0 kg/cm
)
(VIN J) ........................ 185 psi (13.0 kg/cm)
(VIN K) ........................ 156 psi (10.9 kg/cm)
3.5L (VIN M & P) ................. 171 psi (12.0 kg/cm)
Maximum Variation
Between Cylinders ( 2) ............... 14 psi (1.0 kg/cm
)
( 1) - See A - ENGINE/VIN ID article for VIN information.
( 2) - On Eclipse 2.0L non-turbo engine, maximum variation
between cylinders is 25%.









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Exhaust System Backpressure
The exhaust system can be tested with a vacuum or pressure
gauge. If using a pressure gauge, remove HO2S or air injection check
valve (if equipped). Connect a 0-5 psi pressure gauge and run engine
at 2500 RPM. If exhaust system backpressure is greater than 2 psi,
exhaust system or catalytic converter is plugged.
If using a vacuum gauge, connect vacuum gauge hose to intake
manifold vacuum port. Start engine. Observe vacuum gauge. Open
throttle part way and hold steady. If vacuum gauge indication slowly
drops after stabilizing, inspect exhaust system for restriction.
FUEL SYSTEM
* PLEASE READ THIS FIRST *
WARNING: ALWAYS relieve fuel pressure before disconnecting any fuel
injection-related component. DO NOT allow fuel to contact
engine or electrical components.
RELIEVING FUEL PRESSURE
1) On Diamante, disconnect fuel pump harness connector at
fuel tank from underneath vehicle. On Montero and Montero Sport,
remove cargo compartment carpet, remove access plate and disconnect
fuel pump harness connector. On all other models, remove rear seat
cushion, remove access plate (if required) and disconnect fuel pump
harness connector.
2) On all models, start engine. Let engine run until it
stops. Turn ignition off. Disconnect negative battery cable. Connect
fuel pump harness connector. Install rear seat and/or carpet as
necessary.
WARNING: Before disconnecting high pressure fuel hose at fuel

DTC P0303
Cylinder No. 3 misfire detected. Possible causes are:
connector or harness, faulty ignition coil, ignition power transistor,
spark plug, ignition circuit, injector, HO2S, compression pressure,
timing belt, air intake system, fuel pressure, or CKP sensor.
DTC P0304
Cylinder No. 4 misfire detected. Possible causes are:
connector or harness, faulty ignition coil, ignition power transistor,
spark plug, ignition circuit, injector, HO2S, compression pressure,
timing belt, air intake system, fuel pressure, or CKP sensor.
DTC P0305
Cylinder No. 5 misfire detected. Possible causes are:
connector or harness, faulty ignition coil, ignition power transistor,
spark plug, ignition circuit, injector, HO2S, compression pressure,
timing belt, air intake system, fuel pressure, or CKP sensor.
DTC P0306
Cylinder No. 6 misfire detected. Possible causes are:
connector or harness, faulty ignition coil, ignition power transistor,
spark plug, ignition circuit, injector, HO2S, compression pressure,
timing belt, air intake system, fuel pressure, or CKP sensor.
DTC P0325
Knock Sensor (KS) circuit failure. Possible causes are:
connector or harness, or faulty KS.
DTC P0335
Crankshaft Position (CKP) sensor circuit failure. Possible
causes are: connector or harness, or faulty CKP sensor.
DTC P0340
Camshaft Position (CMP) sensor circuit failure. Possible
causes are: connector or harness, or faulty CMP sensor.
DTC P0400
Exhaust Gas Recirculation (EGR) flow failure. Possible causes\
are: connector or harness, faulty EGR valve, EGR solenoid, EGR valve
control vacuum, or manifold differential pressure sensor.
DTC P0403
Exhaust Gas Recirculation (EGR) solenoid failure. Possible
causes are: connector or harness, or faulty EGR solenoid.
DTC P0420
Catalyst efficiency below threshold. Possible causes are:
cracked exhaust manifold, or faulty catalytic converter.
DTC P0421
Warm-up catalyst efficiency below threshold (bank 1).
Possible causes are: faulty exhaust manifold. If exhaust manifold is
okay, replace catalytic converter.
DTC P0431
Warm-up catalyst efficiency below threshold (bank 2).
Possible causes are: faulty exhaust manifold. If exhaust manifold is
okay, replace catalytic converter.
DTC P0442
Evaporative (EVAP) emission control system leak detected.
Possible causes are: connector or harness, faulty EVAP purge solenoid,

continuity between chassis ground and EGR solenoid connector terminal
No. 2. If continuity does not exist, repair wiring harness as
necessary. If continuity exists, condition required to set DTC is not
present at this time. Go to next step.
12) 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 P0420, P0421 & P0431: CATALYST EFFICIENCY BELOW
THRESHOLD
NOTE: For terminal identification, see TERMINAL IDENTIFICATION. For
circuit and wire color identification, see
L - WIRING DIAGRAMS article.
Specific self-diagnostic test not available from manufacturer
at time of publication. Check catalytic converter and check for
cracked exhaust manifold. Also, see F - BASIC TESTING article.
DTC P0442: EVAPORATIVE (EVAP) EMISSION CONTROL SYSTEM LEAK
DETECTED
NOTE: For terminal identification, see TERMINAL IDENTIFICATION. For
circuit and wire color identification, see
L - WIRING DIAGRAMS article.
1) Remove fuel cap. Push fuel pipe restrictor to operate On-
board Fuel Vent Valve (OFLV). Install and tighten fuel cap. Remove
fuel cap and ensure distance between filler tube and OFLV is 1.1" (28
mm). If distance is as specified, go to next step. If distance is not
as specified, replace fuel tank filler tube assembly. Go to step 24).
2) Disconnect and plug air filter-to-EVAP vent solenoid hose
at air filter. Disconnect intake manifold plenum-to-EVAP purge
solenoid at intake manifold plenum. Install a "T" fitting between
vacuum hose and intake manifold plenum. Connect a hand-held
pressure/vacuum pump to "T" fitting. Go to next step.
CAUTION: DO NOT apply more than 0.57 psi in following step. Applying
more than specified psi can crack fuel tank.
NOTE: Ensure fuel tank is at least 1/4 full. The lower the fuel
level in fuel tank, the longer it takes to pressurize fuel
system.
3) Using scan tool, read Fuel Tank Differential Pressure
(FTDP) sensor (item 73). Using hand-held pressure/vacuum pump, apply\
0.42 psi. If scan tool reading reaches 0.42 psi, go to next step. If
reading does not reach 0.42 psi, go to step 9).
4) Wait 20 seconds and read scan tool. If scan tool reading
increases 0.06 psi or less, go to next step. If scan tool reading
increases more than 0.06 psi, go to step 21).
5) Disconnect EVAP canister purge hose. Connect Purge Flow
Indicator (MB995061) between EVAP canister and disconnected hose. Turn\
engine on and allow it to reach operating temperature. Turn all lights
and accessories off. Place transmission in Park or Neutral. Observe
purge flow indicator while increasing engine RPM several times. If
purge flow indicator reads less than 2.5 SCFH (20 cm(3)/sec), check
EVAP canister purge hose and EVAP canister port for clogging. If hose
and port are okay, check EVAP purge solenoid. See DTC P0443. If
solenoid is okay, replace EVAP canister. Go to step 24).
6) Using scan tool, read Engine Coolant Temperature (ECT)
sensor temperature (item 21). Compare scan tool reading with

allowing metal objects to contact the battery posts and the
vehicle at the same time.
CAUTION: Never disconnect the battery while the engine is running;
doing so could damage the car's electrical components.
REPLACING BLOWN FUSES
Before replacing a blown fuse, remove ignition key, turn off
all lights and accessories to avoid damaging the electrical system. Be
sure to use fuse with the correct indicated amperage rating. The use
of an incorrect amperage rating fuse may result in a dangerous
electrical system overload.
BRAKE PAD WEAR INDICATOR
Indicator will cause a squealing or scraping noise, warning
that brake pads need replacement.
BRAKE FLUID
WARNING: DO NOT use reclaimed fluid or fluid that has been stored
in old or open containers. It is essential that foreign
particles and other liquids are kept out of the brake fluid
reservoir.
CATALYTIC CONVERTER
Continued operation of vehicle with a severe malfunction
could cause converter to overheat, resulting in possible damage to
converter and vehicle.
ENGINE COOLANT SERVICE
WARNING: To avoid the danger of being scalded never change the coolant
when the engine is hot.
WARNING: Never remove the radiator cap when the engine is hot Serious
burns could be caused by high pressure fluid escaping from
the radiator.
CAUTION: When adding or replacing engine coolant, use a high quality
ethylene glycol antifreeze diluted with 50% distilled water.
When putting the cap on the reserve tank, line up the arrow
on the cap and the arrow on the tank, or coolant can leak out
ENGINE DRIVE BELT SERVICE
WARNING: Be sure the ignition key is OFF. The engine could rotate
unexpectedly.
ENGINE OIL
WARNING: The engine oil may be high enough to burn your fingers
when the drain plug is loosened. Wait until the drain plug
is cool enough to touch with you bare hands.
WARNING: Continuous contact with used engine oil has been found to
cause skin cancer in laboratory animals. Brief contact with
used engine oil may irritate skin. To minimize your exposure
to used oil, wear a long sleeve shirt and moisture-proof
gloves when changing oil. If oil contacts your skin, wash

1) Front HO2S is mounted in exhaust pipe below exhaust
header. Rear HO2S is mounted behind catalytic converter. HO2S is
equipped with a permanent pigtail which must be protected from damage
when HO2S is removed. Ensure HO2S is free of contaminants. Avoid using
cleaning solvents of any type.
2) HO2S may be difficult to remove when engine temperature is
less than 120
F (48C). If using original sensor, always use anti-
seize compound on threads before installation. New sensor threads are
precoated with anti-seize. Tighten HO2S to specification. See
TORQUE SPECIFICATIONS .
THROTTLE BODY
Removal
1) Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELEASE.
Drain enough coolant to ensure coolant level is below throttle body.
Disconnect air intake hose.
2) Remove accelerator, cruise control and A/T throttle valve
cables (if equipped). Disconnect fuel vapor hose, electrical harness
connector, vacuum hose and coolant hoses. Remove throttle body
retaining bolts.
Disassembly
Remove throttle position sensor. Remove idle air control
motor. Remove throttle bracket and connector bracket (if equipped).
Remove idle position switch and adjusting nut (if equipped).
CAUTION: DO NOT remove throttle valve. DO NOT use cleaning solvents
on throttle position sensor, idle air control motor or idle
position switch.
Cleaning
1) Clean all parts except throttle position sensor, idle air
control motor and idle position switch in solvent.
WARNING: Safety glasses MUST be worn whenever compressed air is used
for parts cleaning.
2) Check vacuum port and passage for clogging. Clean vacuum,
vapor and fuel passages using compressed air.
Reassembly
To reassemble, reverse disassembly procedure.
Installation
To install, reverse removal procedure.
THROTTLE POSITION (TP) SENSOR
Removal & Installation
Throttle Position (TP) sensor is located on throttle body.
Disconnect TP sensor electrical connector. Remove TP sensor screws and
TP sensor. To install, reverse removal procedure. Tighten TP sensor
screws to specification. See TORQUE SPECIFICATIONS. For TP sensor
adjustment procedure, see D - ADJUSTMENTS article.
TURBOCHARGERS
Removal (Eclipse)
1) Disconnect negative battery cable. Drain engine coolant
and oil. On models equipped with A/C, remove condenser fan motor
assembly. Remove front heated oxygen sensor. Remove oil dipstick guide
and "O" ring.

and remove. Disconnect all external solenoid and switch connections.
3) On Montero 4WD, remove catalytic converter and front
exhaust pipe. On all models, disconnect speedometer cable and control
cables at transmission. Remove starter and bellhousing cover. Place
reference mark on torque converter and drive plate for reassembly
reference. Remove torque converter bolts. Push torque converter back
and away from drive plate.
4) Disconnect transmission cooler lines. Remove oil filler
tube. Secure transmission on a jack. Raise transmission slightly to
take weight off mount. Remove crossmember-to-mount bolts and
crossmember.
5) Remove transfer case mounting bracket and mount (if
equipped). Remove transmission-to-engine mounting bolts. Carefully
lower transmission from vehicle.
CAUTION: Ensure torque converter is fully seated in transmission
before installation.
Installation
1) To install, reverse removal procedure. Tighten
transmission-to-engine bolts and torque converter-to-drive plate bolts
to specification. See TORQUE SPECIFICATIONS. Tighten mount bolts with
weight of engine and transmission on mounts. Ensure reference marks on
drive shaft(s) and torque converter-to-drive plate are matched.
2) Apply sealant to transfer case gearshift assembly gasket
before installation. Coat transmission oil filler tube "O" ring with
transmission fluid before installation. Refill transmission fluid to
specified level. See LUBRICATION in TRANSMISSION SERVICING - A/T
article. Adjust all control cables. See ADJUSTMENTS in
TRANSMISSION SERVICING - A/T article.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS - FWD MODELS








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Applications Ft. Lbs. (N.m)\
Ball Joint Nut ............................................ 74 (100)\
Center Crossmember Assembly Front Bolt ..................... 69 (93)\
Center Crossmember Assembly Rear Bolt ...................... 52 (70)\
Starter Bolts .............................................. 22 (30)\
Tie Rod End Nut ............................................ 21 (28)\
Torque Converter-To-Drive Plate Bolt ................. 33-38 (45-52)\
Transaxle-To-Engine Block Bolt
8-mm Bolt .................................................... ( 1)
10-mm Bolt ......................................... 22-25 (30-34)\
12-mm Bolt ......................................... 31-40 (42-54)\
Upper Coupling Bolts
2.4L ..................................................... 35 (48)\
3.0L ..................................................... 54 (73)\
Lower Coupling Bolts
2.4L ..................................................... 35 (48)\
3.0L ..................................................... 65 (88)\
( 1) - Tighten to 84-108 INCH lbs. (10-12 N.m).









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TORQUE SPECIFICATIONS - RWD MODELS








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Applications Ft. Lbs. (N.m)\
Engine-To-Transmission Bolt ................................ 65 (88)\