1998 MITSUBISHI MONTERO lock

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) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Inoperative includes intermittent operation.









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WIPER ARMS AND BLADES
NOTE: Windshield coatings or waxes can cause blades to not
function as intended. Clean surface before making final
judgment about blade replacement.
WIPER ARM AND BLADE INSPECTION









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Condition Code Procedure
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.
Attaching socket
stripped ............... A ............ Require replacement.
Bent .................... A .. Require repair or replacement.
Loose ................... 2 .. Suggest repair or replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 .. Suggest repair or replacement.
Size incorrect .......... 2 ............ Suggest replacement.
Tension insufficient .... B .. Require repair or replacement.
Torn .................... A ............ Require replacement.
Worn, affecting
performance ............ A ............ Require replacement.
Worn, not affecting
performance ............ 1 ............ Suggest replacement.









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WIPER BLADES
See WIPER ARMS AND BLADES .
WIPER HOSES AND NOZZLES
WIPER HOSE AND NOZZLE INSPECTION








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Condition Code Procedure
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.
Blocked ................. A .. Require repair or replacement.

ENGINE OVERHAUL PROCEDURES - GENERAL INFORMATION
1998 Mitsubishi Montero
Engine Overhaul Procedures - General Information
ALL PISTON ENGINES
* PLEASE READ THIS FIRST *
Examples used in this article are general in nature and do
not necessarily relate to a specific engine or system. Illustrations
and procedures have been chosen to guide mechanic through engine
overhaul process. Descriptions of processes of cleaning, inspection,
assembly and machine shop practice are included.
Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and specifications
for the vehicle being repaired.
ENGINE IDENTIFICATION
The engine may be identified from its Vehicle Identification
Number (VIN) stamped on a metal tab. Metal tab may be located in
different locations depending on manufacturer. Engine identification
number or serial number is located on cylinder block. Location varies
with manufacturer.
INSPECTION PROCEDURES
* 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.
GENERAL
Engine components must be inspected to meet manufacturer's
specifications and tolerances during overhaul. Proper dimensions and
tolerances must be met to obtain proper performance and maximum engine
life.
Micrometers, depth gauges and dial indicator are used for
checking tolerances during engine overhaul. Magnaflux, Magnaglo, dye-
check, ultrasonic and x-ray inspection procedures are used for parts
inspection.
MAGNETIC PARTICLE INSPECTION
Magnaflux & Magnaglo
Magnaflux is an inspection technique used to locate material
flaws and stress cracks. The part in question is subjected to a strong
magnetic field. The entire part, or a localized area, can be
magnetized. The part is coated with either a wet or dry material that
contains fine magnetic particles.
Cracks which are outlined by the particles cause an
interruption in the magnetic field. The dry powder method of Magnaflux
can be used in normal light. A crack will appear as an obvious bright
line.
Fluorescent liquid is used in conjunction with a blacklight
in a second Magnaflux system called Magnaglo. This type of inspection
demands a darkened room. The crack will appear as a glowing line in
this process. Both systems require complete demagnetizing upon

NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
REMOVAL
Remove intake and exhaust manifolds and valve cover. Cylinder
head and camshaft carrier bolts (if equipped), should be removed only
when the engine is cold. On many aluminum cylinder heads, removal
while hot will cause cylinder head warpage. Mark rocker arm or
overhead cam components for location.
Remove rocker arm components or overhead cam components.
Components must be installed in original location. Individual design
rocker arms may utilize shafts, ball-type pedestal mounts or no rocker
arms. For all design types, wire components together and identify
according to the corresponding valve. Remove cylinder head bolts.
Note length and location. Some applications require cylinder head
bolts be removed in proper sequence to prevent cylinder head damage.
See Fig. 1 . Remove cylinder head.
Fig. 1: Typical Cylinder Head Tightening or Loosening Sequence
This Graphic For General Information Only
INSTALLATION
Ensure all surfaces and head bolts are clean. Check that head
bolt holes of cylinder block are clean and dry to prevent block damage
when bolts are tightened. Clean threads with tap to ensure accurate
bolt torque.
Install head gasket on cylinder block. Some manufacturer's
may recommend sealant be applied to head gasket prior to installation.
Note that all holes are aligned. Some gasket applications may be
marked so certain area faces upward. Install cylinder head using care
not to damage head gasket. Ensure cylinder head is fully seated on
cylinder block.
Some applications require head bolts be coated with sealant
prior to installation. This is done if head bolts are exposed to water
passages. Some applications require head bolts be coated with light
coat of engine oil.

Install head bolts. Head bolts should be tightened in proper
steps and sequence to specification. See Fig. 1. Install remaining
components. Tighten all bolts to specification. Adjust valves if
required. See VALVE ADJUSTMENT in this article.
NOTE: Some manufacturers require that head bolts be retightened
after specified amount of operation. This must be done to
prevent head gasket failure.
VALVE ADJUSTMENT
Engine specifications will indicate valve train clearance and
temperature at which adjustment is to be made on most models. In most
cases, adjustment will be made with a cold engine. In some cases, both
a cold and a hot clearance will be given for maintenance convenience.
On some models, adjustment is not required. Rocker arms are
tightened to specification and valve lash is automatically set. On
some models with push rod actuated valve train, adjustment is made at
push rod end of rocker arm while other models do not require
adjustment.
Clearance will be checked between tip of rocker arm and tip
of valve stem in proper sequence using a feeler gauge. Adjustment is
made by rotating adjusting screw until proper clearance is obtained.
Lock nut is then tightened. Engine will be rotated to obtain all valve
adjustments to manufacturer's specifications.
Some models require hydraulic lifter to be bled down and
clearance measured. Different length push rods can be used to obtain
proper clearance. Clearance will be checked between tip of rocker arm
and tip of valve stem in proper sequence using a feeler gauge.
On overhead cam engines designed without rocker arms actuate
valves directly on a cam follower. A hardened, removable disc is
installed between the cam lobe and lifter. Clearance will be checked
between cam heel and adjusting disc in proper sequence using a feeler
gauge. Engine will be rotated to obtain all valve adjustments.
On overhead cam engines designed with rocker arms, adjustment
is made at push rod end of rocker arm. Ensure that the valve to be
adjusted is riding on the heel of the cam on all engines. Clearance
will be checked between tip of rocker arm and tip of valve stem in
proper sequence using a feeler gauge. Adjustment is made by rotating
adjusting screw until proper clearance is obtained. Lock nut is then
tightened. Engine will be rotated to obtain all valve adjustments to
manufacturer's specifications.
CYLINDER HEAD OVERHAUL
* 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.
DISASSEMBLY
Mark valves for location. Using valve spring compressor,
compress valve springs. Remove valve locks. Carefully release spring
compressor. Remove retainer or rotator, valve spring, spring seat and
valve. See Fig. 2.

than .010" (.25 mm) from tip. Chamfer sharp edge of reground valve
tip. Recheck valve stem installed height.
VALVE STEM OIL SEALS
Valve stem oil seals must be installed on valve stem. See
Fig. 2 . Seals are needed due to pressure differential at the ends of
valve guides. Atmospheric pressure above intake guide, combined with
manifold vacuum below guide, causes oil to be drawn into the cylinder.
Exhaust guides also have pressure differential created by
exhaust gas flowing past the guide, creating a low pressure area. This
low pressure area draws oil into the exhaust system.
Replacement (On Vehicle)
Mark rocker arm or overhead cam components for location.
Remove rocker arm components or overhead cam components. Components
must be installed in original location. Remove spark plugs. Valve stem
oil seals may be replaced by holding valves against seats using air
pressure.
Air pressure must be installed in cylinder using an adapter
for spark plug hole. An adapter can be constructed by welding air hose
connection to spark plug body with porcelain removed.
Install adapter in spark plug hole. Apply a minimum of 140
psi (9.8 kg/cm
) to adapter. Air pressure should hold valve closed. If
air pressure does not hold valve closed, check for damaged or bent
valve. Cylinder head must be removed for service.
Using valve spring compressor, compress valve springs. Remove
valve locks. Carefully release spring compressor. Remove retainer or
rotator and valve spring. Remove valve stem oil seal.
If oversized valves have been installed, oversized oil seals
must be used. Coat valve stem with engine oil. Install protective
sleeve over end of valve stem. Install new oil seal over valve stem
and seat on valve guide. Remove protective sleeve. Install spring
seat, valve spring and retainer or rotator. Compress spring and
install valve locks. Remove spring compressor. Ensure valve locks
are fully seated.
Install rocker arms or overhead cam components. Tighten all
bolts to specification. Adjust valves if required. Remove adapter.
Install spark plugs, valve cover and gasket.
VALVE SPRING INSTALLED HEIGHT
Valve spring installed height should be checked during
reassembly. Measure height from lower edge of valve spring to the
upper edge. DO NOT include valve spring seat or retainer. Distance
must be within specifications. If valves and/or seats have been
ground, a valve spring shim may be required to correct spring height.
See Fig. 12 .
Fig. 12: Measuring Valve Spring Installed Height - Typical
This Graphic For General Information Only

ROCKER ARMS & ASSEMBLIES
Rocker Studs
Rocker studs are either threaded or pressed in place.
Threaded studs are removed by locking 2 nuts on the stud. Unscrew the
stud by turning the jam nut. Coat the stud threads with Loctite and
install. Tighten to specification.
Pressed in stud can be removed using a stud puller. Ream the
stud bore to proper specification and press in a new oversize stud.
Pressed in studs are often replaced by cutting threads in the stud
bore to accept a threaded stud.
Rocker Arms & Shafts
Mark rocker arms for location. Remove rocker arm retaining
bolts. Remove rocker arms. Inspect rocker arms, shafts, bushings and
pivot balls (if equipped) for excessive wear. Inspect rocker arms
for wear in valve stem contact area. Measure rocker arm bushing I.D.
Replace bushings if excessively worn.
The rocker arm valve stem contact point can be reground,
using special fixture for valve grinding machine. Remove minimum
amount of material as possible. Ensure all oil passages are clear.
Install rocker arms in original locations. Ensure rocker arm is
properly seated in push rod. Tighten bolts to specification. Adjust
valves if required. See VALVE ADJUSTMENT in this article.
Pushrods
Remove rocker arms. Mark push rods for location. Remove push
rods. Push rods can be steel or aluminum, solid or hollow. Hollow
pushrods must be internally cleaned to ensure oil passage to the
rocker arms is cleaned. Check the pushrod for damage, such as loose
ends on steel tipped aluminum types.
Check push rod for straightness. Roll push rod on a flat
surface. Using feeler gauge, check clearance at center. Replace push
rod if bent. The push rod can also be supported at each end and
rotated. A dial indicator is used to detect bends in the push rod.
Lubricate ends of push rod and install push rod in original
location. Ensure push rod is properly seated in lifter. Install rocker
arm. Tighten bolts to specification. Adjust valves if required. See
VALVE ADJUSTMENT in this article.
LIFTERS
Hydraulic Lifters
Before replacing a hydraulic lifter for noisy operation,
ensure noise is not caused by worn rocker arms or valve tips.
Hydraulic lifter assemblies must be installed in original locations.
Remove the 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 a hydraulic lifter remover or magnet. Different type lifters are
used. See Fig. 13.

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

using ridge reamer. DO NOT remove an excessive amount of material.
Ensure ridge is completely removed.
PISTON & CONNECTING ROD REMOVAL
Note top of piston. Some pistons may contain a notch, arrow
or be marked "FRONT". Piston must be installed in proper direction to
prevent damage with valve operation.
Check that connecting rod and cap are numbered for cylinder
location and which side of cylinder block the number faces. Proper cap
and connecting rod must be installed together. Connecting rod cap must
be installed on connecting rod in proper direction to ensure bearing
lock procedure. Mark connecting rod and cap if necessary. Pistons must
be installed in original location.
Remove cap retaining nuts or bolts. Remove bearing cap.
Install stud protectors on connecting rod bolts. This protects
cylinder walls from scoring during removal. Ensure proper removal of
ridge. Push piston and connecting rod from cylinder. Connecting rod
boss can be tapped with a wooden dowel or hammer handle to aid in
removal.
PISTON & CONNECTING ROD
Disassembly
Using ring expander, remove piston rings. Remove piston pin
retaining rings (if equipped). On pressed type piston pins, special
fixtures and procedures according to manufacturer must be used to
remove piston pins. Follow manufacturer's recommendations to avoid
piston distortion or breakage.
Cleaning
Remove all carbon and varnish from piston. Pistons and
connecting rods may be cleaned in cold type chemical tank. Using ring
groove cleaner, clean all deposits from ring grooves. Ensure all
deposits are cleaned from ring grooves to prevent ring breakage or
sticking. DO NOT attempt to clean pistons using wire brush.
Inspection
Inspect pistons for nicks, scoring, cracks or damage in ring
areas. Connecting rod should be checked for cracks using Magnaflux
procedure. Piston diameter must be measured in manufacturers specified
area.
Using telescopic gauge and micrometer, measure piston pin
bore of piston in 2 areas, 90 degrees apart. This is done to check
diameter and out-of-round.
Install proper bearing cap on connecting rod. Ensure bearing
cap is installed in proper location. Tighten bolts or nuts to
specification. Using inside micrometer, measure inside diameter in 2
areas, 90 degrees apart.
Connecting rod I.D. and out-of-round must be within
specification. Measure piston pin bore I.D. and piston pin O.D. All
components must be within specification. Subtract piston pin diameter
from piston pin bore in piston and connecting rod to determine proper
fit.
Connecting rod length must be measured from center of
crankshaft journal inside diameter to center of piston pin bushing
using proper caliper. Connecting rods must be the same length.
Connecting rods should be checked on an alignment fixture for bent or
twisted condition. Replace all components which are damaged or not
within specification.
PISTON & CYLINDER BORE FIT