1998 MITSUBISHI MONTERO head

CLOCKSPRING CENTERING
WARNING: If front wheels are not in straight-ahead position or
clockspring mating marks are not aligned before installing
clockspring, the steering wheel may not turn completely, or
flat cable inside clockspring may be severed, disabling SRS
system and possibly causing serious injury to driver.
With clockspring removed, ensure front wheels are in
straight-ahead position. Turn clockspring fully clockwise, and then
turn it back approximately 3.3 turns counterclockwise to align mating
marks. See Fig. 8.
Fig. 8: Aligning Clockspring Mating Marks
Courtesy of Mitsubishi Motor Sales of America.
WIRE REPAIR
DO NOT repair SRS wiring or harness connectors. If SRS wiring
or harness connectors are faulty, replace faulty wiring harness.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








\









\









\









\









\









\







Application Ft. Lbs. (N.m)
Steering Wheel Nut ............................... 29 (39)

specified, bleed system and inspect hydraulic and clutch components.
See CLUTCH PEDAL SPECIFICATIONS table.
CLUTCH PEDAL INTERLOCK SWITCH
1) Place transmission in Neutral and apply parking brake.
Turn ignition switch to START position with clutch pedal not
depressed. Engine should not crank. If engine cranks, adjust or
replace interlock switch.
2) Disconnect interlock switch connector. Interlock switch
connector is located at clutch pedal. Depress and release interlock
switch. Using ohmmeter, check continuity between interlock switch
terminals. If continuity exists with interlock switch depressed and
does not exist with switch released, switch is okay. Adjust or replace
as necessary.
REMOVAL & INSTALLATION
CLUTCH ASSEMBLY
Removal (2WD Models)
1) Disconnect negative battery cable. Remove shift knob, dust
cover retaining plate, gaskets, stopper plate and control lever
assembly. Raise and support vehicle.
2) Remove front exhaust pipe. Drain transmission fluid. Index
mark drive shaft flange and remove drive shaft.
3) Disconnect back-up light switch connector, speedometer
cable connection and exhaust pipe mounting bracket. Remove lower
bellhousing cover. Disconnect clutch cable from clutch lever.
4) Support transmission with jack. Remove rear engine mount
nuts and bolts from transmission. Remove crossmember with rear engine
mount. Remove remaining bellhousing bolts, move transmission toward
rear and lower from vehicle.
5) If reusing pressure plate, index mark pressure plate to
flywheel for installation reference. Install a clutch alignment tool
to prevent pressure plate and clutch disc from dropping. Loosen
pressure plate bolts gradually in a crisscross pattern to avoid
warping pressure plate flange during removal. Remove pressure plate
and clutch disc. See Fig. 3.
Inspection
1) Check release bearing and release fork for damage or wear.
DO NOT clean release bearing assembly in solvent.
2) Inspect pressure plate surface for wear, cracks, and/or
discoloration. Measure diaphragm spring ends for wear and uneven
height. Replace assembly if height difference between fingers exceeds
.02" (.5 mm).
3) Check facing of clutch disc for loose rivets, uneven
contact, deterioration, seizure or oil saturation. Measure distance
from clutch disc surface to head of rivet. Replace clutch disc if
distance is less than .012" (.30 mm). Replace worn or defective
components as necessary. See Fig. 4.
CAUTION: Install clutch disc with manufacturer's stamp mark (located
near hub of clutch disc) toward pressure plate.
Installation
1) Using a clutch alignment tool, install pressure plate and
clutch disc. If reusing pressure plate, ensure index marks are
aligned. Tighten bolts evenly in a crisscross pattern to
specification. See TORQUE SPECIFICATIONS . See Fig. 3.
2) Clean release bearing sliding surface. DO NOT clean

DO NOT clean release bearing assembly in solvent. Inspect hydraulic
system components for fluid leakage. Inspect cylinder dust boot for
cracks or deterioration.
2) Inspect pressure plate surface for wear, cracks, and/or
discoloration. Measure diaphragm spring ends for wear and uneven
height. Replace assembly if height difference between fingers exceeds
.02" (.5 mm).
3) Check facing of clutch disc for loose rivets, uneven
contact, deterioration, seizure or oil saturation. Measure depth from
clutch disc surface to head of rivet. Replace clutch disc if
measurement is less than .012" (.30 mm). See Fig. 4. Replace worn or
defective components as necessary.
Fig. 4: Measuring Clutch Disc (Typical)
Courtesy of Mitsubishi Motor Sales of America.
CAUTION: Install clutch disc with manufacturer's stamp mark (located
near hub of clutch disc) toward pressure plate.
Installation
1) Using a clutch alignment tool, install pressure plate and
clutch disc. Tighten bolts evenly in a crisscross pattern to
specification. See TORQUE SPECIFICATIONS .
2) Clean release bearing sliding surface. Apply a light
coating of multipurpose grease to release bearing sliding surface.

D - ADJUSTMENTS
1998 Mitsubishi Montero
1998 ENGINE PERFORMANCE
Mitsubishi - On-Vehicle Adjustments
Diamante, Eclipse, Galant, Mirage, Montero, Montero Sport,
3000GT
ENGINE MECHANICAL
Before performing any on-vehicle adjustments to fuel or
ignition system, ensure engine mechanical condition is okay (i.e.,
engine compression).
VALVE CLEARANCE
VALVE ADJUSTMENT
NOTE: All models use hydraulic valve lifters. Adjustment is not
required.
CHECKING HYDRAULIC VALVE LIFTERS
1) Warm engine to normal operating temperature. Remove valve
cover. Position cylinder No. 1 at TDC on compression stroke. On 4-
cylinder engines, check intake rockers on cylinders No. 1 and 2. Check
exhaust rockers on cylinders No. 1 and 3. On V6 engines, check intake
rockers on cylinders No. 1, 5 and 6. Check exhaust rockers on
cylinders No. 1, 2 and 3.
2) Push downward on end of rocker arm, above lash adjuster.
Rotate crankshaft 360 degrees. On 4-cylinder engines, check intake
rockers on cylinders No. 3 and 4. Check exhaust rockers on cylinders
No. 2 and 4. On V6 engines, check intake rockers on cylinders No. 2, 3
and 4. Check exhaust rockers on cylinders No. 4, 5 and 6. If lash
adjuster is normal, it will feel solid.
3) If lash adjuster moves downward easily when pushed,
replace adjuster. If lash adjuster feels soft or spongy, air has
probably entered lash adjuster. If this occurs, check engine oil
level. If engine oil level is okay, check oil screen and oil screen
gasket for damage.
4) After repairing cause of air ingestion, warm engine to
operating temperature. Drive vehicle at low speed for approximately 5
minutes. Turn engine off for a few minutes.
5) Restart engine and drive at low speed for approximately 5
minutes. Repeat this step several times for about one hour. This helps
remove air from engine oil.
IGNITION TIMING
NOTE: Perform all checks with engine at normal operating
temperature, cooling fan and accessories off, transmission
in Park or Neutral, and front wheels in straight-ahead
position. Ignition timing check procedure for Eclipse 2.0L
non-turbo not available from manufacturer at time of
publication.
Diamante
1) Ignition timing is controlled by Powertrain Control Module
(PCM) and is not adjustable. Manufacturer provides procedure for
checking timing. DO NOT attempt to adjust ignition timing by rotating

is 600-700 RPM. Turn engine off. Curb idle speed is automatically
controlled by Idle Air Control (IAC) system. If curb idle speed is not\
as specified, see DTC P0505 in G - TESTS W/CODES article.
4) Disconnect waterproof female connector from Brown ignition
timing check connector. See Fig. 4. Using a jumper wire, ground
ignition timing check terminal to read basic ignition timing. Using
timing light, read basic ignition timing value. See
IGNITION TIMING SPECIFICATIONS table. If basic ignition timing is
within specification, go to next step. If basic ignition timing is not
within specification, see DTC P0335 in G - TESTS W/CODES article.
5) Remove jumper wire to read actual ignition timing. Using
timing light, read actual ignition timing value. If actual ignition
timing is not within specification, see DTC P0335 in G - TESTS W/CODES
article.
All Other Models
1) Ignition timing is controlled by Powertrain Control Module
(PCM) and is not adjustable. Manufacturer provides procedure for
checking timing. On models with distributor, DO NOT attempt to adjust
ignition timing by rotating distributor.
2) Connect scan tool to Data Link Connector (DLC). DLC is
located below dash, near steering column. See Fig. 2. Install a timing
light. Start engine and allow it to idle.
3) Using scan tool, read curb idle speed (RPM). Ensure curb
idle speed is about 750 RPM. Turn engine off. Curb idle speed is
automatically controlled by Idle Air Control (IAC) system. If curb
idle speed is not as specified, see DTC P0505 in G - TESTS W/CODES
article.
CAUTION: MFI system actuator test must be cancelled or test will
continue to run for 27 minutes. Driving vehicle under this
condition may damage engine.
4) Using scan tool, select MFI SYSTEM ACTUATOR TEST, then
select item 17 (BASIC IGNITION TIMING). Read basic ignition timing
value. See IGNITION TIMING SPECIFICATIONS table. If basic ignition
timing is within specification, go to next step. If basic ignition
timing is not within specification, cancel MFI system actuator test.
See DTCS P0100 (except Mirage 1.5L), P0105, P0115 and P0335 in G -
TESTS W/CODES article.
5) Read actual ignition timing value. If actual ignition
timing is not within specification, cancel MFI system actuator test.
See DTCS P0100 (except Mirage 1.5L), P0105, P0115 and P0335 in G -
TESTS W/CODES article.
IDLE SPEED & MIXTURE
* PLEASE READ THIS FIRST *
NOTE: Perform adjustments with engine at normal operating
temperature, cooling fan and accessories off, transmission
in Park or Neutral, and front wheels in straight-ahead
position.
BASIC IDLE SPEED
NOTE: Basic idle speed adjustment information on Eclipse 2.0L
non-turbo engine is not available from manufacturer at time
of publication.
3000GT
1) Ensure vehicle is at normal operating temperature with all

MIXTURE. Perform all adjustments with engine at normal
operating temperature, front wheels in straight-ahead
position, cooling fan and all accessories off, and
transmission in Park or Neutral.
Eclipse 2.0L Non-Turbo
1) TP sensor is not adjustable. Disconnect TP sensor
connector. Using external ohmmeter, measure resistance between TP
sensor terminals No. 1 and 3. See Fig. 8. If resistance is not 3500-
6500 ohms, replace TP sensor.
2) While slowly rotating throttle valve from idle to full
open, measure resistance between TP sensor terminals No. 2 and 3. If
resistance does not change smoothly in proportion to throttle opening,
replace TP sensor.
Montero
1) Disconnect TP sensor connector. Using jumper wires,
connect an external ohmmeter between TP sensor terminals No. 1 and 2.
See Fig. 9 . Insert .025" (.65 mm) feeler gauge between fixed speed
adjusting screw and throttle lever.
2) Loosen TP sensor mounting screws and rotate TP sensor
fully clockwise. Ensure there is continuity between terminals No. 1
and 2. Rotate TP sensor counterclockwise until there is no continuity,
and tighten screws. Install Test Harness (MB991348) between TP sensor
and harness connector.
3) Turn ignition on. Using external voltmeter, measure TP
sensor output voltage between terminals No. 1 and 3. If voltage is not
.4-1.0 volt, check harness and sensor. See DTC P0120 in G - TESTS
W/CODES article.
All Other Models
1) Disconnect TP sensor connector. Using jumper wires,
connect an external ohmmeter between TP sensor terminals No. 1 and 2
on Diamante or No. 3 and 4 on all other models. See Fig. 9. On
Diamante and Mirage 1.8L with cruise control, insert .055" (1.40mm)
feeler gauge between fixed speed adjusting screw and throttle lever.
On Galant, insert .025" (.65 mm) feeler gauge between fixed speed
adjusting screw and throttle lever. On all other models, insert .018"
(.45 mm) feeler gauge between fixed speed adjusting screw and throttle\
lever.
2) Loosen TP sensor mounting screws and rotate TP sensor
fully counterclockwise. Ensure there is continuity between terminals
No. 1 and 2 on Diamante, or No. 3 and 4 on all other models. Rotate TP
sensor clockwise until there is no continuity and tighten screws.
Install Test Harness (MB991348) between TP sensor and harness
connector.
3) Turn ignition on. Using external voltmeter, measure TP
sensor output voltage between terminals No. 1 and 3 on Diamante, or
No. 2 and 4 on all other models. If voltage is not .4-1.0 volt, check
harness and sensor. See DTC P0120 in G - TESTS W/CODES article.
Fig. 8: TP Sensor Connector Terminals (Eclipse 2.0L Non-Turbo)
Courtesy of Mitsubishi Motor Sales of America

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

FLANGES
FLEX PLATES
FLUID LEVEL INDICATORS
FLUIDS AND LUBRICANTS
FLYWHEELS
FORCE MOTORS
GUIDES
HALF SHAFTS
HOSES, LINES AND TUBES
HOUSINGS (BELL, CASE, TAIL (EXTENSION) AND AUXILIARY)
INTERMEDIATE SHAFT SUPPORT BEARINGS
KEY INTERLOCK SYSTEMS
LIMITED SLIPS
LINES
LINKAGES (EXTERNAL)
LOCKING HUB ASSEMBLIES
LOCKING HUB CONTROL KNOBS
LUBRICANTS
METAL-CLAD SEALS
METALASTIC JOINTS
MODULATOR PINS
MODULATORS
MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION)
ODOMETER DRIVES (MECHANICAL)
ODOMETER HEADS (MECHANICAL)
OIL PANS
PANS
PILOT HOLES
PRESSURE PLATES
PRESSURE SWITCHES
RACES
RUBBER JOINTS (METALASTIC)
SCREENS
SEALS
SEALS (METAL-CLAD)
SELECTOR INTERLOCK SYSTEMS
SERVOS
SHIFT INTERLOCK SYSTEMS (SELECTOR AND KEY INTERLOCK SYSTEMS)
SENSORS
SIDE COVERS
SLIP YOKES
SOLENOIDS
SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)
SPEEDOMETER-DRIVEN GEAR HOUSINGS
SPEEDOMETER/ODOMETER DRIVES (MECHANICAL)
SPEEDOMETER/ODOMETER HEADS (MECHANICAL)
SPEEDOMETERS AND ODOMETERS (ELECTRONIC)
SWITCHES
TONE WHEELS
TOOTHED RINGS (TONE WHEELS)
TORQUE CONVERTERS
TRANSAXLE MOUNTS
TRANSDUCERS (TRANSMISSION)
TRANSMISSION COOLERS
TRANSMISSION MOUNTS
TRANSMISSION PANS
TRANSMISSION RANGE INDICATORS (PRNDL)
TUBES
UNIVERSAL JOINTS (CARDON OR CROSS TYPE)
VACUUM CONTROLS
VACUUM HOSES
VACUUM MOTORS
VACUUM-OPERATED SWITCHES