1998 MITSUBISHI MONTERO Service Manual

Removal & Installation
1) Drain master cylinder. Remove cotter pin, washer and
clevis pin. Disconnect push rod from clutch pedal. Remove and plug
hydraulic line at clutch master cylinder.
2) Remove retaining nuts, clutch master cylinder and gasket.
To install, reverse removal procedure. Apply grease to clevis pin
before installing. Fill reservoir and bleed clutch system. See
BLEEDING CLUTCH HYDRAULIC SYSTEM .
CLUTCH RELEASE CYLINDER
Removal & Installation
Remove and plug hydraulic line at release cylinder. Remove
cylinder-to-transmission bolts. Remove clutch release cylinder. To
install, reverse removal procedure. Apply grease to push rod-to-
release fork contact area. Bleed clutch system. See
BLEEDING CLUTCH HYDRAULIC SYSTEM .
BLEEDING CLUTCH HYDRAULIC SYSTEM
Attach hose to bleeder fitting located on clutch release
cylinder, next to hydraulic line. Submerge other end of hose in
container half full of clean brake fluid. Fill reservoir with brake
fluid. Open bleeder fitting. Have assistant press clutch pedal to full
release position. Close bleeder fitting. Release clutch pedal. Repeat
until air bubbles no longer emerge from hose. Refill reservoir.
OVERHAUL
CLUTCH MASTER CYLINDER
NOTE: DO NOT disassemble piston assembly.
Disassembly
Remove piston stop ring, damper and push rod assembly. See
Fig. 6 . Remove piston assembly. Note position of reservoir band for
reassembly reference. Remove reservoir.
Inspection & Reassembly
Inspect components for corrosion, scoring or damage. Replace
if necessary. Apply brake fluid to components during reassembly. On
Montero, adjust clutch master cylinder push rod to 5.90" (150 mm). On
Montero Sport, push rod adjustment is correct after adjusting clutch
pedal free play and pedal height. See CLUTCH PEDAL FREE PLAY and
CLUTCH PEDAL HEIGHT under ADJUSTMENTS. To reassemble, reverse
disassembly procedure. Ensure piston moves freely in bore.
Fig. 6: Exploded View Of Clutch Master Cylinder (Typical)
Courtesy of Mitsubishi Motor Sales of America.

CLUTCH RELEASE CYLINDER
Disassembly
Remove valve plate and spring. See Fig. 7. Remove push rod
and boot. Cover piston assembly opening with a rag. Slowly apply air
pressure to hydraulic line opening to force piston from body.
Inspection & Reassembly
Inspect components for corrosion, scoring or damage. Replace
if necessary. Apply brake fluid to components during reassembly. To
reassemble, reverse disassembly procedure. Ensure piston moves freely
in bore.
Fig. 7: Exploded View Of Clutch Release Cylinder (Typical)
Courtesy of Mitsubishi Motor Sales of America.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\
Clutch Pedal Position Switch Adjusting Nut Or Bolt ......... 10 (13)\
Bellhousing-To-Engine Mounting Bolt
Montero
10 x 40 mm ............................................. 26 (36)\
10 x 55 mm ............................................. 22 (31)\
12 x 40 mm ............................................. 54 (75)\
12 x 55 mm ............................................. 65 (90)\
Montero Sport
2WD .................................................... 19 (26)\
4WD .................................................... 55 (75)\
Clutch Master Cylinder Mounting Nut ........................ 10 (13)\

Clutch Pedal Mounting Nut .................................. 21 (29)\
Flywheel Bolt
Montero .................................................. 54 (74)\
Montero Sport ........................................... 98 (132)\
Fulcrum Ball ............................................... 26 (35)\
Hydraulic Line Flare Nut ................................... 11 (15)\
Push Rod Jam Nut ........................................... 10 (13)\
Release Cylinder Mounting Bolt ............................. 27 (36)\
Starter Mounting Bolt ...................................... 23 (31)\
Transfer Case Roll Stopper Bolt ............................ 33 (44)\
Transmission Crossmember Mounting Bolt ..................... 47 (64)\
Transmission Support Bolt
Front (Crossmember) ...................................... 29 (39\
)
Rear ..................................................... 26 (35)\









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COMPUTER RELEARN PROCEDURES
1998 Mitsubishi Montero
GENERAL INFORMATION
Computer Relearn Procedures
All Models
* PLEASE READ THIS FIRST *
The following general procedures are to be used if
driveability problems are encountered after power loss or battery has
been disconnected. These procedures may provide an aid in eliminating
these problems.
To reduce the possibility of complaints, after any service
which requires battery power to be disconnected, vehicle should be
road tested.
COMPUTER RELEARN PROCEDURES
Vehicles equipped with engine or transmission computers may
require a relearn procedure after vehicle battery is disconnected.
Many vehicle computers memorize and store vehicle operation patterns
for optimum driveability and performance. When vehicle battery is
disconnected, this memory is lost. The computer will use default data
until new data from each key start is stored. As computer memorizes
vehicle operation for each new key start, driveability is restored.
Vehicle computers may memorize vehicles operation patterns for 40 of
more key starts.
Customers often complain of driveability problems during
relearn stage because vehicle acts differently then before being
serviced. Depending on type and make of vehicle and how it is
equipped, the following complaints (driveability problems) may exist:
* Harsh Or Poor Shift Quality
* Rough Or Unstable Idle
* Hesitation Or Stumble
* Rich Or Lean Running
* Poor Fuel Mileage
These symptoms and complaints should disappear after a number
of drive cycles have been memorized. To reduce the possibility of
complaints, after any service which requires battery power to be
disconnected, vehicle should be road tested. If a specific relearn
procedure is not available, the following procedure may be used:
Automatic Transmission
* Set parking brake, start engine in "P" or "N" position.
Warm-up vehicle to normal operating temperature or until
cooling fan cycles.
* Allow vehicle to idle for one minute in "N" position. Select
"D" and allow engine to idle for one minute.
* Accelerate at normal throttle position (20-50%) until vehicle
shifts into top gear.
* Cruise at light to medium throttle.
* Decelerate to a stop, allowing vehicle to downshift, and use
brakes normally.
* Process may be repeated as necessary.
Manual Transmission

* Place transmission in Neutral position.
* Ensure emergency brake has been set and all accessories
are turned off.
* Start engine and bring to normal operating temperature.
* Allow vehicle to idle in Neutral for one minute.
* Initial relearn is complete: process will be completed during
normal driving.
Some manufacturers identify a specific relearn procedure
which will help establish suitable driveability during relearn stage.
These procedures are especially important if vehicle is equipped with
and electronically controlled automatic transmission or transaxle.
Always complete procedure before returning vehicle to customer.

COOLING SYSTEM SPECIFICATIONS & ENGINE COOLING FANS
1998 Mitsubishi Montero
1997-98 ENGINE COOLING
Mitsubishi Specifications & Electric Cooling Fans
Diamante, Eclipse, Galant, Mirage, Montero, Montero Sport,
3000GT
SPECIFICATIONS
BELT ADJUSTMENT
NOTE: Use illustration for water pump drive belt routing. See
Figs. 1-6. The terms alternator and generator are used
interchangeably.
BELT ADJUSTMENT









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Application Deflection (1) In. (mm)
Diamante ....................................................... ( 2)
Eclipse & Galant
2.0L Non-Turbo ............................................... ( 2)
2.0L Turbo & 2.4L
Generator & Water Pump .................... 0.35-0.45 (9.0-11.4)\
Water Pump & Power Steering ................ 0.22-0.32 (5.6-8.1)\
Mirage
1.5L ........................................ 0.34-0.45 (8.6-11.4)\
1.8L ......................................................... ( 2)
Montero
A/C .......................................... 0.26-0.30 (6.6-7.6)\
Generator & Water Pump ................... ( 3) 0.22-0.26 (5.6-6.6)
Water Pump & Power Steering ................ 0.54-0.70 (13.7-17.8)\
Montero Sport
2.4L
A/C ........................................ 0.24-0.26 (6.1-6.6)\
Generator & Water Pump ................. ( 4) 0.28-0.35 (7.1-8.9)
Water Pump & Power Steering ................ 0.22-0.30 (5.6-7.6)\
3.0L
A/C ........................................ 0.22-0.26 (5.6-6.6)\
Generator & Water Pump ................. ( 3) 0.20-0.27 (5.1-6.8)
Water Pump & Power Steering .............. 0.52-0.68 (13.2-17.3)\
3000GT ......................................................... ( 3)
( 1) - With 22 lbs. (10 kg) pressure applied midway on belt run.
Values are for a used belt.
( 2) - Water pump is driven by timing belt. Timing belt deflection is
controlled by timing belt automatic tensioner.
( 3) - Measured between water pump pulley and crankshaft pulley.
( 4) - Measured between water pump pulley and generator pulley.









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Fig. 1: Routing Timing/Water Pump Belt (Diamante & 3000GT SOHC)
Courtesy of Mitsubishi Motor Sales of America.
Fig. 2: Routing Alternator & Water Pump Belt (Eclipse - 2.0L
Turbo & 2.4L, Galant & Mirage - 1.5L)
Courtesy of Mitsubishi Motor Sales of America.

Fig. 3: Routing Timing/Water Pump Belt (Eclipse - 2.0L Non-Turbo)
Courtesy of Mitsubishi Motor Sales of America.