1998 MITSUBISHI MONTERO check engine

(62-73 kPa) of vacuum applied to the brake booster.
PARKING/EMERGENCY BRAKE
NOTE: Adjust service brakes before adjusting parking brake.
Start engine, and apply brake pedal. Pull parking brake lever
with a force of 44-45 lbs. (196-200 N). Parking brake lever should
move up 3-5 notches on Diamante, Stealth and 3000GT, 4-6 notches on
Montero, and 5-7 notches on all other models. If adjustment is
necessary, turn adjusting nut located under console or at end of cable
rod. See Fig. 6.
Fig. 6: Adjusting Parking/Emergency Brake (Typical)
Courtesy of Mitsubishi Motor Sales of America.
REAR BRAKE SHOES
Fully release parking brake and depress brake pedal several
times to center shoes and adjust brake shoe clearance. Adjust shoes so
brake shoes lightly contact brake drum. Adjust parking brake, and
check pedal travel. Rotate brake drum to verify free movement.
STOPLIGHT SWITCH
Loosen lock nut, and adjust switch-to-pedal arm clearance to
0.02-0.04" (0.5-1.0 mm). Tighten lock nut. DO NOT depress master
cylinder push rod during stoplight switch adjustment.
TESTING

POWER BRAKE BOOSTER
System Check
1) Run engine for 1-2 minutes. Shut engine off, and depress
brake pedal several times with normal pressure. If pedal height
gradually becomes higher with successive applications, power brake
booster is okay. If pedal height remains steady, power brake booster
is not operating properly, go to next step.
2) With engine stopped, depress brake pedal repeatedly until
pedal height no longer falls. Hold brake pedal down, and start engine.
If pedal moves downward slightly, power brake booster is okay. If
pedal height does not change, power brake booster is not operating
properly, go to next step.
3) With engine running, press and hold brake pedal. Shut off
engine. Hold brake pedal for 30 seconds. Brake pedal height should not
change. If pedal rises, power brake booster is not operating properly,
go to next step.
4) If brake booster operation is not as specified in each
step, disconnect vacuum hose at brake booster and check for sufficient
vacuum with engine running. Also check brake booster check valve
operation. Repair or replace as necessary.
Check Valve Inspection
Remove vacuum hose from power brake booster. Do not remove
check valve from hose. Check valve should hold vacuum in one direction
and allow air to pass in other direction.
LOAD-SENSING PROPORTIONING VALVE (LSPV)
Montero
1) Before diagnosing Load-Sensing Proportioning Valve (LSPV)\
,
ensure all other brake components are operating properly. When all
other brake system components are determined to be okay, ensure LSPV
spring length is within specification. See Fig. 1. See LOAD-SENSING
PROPORTIONING VALVE (LSPV) under ADJUSTMENTS.
2) After spring length is determined to be within
specification, connect pressure gauges to input and output ports of
LSPV. See Fig. 7. Bleed brake system. See BLEEDING BRAKE SYSTEM.
Fig. 7: Connecting Pressure Gauges To LSPV (Montero)
Courtesy of Mitsubishi Motor Sales of America.
3) With vehicle unloaded at correct ride height and LSPV
spring correctly adjusted to 8.9" (227 mm), slowly depress brake pedal\

pressure at specified pressure range (split point). See
SPLIT POINT PRESSURE SPECIFICATIONS table.
SPLIT POINT PRESSURE SPECIFICATIONS









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Application psi (kg/cm)
Diamante .......................................... 312-383 (22-27)\
Eclipse
Without ABS ...................................... 320-391 (22-27)\
With ABS ......................................... 320-391 (22-27)\
Galant ............................................. 462-533 (33-38)\
Mirage
2-Door ........................................... 320-392 (22-26)\
4-Door ........................................... 391-463 (27-32)\
Montero Sport .................................................. ( 1)
( 1) - Information not available from manufacturer.









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3) Continue depressing brake pedal, and check readings on
pressure gauges. See PROPORTIONING VALVE PRESSURE SPECIFICATIONS
table. If fluid pressures or split point are not within specification,
replace proportioning valve.
PROPORTIONING VALVE PRESSURE SPECIFICATIONS









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Application/ Inlet Pressure (1) Outlet Pressure
Model psi (kg/cm) psi (kg/cm)
Diamante ................... 1138 (80) ........... 676-747 (48-53\
)
Eclipse
With ABS ................. 996 (69) ............ 569-640 (39-44\
)
Without ABS .............. 925 (61) ............ 462-533 (32-37\
)
Galant ..................... 996 (69) ................... 604 (43\
)
Mirage
2-Door ................... 1422 (98) ........... 566-680 (39-47\
)
4-Door ................... 1422 (98) ........... 619-733 (43-51\
)
3000GT
Hatchback ................ 906 (64) ............ 651-723 (46-51\
)
Convertible .............. 1117 (79) ........... 846-917 (60-65\
)
Montero Sport ................. ( 1) .......................... ( 1)
( 1) - Information is not available from manufacturer.









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REMOVAL & INSTALLATION
FRONT DISC BRAKE PADS
CAUTION: DO NOT remove or contaminate special grease coating on lock
pins.
Removal & Installation (Except 3000GT AWD)
1) Raise and support vehicle. Remove front wheels. Remove
lower lock pin or sleeve bolt. See Figs. 13-15. Lift caliper body
upward. Support caliper aside. Remove shims and pads from support
mounting. Remove pad clips.
2) If installing new pads, compress piston to bottom of bore.
Install retaining clips, pads and shims. Start engine and depress
brake pedal several times to expand caliper piston. Check brake fluid
level.

Removal & Installation (3000GT AWD)
1) Raise and support vehicle. Remove front wheels. Remove
clip, brake pad retaining pins and spring. See Fig. 17. Remove shims
and pads from caliper. Keep track of location of shims for reassembly.
2) Compress caliper pistons fully in bores. Install shims on
brake pads. Install brake pads. Install spring clip, pad retaining
pins and clip. Start engine and depress brake pedal several times to
expand caliper piston. Check brake fluid level.
FRONT BRAKE CALIPER
Removal
Raise and support vehicle. Remove front wheels. Remove hose
clip from brake hose mount (if equipped). Disconnect brake hose from
caliper. Remove upper and lower caliper-to-steering knuckle bolts.
Lift caliper body upward. Remove caliper.
Installation
To install, reverse removal procedure. Tighten bolts to
specification. See TORQUE SPECIFICATIONS . Bleed brake system. See
BLEEDING BRAKE SYSTEM .
FRONT BRAKE ROTOR
Removal & Installation (Except Montero & Montero Sport)
Raise vehicle, and remove wheel(s). Remove caliper. See
FRONT BRAKE CALIPER . Slide rotor off hub. To install, reverse removal
procedure.
Removal (Montero & Montero Sport)
Raise and support vehicle. Remove brake caliper. See
FRONT BRAKE CALIPER . On 4WD, remove Remove bearing grease cap, snap
ring, shim, 6 bolts and drive flange from axle shaft. On 2WD remove 6
bolts and hub cover. Remove screw(s) from lock washer. Remove lock
washer. Remove lock nut using Lock Nut Wrench (MB990954). Remove hub
assembly. Place match marks on rotor and hub. Remove rotor from front
hub.
Installation
1) Install rotor on hub. Service wheel bearings and seals as
necessary. Install front hub assembly. Install lock nut, and tighten
it to 119 ft. lbs. (165 N.m). Loosen lock nut, and retighten it to 18
ft. lbs. (24 N.m). Loosen lock nut 30-40 degrees. Install lock washer
and screw(s).
2) On 2WD, reverse removal procedure for remaining
components. On 4WD, install drive flange, shim and snap ring. Using
feeler gauge, check axle shaft-to-hub clearance. Clearance should be
0.016-0.028" (0.41-0.71 mm). Use appropriate shim to obtain correct
clearance. Shim is located behind snap ring on end of axle shaft.
Recheck clearance if necessary. Install remaining components.
PARKING BRAKE SHOES
Removal & Installation (Diamante)
1) Raise and support vehicle. Remove rear wheels. Remove rear
disc brake caliper and rotor. If rotor removal is difficult, rotate
rotor until hole in rotor is upward. Back-off brake shoe adjustment
with a flat blade screwdriver through hole in rotor.
2) Disconnect rear speed sensor. See Fig. 9. Remove 4 bolts
and hub. Remove screw and shoe hold-down spring. Remove shoe. To
install, reverse removal procedure. Adjust brake shoe by turning
adjuster star wheel.

Generator ........ .30-.41 (7.5-10.5) ..... .35-.47 (9.0-12.0\
)
P/S (W/O A/C) .... .26-.37 (6.5-9.5) ..... .43-.55 (11.0-14\
.0)
P/S & A/C ........ .32-.35 (8.0-9.0) ..... .39-.43 (10.0-11.0\
)
2.0L Turbo & 2.4L
A/C .............. .22-.24 (5.5-6.0) ....... .26-.30 (6.5-7.5\
)
Generator ........ .30-.35 (7.5-9.0) .............. .39 (10.0\
)
P/S .............. .18-.22 (4.5-5.5) ....... .24-.28 (6.0-7.0\
)
Galant
A/C ................ .22-.24 (5.5-6.0) ....... .26-.30 (6.5-7.6\
)
Generator .......... .30-.35 (7.5-8.8) .............. .39 (10.0\
)
P/S ................ .18-.22 (4.5-5.6) ....... .24-.28 (6.0-7.0\
)
Mirage
1.5L
A/C .............. .13-.17 (3.4-4.3) ....... .20-.22 (5.0-5.7\
)
Generator ........ .26-.33 (6.6-8.3) ...... .36-.42 (9.2-10.6\
)
P/S .............. .28-.36 (7.2-9.0) ..... .40-.46 (10.2-11.6\
)
1.8L
Generator ........ .28-.31 (7.0-8.0) ...... .33-.39 (8.5-10.0\
)
P/S & A/C ........ .28-.36 (7.0-9.0) ..... .39-.43 (10.0-11.0\
)
Montero
A/C ................ .20-.24 (5.0-6.0) ....... .26-.30 (6.5-7.5\
)
Generator .......... .16-.20 (4.0-5.0) ....... .22-.26 (5.5-6.5\
)
P/S ................ .42-.54 (10.7-13.7) ... .58-.66 (14.8-16.8\
)
Montero Sport
2.4L
A/C .............. .20-.22 (5.0-6.0) ....... .24-.26 (6.0-6.5\
)
Generator ........ .22-.29 (5.5-7.5) ....... .30-.33 (7.5-8.5\
)
P/S .............. .16-.24 (4.0-6.0) ....... .24-.28 (6.0-7.0\
)
3.0L
A/C .............. .17-.20 (4.3-5.1) ....... .22-.26 (5.6-6.5\
)
Generator ........ .22-.29 (5.5-7.5) ....... .31-.35 (8.0-9.0\
)
P/S .............. .44-.52 (11.0-13.0) ... .56-.64 (14.0-16.0\
)
3000GT
SOHC
A/C .............. .26-.28 (6.5-7.0) ....... .30-.34 (7.5-8.5\
)
Generator & P/S .. .16-.20 (4.0-5.0) ....... .24-.32 (6.0-8.0\
)
DOHC
Generator ........ .14-.16 (3.5-4.0) ....... .16-.20 (4.0-5.0\
)
P/S .............. .30-.35 (7.5-9.0) ..... .41-.49 (10.4-12.4\
)
(1) - With 22 lbs. (10 kg) pressure applied midway between pulleys.









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MECHANICAL CHECKS
ENGINE COMPRESSION
Check engine compression with engine at normal operating
temperature, all spark plugs removed and throttle wide open.
COMPRESSION SPECIFICATIONS TABLE









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Application (1) Specification
Compression Ratio
1.5L (VIN A) ..................................... 9.0:1
1.8L (VIN C) ..................................... 9.5:1
2.0L
(VIN F) ........................................ 8.5:1
(VIN Y) ........................................ 9.6:1
2.4L (VIN G) ..................................... 9.5:1
3.0L

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

release bearing with solvent. Apply a light coat of multipurpose
grease to release bearing sliding surface. Apply a very light coating
of grease to input shaft splines. DO NOT allow grease or dirt on
clutch disc or pressure plate surfaces.
3) To install remaining components, reverse removal
procedure. Refill all fluids to proper levels. Adjust all control
cables, clutch pedal height and free play. See CLUTCH PEDAL HEIGHT and
CLUTCH PEDAL FREE PLAY under ADJUSTMENTS. See Fig. 1.
Removal (4WD Models)
1) Remove switch panel from rear console. Remove suspension
control switch or hole cover. Disconnect rear console harness
connector. Remove side panel. Remove rear console assembly. Remove
shift lever knob(s). Remove floor console harness connector. Remove
front console assembly.
2) Move transmission lever to Neutral position and transfer
lever to 4H (4WD high range) position. Remove control lever boot
retainer and boot. Remove transmission and transfer control lever
assemblies. Remove control lever bushing (transmission), gaskets and
stopper plates.
3) Raise and support vehicle. Remove skid plate and front
exhaust pipe. Drain transmission and transfer case fluid. Index mark
front and rear drive shaft flanges. Remove front and rear drive
shafts.
4) Remove drive shaft dust seals. Disconnect HI/LO and
2WD/4WD detection switch connectors. Disconnect back-up light switch
connector. Disconnect center differential lock detection switch
connector. Disconnect center differential lock operation switch
connector. Disconnect 4WD operation detection switch.
5) Disconnect speedometer cable. Remove clutch slave cylinder
heat shield. Remove clutch slave cylinder (without disconnecting
hydraulic line) and wire aside. Remove starter and starter cover.
Remove heat shield, both transmission stays and bellhousing lower
cover.
6) Support transmission with transmission jack. Remove
transfer case roll stopper and bracket. Remove crossmember and engine
mounting rear insulator. Remove transfer case protector bracket and
mass damper. Remove remaining bellhousing bolts. Pull toward rear of
vehicle to free transmission input shaft from clutch. Lower
transmission/transfer assembly from vehicle.
7) If reusing pressure plate, mark pressure plate to flywheel
for installation reference. Insert 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 .
Fig. 3: Removing & Installing Clutch On Flywheel (Typical)
Courtesy of Mitsubishi Motor Sales of America.
Inspection
1) Check release bearing and release fork for damage or wear.

Repair or replace components as necessary. If no problems exist, go to
next step.
2) Ground fan motor 3-pin connector terminal No. 3 (Black
wire). Using a fused jumper wire, connect battery voltage to 3-pin
connector terminal No. 2 (Blue wire). See WIRING DIAGRAMS. Fan motor
should operate with no abnormal noises or interferences. Repair or
replace components as necessary.
Engine Coolant Temperature (ECT) Sensor
Remove ECT sensor from vehicle. Suspend sensor in water so
that sensor does not touch container. Slowly heat water. Using an
ohmmeter, check sensor continuity as temperature increases. Replace
ECT sensor if resistance is not as specified. See
ENGINE COOLANT TEMPERATURE SENSOR RESISTANCE table.
ENGINE COOLANT TEMPERATURE SENSOR RESISTANCE









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Temperature F (C) Ohms
Diamante, Eclipse 2.0L Turbo & 2.4L
32 (0) ................................................. 5100-6500\
68 (20) ................................................ 2100-2700\
104 (40) ................................................ 900-1300\
176 (80) ................................................. 260-360\
Eclipse Non-Turbo
77 (25) ................................................. 900-1100\
212 (100) ................................................ 600-800\
Galant & Mirage
68 (20) ................................................ 2100-2700\
176 (80) ................................................. 260-360\
Montero
68 (20) ................................................ 2130-2610\
176 (80) ................................................. 258-322\
Montero Sport
68 (20) ................................................ 2100-2700\
176 (80) ................................................. 260-360\
3000GT
32 (0) ...................................................... 5800\
68 (20) ..................................................... 2400\
104 (40) .................................................... 1100\
176 (80) ..................................................... 300\









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Electric Cooling Fan Relay (Diamante, Eclipse, Galant &
Mirage)
1) Remove radiator fan motor relay from relay box located at
right side of engine compartment. Check for continuity between relay
terminals No. 1 and 3. If continuity exists, go to next step. If
continuity does not exist, replace cooling fan relay. See Fig. 8.
2) Using a fused jumper wire, connect battery voltage to
cooling fan relay terminal No. 1. Using another jumper wire, connect
cooling fan relay terminal No. 3 to battery ground. With cooling fan
relay energized, there should be continuity between cooling fan relay
terminals No. 4 and 5. With cooling fan relay not energized, there
should be no continuity between terminals No. 4 and 5. If continuity
does not exist as specified, replace cooling fan relay. See Fig. 8.
Electric Cooling Fan Relay (Montero, Montero Sport & 3000GT)
1)Remove relay from relay box in engine compartment relay
box. Check for continuity between relay terminals No. 2 and 4. If
continuity exists, go to next step. If continuity does not exist,
replace cooling fan relay. See Fig. 9.
2) Using a fused jumper wire, connect battery voltage to