1998 MITSUBISHI MONTERO engine coolant

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Component Component Location








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ABS Speed Sensors (4) On bracket, on each wheel hub.\
Air Inlet Sensor In evaporator air duct.
Camshaft Position Sensor At bottom of left camshaft
gear.
Crankshaft Position Sensor Above crankshaft gear.
Engine Coolant Temperature Gauge Unit On thermostat housing.
Engine Coolant Temperature Sensor On thermostat housing.
Front Impact Sensor (Left) (SRS) On left front of engine
compartment.
Front Impact Sensor (Right) (SRS) On right front of engine
compartment.
Fuel Gauge Unit In fuel tank.
Fuel Tank Differential Pressure Sensor
(Calif.) Top of fuel tank.
G-Sensor (ABS) In center console, rear of
parking brake lever.
Geomagnetic Sensor (Compass) On top center of dash.

Center Differential Lock Operation
Detection Switch On transfer case.
Dual Pressure Switch On high pressure line, on
receiver-drier.
Engine Coolant Temperature Switch Top right front of engine.
Free Wheel Engage Switch Right side of engine
compartment.
High Range/Low Range Detection Switch On transfer case.
Low Range Operation Detection Switch On transfer case.
Oil Pressure Switch Lower left front of engine.
Parking Brake Switch At base of parking brake
lever.
Power Steering Pressure Switch On power steering pump.
Rear Differential Lock Detection
Switch Under rear of vehicle, on
differential.
Reed Switch Integral with speedometer.
Seat Belt Switch On driver-side seat belt
buckle.
Stoplight Switch On bracket, above brake pedal.
2WD/4WD Detection Switch On transfer case.
4WD Operation Detection Switch On transfer case.









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MISCELLANEOUS









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Component Component Location








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Amplifier Under center console, below
floor.
Data Link Connector (DLC) Behind left side of dash,
near relay box.

Wire lead conductors
exposed ................ B .. Require repair or replacement.
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) - Refer to manufacturer's diagnostic trouble code procedure
and require repair or replacement of affected
component(s).
( 2) - Determine cause and correct prior to repair or replacement
of part.
( 3) - Determine source of contamination, such as engine
coolant, fuel, metal particles, or water. Require
repair or replacement.
( 4) - Inoperative includes intermittent operation or out of OEM
specification. Some components may be serviceable; check
for accepted cleaning procedure.









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CRUISE CONTROL BRAKE SWITCHES
See SWITCHES.
CRUISE CONTROL CABLES
See CRUISE CONTROL LINKAGES AND CABLES .
CRUISE CONTROL CLUTCH SWITCHES
See SWITCHES.
CRUISE CONTROL LINKAGES AND CABLES
CRUISE CONTROL LINKAGE AND CABLE 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.
Bent .................... A .. Require repair or replacement.
Binding ................. A .. Require repair or replacement.
Bracket bent, affecting
performance ............ A .. Require repair or replacement.
Bracket bent, not
affecting performance .. .. ........ No service suggested or
required.
Bracket broken, affecting
performance ............ A ............ Require replacement.
Bracket broken, not
affecting performance .. .. ........ No service suggested or
required.
Bracket corroded,
affecting performance .. A .. Require repair or replacement.
Bracket corroded, not
affecting performance .. 2 .. Suggest repair or replacement.

These 3 orifices are opened and closed by electric solenoids. The
solenoids are, in turn, controlled by the Electronic Control Module
(ECM). When a solenoid is energized, the armature with attached shaft
and swivel pintle is lifted, opening the orifice. See Fig. 11.
The ECM uses inputs from the Coolant Temperature Sensor
(CTS), Throttle Position Sensor (TPS) and Mass Airflow (MAF) senso\
rs
to control the EGR orifices to make 7 different combinations for
precise EGR flow control. At idle, the EGR valve allows a very small
amount of exhaust gas to enter the intake manifold. This EGR valve
normally operates above idle speed during warm engine operation.
Verify EGR valve is present and not modified or purposely
damaged. Ensure thermal vacuum switches, pressure transducers, speed
switches, etc., (if applicable) are not by-passed or modified. Ensure
vacuum hose(s) to EGR valve is not plugged. Ensure electrical
connector to EGR valve is not disconnected.
Fig. 11: Typical Digital EGR Valve
Courtesy of General Motors Corp.
Integrated Electronic EGR Valve
This type functions similar to a ported EGR valve with a

Engine pre-oiling can be done using pressure oiler (if
available). Connect pressure oiler to cylinder block oil passage
such as oil pressure sending unit. Operate pressure oiler long enough
to ensure correct amount of oil has filled crankcase. Check oil level
while pre-oiling.
If pressure oiler is not available, disconnect ignition
system. Remove oil pressure sending unit and replace with oil pressure
test gauge. Using starter motor, rotate engine starter until gauge
shows normal oil pressure for several seconds. DO NOT crank engine
for more than 30 seconds to avoid starter motor damage.
Ensure oil pressure has reached the most distant point from
the oil pump. Reinstall oil pressure sending unit. Reconnect ignition
system.
INITIAL START-UP
Start the engine and operate engine at low speed while
checking for coolant, fuel and oil leaks. Stop engine. Recheck coolant
and oil level. Adjust if necessary.
CAMSHAFT
Break-in procedure is required when a new or reground
camshaft has been installed. Operate and maintain engine speed between
1500-2500 RPM for approximately 30 minutes. Procedure may vary due to
manufacturers recommendations.
PISTON RINGS
Piston rings require a break-in procedure to ensure seating
of rings to cylinder walls. Serious damage may occur to rings if
correct procedures are not followed.
Extremely high piston ring temperatures are produced obtained
during break-in process. If rings are exposed to excessively high RPM
or high cylinder pressures, ring damage can occur. Follow piston ring
manufacturer's recommended break-in procedure.
FINAL ADJUSTMENTS
Check or adjust ignition timing and dwell (if applicable).
Adjust valves (if necessary). Adjust carburetion or injection idle
speed and mixture. Retighten cylinder heads (if required). If
cylinder head or block is aluminum, retighten bolts when engine is
cold. Follow the engine manufacturer's recommended break-in procedure
and maintenance schedule for new engines.
NOTE: Some manufacturer's require that head bolts be retightened
after specified amount of operation. This must be done to
prevent head gasket failure.

CLUTCH PEDAL POSITION SWITCHES
COLD START INJECTORS
CONNECTORS
COOLANT
COOLANT RECOVERY TANKS
COOLING FAN MOTOR MODULES
COOLING FAN MOTOR RELAYS AND MODULES
COOLING FAN MOTOR RESISTORS
COOLING FAN MOTOR SENSORS AND SWITCHES
COOLING FAN MOTOR SWITCHES
COOLING FAN MOTORS
CRANKSHAFT POSITION SENSORS
DECEL VALVES
DEFLECTORS
DIP STICKS AND TUBES
DIP STICK TUBES
DISTRIBUTOR ADVANCES AND RETARDERS (MECHANICAL AND VACUUM)
DISTRIBUTOR BOOTS AND SHIELDS
DISTRIBUTOR CAPS
DISTRIBUTOR RETARDERS (MECHANICAL AND VACUUM)
DISTRIBUTOR ROTORS
DISTRIBUTOR SHIELDS
DISTRIBUTORS
EARLY FUEL EVAPORATION VALVES (HEAT RISER ASSEMBLIES)
EGR COOLERS
EGR EXHAUST MANIFOLD PASSAGES
EGR INTAKE AND EXHAUST MANIFOLD PASSAGES
EGR PLATES AND COOLERS
ELECTRONIC SPARK CONTROL MODULES
ELECTRONIC TRANSMISSION CONTROL DEVICES
ELECTRONIC TRANSMISSION FEEDBACK DEVICES
ENGINE COOLANT TEMPERATURE SENSORS
ENGINE COOLING SYSTEMS
ENGINE COVERS (OIL PAN, VALVE COVER, TIMING COVER)
ENGINE OIL
ENGINE OIL CANISTERS
ENGINE OIL COOLERS (EXTERNAL)
ENGINE OIL DRAIN PLUGS AND GASKETS
ENGINE OIL FILTERS AND CANISTERS
ENGINE OIL GASKETS
ENGINE OIL PRESSURE GAUGES (MECHANICAL)
EVAPORATIVE EMISSION (EVAP) CANISTER FILTERS
EVAPORATIVE EMISSION (EVAP) CANISTER PURGE DEVICES
EVAPORATIVE EMISSION (EVAP) CANISTERS
EVAPORATIVE EMISSION (EVAP) FEEDBACK DEVICES
EXHAUST GAS RECIRCULATION DEVICES
EXHAUST GAS RECIRCULATION FEEDBACK DEVICES
EXPANSION PLUGS
FAN CONTROL SENSORS
FUEL
FUEL ACCUMULATORS AND DAMPERS
FUEL AND COLD START INJECTORS
FUEL DAMPERS
FUEL DELIVERY CHECK VALVES
FUEL DISTRIBUTORS (BOSCH CIS)
FUEL FILLER NECKS AND RESTRICTORS
FUEL FILTERS
FUEL INJECTORS
FUEL LEVEL SENDERS7
FUEL PRESSURE REGULATORS
FUEL PUMPS (IN-TANK AND EXTERNAL, ELECTRICAL OR MECHANICAL)
FUEL RAILS
FUEL RESTRICTORS

Reasons to Suggest Repair or Replacement
1 - Part is close to the end of its useful life (just above
discard specifications, or weak; failure likely to occur
soon, etc.)
2 - To address a customer need, convenience, or request (to
stiffen ride, enhance performance, eliminate noise,
etc.)
3 - To comply with maintenance recommended by the vehicle's
Original Equipment Manufacturer (OEM)
4 - Technician's recommendation based on substantial and
informed experience
NOTE: Suggested services are always optional. When presenting
suggested repairs to the customer, you must present the
facts, allowing the customer to draw their own conclusions
and make an informed decision about how to proceed.
ENGINE ASSEMBLIES
SERVICE PROCEDURES REQUIRED AND SUGGESTED FOR PROPER VEHICLE
OPERATION
CYLINDER HEAD ASSEMBLIES
NOTE: A Cylinder Head Assembly is a cylinder head fitted with
valves, associated springs, retainers, and on overhead
camshaft cylinder heads (OHC), camshaft, camshaft
bearings, lash adjusters, tappets and rockers.
CYLINDER HEAD ASSEMBLY INSPECTION









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Condition Code Procedure
Adjustable valve lash is
out of specification ... B ................. Require repair.
Internal component failure
(any component) ........ A ........... ( 1) Require repair or
replacement of cylinder
head assembly.
( 1) - It is Required that all other failure related components
be inspected for cause and condition. Additional components
or assemblies may be Suggested for repair or replacement,
such as a water pump on a short block (reason code 4,
technician's recommendation based on substantial and
informed experience).
Example:
If there is a failed head gasket with an external coolant
leak, in addition to Requiring replacement of the head
gasket, inspection of the following for cause and condition
is Required: Block, Cooling System, Cylinder Head. It may
be Suggested that additional inspections be performed, such
as the other head gasket on a V-type engine.









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LONG BLOCK ASSEMBLIES
NOTE: A Long Block Assembly is a short block assembly together
with a cylinder head assembly and all those components
fitted within the rocker or cam cover, and timing cover

(the whole presented as an assembly). A rebuilt or new
oil pump, or kit shall be supplied or fitted as
appropriate.
LONG BLOCK ASSEMBLY INSPECTION









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Condition Code Procedure
Internal component failure
(any component) ........ A ........... (1) Require repair or
replacement of the long
block assembly.
( 1) - It is Required that all other failure related components
be inspected for cause and condition. Additional components
or assemblies may be Suggested for repair or replacement
such as a water pump on a short block (reason code 4,
technician's recommendation based on substantial and
informed experience).
Example:
If there is a failed head gasket with an external coolant
leak, in addition to Requiring replacement of the head
gasket, inspection of the following for cause and
condition is Required: Block, Cooling System, Cylinder
Head. It may be Suggested that additional inspections be
performed, such as the other head gasket on a V-type
engine.









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SHORT BLOCK ASSEMBLIES
NOTE: A Short Block Assembly is a cylinder block and all those
components contained within the limits of the block deck
or decks, the pan rail, the block rear face and the
timing cover (where fitted), including the crankshaft.
SHORT BLOCK ASSEMBLY INSPECTION









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Condition Code Procedure
Any internal component
failure ................ A ........... ( 1) Require repair or
replacement of the short
block assembly.
( 1) - It is Required that all other failure related components
be inspected for cause and condition. Additional
components or assemblies may be Suggested for repair or
replacement, such as a water pump on a short block
(reason code 4, technician's recommendation based on
substantial and informed experience).
Example:
If there is a failed head gasket with an external coolant
leak, in addition to Requiring replacement of the head
gasket, inspection of the following for cause and condition
is Required: Block, Cooling System, Cylinder Head. It may
be Suggested that additional inspections be performed,
such as the other head gasket on a V-type engine.









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