1998 MITSUBISHI MONTERO torque

except Eclipse 2.0L non-turbo and Montero. On Eclipse 2.0L non-turbo,
resistance should not exceed 8000 ohms. On Montero, resistance should
not exceed 26,000 ohms.
SPARK PLUGS
SPARK PLUG TYPE TABLE








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Application (1) Nippondenso No.
1.5L (VIN A) ................................... W16EPR-11
1.8L (VIN C) ................................... K16PR-U11
2.0L (VIN F) ......................... W20ETR-L8 Or W20EPR
2.0L (VIN Y) .................................. ( 2) RC9YC5
2.4L (VIN G) ................................... K16PR-U11
3.0L
(VIN H) ....................................... W16EPR11
(VIN J, K & P) .............................. PK20PR-P11
3.5L
(VIN P) ...................................... PK20PR-11
(VIN M) ..................................... PK16PR-P11
( 1) - See A - ENGINE/VIN ID article for VIN information.
( 2) - Champion Spark Plug.









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SPARK PLUG SPECIFICATIONS TABLE








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Application (1) Gap In. (mm) Torque Ft. Lbs. (N.m)
Diamante ....... .039-.043 (1.0-1.1) ..... 15-21 (20-30)
Eclipse 2.0L
Non-Turbo .... .048-.053 (1.2-1.4) ........... 20 (28)
Turbo ........ .028-.031 (.7-.8) ............. 18 (25)
All Others ..... .039-.043 (1.0-1.1) ........... 18 (25)
( 1) - DO NOT adjust gap on Platinum spark plugs.









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FIRING ORDER
Fig. 1: Firing Order Firing Order (4-Cylinder)

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.

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)\

Check ring gear, pinion and side gears for wear or damage. Replace
components as necessary.
Reassembly & Adjustments
1) Place side gear thrust spacers behind side gears, in
original position. Assemble side gears in differential case. Install
pinion gears and washers. Rotate pinion gears to mesh with side gears.
2) Install pinion shaft without lock pin. Check pinion and
side gear backlash. Install wooden wedge to lock side gears. Using
dial indicator, measure gear backlash. See Fig. 5.
3) Backlash must be within specification. See
PINION & SIDE GEAR BACKLASH SPECIFICATIONS table. Adjust backlash by
using different side gear spacers. Ensure both sides are equally
shimmed. If backlash cannot be adjusted within specifications, replace
side and pinion gears as matched set.
4) Install pinion shaft lock pin. Using a punch, securely
stake lock pin in 2 places. Ensure adhesive is removed from ring gear
mounting bolts and gear mounting surface. Clean internal threads with
tap.
5) Install ring gear on differential case. Ensure alignment
marks on differential case and ring gear are aligned. Apply Loctite
271 to bolts and install bolts. Tighten bolts alternately in diagonal
sequence to specification. See TORQUE SPECIFICATIONS.
PINION & SIDE GEAR BACKLASH SPECIFICATIONS









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Application In. (mm)\
Standard ................................................ .003 (.08)\
Wear Limit .............................................. .008 (.20)\









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Fig. 5: Checking Pinion & Side Gear Backlash
Courtesy of Mitsubishi Motor Sales of America.
Drive Pinion Depth
1) Install pinion bearing races in carrier housing. Ensure

races are fully seated. Install Pinion Height Gauge (MB990901-01) with\
pinion bearings. See Fig. 6. DO NOT install oil seal.
2) Using INCH-lb. torque wrench, measure pinion rotating
torque. Gradually tighten pinion height gauge to increase rotating
torque to proper specification. See
PINION ROTATING TORQUE SPECIFICATIONS table. Install Cylinder Gauge
(MB990903-01). Ensure flat areas are aligned and that gauge contacts
carrier bearing bores firmly. See Fig. 6.
3) Select adjusting shim with same thickness as gap between
cylinder gauge and pinion height gauge. Use minimum amount of
adjusting shims. Install selected adjusting shims between drive pinion
gear and rear drive pinion bearing. Using Bearing Installer (MB990802-
01), install rear pinion bearing.
PINION ROTATING TORQUE SPECIFICATIONS









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Application INCH Lbs. (N.m)\
Oil Seal Not Installed
With Lubrication ............................... 1.3-2.2 (.15-.25)\
Without Lubrication ............................ 2.6-4.3 (.30-.50)\
Oil Seal Installed
With Lubrication ............................... 3.1-3.9 (.35-.45)\
Without Lubrication ............................ 4.3-6.1 (.50-.70)\









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Fig. 6: Setting Drive Pinion Depth
Courtesy of Mitsubishi Motor Sales of America.
Drive Pinion Preload
1) Install drive pinion in differential carrier. Install

spacer, pinion front shim(s) and front pinion bearing. DO NOT install
oil seal at this time. Install pinion companion flange, washer and
retaining nut. Tighten nut to 137 ft. lbs. (190 N.m).
2) Using INCH-lb. torque wrench, check pinion rotating torque
without pinion oil seal. See PINION ROTATING TORQUE SPECIFICATIONS
table. Adjust rotating torque by replacing drive pinion front shims or
spacer. Once correct rotating torque is obtained, install oil seal.
Coat seal lip with grease.
3) Install pinion flange so alignment marks are correct.
Apply light coat of grease to flange washer contact area. Install NEW
retaining nut. Check pinion rotating torque with pinion oil seal
installed. Rotating torque must be within specification. See
PINION ROTATING TORQUE SPECIFICATIONS table.
Side Bearing Installation
1) Using Bearing Installer (MB990802-01), install bearings o\
n
differential case. Select 2 side bearing adjusting shims thinner than
those removed. Shims must be equal in thickness on both sides. Install
shims on each side of case assembly. Install case assembly in
differential carrier housing.
2) Push case assembly fully to one side of carrier. Using 2
feeler gauges (feeler gauges 180 degrees opposed), measure clearance
between carrier and side bearing. Remove shims from one side of
differential carrier.
3) Measure thickness of shims removed. Add .002" (.05 mm) to\
50% of measured clearance and then add thickness measurement of
removed shim. This is thickness of new shim that should be installed
on each side of case. Install equal thickness shims on each side of
case assembly.
NOTE: Ensure zero clearance exists between gear carrier and
adjusting shim.
4) Install side bearing shims and differential case assembly
in differential carrier. Using brass drift, tap shims to fit them to
side bearing outer race. Install bearing caps. Tighten bolts to
specification. See TORQUE SPECIFICATIONS . Check ring gear backlash.
Ring Gear Backlash
1) Lock drive pinion in place. Using dial indicator, check
ring gear backlash at heel of ring gear tooth. Measure at 4 locations
of ring gear. Gear backlash should be .004-.006" (.10-.15 mm).
2) If backlash is not within specification, change side
bearing adjusting shims and recheck backlash. See
GEAR TOOTH CONTACT PATTERNS article in GENERAL INFORMATION. Check gear
tooth contact using Prussian Blue.
CAUTION: When changing shims, total thickness of all shims must
remain constant to ensure correct bearing preload.
Ring Gear Runout
Using dial indicator, measure runout at back side of ring
gear. Runout should not exceed .002" (.05 mm). If runout is excessive,\
change ring gear-to-differential case mounting position. Ensure ring
gear mounting bolts are tightened to correct specification. Recheck
runout. Install cover and gasket.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS








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Application Ft. Lbs. (N.m)\

TESTING & INSPECTION
AXLE SHAFT END PLAY
Montero & Montero Sport
Using dial indicator, check axle shaft end play. End play
should be .010" (.25 mm). If end play is not within specification,
replace axle bearing. See AXLE SHAFT OVERHAUL under OVERHAUL.
AXLE TOTAL BACKLASH
1) Raise and support rear axle. Place transmission in
Neutral. Apply parking brake. Rotate drive shaft clockwise. Place
reference marks on pinion dust cover and differential housing.
2) Rotate drive shaft counterclockwise, and measure distance
between reference marks. Differential must be removed and backlash
adjusted if distance exceeds 0.2" (5 mm). See RING GEAR BACK-LASH
procedure under DIFFERENTIAL ASSEMBLY (LIMITED SLIP) under OVERHAUL.
LIMITED SLIP DIFFERENTIAL PRELOAD
1) Place transmission in Neutral. Block front wheels. Raise
one rear wheel off ground and remove wheel. Release parking brake.
2) Using torque wrench and axle puller adapter, measure
starting torque while rotating wheel in forward direction. See Fig. 1.
Differential must be repaired if torque is less than 18 ft. lbs. (25
N.m).
Fig. 1: Testing Limited Slip Differential Preload
Courtesy of Mitsubishi Motor Sales of America.
LOCKING DIFFERENTIAL (MONTERO)
Air Pump