1998 MITSUBISHI MONTERO engine

B - EMISSION APPLICATION
1998 Mitsubishi Montero
1998 ENGINE PERFORMANCE
Mitsubishi - Emission Applications
Diamante, Eclipse/Spyder, Galant, Mirage, Montero/Sport,
3000GT
EMISSION APPLICATIONS
EMISSION APPLICATIONS TABLE








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Model, Engine & Fuel System Emission Control Systems/Devices
Diamante
3.5L V6 SFI
Major Control Systems/Devices .... PCV, EVAP, TWC, FR, EGR, SPK,
( 1) HO2S, CEC, MIL
Components/Other Related Devices ........... EVAP-CPCS, EVAP-VC,
EVAP-VSOL, EGR-CS, EGR-VCV, SPK-CC
Eclipse
2.0L 4-Cyl. SFI
Non-Turbo
Major Control Systems/Devices ....... PCV, EVAP, TWC, FR, EGR,
SPK, ( 1) HO2S, CEC, MIL
Components/Other Related Devices ......... EVAP-CPCS, EVAP-VC,
EVAP-VSOL, EGR-TS, SPK-CC
Turbo
Major Control Systems/Devices PCV, EVAP, TWC, FR, EGR,
SPK, ( 1) HO2S, CEC, MIL
Components/Other Related Devices .... (2) EVAP-CKV, EVAP-CPCS,
EVAP-CPCV, EVAP-VC, EVAP-VSOL, EGR-SOL, SPK-CC
Eclipse Spyder
2.0L 4-Cyl. Turbo SFI
Major Control Systems/Devices ......... PCV, EVAP, TWC, FR, EGR,
SPK, ( 1) HO2S, CEC, MIL
Components/Other Related Devices ..... (2) EVAP-CKV, EVAP-CPCS,
EVAP-CPCV, EVAP-VC, EVAP-VSOL, EGR-SOL, SPK-CC
2.4L 4-Cyl. SFI
Major Control Systems/Devices ......... PCV, EVAP, TWC, FR, EGR,
SPK, ( 1) HO2S, CEC, MIL
Components/Other Related Devices ........... EVAP-CPCS, EVAP-VC,
EVAP-VSOL, EGR-SOL, EGR-VCV, SPK-CC
Galant
2.4L 4-Cyl. SFI
Major Control Systems/Devices .......... PCV, EVAP, (3) TWC, FR,
( 4) EGR, SPK, ( 1) HO2S, CEC, MIL
Components/Other Related Devices ........... EVAP-CPCS, EVAP-VC,
EVAP-VSOL, ( 4) EGR-CS, ( 4) EGR-VCV, SPK-CC
Mirage
1.5L 4-Cyl. SFI
Major Control Systems/Devices .......... PCV, EVAP, (3) TWC, FR,
EGR, SPK, ( 1) HO2S, CEC, MIL
Components/Other Related Devices ........... EVAP-CPCS, EVAP-VC,
EVAP-VSOL, EGR-SOL, EGR-VCV, SPK-CC
1.8L 4-Cyl. SFI
Major Control Systems/Devices .... PCV, EVAP, TWC, FR, EGR, SPK,
( 1) HO2S, CEC, MIL
Components/Other Related Devices ........... EVAP-CPCS, EVAP-VC,
EVAP-VSOL, EGR-SOL, EGR-VCV, SPK-CC
Montero
3.5L V6 SFI

Major Control Systems/Devices ..... PCV, EVAP, (5) TWC, ( 4) EGR,
FR, SPK, ( 6) ( 7) HO2S, CEC, MIL
Components/Other Related Devices ........... EVAP-CPCS, EVAP-VC,
EVAP-VSOL, ( 4) EGR-SOL, ( 4) EGR-VCV, SPK-CC
Montero Sport
2.4L 4-Cyl. SFI
Major Control Systems/Devices ..... PCV, EVAP, TWC, FR, ( 4) EGR,
SPK, ( 1) HO2S, CEC, MIL
Components/Other Related Devices ........... EVAP-CPCS, EVAP-VC,
EVAP-VSOL, ( 4) EGR-SOL, ( 4) EGR-VCV, SPK-CC
3.0L V6 SFI
Major Control Systems/Devices ..... PCV, EVAP, TWC, (4) EGR, FR,
SPK, ( 6) ( 7) HO2S, CEC, MIL
Components/Other Related Devices ........... EVAP-CPCS, EVAP-VC,
EVAP-VCS, EVAP-VSOL, ( 4) EGR-VCS, SPK-CC
3000GT
3.0L V6 SFI
Non-Turbo
Major Control Systems/Devices ........ PCV, EVAP, (8) TWC, FR,
EGR, SPK, ( 9) HO2S, CEC, MIL
Components/Other Related Devices ......... EVAP-CPCS, EVAP-VC,
EGR-SOL, EGR-VCV, SPK-CC
Turbo
Major Control Systems/Devices ........ PCV, EVAP, (8) TWC, FR,
EGR, SPK, ( 9) HO2S, CEC, MIL
Components/Other Related Devices ........ EVAP-CKV, EVAP-CPCS,
EVAP-VC, EGR-SOL, EGR-VCV, SPK-CC
( 1) - Equipped with 2 HO2Ss.
( 2) - Equipped with 2 EVAP-CKVs.
( 3) - California equipped with 2 TWCs.
( 4) - Federal.
( 5) - California equipped with 3 TWCs.
( 6) - Federal equipped with 2 HO2Ss.
( 7) - California equipped with 4 HO2Ss.
( 8) - Equipped with 3 TWCs.
( 9) - Equipped with 4 HO2Ss.









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NOTE: California or Federal refers to installed emissions
equipment. California emissions models may be available in
all states.
APPLICATION ABBREIVEATIONS
APPLICATION ABBREIVEATIONS TABLE








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Application Abbreiveation
CEC .................................... Computerized Engine Control
EGR ...................................... Exhaust Gas Recirculation
EGR-CS ........................................ EGR Control Solenoid
EGR-SOL ............................................... EGR Solenoid
EGR-TS ..................................... EGR Transducer Solenoid
EGR-VCV ................................... EGR Vacuum Control Valve
EVAP ....................................... Fuel Evaporative System
EVAP-CKV .......................................... EVAP Check Valve
EVAP-CPCS ..................... EVAP Canister Purge Control Solenoid
EVAP-CPCV ........................ EVAP Canister Purge Control Valve
EVAP-VC ........................................ EVAP Vapor Canister
EVAP-VCS .............................. EVAP Vacuum Control Solenoid
EVAP-VSOL ................................ EVAP Ventilation Solenoid

SHOE HARDWARE
SHOES
SOCKETS
SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)
STEEL BRAKE LINES
STOPLIGHT SWITCHES
SWITCHES
TIRES
TOOTHED RINGS (TONE WHEEL)
VACUUM BOOSTERS
VACUUM HOSES
VALVES
WHEEL ATTACHING HARDWARE
WHEEL BEARINGS, RACES AND SEALS
WHEEL CYLINDERS
WIRING HARNESSES
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW OF MOTORIST ASSURANCE PROGRAM
The Motorist Assurance Program is the consumer outreach
effort of the Automotive Maintenance and Repair Association, Inc.
(AMRA). Participation in the Motorist Assurance Program is drawn from
retailers, suppliers, independent repair facilities, vehicle
manufacturers and industry associations.
Our organization's mission is to strengthen the relationship
between the consumer and the auto repair industry. We produce
materials that give motorists the information and encouragement to
take greater responsibility for their vehicles-through proper,
manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt:\
1) a Pledge of Assurance to their Customers and
2) the Motorist Assurance Program Standards of Service.
All participating service providers have agreed to subscribe
to this Pledge and to adhere to the promulgated Standards of Service
demonstrating to their customers that they are serious about customer
satisfaction.
These Standards of Service require that an inspection of the
vehicle's (problem) system be made and the results communicated to the\
customer according to industry standards. Given that the industry did
not have such standards, the Motorist Assurance Program successfully
promulgated industry inspection communication standards in 1994-95 for
the following systems: Exhaust, Brakes, ABS, Steering and Suspension,
Engine Maintenance and Performance, HVAC, and Electrical Systems.
Further, revisions to all of these inspection communication standards
are continually re-published. In addition to these, standards for
Drive Train and Transmissions have recently been promulgated.
Participating shops utilize these Uniform Inspection & Communication
Standards as part of the inspection process and for communicating
their findings to their customers.
The Motorist Assurance Program continues to work
cooperatively and proactively with government agencies and consumer
groups toward solutions that both benefit the customer and are
mutually acceptable to both regulators and industry. We maintain the
belief that industry must retain control over how we conduct our
business, and we must be viewed as part of the solution and not part
of the problem. Meetings with state and other government officials
(and their representatives), concerned with auto repair and/or
consumer protection, are conducted. Feedback from these sessions is
brought back to the association, and the program adjusted as needed.
To assure auto repair customers recourse if they were not

satisfied with a repair transaction, the Motorist Assurance Program
offers mediation and arbitration through MAP/BBB-CARE and other non-
profit organizations. MAP conducted pilot programs in twelve states
before announcing the program nationally in October, 1998. During the
pilots, participating repair shops demonstrated their adherence to the
Pledge and Standards and agreed to follow the UICS in communicating
the results of their inspection to their customers. To put some
"teeth" in the program, an accreditation requirement for shops was
initiated. The requirements are stringent, and a self-policing method
has been incorporated which includes the "mystery shopping" of
outlets.
We welcome you to join us as we continue our outreach with
your support, both the automotive repair industry and your customers
will reap the benefits. Please visit MAP at our Internet site www.
motorist.org or contact us at:
1444 I Street, NW Suite 700
Washington, DC 20005
Phone (202) 712-9042 Fax (202) 216-9646
January 1999
MAP UNIFORM INSPECTION GENERAL GUIDELINES
OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS
It is MAP policy that all exhaust, brake, steering,
suspension, wheel alignment, drive-line, engine performance and
maintenance, and heating, ventilation and air conditioning, and
electrical services be offered and performed under the standards and
procedures specified in these sections.
Before any service is performed on a vehicle, an inspection
of the appropriate system must be performed. The results of this
inspection must be explained to the customer and documented on an
inspection form. The condition of the vehicle and its components will
indicate what services/part replacements may be "Required" or
"Suggested". In addition, suggestions may be made to satisfy the
requests expressed by the customer.
When a component is suggested or required to be repaired or
replaced, the decision to repair or replace must be made in the
customer's best interest, and at his or her choice given the options
available.
This section lists the various parts and conditions that
indicate a required or suggested service or part replacement.
Although this list is extensive, it is not fully inclusive. In
addition to this list, a technician may make a suggestion. However,
any suggestions must be based on substantial and informed experience,
or the vehicle manufacturer's recommended service interval and must be
documented.
Some conditions indicate that service or part replacement is
required because the part in question is no longer providing the
function for which it is intended, does not meet a vehicle
manufacturer's design specification or is missing.
Example:
An exhaust pipe has corroded severely and has a hole in it
through which exhaust gases are leaking. Replacement of the
exhaust pipe in this case is required due to functional
failure.
Example:
A brake rotor has been worn to the point where it measures
less than the vehicle manufacturer's discard specifications.

same axle to eliminate uneven braking behavior. Always wash drums
after servicing or before installing.
DRUM INSPECTION









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Condition Code Procedure
Balance weight missing .. .. ........ No service suggested or
required.
Bell-mouthed, affecting
performance ............ A ....... Require reconditioning or
replacement.
Cooling fin broken ...... .. ........ No service suggested or
required.
Cracked ................. B ............ Require replacement.
Drum diameter is greater
than OEM "machine to"
specifications but less
than "discard at"
specifications, and the
drum does not require
reconditioning ......... 1 ........ (1) Suggest replacement.
Drum diameter will exceed
OEM "machine to"
specifications after
required
reconditioning ......... B ........ ( 2) Require replacement.
Hard-spotted ............ 2 ....... Suggest reconditioning or
replacement.
Measured diameter is
greater than OEM discard
specifications ......... B ............ Require replacement.
Out-of-round (runout),
affecting performance .. A ....... Require reconditioning or
replacement.
Out-of-round (runout),
exceeding manufacturer's
specifications ......... B ....... Require reconditioning or
replacement.
Scored .................. B ....... Require reconditioning or
replacement.
Surface threaded due to
improper machining ..... B ....... Require reconditioning or
replacement.
Tapered, affecting
performance ............ A ....... Require reconditioning or
replacement.
( 1) - Only applies to vehicles for which OEM "machine to"
specifications exist. If OEM does not supply "machine to"
specifications, the drum may be worn to discard
specifications.
( 2) - If OEM does not supply "machine to" specifications, you
may machine to discard specifications.









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ELECTRICAL PUMPS AND MOTORS
Copied fuel pump conditions from engine UIGs & deleted
pulsator from leaking conditions.
ELECTRICAL PUMP AND MOTOR INSPECTION









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NOTE: Copied Vehicle Speed Sensors from Engine UIGs & added
Air Gap incorrect, loose, and wire lead misrouted. For
"contaminated" removed coolant & fuel examples from note.
SPEED SENSOR INSPECTION









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Condition Code Procedure
Air gap incorrect ....... B ....... (1) Require adjustment or
replacement.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware
threads damaged ........ A ... Require repair or replacement
of hardware.
Attaching hardware
threads stripped
(threads missing) ...... A .. Require repair or replacement
of hardware.
Connector broken ........ A .. Require repair or replacement.
Connector (Weatherpack
type) leaking ........... A .. Require repair or replacement.
Connector melted ........ A ........... ( 2) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Contaminated ............ A ........... ( 3) Require repair or
replacement.
Inoperative ............. B ........... ( 4) Require repair or
replacement. Further
inspection required.
Lead routing incorrect .. B ..... Require rerouting according
to vehicle manufacturer's
specifications.
Leaking ................. A .. Require repair or replacement.
Loose ................... A .. Require repair or replacement.
Missing ................. C ............ Require replacement.
Resistance out of
specification .......... B .. Require repair or replacement.
Sensor housing cracked .. 2 ............ Suggest replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned,
affecting performance .. A ........... ( 2) Require repair or
replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement.
Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Terminal loose,
affecting performance .. B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped
(threads missing) ...... A ............ Require replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Wire lead misrouted ..... B . Require re-routing according to
vehicle manufacturer's

Diamante, Eclipse,
Montero Sport & Galant .......................... 6.9-7.1 (175-181)\
Mirage ........................................... 6.4-6.6 (164-167)\
Montero .......................................... 7.3-7.5 (186-191)\
3000GT ........................................... 7.0-7.2 (177-182)\









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3) Tighten lock nut, and ensure brake pedal height is within
specification. Start engine to evacuate brake booster chamber. Stop
engine, and apply brake several times to remove vacuum from brake
booster.
4) Using hand pressure, depress brake pedal to measure free
play before resistance is felt. Free play distance for all models is
0.10-0.31" (3-8 mm). If distance is not within specification, it is
probably caused by excessive play between the brake pedal arm and the
clevis pin. Check and replace as necessary.
5) Start engine and apply 110 lbs. (490 N) of pressure to
brake pedal. With the carpet pulled back, measure the distance between
the brake pedal and the floorboard. If the distance is not 3.1-3.5"
(80-90 mm) check for air in brake hydraulic system, brake adjustment
or defective parking brake component or adjustment. Adjust or repair
as necessary.
LOAD-SENSING PROPORTIONING VALVE (LSPV)
Montero
1) Park vehicle on level surface. Remove excess weight from
vehicle. Make sure the lever is all the way towards the valve side.
Measure length of entire spring. See Fig. 1.
If spring length is not within specification, adjust spring
support until correct length is obtained. See LSPV SPRING LENGTH
table.
Fig. 1: Adjusting Load-Sensing Proportioning Valve Spring (Montero)
Courtesy of Mitsubishi Motor Sales of America.
BRAKE BOOSTER PUSH ROD

Fig. 3: Adjusting Brake Booster Push Rod Clearance
Courtesy of Mitshbishi Motor Sales of America.
Adjustment (Diamante)
1) Start engine and depress the brake pedal at least two