1998 MITSUBISHI MONTERO fuel pressure

DISTRIBUTOR
NOTE: Eclipse, Mirage 1.8L, Montero, Montero Sport 3.0L and 3000GT
DOHC use Distributorless Ignition System (DIS). All other
models use distributor type ignition systems with
non-serviceable distributors on which only the rotor and
distributor cap can be changed.
FUEL SYSTEM
* PLEASE READ THIS FIRST *
WARNING: Always relieve fuel pressure before disconnecting any fuel
injection-related component. DO NOT allow fuel to contact
engine or electrical components.
FUEL SYSTEM PRESSURE RELEASE
Relieving Fuel Pressure
1) On Diamante, disconnect fuel pump harness connector at
fuel tank from underneath vehicle. On Montero and Montero Sport,
remove cargo compartment carpet, remove access plate and disconnect
fuel pump harness connector. On all other models, remove rear seat
cushion and remove access plate (if required) to disconnect fuel pump
harness connector.
2) On all models, start engine. Let engine run until it
stops. Turn ignition off. Disconnect negative battery cable. Connect
fuel pump harness connector. Reinstall rear seat (if necessary.)
FUEL PUMP
Removal & Installation (Diamante, Eclipse, Galant & Montero)
1) Fuel pump assembly is located inside fuel tank. Release
fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove access panel
under seat, in trunk or in rear cargo area. Disconnect electrical
connectors and fuel hoses at fuel tank.
2) Remove fuel filler hose from fuel tank. Remove fuel pump
assembly. To install, reverse removal procedure. Tighten nuts to
specification. See TORQUE SPECIFICATIONS .
Removal & Installation (Mirage, Montero Sport & 3000GT)
1) Fuel pump assembly is located inside fuel tank. Release
fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Raise vehicle on
hoist. Drain fuel into suitable container. Disconnect electrical
connectors and breather/fuel hoses at fuel tank.
2) Remove fuel filler hose from fuel tank. Support fuel tank
with transmission jack. Remove nuts securing fuel tank. Remove fuel
tank from vehicle. Remove fuel pump assembly. To install, reverse
removal procedure. Tighten nuts to specification. See
TORQUE SPECIFICATIONS .
FUEL RAILS & INJECTORS
WARNING: Use a rag to cover fuel hose connection before disconnecting
high pressure fuel hose at fuel rail. Some residual fuel
pressure may still be in system.
CAUTION: DO NOT drop injectors while removing or installing fuel rail.
Removal (Diamante, Montero Sport 2.4L & 3000GT)

1) Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELEASE.
Disconnect negative battery cable. Drain coolant. Remove air intake
hose. Remove throttle body and gasket with control cables and vacuum
hoses attached.
2) Remove EGR pipe (if equipped). Disconnect power brake
hose. Label and disconnect vacuum hoses and wiring harness connectors
as necessary. Remove intake plenum brackets and mounting bolts. Remove
intake plenum and gasket.
3) Disconnect high pressure fuel hose at fuel rail.
Disconnect fuel return hose. Disconnect vacuum hoses. Disconnect
injector electrical connectors. Remove fuel rail bolts, and lift fuel
rail and injectors from engine. Injectors may be removed after fuel
rail is removed from intake manifold.
Installation
To install, reverse removal procedure. Use NEW insulators and
"O" rings when installing injectors. Install injectors into fuel rail
with a twisting motion. Ensure injectors rotate smoothly when
installing. Refill cooling system.
Removal (Eclipse, Galant, Mirage & Montero Sport 3.0L)
1) Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELEASE.
Disconnect negative battery cable. Disconnect PCV hose and breather
hoses. Disconnect high pressure fuel hose at fuel rail. Disconnect
fuel return hose and vacuum hoses.
2) Disconnect injector electrical connectors. Remove fuel
rail bolts, and lift fuel rail and injectors from engine. Injectors
may be removed after fuel rail is removed from intake manifold.
Installation
To install, reverse removal procedure. Use NEW insulators and
"O" rings when installing injectors. Use lubricant on "O" rings.
Install injectors into fuel rail with a twisting motion. Ensure
injectors rotate smoothly when installing.
Removal (Montero)
1) Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELEASE.
Disconnect negative battery cable. Remove air intake hose. Remove
accelerator cable adjusting bolts. On A/T models, remove throttle
control cable. On all models, remove accelerator cable. Label and
disconnect all vacuum hoses from throttle body and upper intake
manifold (air intake plenum).
2) Remove EGR pipe and gasket. Remove ignition coil (if
necessary). Remove engine oil filler neck bracket. Disconnect PCV
hose. Remove throttle body, leaving coolant hoses connected. Remove
throttle body gasket. Remove front and rear intake plenum brackets.
Remove intake plenum mounting bolts. Remove intake plenum and gasket.
3) Disconnect high pressure fuel hose at fuel rail.
Disconnect fuel return hose. Disconnect vacuum hoses. Disconnect
injector electrical connectors. Remove fuel rail bolts, and lift fuel
rail and injectors from engine. Injectors may be removed after fuel
rail is removed from intake manifold.
Installation
To install, reverse removal procedure. Use NEW insulators and
"O" rings when installing injectors. Use lubricant on "O" rings.
Install injectors into fuel rail using a twisting motion. Ensure
injectors rotate smoothly when installing. Adjust throttle control and
accelerator cables (if necessary). Refill cooling system.
HEATED OXYGEN SENSOR (HO2S)
Removal & Installation

1) Front HO2S is mounted in exhaust pipe below exhaust
header. Rear HO2S is mounted behind catalytic converter. HO2S is
equipped with a permanent pigtail which must be protected from damage
when HO2S is removed. Ensure HO2S is free of contaminants. Avoid using
cleaning solvents of any type.
2) HO2S may be difficult to remove when engine temperature is
less than 120
F (48C). If using original sensor, always use anti-
seize compound on threads before installation. New sensor threads are
precoated with anti-seize. Tighten HO2S to specification. See
TORQUE SPECIFICATIONS .
THROTTLE BODY
Removal
1) Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELEASE.
Drain enough coolant to ensure coolant level is below throttle body.
Disconnect air intake hose.
2) Remove accelerator, cruise control and A/T throttle valve
cables (if equipped). Disconnect fuel vapor hose, electrical harness
connector, vacuum hose and coolant hoses. Remove throttle body
retaining bolts.
Disassembly
Remove throttle position sensor. Remove idle air control
motor. Remove throttle bracket and connector bracket (if equipped).
Remove idle position switch and adjusting nut (if equipped).
CAUTION: DO NOT remove throttle valve. DO NOT use cleaning solvents
on throttle position sensor, idle air control motor or idle
position switch.
Cleaning
1) Clean all parts except throttle position sensor, idle air
control motor and idle position switch in solvent.
WARNING: Safety glasses MUST be worn whenever compressed air is used
for parts cleaning.
2) Check vacuum port and passage for clogging. Clean vacuum,
vapor and fuel passages using compressed air.
Reassembly
To reassemble, reverse disassembly procedure.
Installation
To install, reverse removal procedure.
THROTTLE POSITION (TP) SENSOR
Removal & Installation
Throttle Position (TP) sensor is located on throttle body.
Disconnect TP sensor electrical connector. Remove TP sensor screws and
TP sensor. To install, reverse removal procedure. Tighten TP sensor
screws to specification. See TORQUE SPECIFICATIONS. For TP sensor
adjustment procedure, see D - ADJUSTMENTS article.
TURBOCHARGERS
Removal (Eclipse)
1) Disconnect negative battery cable. Drain engine coolant
and oil. On models equipped with A/C, remove condenser fan motor
assembly. Remove front heated oxygen sensor. Remove oil dipstick guide
and "O" ring.

2) Disconnect air intake hose and vacuum hoses. Remove air
hose and air outlet housing. Remove heat protectors. Disconnect
exhaust pipe. Remove power steering oil pump and bracket. Remove
engine hanger bracket. Disconnect oil inlet pipe.
3) Disconnect engine coolant hoses and tubes from
turbocharger. Remove exhaust manifold nuts and bolts. Remove exhaust
manifold and gaskets. Disconnect oil pressure and return pipes. Remove
turbocharger and exhaust manifold assembly. Separate turbocharger from
exhaust manifold.
Removal (3000GT - Front)
1) Disconnect negative battery cable. Drain engine oil and
coolant. Remove radiator. Disconnect exhaust pipe. Remove air intake
hose, air hoses and air pipe. Remove generator and belt. Remove oil
dipstick guide.
2) Remove heat protector. Disconnect front heated oxygen
sensor connector. Remove oil return pipe. Remove turbocharger support
bracket, and remove turbocharger from exhaust manifold.
Removal (3000GT - Rear)
1) Disconnect battery cables, and remove battery. Drain
engine oil and cooling system. Remove accelerator cable. Remove air
hose, air pipe and heat protectors. Disconnect clutch booster vacuum
hose. Remove air intake hoses and EGR pipe. Disconnect heated oxygen
sensor connectors.
2) Remove oil pipe and EGR valve. Disconnect exhaust fitting,
and remove rear heat protector. Remove oil return pipe. Remove
turbocharger assembly.
Inspection (All Models)
Check turbine and compressor wheels for cracking and other
damage. Ensure turbine and compressor wheels turn smoothly. Check for
oil leakage from turbocharger assembly. Check for proper wastegate
valve operation. See I - SYSTEM/COMPONENT TESTS article.
CAUTION: Apply light coat of oil to inner surface of flared area on
water pipe (flare nut fitting) before connecting to engine.
Installation (All Models)
1) To install, reverse removal procedure. Before oil pipe
flare nut (above turbocharger) is installed, pour clean engine oil
into turbocharger oil pipe installation hole. Ensure oil and air hoses
are properly installed and securely clamped.
2) Use NEW gaskets. Adjust accelerator cable (if necessary).\
Refill engine oil and coolant. Check for oil and coolant leaks.
Tighten all bolts to specification. See TORQUE SPECIFICATIONS.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLE








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Applications Ft. Lbs. (N.m)
Coolant Pipe-To-Turbocharger Banjo Bolt .......... 31 (42)
EGR Valve ........................................ 16 (22)
Engine Coolant Temperature Sensor ................ 22 (30)
Exhaust Manifold-To-Engine Nuts ............ 18-21 (24-29)
Exhaust Manifold-To-Turbocharger Bolts ..... 40-47 (54-64)
Exhaust Pipe Bolts ......................... 21-36 (29-49)
Fuel Filter Line ................................. 27 (36)
Fuel Tank Drain Plug ....................... 11-18 (15-24)
Fuel Tank Nuts ............................. 15-21 (20-29)

Heated Oxygen Sensor
Front .................................... 29-33 (39-44)
Rear ..................................... 15-29 (20-39)
Heat Protector Bolts .................. 8.8-11 (12.0-15.0)
Intake Manifold Plenum Bolt/Nut .................. 13 (18)
Knock Sensor ............................... 15-18 (20-24)
Oil Return Pipe-To-Engine .................. 10-14 (14-19)
Oil Supply Pipe-To-Engine Nut .................... 14 (19)
Oil Supply Pipe-To-Turbocharger Nut .............. 14 (19)
Plenum-To-Intake Manifold Bolts ............ 11-15 (15-20)
Throttle Body .................................... 14 (19)
Turbocharger-To-Exhaust Manifold Bolt/Nut
Step 1 ......................................... 21 (29)
Step 2 ........................ Additional 60-70 Degrees
Water Pipe-To-Turbocharger
Eclipse .................................. 25-36 (34-49)
3000GT ......................................... 22 (30)
INCH Lbs. (N.m)
Camshaft Position Sensor .......................... 80 (9)
Crankshaft Position Sensor ........................ 80 (9)
Distributor Hold-Down Bolt ...................... 106 (12)
Engine Cover ............................. 22-40 (2.5-4.5)
Fuel Pressure Regulator ........................... 80 (9)
Fuel Pump Nuts .................................. 22 (2.5)
Fuel Rail Bolts ....................... 80-106 (9.0-12.0)
TP Sensor Screws ......................... 13-22 (1.5-2.5)
Wastegate Actuator Bolts ............... 80-106 (9.0-12.0)









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in the section(s) you are accessing.
BASIC GASOLINE ENGINE - MECHANICAL TROUBLE SHOOTING CHART









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CONDITION POSSIBLE CAUSE CORRECTION








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Engine Lopes At Intake manifold-to-head Replace manifold
Idle leaks gasket, See ENGINES
Blown head gasket Replace head gasket,
See ENGINES
Worn timing gears, chain Replace gears, chain or
or sprocket sprocket
Worn camshaft lobes Replace camshaft, See
ENGINES
Overheated engine Check cooling system,
See COOLING
Blocked crankcase vent Remove restriction
valve
Leaking EGR valve Repair leak and/or
replace valve
Faulty fuel pump Replace fuel pump









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Engine Has Low Leaking fuel pump Repair leak and/or
Power replace fuel pump
Excessive piston-to-bore Install larger pistons,
clearance See ENGINES
Sticking valves or weak Check valve train
valve springs components, See ENGINES
Incorrect valve timing Reset valve timing, See
ENGINES
Worn camshaft lobes Replace camshaft, See
ENGINES
Blown head gasket Replace head gasket.
See ENGINES.
Clutch slipping Adjust pedal and/or
replace components, See
ENGINES
Engine overheating Check cooling system,
See COOLING
Auto. Trans. pressure
regulator valve faulty Replace pressure
regulator valve
Auto. Trans. fluid level Add fluid as necessary
too low
Improper vacuum diverter
valve operation Replace vacuum diverter
valve
Vacuum leaks Inspect vacuum system
and repair as required
Leaking piston rings Replace piston rings,
See ENGINES









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Faulty High Low fuel pump volume Replace fuel pump
Speed Operation
Leaking valves or worn Replace valves and/or
springs, See ENGINES
Incorrect valve timing Reset valve timing,See
ENGINES
Intake manifold restricted Remove restriction
Worn distributor shaft Replace distributor









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Faulty Improper fuel pump stroke Remove pump and reset
Acceleration pump stroke

Incorrect ignition timing Reset ignition timing,
See TUNE-UP
Leaking valves Replace valves, See
ENGINES
Worn fuel pump diaphragm Replace diaphragm or
or piston piston









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Intake Backfire Improper ignition timing Reset ignition timing,
See TUNE-UP
Faulty accelerator pump Replace accelerator
discharge pump
Improper choke operation Check choke and adjust
as required
Defective EGR valve Replace EGR valve
Fuel mixture too lean Reset air/fuel mixture,
See TUNE-UP
Choke valve initial Reset choke valve
clearance too large initial clearance









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Exhaust Backfire Vacuum leak Inspect and repair
vacuum system
Faulty vacuum diverter Replace vacuum diverter
valve valve
Faulty choke operation Check choke and adjust
as required
Exhaust system leak repair exhaust system
leak









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Engine Ignition timing too far Reset ignition timing,
Detonation advanced See TUNE-UP
Faulty ignition system Check ignition timing,
See TUNE-UP
Spark plugs loose or Retighten or replace
faulty plugs
Fuel delivery system Inspect lines, pump and
clogged filter for clog
EGR valve inoperative Replace EGR valve
PCV system inoperative Inspect and/or replace
hoses or valve
Vacuum leaks Check vacuum system and
repair leaks
Excessive combustion
chamber deposits Remove built-up
deposits
Leaking, sticking or Inspect and/or replace
broken valves valves









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External Oil Fuel pump improperly seated Remove pump, replace
Leakage or worn gasket gasket and seat
properly
Oil pan gasket broken or Straighten pan and
pan bent replace gasket
Timing chain cover gasket Replace timing chain
broken cover gasket
Rear main oil seal worn Replace rear main oil
seal
Oil pan drain plug not Remove and reinstall
seated properly drain plug
Camshaft bearing drain Remove restriction
hole blocked
Oil pressure sending Remove and reinstall
switch leaking sending switch









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Air in fuel system Bleed air from system
Incorrect or contaminated Replace fuel
fuel
Injector nozzle malfunction Check nozzles, see
FUEL SYSTEMS









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Engines Starts Injection pump timing Reset pump timing, see
and Idles Rough incorrect FUEL SYSTEMS
W/out Smoke or Engine not fully broken in Put more miles on
Noise, But Clears engine
After Warm-Up Air in system Bleed air from system
Injector nozzle malfunction Check nozzles, see
FUEL SYSTEMS









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Engine Idles Blocked fuel filter Replace fuel filter
Correctly, Injection pump timing Reset pump timing, see
Misfires Above incorrect FUEL SYSTEMS
Idle Incorrect or contaminated Replace fuel
fuel









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Engine Won't Fast idle adjustment Reset fast idle, see
Return To Idle incorrect TUNE-UP
Internal injection pump Replace injection pump,
malfunction see FUEL SYSTEMS
External linkage binding Check linkage and
remove binding









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Fuel Leaks On Loose or broken fuel line Check lines and
Ground connections
Internal injection pump Replace injection pump,
seal leak see FUEL SYSTEMS









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Cylinder Injector nozzles sticking Test injectors, see
Knocking Noise open FUEL SYSTEMS
Very low nozzle opening Test injectors and/or
pressure replace









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Loss of Engine Restricted air intake Remove restriction
Power EGR valve malfunction Replace EGR valve
Blocked or damaged exhaust Remove restriction
system and/or replace
components
Blocked fuel tank filter Replace filter
Restricted fuel filter Remove restriction
and/or replace filter
Block vent in gas cap Remove restriction
and/or replace cap
Tank-to-injection pump fuel Check fuel lines and
supply blocked connections
Blocked fuel return system Remove restriction
Incorrect or contaminated Replace fuel
fuel
Blocked injector nozzles Check nozzle for
blockage, see FUEL
SYSTEMS
Low compression Check valves, rings,
pistons, see ENGINES









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Loud Engine Basic timing incorrect Reset timing, see
Noise With Black FUEL SYSTEMS
Smoke EGR valve malfunction Replace EGR valve
Internal injection pump Replace injection pump,
malfunction see FUEL SYSTEMS