1998 MITSUBISHI MONTERO battery

replacement of part.
(2) - Determine source of contamination, such as engine coolant,
fuel, metal particles, or water. Require repair or
replacement.
( 3) - Inoperative includes intermittent operation or out of
OEM specification. Some components may be serviceable;
check for accepted cleaning procedure.









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BATTERIES
Proper operation of any electrical system or component can be
affected by battery condition. The battery(ies) must meet or exceed
minimum specification for vehicle as equipped and test to that
specific battery's CCA.
Definition of Terms
* Battery Performance Testing
Testing that determines whether or not a battery meets both
vehicle OEM and battery manufacturer's specifications.
* Cold Cranking Amp (CCA) Rating
The number of amperes a new, fully charged battery at
0
 F (-17.8 C) can deliver for 30 seconds and maintain at
least a voltage of 1.2 volts per cell (7.2 volts for a
12-volt battery).
* Cranking Amps (CA)
The number of amperes a new, fully charged battery, typically
at 32
 F (0 C) can deliver for 30 seconds and maintain at
least a voltage of 1.2 volts per cell (7.2 volts for a
12-volt battery).
* OEM Cranking Amps
The minimum CCA required by the original vehicle manufacturer
for a specific vehicle.
BATTERY INSPECTION









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Condition Code Procedure
Battery frozen .......... .. ......... ( 1) Further inspection
required.
Case leaking ............ A ............ Require replacement.
Casing swollen .......... A .......... ( 2) Further inspection
required.
Circuit open internally . A ............ Require replacement.
Electrolyte
contamination .......... A .......... ( 2) Further inspection
required.
Electrolyte
discoloration .......... A .......... ( 2) Further inspection
required.
Fails to accept and
hold charge ............ A ........ ( 3) Require replacement.
Fluid level low ......... B .......... ( 4) Further inspection
required.
Out of performance
specification
for battery ............ B ........ ( 5) Require replacement.
Out of specification for
application ............ B ........ ( 5) Require replacement.

Post (top or side) burned,
affecting performance .. A ........... (6) Require repair or
replacement.
Post (top or side) burned,
not affecting
performance ............ 2 ........... ( 6) Suggest repair or
replacement.
Post (top or side)
corroded, affecting
performance ............ A ................. Require repair.
Post (top or side)
corroded, not affecting
performance ............ 2 ................. Suggest repair.
Post (top or side)
loose .................. A ............ Require replacement.
Post (top or side)
melted, affecting
performance ............ A ........... ( 6) Require repair or
replacement.
Post (top or side)
melted, not affecting
performance ............ 2 ........... ( 6) Suggest repair or
replacement.
Specific gravity low .... B .......... ( 7) Further inspection
required.
State of charge low ..... A .......... ( 7) Further inspection
required.
Top dirty ............... 2 ....... Suggest cleaning battery.
Top wet ................. A ... ( 8) Require cleaning battery.
Further inspection required.
Vent cap loose .......... A ... Require repair or replacement
of vent cap.
Vent cap missing ........ C ..... Require replacement of vent
cap.
( 1) - DO NOT attempt to charge a frozen battery. Allow
battery to warm thoroughly and then performance-test.
If battery fails performance test, require replacement.
( 2) - No service suggested or required unless the battery
fails performance test, in which case, require
replacement.
( 3) - This phrase refers to a battery that fails to either
accept and/or retain a charge using appropriate times
listed in the Battery Charging Guide of the BCI Service
Manual, battery charger operating manual, or battery
manufacturer's specifications.
( 4) - Determine cause of low fluid level. Refill to proper
level(s) with water (distilled water preferred).
Recharge battery and performance-test.
( 5) - The battery may meet battery manufacturer's
specifications but test below the minimum
specification defined by the vehicle's OEM for
that vehicle.
( 6) - Determine cause and correct prior to repair or
replacement of part.
( 7) - Recharge and test to manufacturer's specifications.
If battery fails performance test, require replacement.
( 8) - Check fluid level and adjust to manufacturer's
specification. Suggest checking charging system
for proper operation.









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BATTERY CABLES, WIRES AND CONNECTORS

BATTERY CABLE, WIRE AND CONNECTOR INSPECTION








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Condition Code Procedure
Application incorrect ... B .. Require repair or replacement.
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.
Connector broken ........ A .. Require repair or replacement.
Connector melted ........ A ........... (1) Require repair or
replacement.
Connector missing ....... C ............ Require replacement.
Insulation damaged,
conductors exposed ..... A ........... ( 2) Require repair or
replacement.
Insulation damaged,
conductors not exposed . 1 ............ Suggest replacement.
Open .................... A .. Require repair or replacement.
Protective shield
(conduit) melted ....... 2 ........... ( 1) Suggest repair or
replacement.
Protective shield
(conduit) missing ...... 2 .. Suggest repair or replacement.
Resistance (voltage drop)
out of specification ... A .. Require repair or replacement.
Routed incorrectly ...... B ................. Require repair.
Secured incorrectly ..... B ................. Require repair.
Shorted ................. A .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A ........... ( 1) 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.
Voltage drop out of
specification .......... A .. Require repair or replacement.
( 1) - Determine cause and correct prior to repair or
replacement of part.
( 2) - Exposed conductor at replacement (aftermarket) terminal
end does not require repair or replacement.









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BATTERY CONNECTORS
See BATTERY CABLES, WIRES AND CONNECTORS .
BATTERY TRAYS AND HOLD DOWN HARDWARE

BATTERY TRAY AND HOLD DOWN HARDWARE INSPECTION








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Condition Code Procedure
Battery improperly
secured ................ 2 ................. Suggest repair.
Bent, affecting
performance ............ A .. Require repair or replacement.
Bent, not affecting
performance ............ .. ....... No service suggested or
required.
Broken, affecting
performance ............ A .. Require repair or replacement.
Broken, not affecting
performance ............ .. ....... No service suggested or
required.
Corroded, affecting
performance ............ A .. Require repair or replacement.
Corroded, not affecting
performance ............ 2 .. Suggest repair or replacement.
Cracked, affecting
performance ............ A .. Require repair or replacement.
Cracked, not affecting
performance ............ 1 .. Suggest repair or replacement.
Missing ................. C ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Water drain clogged ..... A ................. Require repair.









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BATTERY WIRES
See BATTERY CABLES, WIRES AND CONNECTORS .
BELT-DRIVEN AIR PUMPS
BELT-DRIVEN AIR PUMP 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.
Inoperative ............. A ........ ( 1) Require replacement.
Leaking ................. A ............ Require replacement.
Missing ................. C ............ Require replacement.
Noisy ................... 2 ............ Suggest replacement.
Pulley alignment
incorrect .............. B .. Require repair or replacement.
Pulley bent ............. A ............ Require replacement.
Pulley cracked .......... A ............ Require replacement.
Pulley loose ............ A .. Require repair or replacement.
Pulley missing .......... C ............ Require replacement.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads

2.0L
(VIN F) ........................................ 8.5:1
(VIN Y) ........................................ 9.6:1
2.4L (VIN G) ..................................... 9.5:1
3.0L
(VIN H) ........................................ 8.9:1
(VIN J) ....................................... 10.0:1
(VIN K) ........................................ 8.0:1
(VIN P) ........................................ 9.0:1
3.5L (VIN M & P) ................................. 9.0:1
Compression Pressure
1.5L (VIN A) ..................... 192 psi (13.4 kg/cm
)
1.8L (VIN C) ..................... 199 psi (13.9 kg/cm)
2.0L (VIN F) ..................... 178 psi (12.5 kg/cm)
2.0L (VIN Y) ............ 170-225 psi (11.7-15.5 kg/cm)
2.4L (VIN G) ..................... 192 psi (13.4 kg/cm)
3.0L
(VIN H & P) .................... 171 psi (12.0 kg/cm
)
(VIN J) ........................ 185 psi (13.0 kg/cm)
(VIN K) ........................ 156 psi (10.9 kg/cm)
3.5L (VIN M & P) ................. 171 psi (12.0 kg/cm)
Maximum Variation
Between Cylinders ( 2) ............... 14 psi (1.0 kg/cm
)
( 1) - See A - ENGINE/VIN ID article for VIN information.
( 2) - On Eclipse 2.0L non-turbo engine, maximum variation
between cylinders is 25%.









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Exhaust System Backpressure
The exhaust system can be tested with a vacuum or pressure
gauge. If using a pressure gauge, remove HO2S or air injection check
valve (if equipped). Connect a 0-5 psi pressure gauge and run engine
at 2500 RPM. If exhaust system backpressure is greater than 2 psi,
exhaust system or catalytic converter is plugged.
If using a vacuum gauge, connect vacuum gauge hose to intake
manifold vacuum port. Start engine. Observe vacuum gauge. Open
throttle part way and hold steady. If vacuum gauge indication slowly
drops after stabilizing, inspect exhaust system for restriction.
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.
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, remove access plate (if required) and 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. Install rear seat and/or carpet as
necessary.
WARNING: Before disconnecting high pressure fuel hose at fuel

delivery pipe, cover fuel hose connection with a rag. Some
residual fuel pressure may still be in system.
FUEL PRESSURE
1) Relieve fuel pressure. See RELIEVING FUEL PRESSURE. On
models with fuel rail service valve, connect fuel pressure gauge to
fuel rail. On models without fuel rail service valve, disconnect high
pressure fuel inlet line at fuel rail. Remove throttle body bracket
(if necessary). Connect fuel pressure gauge with adapter between fuel
rail and high pressure fuel inlet line. See Fig. 1.
Fig. 1: Installing Fuel Pressure Tester (Typical)
Courtesy of Mitsubishi Motor Sales of America
2) On Eclipse 2.0L non-turbo and Montero Sport, use scan tool
to operate fuel pump. On all other models, operate fuel pump by
connecting battery voltage to fuel pump test terminal. See
FUEL PUMP TEST TERMINAL LOCATION table. Ensure no fuel leaks are
present. Disconnect battery voltage from fuel pump test terminal.
FUEL PUMP TEST TERMINAL LOCATION TABLE









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Application Wire Color Location
Diamante .................. Black/Blue ............ (1)
Eclipse (Turbo & 2.4L) .... Black/Blue ............. ( 2)
Galant .................... Black/Blue ............ ( 3)
Mirage .................... Black/Blue ............ ( 1)
Montero ...................... White .............. ( 4)
3000GT .................... Black/Blue ............ ( 6)
( 1) - On firewall, above brake master cylinder.
( 2) - On firewall behind battery.
( 3) - On main wiring harness, near center of firewall.
( 4) - On main wiring harness, near right center of firewall.
( 5) - Near left rear corner of engine compartment, below
cruise control actuator (if equipped).
( 6) - On main wiring harness, near wiper motor on firewall,
behind battery.









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3) Start engine and allow it to idle. Measure fuel pressure
with vacuum hose connected to fuel pressure regulator. Record fuel
pressure reading. See FUEL PUMP PERFORMANCE table. Disconnect and plug
vacuum hose from fuel pressure regulator. Record fuel pressure
reading.
4) Check for fuel pressure in fuel return hose by gently
pinching hose while increasing engine speed. If fuel volume is low,
fuel pressure in return hose will not be felt. Increase engine speed
to 2500-3000 RPM, 2-3 times. Return engine to idle. Fuel pressure
should not drop when engine is returned to idle.
5) Turn ignition off. Ensure fuel pressure reading does not
decrease within 2 minutes. If a decrease is noted, monitor speed of
decrease.
6) If fuel pressure is lower than specification, fuel
pressure drops at idle after increasing engine speed to 2500-3000 RPM,
or no fuel pressure in fuel return hose can be felt, check for clogged
fuel filter, or faulty fuel pressure regulator or fuel pump.
7) If fuel pressure is greater than specification, check for
a faulty fuel pressure regulator or plugged fuel return line. If fuel
pressure does not change when vacuum hose to regulator is connected or
disconnected, check for a leaking or clogged vacuum hose to fuel
pressure regulator or faulty fuel pressure regulator.
8) If fuel pressure decreases suddenly after engine is
stopped, check valve in fuel pump is not seated. Replace fuel pump. If
fuel pressure drops slowly, fuel injector is leaking or fuel pressure
regulator valve seat is leaking. Check for faulty fuel injector or
fuel pressure regulator. Repair as necessary.
9) When fuel pressure test is complete, repeat fuel pressure
release procedure before disconnecting fuel pressure gauge. Install
NEW "O" ring at end of high pressure fuel inlet line. Check for fuel
leaks.
FUEL PUMP PERFORMANCE TABLE









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At Idle w/Vacuum At Idle w/o Vacuum
Application psi (kg/cm) psi (kg/cm)
Eclipse 2.0L
Non-Turbo ........... ( 1) ............ 47-50 (3.3-3.5)
Turbo ............. 33 (2.3) ......... 42-45 (3.0-3.5)
3000GT Turbo ........ 34 (2.4) ......... 43-45 (3.0-3.1)
All Other Models .... 38 (2.7) ......... 47-50 (3.3-3.5)
( 1) - Information is not available from manufacturer at time

Measure between center and right terminals of connector for cylinders
No. 1 and 4, and between center and left terminals of connector for
cylinders No. 2 and 3.
4) On all models, remove ignition wires from coil. Measure
secondary coil resistance between coil towers for cylinders No. 1 and
4 and between coil towers for cylinders No. 2 and 3. Primary and
secondary coil resistance should be within specification. See
IGNITION COIL RESISTANCE (ECLIPSE) table. Connect coil harness
connector. Connect ignition wires to coil.
IGNITION COIL RESISTANCE (ECLIPSE) - Ohms @ 68
F (20C) TABLE








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Application Primary Secondary
2.0L
Non-Turbo ............ .51-.61 ......... 11,500-13,500
Turbo ................ .70-.86 ......... 11,300-15,300
2.4L ................... .74-.90 ......... 20,100-27,300









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Power Transistor (Eclipse 2.0L Turbo & 2.4L)
1) To test the section of the power transistor that controls
cylinders No. 1 and 4, disconnect power transistor connector. Using a
1.5-volt dry cell battery, connect negative end of battery to terminal
No. 3 of power transistor and positive end to terminal No. 7. See
Fig. 4 .
Fig. 4: Identifying Power Transistor Connector Terminals (Eclipse
2.0L Turbo & 2.4L)
Courtesy of Mitsubishi Motor Sales of America
2) Using an analog ohmmeter, check for continuity between
terminals No. 3 and 8 of power transistor. Continuity should exist.
With positive end of 1.5-volt battery disconnected, there should be no
continuity. Replace power transistor if it fails test.
3) To test the section of the power transistor that controls
cylinders No. 2 and 3, connect negative end of 1.5-volt dry cell
battery to terminal No. 3 of power transistor and positive end to
terminal No. 2.
4) Using an analog ohmmeter, check for continuity between
terminals No. 1 and 3 of power transistor. Continuity should exist.
With positive end of 1.5-volt battery disconnected, there should be no
continuity. Replace power transistor if it fails test.
Power Transistor (Mirage)
1) Disconnect power transistor (distributor) connector. Usin\
g
a 1.5-volt dry cell battery, connect negative end of battery to
terminal No. 4 of power transistor and positive end to terminal No. 3.
See Fig. 5 .