1998 MITSUBISHI MONTERO brake

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)\

COMPUTER RELEARN PROCEDURES
1998 Mitsubishi Montero
GENERAL INFORMATION
Computer Relearn Procedures
All Models
* PLEASE READ THIS FIRST *
The following general procedures are to be used if
driveability problems are encountered after power loss or battery has
been disconnected. These procedures may provide an aid in eliminating
these problems.
To reduce the possibility of complaints, after any service
which requires battery power to be disconnected, vehicle should be
road tested.
COMPUTER RELEARN PROCEDURES
Vehicles equipped with engine or transmission computers may
require a relearn procedure after vehicle battery is disconnected.
Many vehicle computers memorize and store vehicle operation patterns
for optimum driveability and performance. When vehicle battery is
disconnected, this memory is lost. The computer will use default data
until new data from each key start is stored. As computer memorizes
vehicle operation for each new key start, driveability is restored.
Vehicle computers may memorize vehicles operation patterns for 40 of
more key starts.
Customers often complain of driveability problems during
relearn stage because vehicle acts differently then before being
serviced. Depending on type and make of vehicle and how it is
equipped, the following complaints (driveability problems) may exist:
* Harsh Or Poor Shift Quality
* Rough Or Unstable Idle
* Hesitation Or Stumble
* Rich Or Lean Running
* Poor Fuel Mileage
These symptoms and complaints should disappear after a number
of drive cycles have been memorized. To reduce the possibility of
complaints, after any service which requires battery power to be
disconnected, vehicle should be road tested. If a specific relearn
procedure is not available, the following procedure may be used:
Automatic Transmission
* Set parking brake, start engine in "P" or "N" position.
Warm-up vehicle to normal operating temperature or until
cooling fan cycles.
* Allow vehicle to idle for one minute in "N" position. Select
"D" and allow engine to idle for one minute.
* Accelerate at normal throttle position (20-50%) until vehicle
shifts into top gear.
* Cruise at light to medium throttle.
* Decelerate to a stop, allowing vehicle to downshift, and use
brakes normally.
* Process may be repeated as necessary.
Manual Transmission

* Place transmission in Neutral position.
* Ensure emergency brake has been set and all accessories
are turned off.
* Start engine and bring to normal operating temperature.
* Allow vehicle to idle in Neutral for one minute.
* Initial relearn is complete: process will be completed during
normal driving.
Some manufacturers identify a specific relearn procedure
which will help establish suitable driveability during relearn stage.
These procedures are especially important if vehicle is equipped with
and electronically controlled automatic transmission or transaxle.
Always complete procedure before returning vehicle to customer.

* PLEASE READ THIS FIRST *
NOTE: For further trouble shooting information, see INPUT
INSPECTION CHART. See Fig. 3. See
INSPECTION CHART FOR TROUBLE SYMPTOMS table under SYMPTOM
TESTS.
PRELIMINARY CHECKS
Inspect vacuum pump, linkage assembly, actuator, cables and
vacuum hoses. Ensure linkage and cables move smoothly. Ensure cables
do not have excessive slack or tension.
CRUISE CONTROL SWITCH FUNCTION TEST
NOTE: If vehicle speed decreases about 9 MPH less than the set
speed, set speed will be canceled. Speed will not set beyond
system limit of 124 MPH.
1) Cruise control switch is part of multifunction switch
mounted on steering column. To operate cruise control system, turn
ignition on. Turn cruise control switch to ON position. Ensure switch
indicator light comes on.
2) With cruise control switch in ON position, drive vehicle
at least 25 MPH. Press and release SET button. Vehicle speed should
stay at set speed. Instrument cluster cruise indicator light should
come on. To increase set speed, turn control switch to RESUME position
and hold until new set speed is reached.
3) To lower set speed, press SET button and hold until new
set speed is reached. To return to set speed after cancellation, move
resume switch to ON position. Vehicle speed should return to previous
setting before cancellation. Set speed should cancel when any of the
following occurs:
* Brake pedal is depressed.
* Cruise control main switch is turned to OFF position.
* Ignition switch is turned to OFF position.
* Transmission is shifted to Neutral.
SYSTEM CANCELS OR WILL NOT RESET AFTER CANCELLATION
1) Check for trouble codes. See RETRIEVING CODES under SELF-
DIAGNOSTIC SYSTEM. If no trouble codes are stored, ensure cruise
control can be set.
2) If cruise control can be set, system may have canceled due
to driving on steep hills, or a loose wiring connection. If cruise
control still cannot be set, perform SYSTEM INPUT TESTS under SYMPTOMS
TESTS.
3) If SYSTEM INPUT TESTS check okay, check vacuum pump
circuit. See CODE 11 under DIAGNOSTIC TESTS. If SYSTEM INPUT TESTS do
not check okay, see INPUT INSPECTION CHART. See Fig. 3.
SYMPTOM TESTS
SYSTEM INPUT TESTS
1) System input tests should be performed if no trouble codes
are stored when performing RETRIEVING CODES under SELF-DIAGNOSTIC
SYSTEM. System input tests cycle each cruise control switch and
sensor.

2) Use scan tool for system input check according to
operating instructions provided with scan tool. Connect leads of
analog voltmeter between cruise control terminal and ground terminal
of data link connector. See Fig. 35.
3) Turn ignition on. To display results of input check, move
cruise control SET switch to ON position. Then turn MAIN switch to ON
position. Within one second, activate RESUME switch. Codes will
display if circuit tested is okay. See Fig. 3.
Fig. 3: Input Inspection Chart
Courtesy of Mitsubishi Motor Sales of America
INSPECTION CHART FOR TROUBLE SYMPTOMS TABLE









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Trouble Symptom Perform Test No.
Communication With Scan Tool Not Possible
(Communication With All Systems Not Possible) ........ 1
Communication With Cruise Control ECU Not Possible ..... 2
Diagnostic Inspection Possible/Input Inspection
Not Possible ......................................... 3
Cruise Control Does Not Cancel
With Brake Pedal Depressed ........................... 4
With Select Lever In Neutral ......................... 5
With CANCEL Switch ON ................................ 6
Diagnosis Display Normal/Cruise Control Will Not Set ... 7
Cruise Control Cannot Be Set ........................... 8
Hunting Occurs At Set Speed ............................ 9
With Cruise Control Main Switch ON,
Switch Indicator Does Not Illuminate
(Cruise Control Operation Normal) .................. 10
Cruise Control Main Switch Illumination Light
Does Not Illuminate ................................. 11
Indicator Light Inside Combination Meter

harness, dash wiring harness and joint connector C-132. Repair as
necessary. If malfunction remains, check harness between cruise
control main switch and power supply. Repair as necessary.
5) Check condition of cruise control ECU connector C-50.
Repair as necessary. If connector is okay and malfunction persists,
replace cruise control ECU.
Test No. 3
Malfunction of cruise control main switch or cruise control
ECU ground circuit may be present. Probable causes are:
* Malfunction of cruise control main switch.
* Malfunction of clockspring.
* Malfunction of connector.
* Malfunction of harness.
1) Check cruise control switches. See
CRUISE CONTROL SWITCH TESTS under COMPONENT TESTS. Replace any failed
switch. If switches are okay, check clockspring. See CLOCKSPRING TEST
under COMPONENT TESTS. If clockspring is okay, go to next step.
Replace clockspring if not okay.
2) Disconnect clockspring connector C-128 and measure voltage
between terminal No. 2 and ground. See Fig. 15. If battery voltage is
present, go to next step. If battery voltage is not present, check
condition of IOD connector A-09X, joint connector C-131, junction
block connector C-81, junction block connector C-94 and junction block
connector C-101. Repair as necessary. See Figs. 4, 16, 19, 21, 22, 26,
27 and 29. If connectors are okay and malfunction remains, check
harness between clockspring and power supply. Repair as necessary.
3) Check condition of cruise control ECU connector C-50 and
clockspring connector C-128. Repair as necessary. See Figs. 13 and 15.
If connectors are okay and malfunction remains, check harness between
clockspring and cruise control ECU. Repair as necessary.
Test No. 4
Malfunction of stoplight switch or stoplight circuit may be
present. Probable causes are:
* Malfunction of stoplight switch.
* Malfunction of connector.
* Malfunction of harness.
* Malfunction of cruise control ECU.
1) If stoplight does not illuminate with brake pedal
depressed, go to next step. If stoplight illuminates with pedal
depressed, replace cruise control ECU.
2) Check stoplight switch. See
BRAKELIGHT/STOPLIGHT SWITCH TEST under COMPONENT TESTS. Replace
stoplight switch as necessary. If stoplight switch is okay, go to next
step.
3) Disconnect stoplight switch connector C-55. See Fig. 14.
At harness side of connector, measure voltage between terminal No. 2
and ground. If battery voltage is present, go to next step. If battery
voltage is not present, check condition of joint connector C-131 and
junction block connector C-94. Repair as necessary. See Fig. 26. If
connectors are okay and malfunction remains, check harness between
stoplight switch and power supply. Repair as necessary.
4) Check condition of cruise control ECU connector C-50 and
stoplight switch connector C-55. Repair as necessary. If connectors
are okay and malfunction remains, check harness between stoplight
switch and cruise control ECU. Repair as necessary.
Test No. 5

CRUISE CONTROL INDICATOR TEST under COMPONENT TESTS. If cruise control
indicator is defective, replace indicator. If indicator checks okay,
go to next step.
2) If cruise control indicator illuminates when cruise
control connector C-50 terminal No. 23 is grounded at harness side,
replace cruise control ECU. If indicator does not illuminate, check
combination meter connector C-12 and cruise control ECU connector C-
50. Repair as necessary. If connectors are okay and malfunction
remains, check harness between combination meter and cruise control
ECU. Repair as necessary.
Test No. 13
1) Perform stoplight switch test. See
BRAKELIGHT/STOPLIGHT SWITCH TEST under COMPONENT TESTS. If switch is
okay, go to next step. If switch is defective, replace brakelight
switch.
2) Check cruise control ECU connector C-50, stoplight switch
connector C-55 and joint connector C-131. Repair as necessary. See
Figs. 13 , 14, 16 and 29. If connectors are okay and malfunction
remains, check harness between joint connector C-131 and cruise
control ECU.
Test No. 14 (A/T)
1) Perform park/neutral switch test. See
PARK/NEUTRAL SWITCH TEST under COMPONENT TESTS. If switch is okay, go
to next step. If switch is defective, replace switch.
2) Check starter relay. Replace if defective. If relay is
okay, check cruise control ECU connector C-50 and joint connector C-
130. Repair as necessary. See Figs. 13, 16 and 28. If connectors are
okay and malfunction remains, check harness between cruise control ECU
and power supply.
COMPONENT TESTS
ACTUATOR TEST
Remove actuator. Apply vacuum to actuator. Actuator linkage
holder should move more than 1.38" (35 mm). Actuator diaphragm should
hold vacuum. Replace actuator if actuator does not test as specified.
BRAKELIGHT/STOPLIGHT SWITCH TEST
Disconnect stoplight switch connector C-55. When brake pedal
is pressed, continuity should be present between terminals No. 2 and
3. See Fig. 14. When brake pedal is released, continuity should be
present between terminals No. 1 and 4. Replace switch if it does not
test as specified.
CLOCKSPRING TEST
WARNING: Deactivate air bag system before performing any service
operation. See AIR BAG RESTRAINT SYSTEMS article. Do not
apply electrical power to any component on steering column
without first deactivating air bag system. Air bag may
deploy.
If clockspring fails any check, replace with a NEW
clockspring.
1) Check connectors and protective tube for damage and
deformities.
2) Visually check case for damage or deformities.

1) To clear trouble codes, disconnect battery cable, or use
alternative method to prevent memory loss.
2) Turn ignition on. Turn main cruise control switch and SET
switch to ON position, and within one second, turn RES switch to ON
position. Hold stoplight switch and cruise control switch in ON
position for greater than 5 seconds. Verify codes are cleared.
DIAGNOSTIC TESTS
CODE 11: VACUUM PUMP DRIVE SYSTEM
Code 11 is displayed if release valve, control valve and
motor drive signals from vacuum pump are not input to cruise control
ECU. Probable causes are:
* Malfunction of vacuum pump.
* Malfunction of stoplight switch.
* Malfunction of connector.
* Malfunction of harness.
* Malfunction of cruise control ECU.
1) Check vacuum pump. See VACUUM PUMP TEST under COMPONENT
TESTS. If vacuum pump is defective, replace vacuum pump. If vacuum
pump is okay, go to next step.
2) Disconnect cruise control actuator harness connector A-57
or A-95. See Fig. 5. At harness side of connector, check voltage
between terminal No. 1 and ground. If battery voltage is present, go
to next step. If battery voltage is not present, check stoplight
switch. See BRAKELIGHT/STOPLIGHT SWITCH TEST under COMPONENT TESTS.
Replace switch if defective. Check cruise control main switch harness
connector C-01 and stoplight switch harness connector C-55. Repair as
necessary. If malfunction remains, check harness between cruise
control main switch and vacuum pump. Repair as necessary.
3) Disconnect cruise control ECU connector C-50. See Fig. 13.
At harness side of connector, check voltage between ground and
terminals No. 12 (driving release valve), No. 13 (driving control
valve), and No. 26 (driving motor). If battery voltage is present, go\
to next step. If battery voltage is not present, check and repair
connectors A-57 or A-95 and C-111 as necessary. See Figs. 5 and 24. If
malfunction remains, check and repair harness between vacuum pump and
cruise control ECU as necessary.
4) Check cruise control ECU connector C-50. Repair as
necessary. If malfunction remains, replace cruise control ECU.
CODE 12: VEHICLE SPEED SENSOR SIGNAL
Code 12 is displayed if vehicle speed signals from vehicle
speed sensor are not input to cruise control ECU when vehicle speed is
25 MPH or more. Probable causes are:
* Malfunction of VSS.
* Malfunction of connector.
* Malfunction of harness.
* Malfunction of cruise control ECU.
1) Check vehicle speed sensor. See VEHICLE SPEED SENSOR TEST
under COMPONENT TESTS. If speed sensor is okay, go to next step. If
speed sensor is defective, repair or replace as necessary.
2) Disconnect combination meter connector C-06. See Fig. 10.
At harness side of connector, with ignition switch in ON position,
measure voltage between terminal No. 1 and ground. If voltage is 4.5
volts or more, go to next step. If voltage is less than 4.5 volts,