1998 MITSUBISHI MONTERO heater

Accessory Mount Stay Bolt (Montero)
8 mm Bolt .............................................. 17 (23)\
10 mm Bolt ............................................. 36 (49)\
Cooling Fan Bracket (Montero) ............................ 30 (41\
)
Engine Hanger (Montero) .................................. 13 (17\
)
Generator Bolt (Diamante) ................................ 15 (21\
)
Generator Bolt (Montero)
8 mm Bolt .............................................. 15 (21)\
10 mm Bolt ............................................. 38 (51)\
Generator Bracket (Diamante)
8 mm Bolt .............................................. 35 (48)\
10 mm Bolt ............................................. 17 (23)\
Generator Pivot Nut (Diamante) ........................... 32 (44\
)
Tensioner Pulley Nut ..................................... 37 (50)\
Tensioner Bracket Stay Bolt (Montero) .................... 18 (24\
)
Intake Manifold & Fuel
Bracket (Montero) ........................................ 18 (24\
)
ECT Sensor ............................................... 22 (30)\
Intake Manifold Nut ...................................... 15 (21)\
Thermostat Case .......................................... 14 (19)\
Water Inlet Fitting Bolt ................................. 14 (19)\
Water Outlet Fitting Bolt ................................ 14 (19)\
Water Passage (Montero) .................................. 14 (19\
)
Heater Pipe Bolt (Diamante) .............................. 13 (18\
)
Intake Plenum & Throttle Body
Air Intake Fitting Bolt & Nut (Montero) .................. 13 (18\
)
EGR Pipe Bolt ............................................ 13 (18)\
EGR Pipe Flair Nut ....................................... 44 (59)\
EGR Valve Bolt ........................................... 16 (22)\
Intake Manifold Plenum (Diamante) ........................ 13 (18\
)
Intake Manifold Plenum Stay Bolt
8 mm Bolt .............................................. 13 (18)\
10 mm Bolt ............................................. 27 (36)\
Water Outlet Fitting Bracket Bolt ........................ 14 (19)\
Bracket (Diamante) ....................................... 18 (24\
)
Motor Mount Brackets
Bracket
8 mm Bolt .............................................. 16 (22)\
10 mm Bolt ............................................. 30 (41)\
12 mm Bolt ............................................. 55 (75)\
Oil Pan & Oil Pump
Drain Plug ............................................... 30 (40)\
Oil Cooler By-Pass Valve (Montero) ....................... 41 (55\
)
Oil Filter Bolt (Montero) ................................ 15 (21\
)
Oil Filter Bracket
8 mm Bolt .............................................. 18 (24)\
10 mm Bolt ............................................. 30 (40)\
Oil Screen
8 mm Bolt ............................................... 14 (19)\
Plug .................................................... 33 (45)\
Piston & Connection Rod
Connecting Rod Cap Nut ................................... 38 (52)\
Rocker Arms & Camshafts
Distributor Adapter Bolt (Diamante) ...................... 17 (23\
)
Rocker Arm Shaft Bolt .................................... 23 (31)\
Spark Plug ................................................. 18 (25)\
Timing Belt
Auto Tensioner Bolt ...................................... 18 (24)\
Camshaft Sprocket Bolt ................................... 65 (88)\
Idler Pulley Bolt ........................................ 32 (44)\
Tensioner Arm Bolt ....................................... 32 (44)\
Tensioner Pulley Bolt .................................... 36 (49)\
Water Pump Bolt (Montero) ................................ 18 (24\
)










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g grams 

GND or GRND Ground 

GRN Green 

GRY Gray 

Ga. Gauge 

Gals. gallons 

Gov. Governor 











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"H" ABBREVIATION TABLE
"H" ABBREVIATION TABLE







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ABBREVIATION DEFINITION 










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H/D Heavy Duty 

HAC High Altitude Compensation 

HC Hydrocarbons 

HEDF High Speed Electro Drive Fan relay or circuit 

HEGO Heated Exhaust Gas Oxygen Sensor 

HEGOG HEGO Ground circuit 

HEI High Energy Ignition 

HLDT Headlight 

HO High Output 

HP High Performance 

HSC High Swirl Combustion 

HSO High Specific Output 

HTR Heater 

HVAC Heating 

Headlt. Headlight 

Hg Mercury 

Hgt. Height 

Htr. Heater 

Hz Hertz (Cycles Per Second) 











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"I" ABBREVIATION TABLE
"I" ABBREVIATION TABLE







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ABBREVIATION DEFINITION 










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I.D. Inside Diameter 

IAC Idle Air Control 

IACV Idle Air Control Valve 

IC Integrated Circuit 

ID Identification 

IDM Ignition Diagnostic Monitor 

IGN Ignition system or circuit 

ILC Idle Load Compensator 

In. Hg Inches of Mercury 

INCH Lbs. Inch Pounds 

INFL REST Inflatable Restraint 

INJ Injector or Injection 

IP Instrument Panel 

IPC Instrument Panel Cluster 

ISA Idle Speed Actuator 

ISC Idle Speed Control 

ISS Idle Stop Solenoid 

ITS Idle Tracking Switch 

IVSV Idle Vacuum Switching Valve 

* A/C-HEATER SYSTEM UNIFORM INSPECTION GUIDELINES *
1998 Mitsubishi Montero
GENERAL INFORMATION
A/C-Heater System Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models
INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)
CONTENTS
Motorist Assurance Program (MAP)
OVERVIEW
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Heating, Ventilation and Air Conditioning
ACCUMULATORS
ACTUATORS (ELECTRICAL)
ACTUATORS (VACUUM)
AIR CONDITIONING FITTINGS
AIR CONDITIONING HOSES
AIR CONDITIONING METAL LINES, HOSES AND FITTING ASSEMBLIES
AIR CONTROL DOORS
AIR DAMS (EXTERNAL)
AIR DISTRIBUTION SYSTEM
BELTS
BLEND DOORS
BLOWER FANS (BLOWER WHEEL OR SQUIRREL CAGE)
BLOWER MOTORS
BLOWER RESISTORS
BLOWER SWITCHES
CABIN AIR FILTERS
CIRCUIT BREAKERS
COMPRESSOR CLUTCH ASSEMBLIES
COMPRESSORS
CONDENSER AIR SEALS
CONDENSER FAN MOTORS
CONDENSERS
CONNECTORS
CONTROL CABLES
CONTROL HEADS (FUNCTION SELECTORS)
CONTROL LINKAGES
CONTROL MODULES
COOLANT
COOLING FAN BLADES
COOLING FAN CLUTCHES
COOLING FAN MOTORS
EVAPORATOR DRAIN TUBES
EVAPORATOR PRESSURE REGULATORS (EPRS)
EVAPORATORS
EXPANSION VALVES
FUNCTION SELECTORS
FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS
FUSIBLE LINKS
GASKETS
HEATER CASES
HEATER CONTROL VALVES
HEATER CORES

HEATER HOSES
HIGH PRESSURE RELIEF VALVES (HPRV)
IDLERS
IN-LINE FILTERS
METAL FITTINGS
METAL LINES
MIX AND AIR CONTROL DOORS (BLEND DOORS)
O-RINGS
ORIFICE TUBES
PILOT-OPERATED ABSOLUTES (POAS)
PLENUMS
PRESSURE CONTROL VALVES
PRESSURE SENSORS
PULLEYS
RADIATORS
RECEIVER-DRIERS
REFRIGERANT
REFRIGERANT OIL
RELAYS
SEALS
SERVICE PORTS
SPRING LOCK COUPLINGS
SUCTION THROTTLING VALVES (STVS)
SWITCHES (ELECTRICAL)
TENSIONERS
THERMISTORS AND PRESSURE SENSORS
THERMOSTATS AND HOUSINGS
VACUUM HOSES AND TUBES
VACUUM RESERVOIRS
VACUUM TUBES
VALVES IN RECEIVER (VIRS)
WATER PUMPS (ELECTRIC AUXILIARY)
WIRING HARNESSES AND CONNECTORS
MOTORIST ASSURANCE PROGRAM (MAP)
OVERVIEW
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

conductors exposed ..... A .. Require repair or replacement.
Insulation damaged,
conductors not exposed . 1 .. Suggest repair or replacement.
Missing ................. C ............ Require replacement.
Routed incorrectly ...... B ................. Require repair.
Secured incorrectly ..... B ................. Require repair.
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.
( 1) - Determine cause and correct prior to replacement
of part.
( 2) - Inoperative includes intermittent operation.









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FUSIBLE LINKS
See FUSES, FUSIBLE LINKS AND CIRCUIT BREAKERS .
GASKETS
GASKET INSPECTION








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Condition Code Procedure
Leaking ................. A ........... ( 1) Require repair or
replacement.
( 1) - Require inspection of mating and sealing surface and
repair or replace as necessary.









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HEATER CASES
See PLENUMS.
HEATER CONTROL VALVES
HEATER CONTROL VALVE INSPECTION








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Condition Code Procedure
Application incorrect ... B ............ Require 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.
Binding ................. 2 .. Suggest repair or replacement.
Coolant leak ............ A .. Require repair or replacement.
Disconnected ............ A .. Require repair or replacement.
Malfunctioning .......... A ........... (1) Require repair or
replacement.
Missing ................. C ............ Require replacement.
Restricted .............. A .. Require repair or replacement.
Seized .................. A .. Require repair or replacement.
Vacuum leak ............. A .. Require repair or replacement.
( 1) - Includes inoperative, intermittent operation, or
failure to perform all functions.









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HEATER CORES
HEATER CORE INSPECTION








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Condition Code Procedure
Air flow obstruction .... A .. 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.
Connection leaking ...... A .. Require repair or replacement.
Corroded ................ 1 .. Suggest repair or replacement.
Disconnected ............ A .. Require repair or replacement.
Fins damaged, affecting
performance ............ A .. Require repair or replacement.
Fins damaged, not
affecting performance .. .. ........ No service suggested or
required.
Internal restrictions,
affecting performance .. A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Missing ................. C ............ Require replacement.









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HEATER HOSES
HEATER HOSE INSPECTION








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Condition Code Procedure
Application incorrect ... B ............ Require replacement.
Connected incorrectly ... A ................. Require repair.
Corroded, not reusable .. 1 ............ Suggest replacement.
Cracked ................. A .. Require repair or replacement.
Hard (brittle) .......... 1 .. Suggest repair or replacement.
Inner fabric (webbing)
damaged ................ A ............ Require replacement.
Insufficient clamping
force, allowing hose to
leak ................... A .. Require repair or replacement.
Leaking ................. A .. Require repair or replacement.
Maintenance intervals ... 3 ............ Suggest replacement.

A/C-HEATER SYSTEM
1998 Mitsubishi Montero
1998 AIR CONDITIONING & HEAT
Mitsubishi - A/C-Heater System
Montero
* PLEASE READ THIS FIRST *
WARNING: To avoid injury from accidental air bag deployment, read and
carefully follow all SERVICE PRECAUTIONS and DISABLING &
ACTIVATING AIR BAG SYSTEM procedures in AIR BAG RESTRAINT
SYSTEM article.
A/C SYSTEM SPECIFICATIONS
A/C SYSTEM SPECIFICATIONS TABLE








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Application Specification
Compressor Type ............... Nippondenso 10PA15 10-Cyl.
Compressor Belt Deflection ( 1)
New .......................... 13/64-15/64" (5.1-6.0 mm)
Used ......................... 17/64-19/64" (6.6-7.5 mm)
Compressor Oil Capacity ..................... ( 2) 2.7 ozs.
Refrigerant (R-134a) Capacity ................. 21-23 ozs.
System Operating Pressures ( 4)
High Side ............... 149-213 psi (10.5-15.0 kg/cm
)
Low Side .................... 14-33 psi (1.0-2.3 kg/cm)
( 1) - With 22 lbs. (100 N.m) force applied midway on longest
span of belt.
( 2) - Use ND 8-OIL refrigerant oil.
( 3) - Use SUN PAG 56 refrigerant oil.
( 4) - With ambient temperature at about 80
F (27C).








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DESCRIPTION
Slight variations exist among manual A/C-heater systems used.
On Montero, a Nippondenso 10-cylinder compressor is used. Cycling of
compressor clutch is controlled by an automatic A/C Control Unit
(ACCU).
Compressors will only operate within normal temperatures and
pressures set for each model. An electric condenser fan operates
whenever A/C system is operating. System components may vary depending
upon model. Systems may include an ACCU, fan switch, evaporator,
temperature sensor, dual-pressure switch, engine coolant temperature
switch, compressor, condenser, receiver-drier and various pipes and
hoses.
OPERATION
A/C CONTROL UNIT (ACCU)
ACCU controls cycling of compressor clutch based on
information received from air thermosensor and air inlet sensor, dual-
pressure switch, A/C switch and A/C engine coolant temperature switch.
ACCU is attached to top of evaporator housing.

A/C SWITCH
When turned on, the A/C system will operate if blower motor
control lever is in a position other than OFF. When activated, A/C
switch allows A/C compressor clutch to engage and operate the
compressor.
A/C ENGINE COOLANT TEMPERATURE SWITCH
The A/C engine coolant temperature switch, located on
thermostat housing, is wired in series with compressor clutch. When
coolant temperature is greater than switch control temperature, power
to compressor is cut and compressor is turned off until temperature
returns to operating range. Switch will turn on at 226
F (108C) and
off at 235-243F (112-118C).
AIR SELECTOR LEVER
The lever moves horizontally to select source of air used
inside passenger compartment. Lever moves from position on left
(outside air mode) to position on right (recirculated air mode). Lev\
er
should be set in recirculated air mode for maximum A/C cooling.
BLOWER MOTOR CONTROL SWITCH
Blower motor control switch rotates to select blower motor
speeds. As switch is rotated from left or OFF position, increasing
speeds of blower operation are selected. In order for A/C system to
operate, blower motor control switch must be in a position other than
OFF.
MODE SELECTOR KNOB
Mode selector knob has six modes available to achieve desired
distribution of air from various outlets. When knob is rotated fully
to left (counterclockwise), airflow is directed to upper passenger
area. In second position (clockwise), airflow is directed to upper
passenger area and slightly to leg area. Position 3, directs air
mostly to leg area and slightly to upper passenger area. Position 4,
directs air exclusively to leg area. Position 5, directs air to leg
area and to windshield and door windows. Position 6, directs air
exclusively to windshield and door windows.
TEMPERATURE CONTROL KNOB
Temperature control knob operates blend-air door in
heater/air conditioning unit, mixing cooled and heated air so that
selected air temperature can be obtained. The system will provide
cooled air when A/C switch is in ON position and blower motor is in
any position other than OFF. Temperature control knob should be on far
left (maximum cooling) side of temperature selection scale when
maximum A/C cooling is desired.
DUAL-PRESSURE SWITCH
The dual-pressure switch, mounted on receiver-drier, is wired
in series with compressor clutch. Whenever system pressures drop below
or increase above control points of switch, power supplied to
compressor will be cut and compressor function will cease until
pressures are back to normal operating ranges.