1997-1999 Mitsubishi Montero Sport Service & Repair Manual

3ervice Manual MONTERO 1998 Volume 1 FOREWORD This Service Manual has been prepared with the latest service information available at the time of publication. It is subdivided into various group categories and each section contains diagnosis, disassembly, repair, and installation procedures along with complete specifications and tightening references. Use of this manual will aid in properly performing any servicing necessary to maintain or ·~"tore the high levels of performance and reliability igned into these outstanding vehicles. WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION THROUGH Nalional l ns1iHJ ie lor AUTOMOTIVE SEFIVICE EXCELLENCE + MITSUBISHI " MOTOR SALES OF AMERICA. Inc. Mitsubishi Motors Corporation reserves the right to make changes in design or to make additions to or improvements in its products without ' ·-;ing any obligations upon itself to install them on its products ·usly manufactured. © 1997 Mitsubishi Motors Corporation Printed in U.S.A. GROUP INDEX 00109001196 General ....................... . Engine ...... . ................. . Engine Lublication ........ . .... . Fuel Engine Cooling .... . ........... . Intake and Exhaust Engine Electrical .. . ............ . Engine and Emission Control Automatic Transmission Alphabetical Index .......... . .. . NOTE: For information on all service manual groups not listed above, please refer to Volume 2.

WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYST EM (SRS) EQUIPPED VEHICLES WARNING! (1) Improper service or maintenance of any component of the SRS, or any SRS-related component , can lead to personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from rendering the SRS i noperative). (2) If it is possible that the SRS components are subjected to heat over 93°C (200°F) in baking or in drying after painti ng , remove the SRS components (air bag module, SRS diagnosis unit, front impact sensors) beforeha nd. (3) Service or ma i ntenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. (4) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 528 - Supplemental Restraint System (SRS), before beginn i ng any service or maintenance of any component of the SRS or any SRS-related component. NO TE Section titles with the aste ri sks (*) in the table of contents in each group indicate operations requiring wa rnings. j TSB Revision

00-1 GENERAL CONTENTS oo1 o9ooo9o4 GENERAL <BODY AND CHASSIS> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 GENERAL <ELECTRICAL> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . • . OOE

00-2 GENERAL <BODY AND CHASSIS> CONTENTS 00109001202 GENERAL DATA AND SPECIFICATIONS ... 28 HOW TO USE THIS MANUAL ... . .... . ..... 3 Expl anation of Manual Contents . . . . . . . . . . . . . . . 4 Explanation of the Troubleshooting Guide . . . . . . 6 Maintenance, Re pair and Servicing Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Model In dications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special To ol Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Terms Definiti on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tightening Torque Indication . . . . . . . . . . . . . . . . . . 3 HOW TO USE TROUBLESHOOTING/ INSPECTION SERVICE POINTS ........ . .... 7 LUBRICATION AND MAINTENANCE ..... .. 30 MAIN SEALANT AND ADHESIVE TABLE ... 53 MAINTENANCE SERVICE ...... .. .. ... . .... 38 Air Cleaner El ement . . . . . . . . . . . . . . . . . . . . . . . . 38 Automatic Transmissi on . . . . . . . . . . . . . . . . . . . . . 43 Automatic Transmission Fluid . . . . . . . . . . . . . . . . 44 Ball Joi nt and Steering Linkage Seals . . . . . . . . 46 Ball Joints with Grease Fitting ........... . ... 47 Brake Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Disc Brake Pads ... .. . .............. . ..... .. 46 Drive Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Drive Shaft Boots ..... .... ... .... ... ........ 46 Engine Coolant .. ... ... ..... ..... . .......... 45 Engine Oil . . ...................... . ......... 41 Engine Oil Fi lter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Evaporative Emission Control System (Except Canister) . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Exhaust System (Connection Portion of Muffler, Pipings and Converter Heat Shields) . . . . . . . . . 48 Front Axle and Rear Axle . .. .... .. .. ........ 47 Fuel Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Ignition Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Propeller Shaft Joints . . . . . . . . . . . . . . . . . . . . . . . 48 Rear Axle Oil (Limited-Slip Differential) . . . . . . . 47 Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 SRS Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Transfer ............ . ............. ... ....... 44 PRECAUTIONS BEFORE SERVICE .. ... . . . Applying Anti-corrosion Agent or Other Underco ... Agents . ..... .. ... . .. . ............ ... ...... . 21 Scan Tool (MUT-II) . . . . . . . . . . . . . . . . . . . . . . . . . 21 Servicing Electrical System . . . . . . . . . . . . . . . . . . 20 Supplemental Restra int System (SRS) . . . . . . . . 20 Vehicle Washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE .......... 32 SCHEDULED MAINTENANCE TABLE .. .. .. 35 TIGHTENING TORQUE ...... ... ........... 29 TOWING AND HOISTING ... . .............. 25 TREATMENT BEFORE/AFTER THE FORDING OF A STREAM .. ..... ... . .. . ........ . .... 22 VEHICLE IDENTIFICATION .... ... . ... ..... . 14 Chassis Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Engine Model Stamping . . . . . . . . . . . . . . . . . . . . . 16 Theft protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Veh icle Identification Code Chart Plate . . . . . . . 14 Vehicle Identification Number Location . . . . . . . . 14 Vehicle Identification Number List . . . . . . . . . . . . 15 Vehicle Information Code Plate ............... 15 Vehicle Safety Certification Label . . . . . . . . . . . . . 1 R

GENERAL - How to Use This Manual 00-3 HOW TO USE THIS MANUAL 00100010364 .lllAINTENANCE, REPAIR AND SERVICING EXPLANATIONS This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair and servicing of the subject model. Unless otherwise specified, each service procedure covers all models. Procedures covering specific models are identified by the model codes, or similar designation (engine type, transaxle type, etc.). A description of these designations is covered in this manual under "VEHICLE IDENTIFICATION". SERVICE ADJUSTMENT PROCEDURES "Service adjustment procedures" are procedures for performing inspections and adjustments of particularly important locations with regard to the construction and for maintenance and servicing, but other inspections (for looseness, play, cracking, damage, etc. ) must also be performed. SERVICE PROCEDURES The service steps are arranged in numerical order. Atten ti on must to be paid in performing vehicle service are described in detail in SERVICE POINTS. fERMS DEFINITION STANDARD VALUE Indicates th e value used as the standard for judging the quality of a part or assembly on inspection or the value to which the part or assembly is corrected and adjusted. It is given by tolerance. LIMIT Shows the standard for judging the quality of a part or assembly on inspection and means the maximum or minimum value within which the part MODEL INDICATIONS or assembly must be kept functionally or in strength. It is a value established outside the range of standard value. REFERENCE VALUE Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly and adjustment procedures, and so they can be completed in a shorter time). CAUTION Indicates the presentation of information particularly vital to the worker during the performance of maintenance and servicing procedures in order to avoid the possibility of injury to the worker, or damage to component parts, or a reduction of component or vehicle function or performance, etc. TIGHTENING TORQUE INDICATION The tighteni ng torque shown in this manual is a basic value with a tolerance of ± 10% except the following cases when the upper and lower limits of tightening torque are given. (1) The tolerance of the basic value is within ± 10%. (2) Special bolts or the like are in use. (3) Special tightening methods are used. SPECIAL TOOL NOTE Only MMC special tool part numbers are ca ll ed out in the repair sections of this manual. Please refer to the special tool cross reference cha rt , which is located in the service manual at the beginning of each group, for a cross reference from the MMC special tool number to the special tool number that is available in your market. The following abbreviations are used in this manual for classification of model types. AfT: Indicates automatic transmission, or models equipped with automatic transmission. MFI: Indicates multiport fu el inj ection, or engines equipped with multiport fuel injection. AJC: Indicates air conditioning. 3.5L Engine: In dicates the 3.5 dm3 (213.4 cu.in.) <6G74> engine, or a model equipped with such an engine. I TSB Revision

00-4 GENERAL - How to Use This Manual EXPLANATION OF MANUAL CONTENTS Mai ntenance and Servicin g Procedures The numbers provided within the diagram indicate the sequence for maintenance and servicing procedures. • Removal steps : The part designation number corresponds to the number in the il lustration to indicate removal steps. • Disassembly steps : The part designation number corresponds to the number in the illustration to indicate disassembly steps. Indicates procedures to be performed before the work in that section is started, and procedures to be performed after the work in that ------ - section is finished. Component Diagra m A diagram of the component parts is provided near the front of each section in order ---- - -- to give the reader a better understanding of the installed condition of component part s. Indicates (by symbols) where l ubrication is ------ - necessary. • Installation steps : Specified in case installation is impossible in reverse order of removal steps. Omitted if installation is possible in reverse order of removal steps. • Reassembly steps : Specified in case reassembly is impossible in reverse order of disassembly steps. Omitted if reassembly is possible in reverse order of disassembly steps. Classif icat io ns of Major Mai ntenance I Service points When there are major points relative to maintenance and servicing procedures (such as essential maintenance and service points. maintenance and service standard values, information regarding the use of special tools, etc.), these are arranged together as major maintenance and servi ce points and explained in detaiL ~A .... : Indicates that there are essential points for removal or disassembly . .... A~: Indicates that there are essential points for installation or reassembly. Symbols f or Lubri cati on, Sealants and Adh esives Information concerning the locations for lubrication and for application of sealants and adhesives is provided, by using symbols, in the diagram of component parts or on the page following the component parts page, and expl ained. TSB Revision ----- ------------- 4iit Grease (multipurpose grease unless there is a brand or type specified) .- Sealant or adhesive Ji Brake fluid or automatic transmission fl ui d ~ Engine oil, gear oil or air conditioner com- pressor oil ,;;iii) Adhesive tape or butyl rubber tape

- - GENERAL - How to Use This Manual Indicates the group title. 1 Indicates the section title. 1 STEERING - Power Steering Gear Box ' Indicates the group number. Indicates the page number. J -- ---- 00-5 POWER STEERING GEAR BOX REMOVAL AND INSTALLATION - - tsNM ,,..., I Denotes tightening ~.r Q4r~~--~ 1 ~ro.~.ue.. .. .... = ).f"\L &-J !\~~~· ~~ 3B 8 ~111 ..... :~~~~/ st,._ 1113 .,.JP<>i=='':.:."--+-- ---1 Denotes able part. non-reus- I FOG UGHT RELAY CONTINUfTY CHECK Tetmlnal 3 4 5 Repair kit or set parts are shown . .--+--1 (Only very frequently used parts are shown.) 0--0 indicates that there is continuity between the termi- Powerionotauppllod o- -o nals. ~~-~~·~StJPPI~~iod~--Le!·:.:·t·:.:·e~Lo-~!f-o~3--t--j E±)--8 indicates terminals to ..... which battery voltage is applied. The title of the page (following the page on which the diagram LUBRICATION AND SEAUNG POINTS -----------------+---1 of Component parts is pres- <ConventloMI power -ng 9"" box:. ented) indicating the locations of 37A-28 STEERING. - Power Steering Gear Box ·~ 14 --· TSB Revision lubrication and sealing procedures.

00-6 GENERAL - How to Use This Manual EXPLANATION OF THE TROUBLESHOOTING GUIDE A Hamesss:Ce connector MFirel~y Volume air t:ow senset • 1l110tfOO,J$ Indicates the circuit diagram for checking. Provides the necessary de- lL scription of circuit opera- ••+--- ~-.~ -,"u~~cy<HzJ tion for basic understand- 19 '"'1 s 92 90 Indicates a connector ter- minal number. ing. Intake ail amo\rll (Li see) In dicates the check to be made. 1CZ .. S1 ! Hfliit'i iniii !l !TIII! fi !I 7fU06.S4 Provides hints (including standards for judgement) when troubleshooting procedures are followed. OPERATION • The volume air llow sensor is incorporated within the air cleaner. it functi ons to convert the amount of engine air intake to pulse signals of a frequency proportional to the amount of engine air intake, and to input those signals to the engine control module. The engine control module then, 6ased upon those signals, calculates the amount of fuel injection, etc. INSPECTION llemNo. Data display 91 U0 193 1rr.r:en ~~ TROUBLESHOOTING HINTS ______ __, Hint t: If the engine sometimes stalls. try starting the engine afld shaking the volume ai r flow sensor harness. If the eflgine then stalls, incorrect or improper contact of the volume air flow sensor conflector is the probable cause. Check conditions Stafldard value V IL Using Scan tool Function Oa1a reading 16 Engine control module · power supply voltage I gnition switch: ON ! s .. i I Indicates the item to be checked. TSB Revision i T Indicates the conditions under which t he check should be made. 00004382 Indicates the specification to be used for judgement of the check results. If there is no particular men- tion of conditions in the "Check Conditions" column, t he column shows the specifications under normal conditions.

1997-1999 Mitsubishi Montero Sport Service & Repair Manual

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