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Mitsubishi Montero (1998+). Manual - part 250

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 (48 C). 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

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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