Mitsubishi Montero (1991+). Manual - part 173

         FUEL SYSTEM PRESSURE RELEASE

WARNING: ALWAYS relieve fuel pressure before disconnecting any fuel

         injection-related component. DO NOT allow fuel to contact

         engine or electrical components.

         1) On Colt and Mirage, remove rear seat cushion. On all

models, disconnect fuel pump harness connector at fuel tank.

         2) Start engine. Let engine run until it stops. Turn ignition

off. Disconnect negative battery terminal. Connect fuel pump harness

connector.

         FUEL PUMP

         Removal & Installation

         1) Fuel pump assembly is located inside fuel tank. Release

fuel pressure from system. See FUEL SYSTEM PRESSURE RELEASE. Raise

vehicle on hoist. Drain fuel into suitable container. Disconnect

electrical connectors and fuel hoses at fuel tank.

         2) Remove fuel filler hose from fuel tank. Remove nuts

securing fuel tank. Remove fuel tank from vehicle and remove fuel pump

assembly. To install, reverse removal procedure. Tighten nuts to

specification. See TORQUE SPECIFICATION table.

         FUEL RAILS & INJECTORS (PFI)

         Use a rag to cover fuel hose connection before disconnecting

high pressure fuel hose at fuel rail. Some residual fuel pressure may

still be in system.

         Removal (Except Pickup & Ram-50 2.4L)

         1) On all models, relieve fuel pressure. See

FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. On

Montero, Pickup, Ram-50, Stealth and 3000GT 3.0L, disconnect air

intake plenum. On Eclipse, disconnect PCV valve hose.

         2) On Colt Vista, disconnect coolant temperature sensor

connector, idle speed control servo connector and brake booster vacuum

hose. On all models, disconnect high pressure fuel hose at fuel rail.

         3) Disconnect fuel return hose. Disconnect vacuum hoses. On

Eclipse, Colt and Colt 200, disconnect throttle cable clamp. Remove

center cover. On all models, disconnect injector electrical

connectors. Remove fuel rail bolts and lift fuel rail and injectors

from engine.

         Installation

         To install, reverse removal procedure. Tighten bolts to

specifications. See TORQUE SPECIFICATIONS table.

         Removal (Pickup & Ram-50 2.4L)

         1) Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELEASE.

Disconnect negative battery cable. Drain coolant. On all models,

disconnect air intake hose. Disconnect breather hose (if applicable)

and vacuum hoses.

         2) Disconnect coolant lines as necessary for clearance.

Disconnect injector electrical connectors. Position all lines, hoses

and electrical connectors out of way. Disconnect throttle and/or

kickdown cables. Remove throttle body assembly and position it out of

the way.

         3) Disconnect high pressure fuel hose at fuel rail.

Disconnect fuel return line and vacuum line connection at fuel rail.

Remove fuel rail bolts and lift fuel rail and injectors from engine.

         Installation

         1) To install, reverse removal procedure. Injectors may be

removed after fuel rail is removed from intake manifold. Use new

insulators and "O" rings when installing injectors.

         2) Use spindle oil or gasoline on "O" ring. Install injectors

into fuel rail with a twisting motion. Adjust throttle and kickdown

cable (if applicable). Do not drop injectors while removing or

installing fuel rail.

         OXYGEN (O2) SENSOR

         Removal & Installation

         1) O2 Sensor is mounted in exhaust pipe below exhaust header.

It is equipped with a permanent pigtail which must be protected from

damage when sensor is removed. Ensure sensor is free of contaminants,

avoid using cleaning solvents of any type. Sensor may be difficult to

remove when engine temperature is less than 120  F (48  C).

         2) Always use anti-seize compound on threads before

installation. On non-turbo models, remove sensor using Remover

(MD998703). On turbo models, use Remover (MD998748) on Eclipse and

Galant, or Remover (MD998770) on Stealth and 3000GT. Tighten oxygen

sensor to specification. See TORQUE SPECIFICATIONS table.

         THROTTLE BODY

         Removal

         Disconnect air intake hose. Remove accelerator and automatic

speed control 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 speed control

motor. Remove throttle bracket and connector bracket (if equipped).

Remove idle position switch and adjusting nut.

NOTE:    DO NOT remove throttle valve. DO NOT use cleaning solvents

         on throttle position sensor, idle speed control motor or

         idle position switch.

         Cleaning

         Clean all parts except those noted in solvent. Check vacuum

port and passage for clogging. Clean vacuum, vapor and fuel passages

with compressed air.

         Reassembly

         To reassemble, reverse disassembly procedure.

         Installation

         To install, reverse removal procedure.

         THROTTLE POSITION SENSOR/SWITCH

         Removal & Installation

         Throttle position sensor/switch is located on throttle body.

Disconnect TPS electrical connector. Remove bolts holding TPS and

remove TPS. To install, reverse removal procedure. Tighten throttle

position sensor/switch to specification. See  TORQUE SPECIFICATIONS

table. For adjustment procedure, see ON-VEHICLE ADJUSTMENTS article.

         TURBOCHARGERS

NOTE:    Removal of turbocharger exhaust housing and water pipes at

         turbocharger is not necessary when removing turbocharger

         assembly. Stealth and 3000GT models have 2 (front and rear)

         turbochargers.

         Removal (Eclipse & Galant)

         1) Disconnect negative battery cable. Drain engine coolant

and oil. On models with A/C, remove condenser fan motor assembly. On

all models, remove oxygen sensor. Remove oil dipstick guide and "O"

ring. See Figs. 8 and 9.

Fig. 8:  Removing Turbocharger (Eclipse & Galant 2.0L)

Courtesy of Mitsubishi Motor Sales of America.

Fig. 9:  Exploded View of Turbocharger Assembly (Eclipse & Galant

2.0L Shown; Stealth & 3000GT Similar)

Courtesy of Mitsubishi Motor Sales of America.

         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 coolant hose and tubes. Remove nuts and bolts

securing exhaust manifold. Remove exhaust manifold and gaskets.

Disconnect oil return pipe. Remove turbocharger assembly.

         Removal (Stealth & 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 alternator and belt. Remove oil

dipstick guide.

         2) Remove heat protector. Disconnect oxygen sensor electrical

connector. Remove oil return pipe. Remove turbocharger support bracket

and remove turbocharger from exhaust manifold. See  Fig. 10.

Fig. 10:  Removing Front Turbocharger (Stealth & 3000GT)

Courtesy of Mitsubishi Motor Sales of America.

         Removal (Stealth & 3000GT Rear)

         1) Disconnect battery cables and remove battery. Drain engine

oil and coolant. Remove accelerator cable. Remove air hose, air pipe

and heat protectors. Disconnect clutch booster vacuum hose. Remove air