Mitsubishi Montero (1991+). Manual - part 2

          released before disconnecting fuel lines.

         Removal

         1) Release fuel pressure. See FUEL PRESSURE RELEASE under

REMOVAL & INSTALLATION. Remove upper intake manifold. See UPPER INTAKE

MANIFOLD under REMOVAL & INSTALLATION.

         2) Drain cooling system. Remove high pressure and return fuel

lines. Cover fuel lines using shop towel during removal as some fuel

may be retained. Remove vacuum hose from pressure regulator.

Disconnect injector harness from injectors.

         3) Remove fuel delivery pipe, fuel injectors and pressure

regulator. See Fig. 3. DO NOT allow injectors to fall from delivery

pipe during removal. Remove vacuum hose and pipe assembly.

         4) On Montero & Pickup, disconnect coolant temperature

sending unit, coolant temperature switch (A/C equipped), coolant

temperature sensor and thermoswitch (A/T equipped). Disconnect upper

radiator and coolant by-pass hoses. Disconnect heater pipe. On all

models, remove intake manifold and gasket.

Fig. 3:  Exploded View of Lower Intake Manifold & Components

Courtesy of Mitsubishi Motor Sales of America, Inc.

         Inspection & Installation

         1) Inspect for damage and cracks on all mounting surfaces. To

install, reverse removal procedure using new gaskets and "O" rings.

Coat "O" ring with fuel before installation.

         2) Install lower intake manifold gasket with adhesive side

toward intake manifold and gasket protrusions facing outboard of

engine. Tighten bolts and nuts to specification. See appropriate

TORQUE SPECIFICATIONS table at end of article. Check for fuel leaks.

         TURBOCHARGER

         Removal (Front)

         1) Drain coolant, and remove radiator. Disconnect exhaust

pipe from turbo. Remove all air intake pipes. Note match marks and

installation depth on air pipes and hoses for reinstallation. Remove

serpentine drive belt. Remove alternator. Remove A/C compressor and

bracket, and support aside.

         2) Remove O2 sensor. Remove dipstick assembly and turbo heat

shield. Disconnect turbo coolant feed and return lines. Disconnect

turbo oil feed and return lines. Remove turbocharger assembly.

         Removal (Rear)

         1) Drain coolant. Remove battery. Disconnect accelerator

cable at bracket and throttle body. Disconnect exhaust pipe from

turbo. Remove all air intake pipes and heat shields. Disconnect

accelerator cable at pedal.

         2) Remove clutch booster vacuum hose. Remove O2 sensor.

Remove EGR pipe and turbo heat shield. Disconnect turbo coolant feed

and return lines. Disconnect turbo oil feed and return lines. Remove

turbocharger assembly.

CAUTION:  DO NOT allow foreign material into turbocharger air intakes

          or coolant and oil passages.

         Inspection (Front & Rear)

         1) Inspect turbocharger for oil leakage. Check turbine and

compressor wheels for cracks and other damage. Both wheels should turn

easily by hand.

         2) Apply 6.8 psi (61 kPa) vacuum to wastegate diaphragm.

Ensure wastegate operates and diaphragm holds vacuum pressure. Use

care when cleaning gasket surfaces so no foreign material enters

turbocharger oil, coolant and air passages.

         Installation (Front & Rear)

         Refill turbocharger with clean engine oil through oil pipe

installation hole. To complete installation, reverse removal

procedure. Align match marks, and install air pipes and hoses to

proper depth.

         EXHAUST MANIFOLDS

         Removal (Montero & Pickup)

         1) Remove splash shields. Remove O2 sensor. Remove exhaust

pipe-to-manifold nuts. Lower exhaust pipe, and remove gasket. Remove

heat protector. To remove right exhaust manifold, remove air duct,

engine lift bracket and alternator bracket.

         2) To remove left exhaust manifold, remove EGR pipe and

gasket. Remove front intake manifold plenum bracket. Remove exhaust

manifolds and gaskets.

         Inspection (Montero & Pickup)

         Clean all gasket mating surfaces. Inspect for damage and

cracks on all mounting surfaces. Check mounting surfaces of manifold

and cylinder head for warpage. Repair or replace components if warpage

exceeds .012" (.30 mm).

         Installation (Montero & Pickup)

         To install, reverse removal procedure using new gaskets.

Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS

(MONTERO & PICKUP) table at end of article.

         Removal (3000GT)

         1) Remove turbocharger(s) (if equipped). See TURBOCHARGER

under REMOVAL & INSTALLATION. On front manifold, remove serpentine

drive belt and alternator. Remove oil dipstick. On rear manifold,

remove EGR pipe (if equipped).

NOTE:    Note locations and direction of installation of exhaust

         manifold plain and spring washers for reinstallation

         reference. DO NOT mix these fasteners.

         2) On all manifolds, remove exhaust pipe-to-manifold nuts.

Lower exhaust pipe, and remove gasket. Remove heat protector. Remove

exhaust manifold nuts and washers. Note locations and direction of

installation of plain and spring washers for reinstallation reference.

DO NOT mix these fasteners. Remove exhaust manifold and gasket.

         Inspection (3000GT)

         Clean all gasket mating surfaces. Inspect for damage and

cracks on all mounting surfaces. Check mounting surfaces of manifold

and cylinder head for warpage. Repair or replace components if warpage

exceeds .012" (.30 mm).

         Installation (3000GT)

         To install, reverse removal procedure using new gaskets.

Install new "O" ring on dipstick guide. Coat "O" ring with oil before

installation. Install manifold nuts and washers in original locations.

Tighten nuts to specification in sequence. See  Fig. 4. See TORQUE

SPECIFICATIONS (3000GT) table at end of article.

Fig. 4:  Exhaust Manifold Tightening Sequence (3000GT)

Courtesy of Mitsubishi Motor Sales of America, Inc.

         CYLINDER HEADS

         Removal (SOHC)

         1) Drain cooling system. Remove upper and lower intake

manifolds and brackets. See UPPER INTAKE MANIFOLD and LOWER INTAKE

MANIFOLD under REMOVAL & INSTALLATION. Remove spark plug wires. Remove

splash shields.

         2) Disconnect O2 sensor. Disconnect exhaust pipe from exhaust

manifold, and support to crossmember using wire. Remove heat shields

and exhaust manifolds. See EXHAUST MANIFOLDS under REMOVAL &

INSTALLATION.

         3) Remove distributor (left or rear head). Remove timing belt

outer covers, camshaft sprockets, timing belt and timing belt inner

covers. See TIMING BELT under REMOVAL & INSTALLATION. Remove accessory

bracket bolts from front of cylinder head. Remove rocker cover and

gasket.

         4) Using Socket (MD998051), loosen cylinder head bolts in 2-3

steps using proper sequence. See Fig. 5. Remove cylinder head and

camshaft assemblies. Note direction of washer installation on head

bolts.

NOTE:    Cylinder head bolts must be loosened in 2-3 steps using

         proper sequence to prevent cylinder head warpage and

         cracking.

Fig. 5:  Cylinder Head Bolt Removal & Tightening Sequence

Courtesy of Mitsubishi Motor Sales of America, Inc.

         Inspection (SOHC)

         Check cylinder head height and warpage at gasket and manifold