Mitsubishi Montero (2002-2004). Manual - part 1076

THERMOSTAT

TSB Revision

ENGINE COOLING

14-13

THERMOSTAT

REMOVAL AND INSTALLATION

M1141002400312

REMOVAL SERVICE POINT

.

<<A>> RADIATOR LOWER HOSE DISCONNECTION
Make mating marks on the radiator hose and the hose clamp. 
Disconnect the radiator hose.

Pre-removal and Post-installation Operation
• Engine Coolant Draining and Refilling (Refer to 

P.14-5

.)

• Intake Air Duct Removal and Installation (Refer to 

GROUP 15, Air Cleaner 

P.15-6

.)

AC204072

12 ± 1 N·m
102 ± 13 in-lb

1

2

3

AB

REMOVAL STEPS

<<A>> >>B<<

1.

RADIATOR LOWER HOSE 
CONNECTION

2.

WATER INLET FITTING

>>A<<

3.

THERMOSTAT

REMOVAL STEPS (Continued)

AC200641AB

MATING MARKS

THERMOSTAT

TSB Revision

ENGINE COOLING

14-14

INSTALLATION SERVICE POINT

.

>>A<< THERMOSTAT INSTALLATION

CAUTION

Make absolutely sure that no oil adheres to the rubber ring 
of the thermostat. Also do not fold or scratch the rubber 
ring during installation.
Install the thermostat so that the jiggle valve is facing straight 
up. Be careful not to fold or scratch the rubber ring.

.

>>B<< RADIATOR LOWER HOSE CONNECTION
1. Insert each hose as far as the projection of the water inlet 

fitting.

2. Align the mating marks on the radiator hose and hose 

clamp, and then connect the radiator hose.

INSPECTION

M1141002500308

.

Thermostat Check
1. Immerse the thermostat in water, and heat the water while 

stirring. Check the thermostat valve opening temperature.

Standard value:
Valve opening temperature: 82 

± 2°C (180 ± 36°F)

AC000279

JIGGLE VALVE

RUBBER RING

AB

AC200642

MATING
MARKS

PROJECTION

WATER OUTLET
FITTING

AB

ACX00400

WATER PUMP

TSB Revision

ENGINE COOLING

14-15

2. Check that the amount of valve lift is at the standard value 

when the water is at the full-opening temperature.
NOTE: Measure the valve height when the thermostat is 
fully closed, and use this measurement to compare the 
valve height when the thermostat is fully open.

Standard value:
Full-opening temperature: 95

°C (203°F)

Amount of valve lift: 10 mm (0.39 inch) or more

WATER PUMP

REMOVAL AND INSTALLATION

M1141002700335

ACX00401AB

VALVE LIFT

Pre-removal and Post-installation Operation
• Engine Coolant Draining and Refilling (Refer to 

P.14-5

.)

• Timing Belt Removal and Installation (Refer to GROUP 

11A, Timing Belt 

P.11A-33

.)

• Camshaft Sprocket Removal and Installation (Refer to 

GROUP 11A, Camshaft and Valve stem seal 

P.11A-15

.)

AC204068

Bolt specifications

Thread diameter × length mm (in)

8 × 25
(0.3 × 1.0)

8 × 22
(0.3 × 0.9)

11

14 ± 1 N·m
120 ± 13 in-lb

12 ± 1 N·m
102 ± 13 in-lb

12 ± 1 N·m
102 ± 13 in-lb

9.0 ± 1.0 N·m
80 ± 9 in-lb

24 ± 3 N·m
18 ± 2 ft-lb

1

5

3

4

2

6

12

13

11

10

7

8

9

N

N

N

N

N

N

AB

14

15

16

17

13 ± 2 N·m
111 ± 22 in-lb

14 ± 1 N·m
120 ± 13 in-lb

WATER PUMP

TSB Revision

ENGINE COOLING

14-16

REMOVAL SERVICE POINT

.

<<A>> RADIATOR UPPER HOSE DISCONNECTION
After making mating marks on the radiator hose and hose 
clamp, disconnect the radiator hose.

INSTALLATION SERVICE POINTS

.

>>A<< O-RING INSTALLATION
Fit the O rings into the groove of the water pipe ends, and apply 
water to the circumference of the O ring and the pipe bores to 
insert the pipe assembly.

.

REMOVAL STEPS 

1.

ENGINE COOLANT 
TEMPERATURE SENSOR 
CONNECTOR

2.

ENGINE COOLANT 
TEMPERATURE GAUGE UNIT 
CONNECTOR

3.

SPARK PLUG CABLE SUPPORT

<<A>> >>B<<

4.

RADIATOR UPPER HOSE 
CONNECTION

5.

WATER HOSE

6.

WATER HOSE

7.

WATER OUTLET FITTING 
BRACKET

8.

WATER OUTLET FITTING

>>A<<

9.

O-RING

10. GASKET
11. WATER PUMP ASSEMBLY
12. GASKET

>>A<<

13. O-RING
14. FITTING
15. GASKET
16. GASKET
17. THERMOSTAT CASE

REMOVAL STEPS  (Continued)

AC200641AB

MATING MARKS

AC200644 AB

O-RING

WATER PIPE