Mitsubishi Montero (2002-2004). Manual - part 443

GENERATOR AND DRIVE BELT

TSB Revision

ENGINE OVERHAUL

11B-5

REMOVAL SERVICE POINT

.

<<A>> CRANKSHAFT BOLT LOOSENING
1. Using special tool MD998781, hold the drive plate or 

flywheel.

2. Remove the crankshaft bolt.

INSTALLATION SERVICE POINT

.

>>A<< CRANKSHAFT BOLT TIGHTENING
1. Using special tool MD998781, hold the drive plate or 

flywheel.

2. Clean the bolt hole in crankshaft bolt and damper pulley’s 

seating surface.

3. Degrease the cleaned seating surface of the damper pulley.
4. Install the damper pulley.
5. Apply oil to the threads of crankshaft bolt and the outer 

surface of washer.

6. Tighten the crankshaft bolt to the specified torque.

Tightening torque: 185 

± 5 N⋅m (137 ± 3 ft-lb) 

AKX01329

MD998781

AB

AKX01329

MD998781

AB

AK101127

CRANKSHAFT
BOLT

AB

DAMPER PULLEY

CRANKSHAFT

CLEAN

DEGREASE

WASHER

INTAKE MANIFOLD PLENUM AND THROTTLE BODY ASSEMBLY

TSB Revision

ENGINE OVERHAUL

11B-6

INTAKE MANIFOLD PLENUM AND THROTTLE BODY 

ASSEMBLY

INTAKE MANIFOLD PLENUMREMOVAL AND INSTALLATION

M1113003300128

AK201072

18 ± 2 N·m
13 ± 1 ft-lb

23

16

13 ± 2 N·m
113 ± 17 in-lb

18 ± 2 N·m
13 ± 1 ft-lb

14 ± 1 N·m
124 ± 9 in-lb

20

14

13

24 ± 3 N·m
113 ± 17 ft-lb

4

3

2

1

9 ± 1 N·m
80 ± 9 in-lb

9 ± 1 N·m
80 ± 9 in-lb

9 ± 1 N·m
80 ± 9 in-lb

9 ± 1 N·m
80 ± 9 in-lb

7

8

6

5

11

12

9

10

15

17

21

22

19

18

26

24

25

27

AB

5 ± 1 N·m
44 ± 9 in-lb

18 ± 2 N·m
13 ± 1 ft-lb

59 ± 10 N·m
43 ± 7 ft-lb

36 ± 6 N·m
27 ± 4 ft-lb

REMOVAL STEPS

1. VACUUM HOSE
2. VACUUM HOSE
3. VACUUM TANK
4. SOLENOID VALVE 
5. PURGE HOSE
6. SOLENOID VALVE 
7. FUEL HOSE
8. FUEL RETURN PIPE
9. BREATHER HOSE
10. BREATHER HOSE
11. VACUUM PIPE AND HOSE
12. BREATHER AND WATER HOSE

13. EXHAUST GAS RECIRCULATION 

VALVE

14. EXHAUST GAS RECIRCULATION 

VALVE GASKET 

15. MANIFOLD DIFFERENTIAL 

PRESSURE SENSOR 

16. O-RING
17. EXHAUST GAS RECIRCULATION 

PIPE

18. EXHAUST GAS RECIRCULATION 

PIPE GASKET 

19. INTAKE MANIFOLD PLENUM STAY
20. WATER OUTLET FITTING BRACKET

REMOVAL STEPS (Continued)

INTAKE MANIFOLD PLENUM AND THROTTLE BODY ASSEMBLY

TSB Revision

ENGINE OVERHAUL

11B-7

INSTALLATION SERVICE POINT

.

>>A<< THROTTLE BODY GASKET INSTALLATION
Install the gasket so that the tab is positioned as shown in the 
illustration.

21. PURGE HOSE BRACKET
22. THROTTLE BODY

>>A<<

23. THROTTLE BODY GASKET
24. INTAKE MANIFOLD PLENUM
25. INTAKE MANIFOLD PLENUM VALVE 

GASKET

26. INTAKE MANIFOLD PLENUM VALVE 

ASSEMBLY

27. INTAKE MANIFOLD PLENUM 

GASKET

REMOVAL STEPS (Continued)

AK201270 AB

TAB

GASKET

IGNITION SYSTEM

TSB Revision

ENGINE OVERHAUL

11B-8

IGNITION SYSTEM

REMOVAL AND INSTALLATION

M1113001600112

AK201073

1

2

25 ± 5 N·m
18 ± 4 ft-lb

3

8

9

10

AB

22 ± 4 N·m
16 ± 3 ft-lb

14 ± 1 N·m
124 ± 9 in-lb

11 ± 1 N·m
97 ± 9 in-lb

7

13 ± 2 N·m
115 ± 18 in-lb

10 ± 2 N·m
89 ± 17 in-lb

6

5

4

10 ± 2 N·m
89 ± 17 in-lb

10 ± 2 N·m
89 ± 17 in-lb

REMOVAL STEPS

1. SPARK PLUG CABLES
2. IGNITION COIL
3. SPARK PLUGS
4. SPARK PLUG CABLE SUPPORT
5. SPARK PLUG CABLE SUPPORT
6. SPARK PLUG CABLE SUPPORT

7. CAMSHAFT POSITION SENSOR
8. O-RING

>>B<<

9. CAMSHAFT POSITION SENSOR 

SUPPORT

<<A>> >>A<<

10. CAMSHAFT POSITION SENSING 

CYLINDER

REMOVAL STEPS (Continued)