Mitsubishi Montero Sport (2004+). Manual - part 584

 

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Mitsubishi Montero Sport (2004+). Manual - part 584

 

 

ENGINE COOLING DIAGNOSIS

TSB Revision

ENGINE COOLING

14-3

SYMPTOM PROCEDURES

INSPECTION PROCEDURE 1: Coolant Leak

DIAGNOSIS

STEP 1. Check for coolant leaks.

WARNING

When pressure testing the cooling system, slowly 
release cooling system pressure to avoid getting 
burned by hot coolant.

CAUTION

• Be sure to completely clean away any moisture from 

the places checked.

• When the tester is removed, be careful not to spill any 

coolant.

• When installing and removing the tester and when test-

ing, be careful not to deform the filler neck of the radia-
tor.

Check that the coolant level is up to the filler neck. Install a radi-
ator tester and apply 160 kPa (23 psi) pressure, and then check 
for leakage from the radiator hose or connections.
Q: Is leakage present from the radiator hose or 

connections?
YES : Repair or replace the appropriate part, then go to 

Step 2.

NO :  There is no action to be taken.

STEP 2. Retest the system.
Q: Can the symptom be reproduced?

YES : Return to Step 1.
NO :  This procedure is complete.

ACX01844 AB

CAP ADAPTER

ADAPTER

ENGINE COOLING DIAGNOSIS

TSB Revision

ENGINE COOLING

14-4

INSPECTION PROCEDURE 2: Engine Overheating

DIAGNOSIS

STEP 1. Remove the radiator cap and check for coolant 
contamination.
Q: Is the coolant contaminated with rust and oil?

YES : Replace it. Refer to GROUP 00, Maintenance Service 

− Engine Coolant (Change) 

P.00-54

.

NO :  There is no action to be taken, go to Step 2.

STEP 2. Check the radiator cap valve opening pressure.
NOTE:  Be sure that the cap is clean before testing. Rust or 
other foreign material on the cap seal will cause an improper 
reading.
(1) Use a cap adapter to attach the cap to the tester.
(2) Increase the pressure until the gauge indicator stops 

moving.

Minimum limit: 64 kPa (9.2 psi)
Standard value: 74 

− 103 kPa (11 − 15 psi)

Q: Does the reading remain at or above the minimum limit?

YES : Go to Step 3.
NO :  Replace the radiator cap. Then go to Step 5.

STEP 3. Check thermostat operation.

Refer to 

P.14-11

.

Q: Is the thermostat operate correctly?

YES : Go to Step 4.
NO :  Replace the thermostat, then go to Step 5.

STEP 4. Check the drive belt for slippage or damage.

Refer to GROUP 00, Maintenance Service 

− Drive Belts 

(Check Condition) 

P.00-46

.

Q: Is the drive belt loose or damaged?

YES : Adjust or replace the drive belt, then go to Step 5.
NO :  There is no action to be taken.

STEP 5. Retest the system.

Check the coolant temperature gauge.
Q: Is the coolant temperature abnormally high?

YES : Return to Step 2.
NO :  This procedure is complete.

ACX01845 AB

CAP ADAPTER

ON-VEHICLE SERVICE

TSB Revision

ENGINE COOLING

14-5

ON-VEHICLE SERVICE

ENGINE COOLANT LEAK CHECK

M1141001000203

WARNING

When pressure testing the cooling system, slowly 
release cooling system pressure to avoid getting 
burned by hot coolant.

CAUTION

• Be sure to completely clean away any moisture from 

the places checked.

• When the tester is taken out, be careful not to spill any 

coolant.

• Be careful when installing and removing the tester and 

when testing not to deform the filler neck of the radia-
tor.

1. Check that the coolant level is up to the filler neck. Install a 

radiator tester and apply 160 kPa (23 psi) pressure, and 
then check for leakage from the radiator hose or 
connections.

2. If there is leakage, repair or replace the appropriate part.

RADIATOR CAP PRESSURE CHECK

M1141001300259

NOTE: Be sure that the cap is clean before testing. Rust or 
other foreign material on the cap seal will cause an improper 
reading.

1. Use a cap adapter to attach the cap to the tester.
2. Increase the pressure until the indicator of the gauge stops 

moving.

Minimum limit: 64 kPa (9.2 psi)
Standard value: 74 

− 103 kPa (11 − 15 psi)

3. Replace the radiator cap if the reading does not remain at or 

above the limit.

ACX01844 AB

CAP ADAPTER

ADAPTER

ACX01845 AB

CAP ADAPTER

ON-VEHICLE SERVICE

TSB Revision

ENGINE COOLING

14-6

ENGINE COOLANT REPLACEMENT

M1141001200519

Check the cooling system parts such as the radiator, heater 
and oil cooler hoses, thermostat and the connections for leak-
age and damage.

.

CHANGING COOLANT

Required Special Tool:

• MB991871: LLC changer

1. Set the temperature control knob to the "HOT" position.

CAUTION

When removing the radiator cap, use care to avoid contact 
with hot coolant or steam. Place a shop towel over the cap 
and turn the cap counterclockwise a little to let the pres-
sure escape through the vinyl tube. After relieving the 
steam pressure, remove the cap by slowly turning it coun-
terclockwise.
2. Remove the radiator cap, radiator drain plug and cylinder 

block drain plug to drain the coolant.

3. Remove the reserve tank and drain the coolant.
4. After completely draining the coolant, reinstall the drain 

plugs and flush the engine and radiator using a radiator 
cleaning fluid.

5. After the flushing is completed, completely drain the 

cleaning fluid.

6. Apply the designated sealant to the screw area of the 

cylinder block drain plug, and then tighten at the standard 
torque.

• Specified sealant: 3M Nut Locking Part number 

4171 or equivalent

• Tightening torque: 39 N⋅m (29 ft-lb)

ACX00896 AC

DRAIN PLUG

RADIATOR CAP

LOOSEN

AC203004

RIGHT BANK

LEFT BANK

DRAIN PLUG

AB

AC200625AB

CYLINDER BLOCK
DRAIN PLUG

 

 

 

 

 

 

 

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