Mitsubishi Montero, Sport 1998-06

Engine

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NOTE
Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer systems and may require the computer to undergo a relearning process, once the negative battery cable is reconnected.


NOTE
Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer systems and may require the computer to undergo a relearning process, once the negative battery cable is reconnected.

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  


CAUTION
The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Drain the engine oil.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Battery
     
    Hood, matchmark for reassembly
     
    Oil dipstick
     
    Engine undercover
     
    Starter
     
    Exhaust pipe from the exhaust manifolds
     
    Transfer case, if equipped with 4WD
     
    Transmission, if equipped with a manual transmission
     

  6.  
  7. If equipped with an automatic transmission and 2WD:
    1. Remove the inspection plate.
    2.  
    3. Matchmark the flexplate to the converter; remove the torque converter bolts and move the torque converter back as far as it will go.
    4.  
    5. Remove the lower bell housing bolts.
    6.  

  8.  
  9. Remove or disconnect the following:

    Air cleaner assembly, ducts and air intake hose
     
    Linkages and cables from the throttle body
     
    Fuel lines and plug the lines
     
    Air conditioning compressor, if equipped and position it aside. It is not necessary to remove the lines from the compressor.
     
    Radiator, shroud
     
    Cooling fan
     
    Heater hoses
     
    Accessory belts
     
    Power steering pump and wires from its brackets and position it to the side. Do not remove the hoses from the pump.
     
    Alternator and wires
     
    Ignition coil and power transistor assembly, if equipped
     
    MDP sensor connector
     
    EGR connector
     
    TP sensor connector
     
    IAC motor connector
     
    Magnetic clutch and refrigerant temperature switch connector
     
    EVAP Purge Solenoid
     
    ECT sensor and gauge connectors
     
    Front and injector wiring harness
     
    CMP sensor
     
    CKP sensor
     
    Distributor signal Generator
     
    Compactor connector
     
    Left and right heated O2 sensor
     
    Oil pressure switch connector
     
    Vacuum hoses
     

  10.  
  11. Attach an engine removal device to the engine support eyes on the engine.
  12.  
  13. If equipped with an automatic transmission, support the transmission with a floor jack. Remove the remaining bell housing bolts.
  14.  
  15. Remove the engine mount nuts and remove the engine from the vehicle.
  16.  

To install:

  1. Lower the engine into position and install the engine mount nuts and bolts. Tighten the nuts to 18-20 ft. lbs. (25-27 Nm), and the bolts to tighten to 33 ft. lbs. (44 Nm).
  2.  
  3. Install or connect the following:

    Bell housing bolts
     

  4.  
  5. Remove the engine removal device and the transmission support.
  6.  
  7. Install or connect the following:

    Transfer case, if equipped
     
    Manual transmission, if equipped
     
    Automatic transmission, if equipped align the torque converter and flexplate and the bolts.
     
    Inspection plate
     
    Starter motor
     
    Exhaust pipe to the exhaust manifolds using new gaskets
     
    Lower radiator hose
     
    Heater hoses
     
    Alternator and wires
     
    Power steering pump and brackets
     
    Air conditioning compressor
     
    Linkages and cables to the carburetor or throttle body
     
    Ignition coil and power transistor assembly, if equipped
     
    MDP sensor connector
     
    EGR connector
     
    TP sensor connector
     
    IAC motor connector
     
    Magnetic clutch and refrigerant temperature switch connector
     
    EVAP Purge Solenoid
     
    ECT sensor and gauge connectors
     
    Front and injector wiring harness
     
    CMP sensor
     
    CKP sensor
     
    Distributor signal Generator
     
    Compactor connector
     
    Left and right heated O2 sensor
     
    Oil pressure switch connector
     
    Vacuum hoses
     
    Air cleaner assembly, ducts and air intake hose
     
    Accessory belts
     
    Radiator, shroud and upper hose
     
    Cooling fan
     
    Battery
     
    Oil dipstick
     
    Hood
     

  8.  
  9. Refill the engine with the specified amount of oil.
  10.  
  11. Refill the radiator with coolant.
  12.  
  13. Check fuel system for leaks.
  14.  
  15. Check the automatic transmission fluid level, if equipped.
  16.  
  17. Recheck all engine adjustments.
  18.  

2.4L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    CAUTION
    The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil and coolant.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:
    CAUTION
    Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.



    Negative battery cable
     



    Battery
     
    Hood, matchmark for reassembly
     
    Oil dipstick
     
    Engine undercover
     
    Lower radiator hose
     
    Starter
     
    Exhaust pipe from the exhaust manifold
     
    Transfer case from vehicle, if equipped with 4WD
     
    Transmission, if equipped with a manual transmission
     

  10.  
  11. If equipped with an automatic transmission and 2WD:
    1. Remove the inspection plate.
    2.  
    3. Matchmark the flexplate and converter. Remove the torque converter bolts and move the torque converter back as far as it will go.
    4.  
    5. Remove the lower bell housing bolts.
    6.  

  12.  
  13. Remove or disconnect the following:

    Air cleaner assembly, ducts and air intake hose
     
    Linkages and cables from the throttle body
     
    Fuel lines and plug the lines
     
    Air conditioning compressor, if equipped and position it aside. It is not necessary to remove the lines from the compressor.
     
    Radiator and shroud
     
    Cooling fan
     
    Heater hoses
     
    Accessory belts
     
    Power steering pump and wires from its brackets and position it to the side. Do not remove the hoses from the pump.
     
    Alternator and wires
     
    Ignition coil and power transistor assembly, if equipped
     
    Manifold Differential Pressure (MDP) sensor connector
     
    Exhaust Gas Recirculation (EGR) connector
     
    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) motor connector
     
    Evaporative Emission (EVAP) Purge Solenoid
     
    Engine Coolant Temperature (ECT) sensor and gauge connectors
     
    Front and injector wiring harness
     
    Crankshaft Position (CKP) sensor
     
    Distributor signal Generator
     
    Heated Oxygen (O 2 S) sensor
     
    Oil pressure switch connector
     
    Vacuum hoses
     

  14.  
  15. Attach an engine removal device to the engine support eyes on the engine.
  16.  
  17. If equipped with an automatic transmission, support the transmission with a floor jack. Remove the remaining bell housing bolts.
  18.  
  19. Remove the engine mount nuts and remove the engine from the vehicle.
  20.  

To install:

  1. Lower the engine into position
  2.  
  3. Install or connect the following:

    Engine mount nuts. Torque the nuts to 14-22 ft. lbs. (30-40 Nm).
     
    Bell housing bolts. Torque the bolts to 54 ft. lbs. (74 Nm).
     

  4.  
  5. Remove the engine removal device and the transmission support.
  6.  
  7. Install or connect the following:

    Transfer case, if equipped
     
    Manual transmission, if equipped
     

  8.  
  9. If equipped with an automatic transmission, align the torque converter and flexplate and install the bolts. Torque the bolts to 33-38 ft. lbs. (45-52 Nm).
  10.  
  11. Install or connect the following:

    Inspection plate
     
    Starter
     
    Exhaust pipe to the exhaust manifold using new gaskets
     
    Lower radiator hose
     
    Heater hoses
     
    Alternator
     
    Power steering pump and all brackets
     
    Air conditioning compressor
     
    Linkages and cables to the throttle body
     
    Ignition coil and power transistor assembly
     
    Manifold Differential Pressure (MDP) sensor connector
     
    Exhaust Gas Recirculation (EGR) connector
     
    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) motor connector
     
    Magnetic clutch and refrigerant temperature switch connector
     
    Evaporative Emission (EVAP) Purge Solenoid
     
    Engine Coolant Temperature (ECT) sensor and gauge connectors
     
    Front and injector wiring harness
     
    Crankshaft Position (CKP) sensor
     
    Distributor signal Generator
     
    Heated Oxygen (O 2 S) sensor
     
    Oil pressure switch connector
     
    Vacuum hoses
     
    Radiator and shroud
     
    Cooling fan
     
    Accessory belts
     
    Engine undercover
     
    Air cleaner assembly, ducts and air intake hose
     
    Oil dipstick
     
    Battery and cables
     
    Hood
     

  12.  
  13. Fill the engine with the specified amount of oil and fill the radiator with coolant.
  14.  
  15. Inspect the fuel system for leaks.
  16.  
  17. Check the automatic transmission fluid level, if equipped.
  18.  
  19. Recheck all engine adjustments.
  20.  

  1. Before servicing the vehicle, refer to the Precautions section.
    CAUTION
    The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil and coolant.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:
    CAUTION
    Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.



    Negative battery cable
     



    Battery
     
    Hood, matchmark for reassembly
     
    Oil dipstick
     
    Engine undercover
     
    Lower radiator hose
     
    Starter
     
    Exhaust pipe from the exhaust manifold
     
    Transfer case from vehicle, if equipped with 4WD
     
    Transmission, if equipped with a manual transmission
     

  10.  
  11. If equipped with an automatic transmission and 2WD:
    1. Remove the inspection plate.
    2.  
    3. Matchmark the flexplate and converter. Remove the torque converter bolts and move the torque converter back as far as it will go.
    4.  
    5. Remove the lower bell housing bolts.
    6.  

  12.  
  13. Remove or disconnect the following:

    Air cleaner assembly, ducts and air intake hose
     
    Linkages and cables from the throttle body
     
    Fuel lines and plug the lines
     
    Air conditioning compressor, if equipped and position it aside. It is not necessary to remove the lines from the compressor.
     
    Radiator and shroud
     
    Cooling fan
     
    Heater hoses
     
    Accessory belts
     
    Power steering pump and wires from its brackets and position it to the side. Do not remove the hoses from the pump.
     
    Alternator and wires
     
    Ignition coil and power transistor assembly, if equipped
     
    Manifold Differential Pressure (MDP) sensor connector
     
    Exhaust Gas Recirculation (EGR) connector
     
    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) motor connector
     
    Evaporative Emission (EVAP) Purge Solenoid
     
    Engine Coolant Temperature (ECT) sensor and gauge connectors
     
    Front and injector wiring harness
     
    Crankshaft Position (CKP) sensor
     
    Distributor signal Generator
     
    Heated Oxygen (O 2 S) sensor
     
    Oil pressure switch connector
     
    Vacuum hoses
     

  14.  
  15. Attach an engine removal device to the engine support eyes on the engine.
  16.  
  17. If equipped with an automatic transmission, support the transmission with a floor jack. Remove the remaining bell housing bolts.
  18.  
  19. Remove the engine mount nuts and remove the engine from the vehicle.
  20.  

To install:

  1. Lower the engine into position
  2.  
  3. Install or connect the following:

    Engine mount nuts. Torque the nuts to 14-22 ft. lbs. (30-40 Nm).
     
    Bell housing bolts. Torque the bolts to 54 ft. lbs. (74 Nm).
     

  4.  
  5. Remove the engine removal device and the transmission support.
  6.  
  7. Install or connect the following:

    Transfer case, if equipped
     
    Manual transmission, if equipped
     

  8.  
  9. If equipped with an automatic transmission, align the torque converter and flexplate and install the bolts. Torque the bolts to 33-38 ft. lbs. (45-52 Nm).
  10.  
  11. Install or connect the following:

    Inspection plate
     
    Starter
     
    Exhaust pipe to the exhaust manifold using new gaskets
     
    Lower radiator hose
     
    Heater hoses
     
    Alternator
     
    Power steering pump and all brackets
     
    Air conditioning compressor
     
    Linkages and cables to the throttle body
     
    Ignition coil and power transistor assembly
     
    Manifold Differential Pressure (MDP) sensor connector
     
    Exhaust Gas Recirculation (EGR) connector
     
    Throttle Position (TP) sensor connector
     
    Idle Air Control (IAC) motor connector
     
    Magnetic clutch and refrigerant temperature switch connector
     
    Evaporative Emission (EVAP) Purge Solenoid
     
    Engine Coolant Temperature (ECT) sensor and gauge connectors
     
    Front and injector wiring harness
     
    Crankshaft Position (CKP) sensor
     
    Distributor signal Generator
     
    Heated Oxygen (O 2 S) sensor
     
    Oil pressure switch connector
     
    Vacuum hoses
     
    Radiator and shroud
     
    Cooling fan
     
    Accessory belts
     
    Engine undercover
     
    Air cleaner assembly, ducts and air intake hose
     
    Oil dipstick
     
    Battery and cables
     
    Hood
     

  12.  
  13. Fill the engine with the specified amount of oil and fill the radiator with coolant.
  14.  
  15. Inspect the fuel system for leaks.
  16.  
  17. Check the automatic transmission fluid level, if equipped.
  18.  
  19. Recheck all engine adjustments.
  20.  

3.0L & 3.5L Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
    CAUTION
    The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Battery
     
    Hood, matchmark for reassembly
     
    Oil dipstick
     
    Engine undercover
     
    Starter
     
    Exhaust pipe from the exhaust manifolds
     
    Transfer case, if equipped with 4WD
     
    Transmission, if equipped with a manual transmission
     

  10.  
  11. If equipped with an automatic transmission and 2WD:
    1. Remove the inspection plate.
    2.  
    3. Matchmark the flexplate to the converter; remove the torque converter bolts and move the torque converter back as far as it will go.
    4.  
    5. Remove the lower bell housing bolts.
    6.  

  12.  
  13. Remove or disconnect the following:

    Air cleaner assembly, ducts and air intake hose
     
    Linkages and cables from the throttle body
     
    Fuel lines and plug the lines
     
    Air conditioning compressor, if equipped and position it aside. It is not necessary to remove the lines from the compressor.
     
    Radiator, shroud
     
    Cooling fan
     
    Heater hoses
     
    Accessory belts
     
    Power steering pump and wires from its brackets and position it to the side. Do not remove the hoses from the pump.
     
    Alternator and wires
     
    Ignition coil and power transistor assembly, if equipped
     
    MDP sensor connector
     
    EGR connector
     
    TP sensor connector
     
    IAC motor connector
     
    Magnetic clutch and refrigerant temperature switch connector
     
    EVAP Purge Solenoid
     
    ECT sensor and gauge connectors
     
    Front and injector wiring harness
     
    CMP sensor
     
    CKP sensor
     
    Distributor signal Generator
     
    Compactor connector
     
    Left and right heated O 2 S sensor
     
    Oil pressure switch connector
     
    Vacuum hoses
     

  14.  
  15. Attach an engine removal device to the engine support eyes on the engine.
  16.  
  17. If equipped with an automatic transmission, support the transmission with a floor jack. Remove the remaining bell housing bolts.
  18.  
  19. Remove the engine mount nuts and remove the engine from the vehicle.
  20.  

To install:

  1. Lower the engine into position and install the engine mount nuts. Tighten the nuts to 20 ft. lbs. (27 Nm), on the Montero, tighten to 33 ft. lbs. (44 Nm).
  2.  
  3. Install or connect the following:

    Bell housing bolts
     

  4.  
  5. Remove the engine removal device and the transmission support.
  6.  
  7. Install or connect the following:

    Transfer case, if equipped
     
    Manual transmission, if equipped
     
    Automatic transmission, if equipped align the torque converter and flexplate and the bolts.
     
    Inspection plate
     
    Starter motor
     
    Exhaust pipe to the exhaust manifolds using new gaskets
     
    Lower radiator hose
     
    Heater hoses
     
    Alternator and wires
     
    Power steering pump and brackets
     
    Air conditioning compressor
     
    Linkages and cables to the carburetor or throttle body
     
    Ignition coil and power transistor assembly, if equipped
     
    MDP sensor connector
     
    EGR connector
     
    TP sensor connector
     
    IAC motor connector
     
    Magnetic clutch and refrigerant temperature switch connector
     
    EVAP Purge Solenoid
     
    ECT sensor and gauge connectors
     
    Front and injector wiring harness
     
    CMP sensor
     
    CKP sensor
     
    Distributor signal Generator
     
    Compactor connector
     
    Left and right heated O 2 S sensor
     
    Oil pressure switch connector
     
    Vacuum hoses
     
    Air cleaner assembly, ducts and air intake hose
     
    Accessory belts
     
    Radiator, shroud and upper hose
     
    Cooling fan
     
    Battery
     
    Oil dipstick
     
    Hood
     

  8.  
  9. Refill the engine with the specified amount of oil.
  10.  
  11. Refill the radiator with coolant.
  12.  
  13. Check fuel system for leaks.
  14.  
  15. Check the automatic transmission fluid level, if equipped.
  16.  
  17. Recheck all engine adjustments.
  18.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
    CAUTION
    The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Battery
     
    Hood, matchmark for reassembly
     
    Oil dipstick
     
    Engine undercover
     
    Starter
     
    Exhaust pipe from the exhaust manifolds
     
    Transfer case, if equipped with 4WD
     
    Transmission, if equipped with a manual transmission
     

  10.  
  11. If equipped with an automatic transmission and 2WD:
    1. Remove the inspection plate.
    2.  
    3. Matchmark the flexplate to the converter; remove the torque converter bolts and move the torque converter back as far as it will go.
    4.  
    5. Remove the lower bell housing bolts.
    6.  

  12.  
  13. Remove or disconnect the following:

    Air cleaner assembly, ducts and air intake hose
     
    Linkages and cables from the throttle body
     
    Fuel lines and plug the lines
     
    Air conditioning compressor, if equipped and position it aside. It is not necessary to remove the lines from the compressor.
     
    Radiator, shroud
     
    Cooling fan
     
    Heater hoses
     
    Accessory belts
     
    Power steering pump and wires from its brackets and position it to the side. Do not remove the hoses from the pump.
     
    Alternator and wires
     
    Ignition coil and power transistor assembly, if equipped
     
    MDP sensor connector
     
    EGR connector
     
    TP sensor connector
     
    IAC motor connector
     
    Magnetic clutch and refrigerant temperature switch connector
     
    EVAP Purge Solenoid
     
    ECT sensor and gauge connectors
     
    Front and injector wiring harness
     
    CMP sensor
     
    CKP sensor
     
    Distributor signal Generator
     
    Compactor connector
     
    Left and right heated O 2 sensor
     
    Oil pressure switch connector
     
    Vacuum hoses
     

  14.  
  15. Attach an engine removal device to the engine support eyes on the engine.
  16.  
  17. If equipped with an automatic transmission, support the transmission with a floor jack. Remove the remaining bell housing bolts.
  18.  
  19. Remove the engine mount nuts and remove the engine from the vehicle.
  20.  

To install:

  1. Lower the engine into position and install the engine mount nuts and bolts. Tighten the nuts to 18-20 ft. lbs. (25-27 Nm), and the bolts to tighten to 33 ft. lbs. (44 Nm).
  2.  
  3. Install or connect the following:

    Bell housing bolts
     

  4.  
  5. Remove the engine removal device and the transmission support.
  6.  
  7. Install or connect the following:

    Transfer case, if equipped
     
    Manual transmission, if equipped
     
    Automatic transmission, if equipped align the torque converter and flexplate and the bolts.
     
    Inspection plate
     
    Starter motor
     
    Exhaust pipe to the exhaust manifolds using new gaskets
     
    Lower radiator hose
     
    Heater hoses
     
    Alternator and wires
     
    Power steering pump and brackets
     
    Air conditioning compressor
     
    Linkages and cables to the carburetor or throttle body
     
    Ignition coil and power transistor assembly, if equipped
     
    MDP sensor connector
     
    EGR connector
     
    TP sensor connector
     
    IAC motor connector
     
    Magnetic clutch and refrigerant temperature switch connector
     
    EVAP Purge Solenoid
     
    ECT sensor and gauge connectors
     
    Front and injector wiring harness
     
    CMP sensor
     
    CKP sensor
     
    Distributor signal Generator
     
    Compactor connector
     
    Left and right heated O 2 sensor
     
    Oil pressure switch connector
     
    Vacuum hoses
     
    Air cleaner assembly, ducts and air intake hose
     
    Accessory belts
     
    Radiator, shroud and upper hose
     
    Cooling fan
     
    Battery
     
    Oil dipstick
     
    Hood
     

  8.  
  9. Refill the engine with the specified amount of oil.
  10.  
  11. Refill the radiator with coolant.
  12.  
  13. Check fuel system for leaks.
  14.  
  15. Check the automatic transmission fluid level, if equipped.
  16.  
  17. Recheck all engine adjustments.
  18.  

3.0L Engine
12v
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
    CAUTION
    The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  4.  
  5. Drain the engine oil.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:
  10.  
  11. Remove the hood.
  12.  
  13. Remove the radiator.
  14.  
  15. Remove the undercover skid plate.
  16.  
  17. Remove the front exhaust pipe.
  18.  
  19. Disconnect the transmission.
  20.  
  21. Remove or disconnect the following:
    NOTE
    Remove the air conditioning compressor (with the hose attached). Suspend the removed oil pump (by using wire or similar material) at a place where no damage will be caused during removal and installation of the engine assembly.


    NOTE
    Remove the oil pump (with the hose attached). Suspend the removed oil pump (by using wire or similar material) at a place where no damage will be caused during removal and installation of the engine assembly.


    NOTE
    Use a spanner or similar tool to disconnect the oil cooler hose.


    NOTE
    Check that all cables, hoses, harness connectors, etc. are disconnected from the engine. Lift the special tool and a chain block slowly to remove the engine assembly upward from the engine compartment.



    Accelerator cable connection
     
    Air intake hose
     
    Drive belt (A/C)
     
    Compressor (A/C)
     



    Ground cable connection
     
    Drive belt (power steering)
     
    Oil pump (power steering)
     



    Oil cooler hose connection
     



    High pressure fuel hose
     
    Fuel return hose connection
     
    Vacuum hose connection
     
    Brake booster vacuum hose connection
     
    Heater hose connections
     
    Heater hose B connection
     
    Generator connector
     
    IAC motor
     
    TPS connector
     
    Crankshaft position sensor connector
     
    Engine coolant temperature
     
    Thermo switch connector (A/T)
     
    Engine coolant temperature gauge unit connector
     
    Distributor signal generator connector
     
    Manifold differential pressure sensor connector
     
    Oil pressure gauge unit connector
     
    Heat protectors
     
    Engine mounting bolt.
     
    Engine assembly
     

  22.  

To install:

Reverse the removal procedure for installation. Use the special tool and a chain block to install the engine assembly. When doing so, check carefully that all pipes and hoses are connected, and that none are twisted, damaged, etc. Tighten mounting bolts to 25 ft. lbs. (34 Nm). Use a spanner or similar tool to connect the oil cooler hose.

  1. Fill the engine with the specified amount of oil and fill the radiator with coolant.
  2.  
  3. Inspect the fuel system for leaks.
  4.  
  5. Check the automatic transmission fluid level, if equipped.
  6.  
  7. Recheck all engine adjustments.
  8.  

24v
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Remove the A/C compressor (with hose attached).


    NOTE
    Remove the power steering oil pump (with the hose attached. Suspend the removed oil pump (by using a wire or similar material) at a place where no damage will be caused during removal/installation of the engine assembly.


    NOTE
    Use a spanner or similar tool to remove the oil cooler hose connection.


    NOTE
    Check that all cables, hoses, harness connectors, etc. are disconnected from the engine. Lift the special tool and a chain block slowly to remove the engine assembly upward from the engine compartment.



    Hood
     
    Battery and battery tray
     
    Auto-cruise control intermediate link
     
    Radiator
     
    Under skid plate, undercover
     
    Front exhaust pipe (Federal)
     
    Warm up Three-way catalytic converter (California)
     
    Transmission and transfer assembly
     
    Power steering drive belt
     
    Generator drive belt
     
    A/C drive belt
     
    Cooling fan
     
    Water pump pulley
     
    A/C compressor
     



    Cover
     
    Power steering pump
     



    Engine control harness connection
     
    Generator and starter harness connection
     
    Engine oil cooler hose connection
     



    Accelerator cable connection
     
    Throttle cable connection
     
    Brake booster vacuum hose connection
     
    Heater hose connection
     
    Fuel hose connection
     
    Fuel return hose connection
     
    Oil pressure switch harness connection
     
    Heat protectors
     
    Engine mounting bolt
     
    Engine assembly
     

  4.  

To install:

To install, reverse removal procedure. Use the special tool and a chain block to install the engine assembly. When doing so, check carefully that all pipes and hoses are connected, and that none are twisted, damaged, etc. Use a spanner or similar tool to connect the oil cooler hose.

  1. Fill the engine with the specified amount of oil and fill the radiator with coolant.
  2.  
  3. Inspect the fuel system for leaks.
  4.  
  5. Check the automatic transmission fluid level, if equipped.
  6.  
  7. Recheck all engine adjustments.
  8.  

3.5L Engines
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:
    NOTE
    Remove the air conditioning compressor (with the hose attached).


    NOTE
    Remove the power steering oil pump (with the hose attached). Suspend the removed oil pump (by using a wire of similar material) at a place where no damage will be caused during removal and installation of the engine assembly.


    NOTE
    Check that all cables, hoses, harness connectors, etc. are disconnected from the engine. Lift the special tool and a chain block slowly to remove the engine assembly upward from the engine compartment.



    Hood
     
    Battery and battery tray
     
    Auto-cruise control intermediate link removal
     
    Radiator
     
    Under skid plate
     
    Front exhaust pipe
     
    Transmission and transfer assembly
     
    Intake manifold plenum cover
     
    Power steering drive belt
     
    A/C drive belt
     
    Cooling fan
     
    Water pump pulley
     
    A/C compressor
     



    Cover
     
    Power steering pump
     



    Ground cable connection
     
    Engine control harness connection
     
    Generator and starter harness connection
     
    Engine oil cooler hose connection
     
    Accelerator cable connection
     
    Throttle cable connection
     
    Brake booster vacuum hose connection
     
    Fuel hose connection
     
    Heater hose connection
     
    Heat protectors
     
    Engine mounting bolt
     
    Engine assembly
     

  4.  

To install:

Reverse removal procedure to install the engine assembly. Use the special tool and a chain block to install the engine assembly. When doing so, check carefully that all pipes and hoses are connected, and that none are twisted or damaged. Use a spanner or similar tool to connect the oil cooler hose.

  1. Fill the engine with the specified amount of oil and fill the radiator with coolant.
  2.  
  3. Inspect the fuel system for leaks.
  4.  
  5. Check the automatic transmission fluid level, if equipped.
  6.  
  7. Recheck all engine adjustments.
  8.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
    CAUTION
    The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  4.  
  5. Disconnect the negative battery cable. Matchmark and remove the hood.
  6.  
  7. Remove the air cleaner assembly. Remove the battery. Drain the engine oil.
  8.  
  9. Drain the cooling system. Remove the radiator. Disconnect the exhaust pipes at the catalytic converters.
  10.  
  11. Remove the transmission assembly.
  12.  
  13. Disconnect all the ignition coil electrical connectors. Disconnect the camshaft position electrical connector.
  14.  
  15. Disconnect the crankshaft position sensor electrical connector, ignition power transistor connector, capacitor connector and engine coolant temperature sensor connector.
  16.  
  17. Disconnect the engine coolant temperature gauge unit connector, front wiring harness and injection wiring harness combination connector.
  18.  
  19. Disconnect the MAP sensor electrical connector, EGR vacuum regulator solenoid valve connector, EVAP solenoid connector and the front right and front left heated oxygen sensor electrical connectors.
  20.  
  21. Disconnect the TPS sensor electrical connector, idle air control motor connector, alternator connector and the power steering pressure switch connector.
  22.  
  23. Disconnect the magnetic clutch and refrigerant temperature switch connector. Disconnect the oil pressure switch connector.
  24.  
  25. Disconnect the throttle cable connection, all vacuum hose connections, fuel return hose connection and the fuel high pressure hose connection.
  26.  
  27. Disconnect the heater hoses. Disconnect the rear heater hose, if the vehicle is equipped with rear heater.
  28.  
  29. Remove the power steering drive belt cover and the power steering belt. Remove the power steering pump retaining bolts. Remove the power steering pump. Position the assembly to the side; it is not necessary to disconnect the fluid lines.
  30.  
  31. Remove the air conditioning belt. Remove the air conditioning compressor retaining bolts. Remove the air conditioning compressor. Position the assembly to the side; it is not necessary to disconnect the refrigerant lines.
  32.  
  33. Remove the front insulator stopper. Remove the engine mount insulator.
  34.  
  35. Install engine lifting tool MB991683 or equivalent.
  36.  
  37. Check that all cables, hoses, harness connectors, etc are disconnected from the engine.
  38.  
  39. Carefully remove the engine assembly from the vehicle.
  40.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Be sure to check and adjust all fluid levels.
  4.  
  5. Start the engine and check for leaks. Correct, as required.
  6.  

3.8L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
    CAUTION
    The fuel injection system remains under pressure after the engine has been OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  4.  
  5. Disconnect the negative battery cable. Remove the battery. Matchmark and remove the hood.
  6.  
  7. Remove the air cleaner assembly. Remove the battery. Drain the engine oil.
  8.  
  9. Drain the cooling system. Remove the radiator. Remove the cooling fan and clutch assembly.
  10.  
  11. Remove the front exhaust pipe.
  12.  
  13. Remove the transmission assembly.
  14.  
  15. Disconnect the TPS sensor electrical connector, EGR connector, right and left front heated oxygen sensor connector and the MAP sensor connector.
  16.  
  17. Disconnect the noise condenser connector, control wiring harness and camshaft position sensor wiring harness connector.
  18.  
  19. Disconnect the knock sensor connector, ignition coil connector, control wiring harness and injection wiring harness combination connector.
  20.  
  21. Disconnect the power steering pump switch connector, air conditioning compressor assembly connector and the intake manifold tuning solenoid connector.
  22.  
  23. Disconnect the engine coolant temperature gauge unit connector, engine coolant temperature gauge sensor connector and all engine grounding cables.
  24.  
  25. Disconnect the purge hose connection. Disconnect the heater hoses. Disconnect the fuel return line and the high pressure line. Discard the O-rings.
  26.  
  27. Remove the power steering pump retaining bolts. Remove the power steering pump. Position the assembly to the side; it is not necessary to disconnect the fluid lines.
  28.  
  29. Remove the air conditioning compressor retaining bolts. Remove the air conditioning compressor. Position the assembly to the side; it is not necessary to disconnect the refrigerant lines. Remove the eye bolts and gaskets.
  30.  
  31. Remove the heat protector. Remove the engine front mount insulator.
  32.  
  33. Install engine lifting tool MB991683 or equivalent.
  34.  
  35. Check that all cables, hoses, harness connectors, etc are disconnected from the engine.
  36.  
  37. Carefully remove the engine assembly from the vehicle.
  38.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Be sure to check and adjust all fluid levels.
  4.  
  5. Start the engine and check for leaks. Correct, as required.
  6.  
  7. On 2006 vehicles, complete the vehicle initialization procedure.
    NOTE
    To complete the initialization procedure the following tools are needed. MB991958 scan tool, MB991824 VCI, MB991827 MUT III USB cable, MB991910 MUT III Main harness -A-

  8.  
  9. Connect the scan tool to the data link connector. To prevent damage to the scan tool be sure that the ignition switch is in the LOCK position before connecting the scan tool.
  10.  
  11. Turn the ignition switch to the ON position.
  12.  
  13. Select -check mode- from the menu screen.
  14.  
  15. Select -erase memory- from the menu screen.
  16.  
  17. Initialize the learning value.
  18.  
  19. After initialization complete the idle learning procedure.
    NOTE
    This procedure must be performed when the PCM is replaced, or when the learning value is initialized, as the idling is not stabilized because the learning value in the MFI engine is not completed.

  20.  
  21. Start the engine. Allow the coolant temperature to reach 176 degrees or more.
  22.  
  23. Stop the engine and place the ignition switch in the LOCK position.
  24.  
  25. After ten seconds, restart the engine.
  26.  
  27. For ten minutes carry out the idling procedure below to confirm that the engine has normal idling.
    NOTE
    If the engine stalls during idling, check the throttle valve of the throttle body for dirt. Correct and perform the procedure again.



    Position the transaxle selector lever in the P range
     
    The engine fan is not to be operated
     
    The engine coolant temperature should be 176 degrees or more
     

  28.  

 
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