Mitsubishi Montero, Sport 1998-06

Removal & Installation

Print

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. If necessary, properly release the fuel pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. 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
     



    Upper radiator shroud
     
    Accessory belts
     
    Air conditioning compressor tensioner pulley, if equipped
     
    Cooling fan and clutch assembly and the water pump pulley
     
    Thermostat and housing on 3.0L, 3.5L engines
     
    Water outlet, gasket and houses
     
    Radiator hoses from the water pump
     
    Crankshaft pulley(s)
     
    Timing belt covers. If the same timing belt will be reused, mark the direction of the timing belt's rotation, for installation in the same direction. Be sure the engine is positioned so the No. 1 cylinder is at the TDC of its compression stroke and the sprockets timing marks are aligned with the engine's timing mark indicators.
     
    Timing belt
     
    Water pump bolts are different lengths, note their positions before removing.
     
    Water pump from the block
     
    Water pipe connection and O-ring
     

  8.  

To install:

  1. Clean and dry the mating surfaces of the block and water pump
  2.  
  3. Install or connect the following:

    New O-ring on the water pipe connection, wet the new O-ring with water to aid in installation
     
    Water pump, with a new gasket, Torque the bolts to 106-133 inch lbs. (12-15 Nm) on 2.4L engine, 17 ft. lbs. (23 Nm) on 3.0L and 3.5L engines

    Click image to see an enlarged view

    Fig. Water pump and related components-2.4L engine

     
    Alternator bracket bolt to 17 ft. lbs. (23 Nm)
     
    Timing belt(s) and covers
     
    Crankshaft pulley(s)
     
    Thermostat and housing on 3.0L, 3.5L engines. Torque the bolts to 12-14 ft. lbs. (17-20 Nm).
     
    Radiator hose to the water pump
     
    Water outlet, new gasket and houses. Torque the bolts to 12-14 ft. lbs. (17-20 Nm).
     
    Water pump pulley
     
    Cooling fan and clutch assembly
     
    Air conditioning compressor tensioner pulley, if equipped
     
    Accessory belts
     
    Upper radiator shroud
     
    Thermostat and housing on 3.0L, 3.5L engines
     
    Negative battery cable
     

  4.  
  5. Refill the radiator with coolant. This cooling system has a self-bleeding thermostat, so system bleeding is not required.
  6.  
  7. Run the vehicle until the thermostat opens and fill the overflow tank. Check for leaks.
  8.  
  9. Once the vehicle has cooled, recheck the coolant level.

    Click image to see an enlarged view

    Fig. Water pump mounting-3.0L engine



    Click image to see an enlarged view

    Fig. Water pump and related components-3.5L engine

  10.  

2.4L Engine



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. If necessary, properly release the fuel pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. 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
     



    Upper radiator shroud
     
    Accessory belts
     
    Air conditioning compressor tensioner pulley, if equipped
     
    Cooling fan and clutch assembly and the water pump pulley
     
    Water outlet, gasket and houses
     
    Radiator hoses from the water pump
     
    Crankshaft pulley(s)
     
    Timing belt covers. If the same timing belt will be reused, mark the direction of the timing belt's rotation, for installation in the same direction. Be sure the engine is positioned so the No. 1 cylinder is at the TDC of its compression stroke and the sprockets timing marks are aligned with the engine's timing mark indicators.
     
    Timing belt
     
    Water pump bolts are different lengths, note their positions before removing.
     
    Water pump from the block
     
    Water pipe connection and O-ring
     

  8.  

To install:

  1. Clean and dry the mating surfaces of the block and water pump
  2.  
  3. Install or connect the following:

    New O-ring on the water pipe connection, wet the new O-ring with water to aid in installation
     
    Water pump, with a new gasket, Torque the bolts to 106-133 inch lbs. (12-15 Nm).

    Click image to see an enlarged view

    Fig. Water pump and related components-2.4L engine

     
    Alternator bracket bolt to 17 ft. lbs. (23 Nm)
     
    Timing belt(s) and covers
     
    Crankshaft pulley(s)
     
    Radiator hose to the water pump
     
    Water outlet, new gasket and houses. Torque the bolts to 12-14 ft. lbs. (17-20 Nm).
     
    Water pump pulley
     
    Cooling fan and clutch assembly
     
    Air conditioning compressor tensioner pulley, if equipped
     
    Accessory belts
     
    Upper radiator shroud
     
    Negative battery cable
     

  4.  
  5. Refill the radiator with coolant. This cooling system has a self-bleeding thermostat, so system bleeding is not required.
  6.  
  7. Run the vehicle until the thermostat opens and fill the overflow tank. Check for leaks.
  8.  
  9. Once the vehicle has cooled, recheck the coolant level.
  10.  

3.0L & 3.5L Engines



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. If necessary, properly release the fuel pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     

  8.  


CAUTION
Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.



Upper radiator shroud
 
Accessory belts
 
Air conditioning compressor tensioner pulley, if equipped
 
Cooling fan and clutch assembly and the water pump pulley
 
Thermostat and housing on 3.0L, 3.5L engines
 
Water outlet, gasket and houses
 
Radiator hoses from the water pump
 
Crankshaft pulley(s)
 
Timing belt covers. If the same timing belt will be reused, mark the direction of the timing belt's rotation, for installation in the same direction. Be sure the engine is positioned so the No. 1 cylinder is at the TDC of its compression stroke and the sprockets timing marks are aligned with the engine's timing mark indicators.
 
Timing belt
 
Water pump bolts are different lengths, note their positions before removing.
 
Water pump from the block
 
Water pipe connection and O-ring
 

To install:

  1. Clean and dry the mating surfaces of the block and water pump
  2.  
  3. Install or connect the following:

    New O-ring on the water pipe connection, wet the new O-ring with water to aid in installation
     
    Water pump, with a new gasket, Torque the bolts to 17 ft. lbs. (23 Nm) on 3.0L and 3.5L engines
     
    Alternator bracket bolt to 17 ft. lbs. (23 Nm)
     
    Timing belt(s) and covers
     
    Crankshaft pulley(s)
     
    Thermostat and housing on 3.0L, 3.5L engines. Torque the bolts to 12-14 ft. lbs. (17-20 Nm).
     
    Radiator hose to the water pump
     
    Water outlet, new gasket and houses. Torque the bolts to 12-14 ft. lbs. (17-20 Nm).
     
    Water pump pulley
     
    Cooling fan and clutch assembly
     
    Air conditioning compressor tensioner pulley, if equipped
     
    Accessory belts
     
    Upper radiator shroud
     
    Thermostat and housing on 3.0L, 3.5L engines
     
    Negative battery cable
     

  4.  
  5. Refill the radiator with coolant. This cooling system has a self-bleeding thermostat, so system bleeding is not required.
  6.  
  7. Run the vehicle until the thermostat opens and fill the overflow tank. Check for leaks.
  8.  
  9. Once the vehicle has cooled, recheck the coolant level.
  10.  


    Click image to see an enlarged view

    Fig. Water pump mounting-3.0L engine



    Click image to see an enlarged view

    Fig. Water pump and related components-3.5L engine


  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. If necessary, properly release the fuel pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. 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
     



    Upper radiator shroud
     
    Accessory belts
     
    Air conditioning compressor tensioner pulley, if equipped
     
    Cooling fan and clutch assembly and the water pump pulley
     
    Thermostat and housing
     
    Water outlet, gasket and houses
     
    Radiator hoses from the water pump
     
    Crankshaft pulley(s)
     
    Timing belt covers. If the same timing belt will be reused, mark the direction of the timing belt's rotation, for installation in the same direction. Be sure the engine is positioned so the No. 1 cylinder is at the TDC of its compression stroke and the sprockets timing marks are aligned with the engine's timing mark indicators.
     
    Timing belt
     
    Water pump bolts are different lengths, note their positions before removing.
     
    Water pump from the block
     
    Water pipe connection and O-ring
     

  8.  

To install:

  1. Clean and dry the mating surfaces of the block and water pump
  2.  
  3. Install or connect the following:

    New O-ring on the water pipe connection, wet the new O-ring with water to aid in installation
     
    Water pump, with a new gasket, Torque the bolts to 17 ft. lbs. (23 Nm) on 3.0L and 3.5L engines
     
    Alternator bracket bolt to 17 ft. lbs. (23 Nm)
     
    Timing belt(s) and covers
     
    Crankshaft pulley(s)
     
    Thermostat and housing on 3.0L, 3.5L engines. Torque the bolts to 12-14 ft. lbs. (17-20 Nm).
     
    Radiator hose to the water pump
     
    Water outlet, new gasket and houses. Torque the bolts to 12-14 ft. lbs. (17-20 Nm).
     
    Water pump pulley
     
    Cooling fan and clutch assembly
     
    Air conditioning compressor tensioner pulley, if equipped
     
    Accessory belts
     
    Upper radiator shroud
     
    Thermostat and housing
     
    Negative battery cable
     

  4.  
  5. Refill the radiator with coolant. This cooling system has a self-bleeding thermostat, so system bleeding is not required.
  6.  
  7. Run the vehicle until the thermostat opens and fill the overflow tank. Check for leaks.
  8.  
  9. Once the vehicle has cooled, recheck the coolant level.

    Click image to see an enlarged view

    Fig. Water pump and related components-3.0L engine



    Click image to see an enlarged view

    Fig. Water pump and related components-3.5L engine

  10.  

3.0L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. If necessary, properly release the fuel pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove the timing belt.
  8.  

3.0L 12V engines remove or disconnect the following:



Radiator hose
 
Water hose
 
Water inlet fitting
 
Water inlet fitting gasket
 
Tensioner bracket stay
 
Water pump
 
Water pump gasket
 
O-ring
 

3.0L 24V engines remove the thermostat and remove or disconnect the following:



Radiator hose
 
Water hose
 
Water outlet fitting bracket
 
Water outlet fitting
 
O-ring
 
Gasket
 
Thermostat case
 
Gasket
 
Water pump bracket
 
Water pump
 
Water pump gasket
 
O-ring

Click image to see an enlarged view

Fig. Removing and installing water pump 3.0L (1996)

 

To install:

To install the water pump reverse the removal procedure. When installing the O-ring, rinse the mounting locations.


CAUTION
Do not apply oil and grease to water pipe O-ring. Keep the water pipe connections free of sand, dust, etc. Insert the water pipe until its end bottoms out.

3.5L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. If necessary, properly release the fuel pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove the timing belt.
  8.  
  9. Remove the thermostat.
  10.  
  11. Remove or disconnect the following:

    Radiator hose
     
    Water hose
     
    Water outlet fitting bracket
     
    Water outlet fitting
     
    O-ring
     
    Gasket
     
    Thermostat case
     
    Gasket
     
    Water pump fitting gasket
     
    Water pump
     
    Water pump gasket
     
    O-ring

    Click image to see an enlarged view

    Fig. Removing and installing water pump 3.5L (1996)

     

  12.  

To install:

To install the water pump reverse the removal procedure. When installing the O-ring, rinse the mounting locations.


CAUTION
Do not apply oil and grease to water pipe O-ring. Keep the water pipe connections free of sand, dust, etc. Insert the water pipe until its end bottoms out.

3.8L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. If necessary, properly release the fuel pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. 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
     



    Timing belt
     
    Camshaft sprocket
     
    Engine Coolant Temperature (ECT) sensor connector
     
    ECT gauge unit connector
     
    Spark plug cable support
     
    Upper radiator hose
     
    Water hoses
     
    Water outlet fitting bracket
     
    Water outlet fitting, O-ring and gasket
     
    Water pump assembly, gasket and O-ring
     
    Fitting, gaskets and thermostat case

    Click image to see an enlarged view

    Fig. Water pump and related components-3.8L engine

     

  8.  

To install:

  1. Clean and dry the mating surfaces of the block and water pump
  2.  
  3. Install or connect the following:

    Thermostat case with new gaskets
     
    Fitting
     
    Water pump assembly, using a new gasket and O-ring. Torque the water pump bolts to 16-20 ft. lbs. (21-27 Nm).
     
    Water outlet fitting, O-ring and gasket
     
    Water outlet fitting bracket
     
    Water hoses
     
    Upper radiator hose
     
    Spark plug cable support
     
    ECT gauge unit connector
     
    ECT sensor connector
     
    Camshaft sprocket
     
    Timing belt
     

  4.  
  5. Refill the radiator with coolant. This cooling system has a self-bleeding thermostat, so system bleeding is not required.
  6.  
  7. Run the vehicle until the thermostat opens and fill the overflow tank. Check for leaks.
  8.  
  9. Once the vehicle has cooled, recheck the coolant level.
  10.  

 
AutoZone Logo