Mitsubishi Montero, Sport 1998-06

Removal & Installation 1 Repair Guide

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Montero



  1. Before servicing the vehicle, refer to the Precautions section.
    2.  
  2. Place the wheels in the straight-ahead position.
    3.  
  3. Drain the cooling system into a clean container for reuse.
    4.  
  4. Discharge and recover the air conditioning system refrigerant.
    5.  
  5. Remove or disconnect the following:

    Negative battery cable
     

    6.  


CAUTION
Wait at least 60 seconds after disconnecting the battery cable before performing any work on the air bag or instrument panel.



Floor console assembly
 
Steering column-to-instrument panel cover screws and the cover
 
Air bag module, carefully, from the steering wheel
 
Electrical connectors from the air bag module
 


CAUTION
Store the air bag module facing up.



Steering wheel nut
 
Press the steering wheel from the steering column, using a steering wheel puller
 
Passenger-s side foot shower duct
 
Glove box stoppers and the glove box
 
Passenger-s air bag module nut and the air bag module
 
Electrical connector from the air bag module
 
Hood lock release handle
 
Fuel filler door lock release handle
 
Knee protector assembly and bracket
 
Meter bezel assembly
 
Under cover, the corner cover and the stopper
 
Glove box assembly
 
Center under cover assembly
 
Radio and tape/CD player
 
Heater/air conditioning control assembly
 
Combination meter and the speaker
 
Glove box striker and the upper glove box frame
 
Multi-meter panel and the multi-meter assembly
 
Side defroster grille
 
Instrument panel assembly, carefully, with the help of an assistant
 
Blower motor assembly
 
Both foot ducts
 
Joint duct from the air conditioning evaporator housing assembly
 
Foot distribution duct
 
Center reinforcement
 
Center ventilation duct
 
Drain hose from the air conditioning evaporator housing assembly
 
Heater hoses from the heater housing assembly
 
Refrigerant lines from the air conditioning evaporator housing assembly and discard the O-rings
 
Heater housing assembly
 
Center duct assembly
 
Heater core from the heater housing
 



Click image to see an enlarged view

Fig. Exploded view of the floor console and related components-Montero



Click image to see an enlarged view

Fig. Exploded view of the passenger-s side air bag module-Montero



Click image to see an enlarged view

Fig. Exploded view of the steering wheel and air bag module-Montero



Click image to see an enlarged view

Fig. Exploded view of the instrument panel and related components-Montero



Click image to see an enlarged view

Fig. Exploded view of the air conditioning evaporator housing, blower motor assembly and related components-Montero



Click image to see an enlarged view

Fig. Exploded view of the heater housing, air conditioning evaporator housing and related components-Montero

To install:

  1. Install or connect the following:

    Heater core to the heater housing
     
    Center duct assembly
     
    Heater housing assembly
     
    Refrigerant lines to the air conditioning evaporator housing assembly, using new O-rings
     
    Heater hoses to the heater housing assembly
     
    Drain hose to the air conditioning evaporator housing assembly
     
    Center ventilation duct
     
    Center reinforcement
     
    Foot distribution duct
     
    Joint duct to the air conditioning evaporator housing assembly
     
    Both foot shower ducts
     
    Blower motor assembly
     
    Instrument panel, carefully with the help of an assistant
     
    Side defroster grille
     
    Multi-meter assembly and the multi-meter panel
     
    Upper glove box frame and the glove box striker
     
    Speaker and the combination meter
     
    Heater/air conditioning control assembly
     
    Radio and tape/CD player
     
    Center under cover assembly
     
    Glove box assembly
     
    Under cover, the corner cover and the stopper
     
    Meter bezel assembly
     
    Knee protector assembly and bracket
     
    Filler door lock release handle
     
    Hood lock release handle
     
    Electrical connector to the passenger-s side air bag module
     
    Passenger-s air bag module and the air bag module nut
     
    Glove box and the glove box stoppers
     
    Foot shower duct
     
    Steering wheel to the steering column
     
    Steering wheel nut and torque the nut to 29 ft. lbs. (39 Nm)
     
    Electrical connectors to the air bag module
     
    Air bag module to the steering wheel
     
    Steering column-to-instrument panel cover and the cover screws
     
    Floor console assembly
     

    2.  
  2. Refill the cooling system.
    3.  
  3. Connect the negative battery.
    4.  
  4. Evacuate and charge the air conditioning system refrigerant.
    5.  
  5. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
    6.  

1996-00
  1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
  2. Place the wheels in the straight-ahead position.
    3.  
  3. Drain the cooling system.
    4.  
  4. Remove the instrument panel.
    5.  
  5. Remove or disconnect the following:

    Water hoses connectrion
     
    Foot shower duct (RH)
     
    Foot shower duct (LH)
     
    Evaporator mounting bolt and nut (Vehicles with A/C)
     
    Joint duct (Vehicles without A/C)
     
    Center duct assembly
     
    Center reinforcement
     
    Heater unit
     
    Foot distribution duct
     
    Heater core

    Click image to see an enlarged view

    Fig. Removing heater core

     

    6.  

To install:

To install the heater core, reverse the removal procedure.

2002-03
  1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
  2. Place the wheels in the straight-ahead position.
    3.  
  3. Drain the cooling system.
    4.  
  4. Discharge and recover the air conditioning system refrigerant.
    5.  
  5. Remove or disconnect the following:
    CAUTION
    Wait at least 90 seconds after disconnecting the battery cable before performing any work on the air bag or instrument panel.


    CAUTION
    Store the air bag module facing up.



    Negative battery cable
     



    Floor console assembly
     
    Steering column-to-instrument panel cover screws and the cover
     
    Air bag module, carefully, from the steering wheel
     
    Electrical connectors from the air bag module
     



    Steering wheel nut
     
    Press the steering wheel from the steering column, using a steering wheel puller
     
    Passenger-s side foot shower duct
     
    Glove box stoppers and the glove box
     
    Passenger-s air bag module nut and the air bag module
     
    Electrical connector from the air bag module
     
    Hood lock release handle
     
    Fuel filler door lock release handle
     
    Knee protector assembly and bracket
     
    Meter bezel assembly
     
    Under cover, the corner cover and the stopper
     
    Glove box assembly
     
    Center under cover assembly
     
    Radio and tape/CD player
     
    Heater/air conditioning control assembly
     
    Combination meter and the speaker
     
    Glove box striker and the upper glove box frame
     
    Multi-meter panel and the multi-meter assembly
     
    Side defroster grille
     
    Instrument panel assembly, carefully, with the help of an assistant
     
    Blower motor assembly
     
    Both foot ducts
     
    Joint duct from the air conditioning evaporator housing assembly
     
    Foot distribution duct
     
    Center reinforcement
     
    Center ventilation duct
     
    Drain hose from the air conditioning evaporator housing assembly
     
    Heater hoses from the heater housing assembly
     
    Refrigerant lines from the air conditioning evaporator housing assembly and discard the O-rings
     
    Heater housing assembly
     
    Center duct assembly
     
    Heater core from the heater housing

    Click image to see an enlarged view

    Fig. Floor console and related components-2002-2003 Montero



    Click image to see an enlarged view

    Fig. Passenger air bag module and related components-2002-2003 Montero



    Click image to see an enlarged view

    Fig. Driver air bag module and related components-2002-2003 Montero



    Click image to see an enlarged view

    Fig. Instrument panel and related components-2002-2003 Montero



    Click image to see an enlarged view

    Fig. Heater/evaporator housing and related components-2002-2003 Montero



    Click image to see an enlarged view

    Fig. Heater core and related components-2002-2003 Montero

     

    6.  

To install:

  1. Install or connect the following:

    Heater core to the heater housing
     
    Center duct assembly
     
    Heater housing assembly
     
    Refrigerant lines to the air conditioning evaporator housing assembly, using new O-rings
     
    Heater hoses to the heater housing assembly
     
    Drain hose to the air conditioning evaporator housing assembly
     
    Center ventilation duct
     
    Center reinforcement
     
    Foot distribution duct
     
    Joint duct to the air conditioning evaporator housing assembly
     
    Both foot shower ducts
     
    Blower motor assembly
     
    Instrument panel, carefully with the help of an assistant
     
    Side defroster grille
     
    Multi-meter assembly and the multi-meter panel
     
    Upper glove box frame and the glove box striker
     
    Speaker and the combination meter
     
    Heater/air conditioning control assembly
     
    Radio and tape/CD player
     
    Center under cover assembly
     
    Glove box assembly
     
    Under cover, the corner cover and the stopper
     
    Meter bezel assembly
     
    Knee protector assembly and bracket
     
    Filler door lock release handle
     
    Hood lock release handle
     
    Electrical connector to the passenger-s side air bag module
     
    Passenger-s air bag module and the air bag module nut
     
    Glove box and the glove box stoppers
     
    Foot shower duct
     
    Steering wheel to the steering column
     
    Steering wheel nut and torque the nut to 29 ft. lbs. (39 Nm)
     
    Electrical connectors to the air bag module
     
    Air bag module to the steering wheel
     
    Steering column-to-instrument panel cover and the cover screws
     
    Floor console assembly
     

    2.  
  2. Refill the cooling system.
    3.  
  3. Connect the negative battery.
    4.  
  4. Evacuate and charge the air conditioning system refrigerant.
    5.  
  5. Run the engine to normal operating temperatures; then, check the climate control operation and check for leaks.
    6.  

2004-06
  1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
  2. Place the wheels in the straight-ahead position.
    3.  
  3. Disconnect the negative battery cable.
    CAUTION
    Wait at least 90 seconds after disconnecting the battery cable before performing any work on the air bag or instrument panel.

    4.  
  4. Drain the cooling system. Discharge the air conditioning system.
    5.  
  5. Remove the air cleaner, air intake hose and air intake duct.
    6.  
  6. Remove the parking brake lever cover, the cup holder, the transfer shift knob, if equipped, and the selector lever knob.
    7.  
  7. Remove the indicator panel. Remove the heated seat switch, if equipped. Remove the coin plug, if equipped.
    8.  
  8. Remove the lower center panel. Remove the rear floor console assembly.
    9.  
  9. Remove the parking brake lever mounting bolt. Remove the front floor console assembly.
    10.  
  10. Remove the rear heater duct -A-. Remove the rear heater duct -B-. Remove the heater duct nozzle.
    11.  
  11. Remove the center panel assembly. Remove the clock or RV meter. Remove the radio and tape player and/or box.
    12.  
  12. Remove the heater control assembly. Remove the glove box stopper, glove box, lock, light switch connector, light switch, and light.
    13.  
  13. Remove the upper glove box striker, upper glove box, and lid lock.
    14.  
  14. Disconnect the front passenger-s side air bag module harness connector.
    15.  
  15. Remove the instrument panel side cover. Remove the air outlet assembly. Remove the instrument cluster trim bezel. Remove the instrument cluster assembly.
    16.  
  16. Remove the lower panel. Remove the switch panel. Remove the column cover. Remove the -B- stay. Remove the corner lower panel.
    17.  
  17. Remove the steering wheel cover, located under the steering wheel.
    18.  
  18. By sliding section -A- of the clock spring connector in the direction of the arrow, in the illustration, disconnect the connector.

    Click image to see an enlarged view

    Fig. Driver air bag module and related components-2004-2006 Montero

    19.  
  19. loosen the bolt completely. Remove the steering wheel and the air bag module assembly.
    20.  
  20. Remove the upper and lower column covers, if not previously done. Remove the wiring harness protector.
    21.  
  21. Remove the clock spring and column switch assembly. Remove the cover. Remove the interlock cable. Disconnect the brake pedal return spring.
    22.  
  22. Remove the steering shaft cover installation bolt.
    NOTE
    The tilt lever should be in the lock position before the steering column shaft assembly is removed, and should remain in the locked position until it is reinstalled. If the steering column shaft assembly is removed with the tilt lever released, or the tilt lever is released after removal the assembly cannot be reinstalled correctly. If the assembly is installed incorrectly, the collision energy absorbing mechanism may be damaged.

    23.  
  23. Ensure that the tilt lever is in the lock position. Remove the steering shaft mounting bolts. Remove the assembly from the vehicle.
    24.  
  24. Remove the photo sensor harness connector.
    25.  
  25. Remove the instrument panel assembly from the vehicle.
    26.  
  26. Disconnect the heater hoses. Disconnect and plug the air conditioning refrigerant lines.
    27.  
  27. Disconnect the harness connectors. Remove foot duct -B- and duct -D-. Remove the front deck crossmember bar. Remove the flange bracket.
    NOTE
    When removing the heater/evaporator unit do not allow it to bump against the SRS-ECU or any of its components.

    28.  
  28. Remove the heater blower motor assembly. Remove the heater/evaporator case from the vehicle.
    29.  
  29. Remove the foot duct -A- and -C-. Remove the air thermo sensor clip. Remove the auto compressor/ECU and air thermo sensor assembly. Remove the resistor.
    30.  
  30. Remove the joint duct. Remove the air duct sub assembly. Remove the heater core from its mounting.

    Click image to see an enlarged view

    Fig. Floor console and related components-2004-2006 Montero



    Click image to see an enlarged view

    Fig. Instrument panel and related components-2004-2006 Montero



    Click image to see an enlarged view

    Fig. Instrument panel retention clip locations-2004-2006 Montero



    Click image to see an enlarged view

    Fig. Heater/evaporator housing and related components-2004-2006 Montero



    Click image to see an enlarged view

    Fig. Heater core and related components-2004-2006 Montero

    31.  

To install:

  1. Installation is the reverse of the removal procedure.
    NOTE
    When installing the heater/evaporator unit do not allow it to bump against the SRS-ECU or any of its components.

    2.  
  2. Ensure that the tilt lever is in the lock position. Install the steering column shaft.
    NOTE
    Do not release the tilt lever until the steering column shaft has been installed. Torque the retaining bolts 13-19 ft. lbs.

    3.  
  3. Before installing the steering shaft cover installation bolt, coat the mounting hole on the toe board with sealant, part number 8633 or equivalent.
    NOTE
    When installing the clock spring, ensure that the mating marks are properly aligned. If not the steering wheel may not rotate completely during a turn, or the flat cable in the clock spring could be damaged. This would prevent normal SRS operation and possibly cause serious injury to the driver.

    4.  
  4. Turn the front wheels to the straight ahead position. Then install the clock spring to the column switch.
    5.  
  5. To align the mating marks of the clock spring, turn the clock spring counterclockwise fully. Then turn it back approximately 3-3/4 turns counterclockwise to align the mating marks.
    NOTE
    When installing the steering wheel, be sure that the harness of the clock spring does not become caught or tangled.



    Click image to see an enlarged view

    Fig. Clock spring alignment-2004-2006 Montero

    6.  
  6. Check and adjust all fluid levels. Properly recharge the air conditioning system.
    7.  

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