Mitsubishi Montero (1991+). Manual — part 3
surfaces. Resurface head if warpage exceeds specification. See
CYLINDER HEAD (SOHC) table under ENGINE SPECIFICATIONS at end of
article. Replace cylinder head if it is not within specification after
resurfacing.
Installation (SOHC)
1) Ensure mating surfaces are clean and dry. Note
identification mark located on front of head gasket. Identification
marks are: "R" for SOHC, "2DN" for DOHC non-turbocharged and "2DT" for
DOHC turbocharged engine. Install head gasket with identification mark
toward timing belt side of engine and facing upward. Ensure all holes
are aligned.
NOTE: Install head gasket with identification mark toward timing
belt side of engine and facing upward. Ensure all holes
align. Install washers on head bolts with chamfered side
toward bolt head.
2) Install cylinder head and bolts. Ensure washers are
installed on head bolts with chamfered side toward bolt head. Using
proper sequence, tighten bolts to specification in 2-3 steps. See
Fig. 5. See appropriate TORQUE SPECIFICATIONS table at end of article.
3) Apply sealant to rocker cover sealing surfaces before
installation. See Fig. 6. Ensure rocker cover gasket projections are
aligned with notches in rocker cover. Coat all "O" rings with oil, and
install a new "O" ring on distributor adapter and oil dipstick tube.
4) Coat camshaft area with oil prior to installing
distributor adapter. To complete installation, reverse removal
procedure. Tighten bolts and nuts to specification. See appropriate
TORQUE SPECIFICATIONS table. After engine reaches normal operating
temperature, allow engine to cool, and retighten cylinder head bolts.
Fig. 6: Applying Sealant to Rocker Cover (SOHC)
Courtesy of Mitsubishi Motor Sales of America, Inc.
Removal (DOHC)
1) Drain cooling system. Remove upper and lower intake
manifolds and brackets. See UPPER INTAKE MANIFOLD and LOWER INTAKE
MANIFOLD under REMOVAL & INSTALLATION.
2) Remove turbocharger(s) (if equipped). See TURBOCHARGER
under REMOVAL & INSTALLATION. Remove heat shields from exhaust
manifolds. Remove exhaust manifolds. See EXHAUST MANIFOLDS under
REMOVAL & INSTALLATION.
3) Remove spark plug wires and ignition coils. Remove rocker
cover and gasket. Remove timing belt and timing belt inner covers. See
TIMING BELT under REMOVAL & INSTALLATION. Remove intake camshaft
sprockets.
4) Remove coolant manifold and coolant inlet pipe. Using
Socket (MD998051), remove cylinder head bolts. Remove cylinder head
and camshaft assemblies. Note direction of washer installation on head
bolts.
Inspection (DOHC)
Check cylinder head height. Check warpage at gasket and
manifold surfaces. Resurface head if warpage exceeds specification.
See CYLINDER HEAD (DOHC) table under ENGINE SPECIFICATIONS at end of
article. After resurfacing, recheck cylinder head height. Replace
cylinder head if it is not within specification.
Installation (DOHC)
1) Ensure mating surfaces are clean and dry. Note
identification mark located on front of head gasket. Identification
marks are: "R" for SOHC, "2DN" for DOHC non-turbocharged and "2DT" for
DOHC turbocharged engine. Install head gasket with identification mark
toward timing belt side of engine and facing upward. Ensure all holes
are aligned.
NOTE: Install head gasket with identification mark toward timing
belt side of engine and facing upward. Ensure all holes
align. Install washers on head bolts with chamfered side
toward bolt head.
2) Install cylinder head and bolts. Ensure washers are
installed on head bolts with chamfered side toward bolt head. Using
proper sequence, tighten bolts to specification in 2-3 steps. See
Fig. 5. See TORQUE SPECIFICATIONS (3000GT) table at end of article. On
turbocharger equipped engines, back off head bolts once, and repeat
tightening procedure.
3) To reinstall camshaft sprocket, hold hexagonal area of
camshaft using wrench while tightening sprocket bolt. Tighten rocker
cover bolts in a crisscross pattern. Start at 4 corners of rocker
cover and move toward center.
NOTE: Rocker cover bolts are color coded. Front cylinder bank
bolts are black; rear cylinder bank bolts are green.
4) To complete installation, reverse removal procedure.
Tighten bolts and nuts to specification. See TORQUE SPECIFICATIONS
(3000GT) table.
FRONT CRANKSHAFT OIL SEAL
Removal & Installation
Remove timing belt and crankshaft sprocket. See TIMING BELT
under REMOVAL & INSTALLATION. Pry oil seal from oil pump. To install,
coat seal lip with grease. Using Seal Installer (MD998717), install
seal in oil pump. Install remaining components. See appropriate TORQUE
SPECIFICATIONS table at end of article.
TIMING BELT
Removal (Montero & Pickup)
1) Drain cooling system. Disconnect upper radiator hose.
Remove upper radiator shroud. Remove cooling fan and fan clutch
assembly. Remove cooling fan pulley. Remove all drive belts. Remove
power steering pump with pressure and return hoses connected, and set
aside.
2) Remove power steering pump brackets. Remove A/C tensioner
pulley and mounting bracket. Remove A/C compressor with hoses
connected, and remove mounting bracket. Remove cooling fan bracket
assembly. Note location and length of bolts for reassembly reference.
3) Remove No. 1 and No. 2 timing belt upper outer covers and
gaskets. See Fig. 7. Remove timing belt lower outer cover and gaskets.
Using Holder (MB998747) and a used "V" belt, remove crankshaft pulley
bolt. Remove crankshaft pulley.
NOTE: "V" belt will be damaged by tool. DO NOT use engine "V"
belt to hold crankshaft pulley unless replacing belt.
4) Remove flange. See Fig. 7. Rotate crankshaft and align all
timing marks. See Fig. 8. Loosen belt tensioner bolt, and rotate belt
tensioner counterclockwise to release belt tension.
5) If reusing timing belt, place arrow on belt to indicate
direction of belt rotation. Remove timing belt and belt tensioner. If
camshaft sprocket requires removal, install Holder (MB990775) on
camshaft sprocket. Remove retaining bolt and camshaft sprocket. Remove
rear timing belt cover (if required).
Fig. 7: Exploded View of Timing Belt Components (SOHC Is Similar)
Courtesy of Mitsubishi Motor Sales of America, Inc.
Fig. 8: Aligning Timing Marks (SOHC)
Courtesy of Mitsubishi Motor Sales of America, Inc.
Inspection (Montero & Pickup)
Inspect timing belt for wear on edges of drive teeth. Inspect
belt for oil contamination, cracks, separation, worn or missing teeth
and hardened back surface. Replace belt if worn, damaged or
contaminated. Inspect belt tensioner for smooth rotation. Replace if
defective.
Installation (Montero & Pickup)
1) Install rear timing belt cover. Tighten bolts to
specification. See TORQUE SPECIFICATIONS (MONTERO & PICKUP) table at
end of article. Install camshaft sprockets (if removed). Using holder,
hold camshaft and tighten retaining bolt to specification.
2) Install belt tensioner and spring. Ensure spring is
secured on pin of water pump and engaged in hole of belt tensioner
with hook of spring pointing from cylinder block.
3) Rotate belt tensioner counterclockwise as much as
possible, and temporarily tighten bolt. Align all timing marks with
No. 1 cylinder at TDC of compression stroke. See Fig. 8.
4) Install timing belt on crankshaft sprocket and then left
camshaft sprocket with all slack removed from tension side of belt.
Route timing belt onto water pump pulley, right camshaft sprocket and
tensioner. Remove any slack from belt by rotating left and then right
camshaft sprockets counterclockwise.
5) Ensure belt is installed in original direction of rotation
and all timing marks are aligned. Install flange on crankshaft. Loosen
belt tensioner bolts slightly, and allow tensioner to apply belt
tension.
6) Using Crankshaft Socket (MD998716), rotate crankshaft 2
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