Repair manual
Wiring diagrams
Mitsubishi Montero III Repair Manual
Step-by-step repair and maintenance instructions for the Mitsubishi Montero III (1999–2006): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
- REMOVAL AND INSTALLATION
- << A >> POWER STEERING OIL PUMP ASSEMBLY/A/C COMPRESSOR ASSEMBLY REMOVAL
- << B >> ENGINE ASSEMBLY REMOVAL
- >> A << ENGINE ASSEMBLY INSTALLATION
- << A >> CAMSHAFT SPROCKET REMOVAL
- >> B << CAMSHAFT SPROCKET INSTALLATION
- >> A << OIL PAN INSTALLATION
- REMOVAL AND INSTALLATION < FRONT OIL SEAL >
- >> B << CRANKSHAFT SPACER/CRANKSHAFT SENSING BLADE/CRANKSHAFT SPROCKET INSTALLATION
- REMOVAL AND INSTALLATION < REAR OIL SEAL >
- << A >> DRIVE PLATE BOLT REMOVAL
- >> B << DRIVE PLATE BOLT INSTALLATION
- << A >> CYLINDER HEAD ASSEMBLY REMOVAL
- >> B << CYLINDER HEAD ASSEMBLY INSTALLATION
- >> C << O-RING INSTALLATION
- >> D << GASKET/WATER PASSAGE ASSEMBLY INSTALLATION
- << A >> DRIVE BELT AUTO TENSIONER REMOVAL
- << B >> POWER STEERING OIL PUMP ASSEMBLY/A/C COMPRESSOR ASSEMBLY REMOVAL
- << C >> CRANKSHAFT PULLEY REMOVAL
- << D >> TIMING BELT REMOVAL
- >> C << CRANKSHAFT PULLEY INSTALLATION
- >> D << ACCESSORY MOUNT ASSEMBLY INSTALLATION
- >> A << CAMSHAFT POSITION SENSOR SUPPORT INSTALLATION
- << A >> TIMING BELT REMOVAL
- << B >> CAMSHAFT SPROCKET BOLT REMOVAL
- >> A << CAMSHAFT SPROCKET BOLT INSTALLATION
- >> B << CRANKSHAFT SENSING BLADE/CRANKSHAFT SPACER/CRANKSHAFT SPROCKET INSTALLATION
- >> C << AUTO-TENSIONER INSTALLATION
- >> D << TIMING BELT INSTALLATION
- >> B << INJECTOR INSTALLATION
- >> C << FUEL PRESSURE REGULATOR INSTALLATION
- >> D << O-RING AND WATER PIPE INSTALLATION
- >> E << THERMOSTAT INSTALLATION
- << A >> ROCKER ARMS AND SHAFT REMOVAL
- >> A << CAMSHAFT INSTALLATION
- >> B << LASH ADJUSTER INSTALLATION
- >> D << CAMSHAFT OIL SEAL INSTALLATION
- << A >> CYLINDER HEAD BOLT REMOVAL
- >> B << VALVE SPRING INSTALLATION
- >> C << RETAINER LOCK INSTALLATION
- >> D << CYLINDER HEAD BOLT INSTALLATION
- VALVE SEAT REPLACEMENT PROCEDURE
- VALVE GUIDE REPLACEMENT PROCEDURE
- << B >> OUTER ROTOR/INNER ROTOR REMOVAL
- >> A << INNER ROTOR/OUTER ROTOR INSTALLATION
- >> C << OIL PAN INSTALLATION
- >> B << OIL RING INSTALLATION
- >> C << PISTON RING NO. 2/PISTON RING NO. 1 INSTALLATION
- >> A << KNOCK SENSOR BRACKET INSTALLATION
- >> E << CRANKSHAFT REAR OIL SEAL INSTALLATION
- SAFETY PRECAUTIONS
- REAR AIR CONDITIONING SYSTEM
- REAR COOLER SYSTEM
- CHARGING
- METHOD BY USING REFRIGERANT RECOVERY AND RECYCLING UNIT
- DISCHARGING SYSTEM
- BLOWER LINER CONTROLLER
- AIR MIX DAMPER MOTOR CHECK
- POTENSIOMETER CHECK
- AIR OUTLET CHANGEOVER DAMPER MOTOR CHECK
- POTENTIOMETER CHECK
- HEATER WATER TEMPERATURE SENSOR CHECK
- AIR THERMO SENSOR CHECK
- AIR MIX DAMPER POTENTIOMETER CHECK
- EXPANSION VALVE (MAGNET VALVE) CHECK
- BLOWER MOTOR CHECK
- RESISTOR CHECK
- PHOTO SENSOR CHECK
- OUTSIDE AIR TEMPERATURE SENSOR CHECK
- << A >> HOSE/PIPE DISCONNECTION
- LUBRICANTS
- DIFFERENTIAL CARRIER OIL SEAL REPLACEMENT
- << A >> CASTLE NUT REMOVAL
- << B >> DRIVE SHAFT REMOVAL
- >> A << DRIVE SHAFT INSTALLATION
- << A >> DOJ BOOT REMOVAL
- >> A << DOJ BOOT INSTALLATION
- << A >> INNER SHAFT REMOVAL
- >> B << INNER SHAFT INSTALLATION
- >> A << DUST SEAL INSTALLATION
- >> B << DUST COVER INSTALLATION
- >> C << BEARING INSTALLATION
- << A >> FRONT PROPELLER SHAFT REMOVAL
- >> B << FRONT PROPELLER SHAFT INSTALLATION
- >> A << OIL SEAL INSTALLATION
- >> D << SPRING PIN INSTALLATION
- >> F << BEARING INSTALLATION
- << B >> DIFFERENTIAL CASE ASSEMBLY REMOVAL
- << C >> SIDE BEARING INNER RACE REMOVAL
- << E >> SELF-LOCKING NUT REMOVAL
- << F >> DRIVE PINION ASSEMBLY REMOVAL
- << G >> DRIVE PINION FRONT BEARING INNER RACE REMOVAL
- << H >> OIL SEAL/DRIVE PINION REAR BEARING INNER RACE/DRIVE PINION REAR OUTER RACE REMOVAL
- << I >> DRIVE PINION FRONT BEARING OUTER RACE REMOVAL
- << J >> LOCK PIN REMOVAL
- >> B << DRIVE PINION FRONT BEARING OUTER RACE INSTALLATION
- >> C << DRIVE PINION REAR BEARING OUTER RACE INSTALLATION
- >> I << SIDE BEARING INNER RACE INSTALLATION
- >> A << VACUUM HOSE INSTALLATION
- >> B << CHECK VALVE INSTALLATION
- >> A << DIFFERENTIAL MOUNT BRACKET ASSEMBLY INSTALLATION
- Removal & Installation (Diamante)
- Removal & Installation (Eclipse & Galant)
- Removal & Installation (Lancer)
- Removal & Installation (Mirage A/T)
- Removal & Installation (Mirage M/T)
- Removal & Installation (Montero & Montero Sport)
- Removal & Installation (Diamante - With Traction Control)
- Removal & Installation (Diamante, Eclipse, Galant, Lancer, Mirage 1.8L, Montero & Montero Sport)
- Removal & Installation (Mirage 1.5L)
- Removal & Installation (Mirage)
- Removal & Installation (Mirage 1.8L)
- Removal & Installation (Diamante, Eclipse, Galant, Lancer, Mirage, Montero & Montero Sport)
- Removal & Installation (Diamante, Eclipse 3.0L, Galant 3.0L & Mirage 1.5L)
- Removal & Installation (Eclipse 2.4L & Galant 2.4L)
- Removal & Installation (Montero)
- Removal & Installation (Montero Sport)
- Removal & Installation (Diamante, Eclipse, Galant, Lancer & Mirage 1.5L)
- Removal (Diamante, Eclipse 3.0L, Galant 3.0L & Mirage 1.5L)
- Installation (Diamante, Eclipse 3.0L, Galant 3.0L & Mirage 1.5L)
- Removal & Installation (Eclipse 2.4L, Galant 2.4L, Lancer & Mirage 1.8L)
- Removal (Diamante, Eclipse 3.0L, Galant 3.0L & Montero)
- Installation (Diamante, Eclipse 3.0L, Galant 3.0L & Montero)
- Removal (Eclipse 2.4L & Galant 2.4L)
- Installation (Eclipse 2.4L & Galant 2.4L)
- Removal (Lancer)
- Installation (Lancer)
- Removal & Installation (Eclipse, Galant, Lancer & Montero)
- Removal (Diamante, Eclipse 3.0L, Galant 3.0L, Montero & Montero Sport)
- Installation (Diamante, Eclipse 3.0L, Galant 3.0L, Montero & Montero Sport)
- Removal & Installation (Eclipse 2.4L, Galant 2.4L, Lancer & Mirage)
- Removal (Diamante)
- Installation (Diamante)
- Removal (Eclipse & Galant)
- Installation (Eclipse & Galant)
- Removal (Mirage)
- Installation (Mirage)
- Removal (Montero)
- Installation (Montero)
- Removal (Montero Sport)
- Installation (Montero Sport)
- Removal (Eclipse 3.0L & Galant 3.0L)
- Installation (Eclipse 3.0L & Galant 3.0L)
- Removal (Lancer & Mirage)
- Installation (Lancer & Mirage)
- Removal (Montero & Montero Sport)
- Installation (Montero & Montero Sport)
- Removal (Diamante & Mirage)
- Installation (Diamante & Mirage)
- Removal (Eclipse, Galant & Lancer)
- Installation (Eclipse, Galant & Lancer)
- Removal & Installation (Diamante, Lancer, Mirage, Montero & Montero Sport)
- Removal & Installation (Diamante & Montero)
- Removal & Installation (Eclipse, Galant, Lancer & Mirage)
- Removal & Installation (Diamante, Montero & Montero Sport)
- Removal & Installation (Eclipse 2.4L, Galant 2.4L & Lancer)
- Removal & Installation (Eclipse 3.0L, Galant 3.0L & Mirage)
- Removal & Installation (Diamante, Lancer, Montero & Montero Sport)
- Engine Performance Diagnostic Routine Outline - General Information
- Engine Performance Safety Precautions
- Parasitic Load Explanation & Test Procedures - General Information
- Waveforms - Injector Pattern Tutorial - General Information
- Electrostatic Discharge Warning - General Information
- State Emission Standards - Diesel
- Before carrying out troubleshooting
- SWS DIAGNOSTIC TROUBLESHOOTING STRATEGY
- FUNCTION DIAGNOSIS
- Scan Tool Or Voltmeter
- INSPECTION PROCEDURE A-1: COMMUNICATION WITH THE SWS MONITOR KIT IS IMPOSSIBLE
- TROUBLESHOOTING HINTS
- DIAGNOSIS — Part 1
- DIAGNOSIS — Part 2
- DIAGNOSIS — Part 3
- INSPECTION PROCEDURE F-3: SUNROOF: SUNROOF TIMER FUNCTION DOES NOT WORK NORMALLY
- TROUBLESHOOTING HINT
- INSPECTION PROCEDURE L-4: HEADLIGHT, TAIL LIGHT: WHEN THE PASSING SWITCH IS TURNED "ON", THE HEADLIGHTS (LOW-BEAM OR HIGH-BEAM) DO NOT ILLUMINATE
- INSPECTION PROCEDURE L-5: HEADLIGHT, TAIL LIGHT: HEADLIGHTS DO NOT ILLUMINATE WHEN THE LIGHTING SWITCH IS AT "AUTO," "TAIL," AND "PASSING" POSITION, BUT ILLUMINATE AT LOW-BEAM WHEN — Part 1
- INSPECTION PROCEDURE L-5: HEADLIGHT, TAIL LIGHT: HEADLIGHTS DO NOT ILLUMINATE WHEN THE LIGHTING SWITCH IS AT "AUTO," "TAIL," AND "PASSING" POSITION, BUT ILLUMINATE AT LOW-BEAM WHEN — Part 2
- >> A << TRANSFER CASE ADAPTER INSTALLATION
- >> A << OIL SEAL INSTALLATION
- >> B << SEALING CAP INSTALLATION
- >> C << PARKING SPRAG SPRING INSTALLATION
- >> A << D-RING INSTALLATION
- >> B << REVERSE CLUTCH PISTON INSTALLATION
- >> C << RETURN SPRING INSTALLATION
- >> E << CLUTCH PLATE/CLUTCH DISC/REACTION PLATE INSTALLATION
- >> H << SNAP RING INSTALLATION
- >> A << ONE-WAY CLUTCH INSTALLATION
- >> B << STOPPER PLATE INSTALLATION
- >> C << THRUST BEARING NUMBER 6 INSTALLATION
- >> D << THRUST BEARING NUMBER 5 INSTALLATION
- >> B << O-RING INSTALLATION
- >> C << SNAP RING INSTALLATION
- << A >> SNAP RING REMOVAL
- >> B << RETURN SPRING INSTALLATION
- << A >> SOLENOID VALVE REMOVAL
- >> A << SOLENOID VALVE INSTALLATION
- >> B << DOWEL PIN INSTALLATION
- >> C << KNOCK BUSHING INSTALLATION
- >> D << KNOCK BUSHING INSTALLATION
- >> E << SPRING/STEEL BALL (LINE RELIEF) INSTALLATION
- >> F << SPRING/STEEL BALL (ORIFICE CHECK BALL)/ BALL (ORIFICE CHECK BALL)/DAMPING VALVE SPRING/ SEAL RING/DAMPING VALVE INSTALLATION
- >> G << MANUAL VALVE INSTALLATION
- >> A << THRUST BEARING NUMBER 11 INSTALLATION
- >> B << THRUST BEARING NUMBER 10 INSTALLATION
- >> B << SNAP RING INSTALLATION
- >> D << SNAP RING INSTALLATION
- << A >> H-L SHIFT RAIL/CHAIN COVER REMOVAL
- << B >> REAR OUTPUT SHAFT/CHAIN/FRONT OUTPUT SHAFT REMOVAL
- >> D << INTERLOCK PLUNGER/CHAIN COVER INSTALLATION
- >> E << H-L SHIFT RAIL/SPRING PIN INSTALLATION
- >> F << OIL SEAL INSTALLATION
- >> G << SPACER INSTALLATION
- >> H << REAR COVER INSTALLATION
- >> I << CONTROL HOUSING INSTALLATION
- >> J << H-L SHIFT RAIL PLUG INSTALLATION
- >> K << PLUG INSTALLATION
- >> L << SPACER INSTALLATION
- >> N << SPRING INSTALLATION
- << A >> CHAIN/FRONT OUTPUT SHAFT/SUN GEAR REMOVAL
- << B >> OIL GUIDE REMOVAL
- >> A << OIL GUIDE INSTALLATION
- >> B << OIL SEAL INSTALLATION
- >> C << REAR BEARING RETAINER INSTALLATION
- >> E << H-L SHIFT FORK/H-L CLUTCH SLEEVE INSTALLATION
- >> I << STEEL BALL/SPACER INSTALLATION
- >> J << 2-4WD SHIFT FORK/2-4WD CLUTCH SLEEVE INSTALLATION
- >> K << SNAP RING INSTALLATION
- >> N << REAR OUTPUT SHAFT INSTALLATION
- >> O << CHAIN COVER INSTALLATION
- >> S << REAR COVER INSTALLATION
- >> U << SHIFT RAIL DRIVE GEAR INSTALLATION
- >> V << TRANSFER CASE COVER INSTALLATION
- >> W << 2-4WD DETECTION SWITCH/4H DETECTION SWITCH/CENTER DIFFERENTIAL LOCK DETECTION SWITCH/2WD DETECTION SWITCH/4LLC DETECTION SWITCH INSTALLATION
- >> B << BOLT INSTALLATION
- << A >> BALL BEARING REMOVAL
- >> A << BALL BEARING INSTALLATION
- >> A << INNER RACE/ROLLER BEARING/SPACER INSTALLATION
- >> C << BALL BEARING INSTALLATION
- << A >> CLUTCH HUB REMOVAL
- >> B << CLUTCH HUB INSTALLATION
- >> E << CLUTCH HUB INSTALLATION
- >> F << SNAP RING INSTALLATION
- >> B << BALL BEARING INSTALLATION
- << B >> BALL BEARING REMOVAL
- >> A << SHIFT RAIL DRIVE GEAR INSTALLATION
- >> A << SPRING PIN INSTALLATION
- >> B << 2-4WD SHIFT RAIL INSTALLATION
- << A >> COVER REMOVAL
- >> A << STEERING LOCK CYLINDER ASSEMBLY/STEERING LOCK BRACKET/SPECIAL BOLT INSTALLATION
- REMOVAL AND INSTALLATION
- << A >>REMOVAL OF DIFFERENTIAL MOUNT BRACKET ASSEMBLY (LH)
- << B >> GEAR BOX ASSEMBLY REMOVAL
- >> A << TIE ROD END (LH) INSTALLATION
- >> B << RETURN TUBE/PRESSURE HOSE ASSEMBLY INSTALLATION
- << A >> RACK SUPPORT COVER REMOVAL
- << B >> LOWER OIL SEAL/PINION AND VALVE ASSEMBLY REMOVAL
- << C >> SEAL RING REMOVAL
- << D >> UPPER BEARING/UPPER OIL SEAL REMOVAL
- << E >> CIRCLIP REMOVAL
- << F >> RACK STOPPER/RACK BUSHING/OIL SEAL/"O" RING/RACK ASSEMBLY REMOVAL
- << G >> LOWER BEARING REMOVAL
- << H >> NEEDLE BEARING REMOVAL
- << I >> OIL SEAL REMOVAL
- >> A << OIL SEAL INSTALLATION
- >> B << NEEDLE BEARING/LOWER BEARING INSTALLATION
- >> C << RACK ASSEMBLY INSTALLATION
- >> E << CIRCLIP INSTALLATION
- >> F << UPPER OIL SEAL/UPPER BALL BEARING INSTALLATION
- >> L << TAB WASHER/TIE ROD INSTALLATION
- >> N << TIE ROD END/TIE ROD END JAM NUT INSTALLATION
- >> O << GEAR MOUNT RUBBER INSTALLATION
- TIE ROD END BALL JOINT DUST COVER REPLACEMENT
- >> B << OIL SEAL INSTALLATION
- >> C << ROTOR INSTALLATION
- >> D << CAM RING INSTALLATION
- >> E << VANE INSTALLATION
- >> B << RETURN HOSE A / COOLER TUBE INSTALLATION
- >> C << RETURN HOSE B INSTALLATION
- >> D << SUCTION HOSE INSTALLATION
- Manufacturer's Suggested Scheduled Maintenance
- Removal & Installation
- Removal (Diamante)
- Installation (Diamante)
- Removal (1997-00 Montero & 1999-04 Montero Sport)
- Installation (1997-00 Montero & 1999-04 Montero Sport)
- Removal (2001-02 Montero)
- Installation (2001-02 Montero)
- Inspection (All Models)
- Diamante
- 1997-2000 Montero & 1999-2004 Montero Sport
- 2001-2002 Montero