2005 MITSUBISHI MONTERO Service and Repair Manual

GROUP INDEX 00 General . . . . . . . . . . . . . . . . . . . . . . . 11 Engine . . . . . . . . . . . . . . . . . . . . . . . . 12 Engine Lubrication . . . . . . . . . . . . . . 13 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Engine Cooling . . . . . . . . . . . . . . . . . 15 Intake and Exhaust . . . . . . . . . . . . . . 16 Engine Electrical . . . . . . . . . . . . . . . . 17 Engine and Emission Control . . . . . 23 Automatic Transmission . . . . . . . . . 25 Propeller Shaft . . . . . . . . . . . . . . . . . 26 Front Axle . . . . . . . . . . . . . . . . . . . . . 27 Rear Axle . . . . . . . . . . . . . . . . . . . . . . 31 Wheel and Tire . . . . . . . . . . . . . . . . . 32 Power Plant Mount . . . . . . . . . . . . . . 33 Front Suspension . . . . . . . . . . . . . . . 34 Rear Suspension . . . . . . . . . . . . . . . Alphabetical Index . . . . . . . . . . . . . . NOTE: For the information on all service manual groups not listed above, please refer to Volume 2. 2006 MITSUBISHI MONTERO SERVICE MANUAL Volume 1 FOREWORD This service manual is subdivided into various group categories. Each section contains diagnostic, disassembly, repair, and installation procedures, along with complete specifications and tightening references. Use of this manual will aid in properly performing any service necessary to maintain or restore the high levels of performance and reliability designed into this Mitsubishi vehicle. This manual is designed for use with the 2006 MONTERO Service Manual Volume 2, and the 2001 MONTERO Body Repair Manual to provide complete service information for the 2006 MONTERO. When reference is made in this manual to a brand name, number, or specific tool, an equivalent product may be used in place of the recommended item. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication approval. The right is reserved to make changes at any time without notice. No part of this publication may be reproduced, stored in any retrieval system of transmitted, in any form or by any means, including but not limited to electronic, mechanical photocopying, recording or otherwise, without the prior written permission of Mitsubishi Motors Corporation. ©2005 Mitsubishi Motors Corporation All Rights, Reserved Printed in USA MSSP-004B-2006(1/2)

Proper service methods and repair procedures are necessary for the safe, reliable operation of all motor vehicles as well as the personal safety of the person doing the repair. There are many types of procedures, techniques, tools, and parts for servicing vehicles, as well as differences in the skills of the people doing the work. This manual cannot give advice or precautions for every possible situation. Because of this, anyone who does not follow the instructions in this manual must first make sure that the choice of methods, tools, or parts will not cause damage to the vehicle or injury to the person doing the work. The following list contains general precautions that should always be followed while working on a vehicle. • Always wear safety glasses for eye protection. • Use safety stands whenever a procedure requires work under the vehicle. • Be sure the ignition switch is always "off" unless otherwise specified by a procedure. • Set the parking brake when working on a vehicle. • Operate the engine only in a well-ventilated area. • Keep clear of moving parts when the engine is running. • To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler. • Do not smoke while working on or near a vehicle. WARNING

CALIFORNIA PROPOSITION 65 WARNING • Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects and reproductive harm. In addition, certain fluids contained in vehicles ad certain products of component wear contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. WARNINGS REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM (SRS) EQUIPPED VEHICLES • Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver and passenger (from rendering the SRS inoperative). • If it is possible that the SRS components are subjected to heat over 93°C (200°F) in baking or in drying after painting, remove the SRS components [air bag module (driver’s side and front passenger’s side), SRS-ECU, clock spring, side impact sensor, front seat assembly (side air bag module)] beforehand. • Service or maintenance of any SRS component or SRS-related component must be performed only at an authorized MITSUBISHI dealer. • MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B, Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of the SRS or any SRS-related component. NOTE Section titles with the asterisks (*) in the table of contents in each group indicate operations requiring warnings. WARNING WARNING

MITSUBISHI PUBLICATION COMMENT FORM Use this form to advise us of any errors you might find in this publication. We also welcome your suggestions that might help us improve Mitsubishi publications. Publication that contains error: __________________________________________________________ Page number where the error appears:____________________________________________________ Figure number where the error appears:___________________________________________________ Vehicle application and system identification: _______________________________________________ Describe, in detail, the error found or your suggestion. Please attach additional pages as necessary. ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ ___________________________________________________________________________________ Dealer ___________________________________ Dealer Code________________________________ From: Name_________________________________________________________________________ City/Town____________________________ State________________ Zip Code______________ Signature____________________________ Date ________________ Phone________________ Mail To: Mitsubishi Motors North America, Inc. 6400 Katella Avenue P.O. Box 6400 Cypress, California 90630-0064 Attn: Technical Information Dept. Fax to: Mitsubishi Motors North America, Inc. Technical Information Dept. (714) 373-1021

2005 MITSUBISHI MONTERO Service and Repair Manual

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