1991-2000 Mitsubishi Montero Service & Repair Manual

11A-1 GROUP 11A ENGINE MECHANICAL CONTENTS GENERAL INFORMATION . . . . . . . . 11A-2 SERVICE SPECIFICATIONS . . . . . . . 11A-2 SEALANTS AND ADHESIVES . . . . . 11A-3 SPECIAL TOOLS . . . . . . . . . . . . . . . . 11A-4 ON-VEHICLE SERVICE . . . . . . . . . . . 11A-7 ALTERNATOR AND POWER STEERING OIL PUMP DRIVE BELT TENSION CHECK AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-7 A/C COMPRESSOR DRIVE BELT TENSION CHECK AND ADJUSTMENT . . . . . . . . . . . . . . . . . . 11A-7 AUTO-TENSIONER CHECK . . . . . . . . . . . 11A-9 VALVE CLEARANCE CHECK AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-12 IDLE SPEED CHECK . . . . . . . . . . . . . . . . . 11A-13 COMPRESSION PRESSURE CHECK . . . . 11A-14 TIMING BELT B TENSION ADJUSTMENT 11A-15 CRANKSHAFT PULLEY . . . . . . . . . . 11A-17 CRANKSHAFT PULLEY REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 11A-17 CAMSHAFT AND VALVE STEM SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-20 CAMSHAFT AND VALVE STEM SEAL REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . 11A-20 OIL PAN AND OIL STRAINER . . . . . . 11A-27 OIL PAN AND OIL STRAINER REMOVAL AND INSTALLATION <2WD (except high rider)> 11A-27 OIL PAN AND OIL STRAINER REMOVAL AND INSTALLATION <2WD (high rider) and 4WD> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-30 OIL PAN AND OIL STRAINER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-32 CRANKSHAFT OIL SEAL . . . . . . . . . 11A-33 CRANKSHAFT OIL SEAL REMOVAL AND INSTALLATION <M/T> . . . . . . . . . . . . . . . . 11A-33 CRANKSHAFT OIL SEAL REMOVAL AND INSTALLATION <A/T> . . . . . . . . . . . . . . . . 11A-36 CYLINDER HEAD GASKET . . . . . . . . 11A-39 CYLINDER HEAD GASKET REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 11A-39 TIMING BELT . . . . . . . . . . . . . . . . . . . 11A-43 TIMING BELT REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-43 VACUUM PUMP . . . . . . . . . . . . . . . . . 11A-50 VACUUM PUMP REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-50 ENGINE ASSEMBLY . . . . . . . . . . . . . 11A-52 ENGINE ASSEMBLY REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11A-52

GENERAL INFORMATION ENGINE MECHANICAL 11A-2 GENERAL INFORMATION M1111000102222 Item Euro 5 Except Euro 5 Total displacement mL 2,477 Bore × Stroke mm 91.1 × 95.0 Compression ratio 16.5 17 Combustion chamber Direct injection type Camshaft arrangement DOHC Number of valve Inlet 8 Exhaust 8 Valve timing Inlet Opening BTDC 13° BTDC 20° Closing ABDC 30° ABDC 40° Exhaust Opening BBDC 38° Closing ATDC 22° Fuel system Common rail fuel injection Rocker arm Double roller type SERVICE SPECIFICATIONS M1111000302118 Item Standard value Limit A/C compressor drive belt tension (When checked) Vibration frequency Hz 222.5 − 251.0 − Tension N 363 − 462 − Deflection mm (Reference) 6.8 − 8.0 − A/C compressor drive belt tension (When adjusted) Vibration frequency Hz 222.5 − 251.0 − Tension N 363 − 462 − Deflection mm (Reference) 6.8 − 8.0 − A/C compressor drive belt tension (When replaced) Vibration frequency Hz 259.8 − 300.0 − Tension N 495 − 660 − Deflection mm (Reference) 5.1 − 6.4 − Alternator and power steering oil pump drive belt tension <Except Euro5> Vibration frequency Hz (Reference) 107 − 151 − Tension N (Reference) 196 − 392 − Alternator and power steering oil pump drive belt tension <Euro5> Vibration frequency Hz (Reference) 87 − 123 − Tension N (Reference) 196 − 392 − Valve clearance (at cold) [indicates clearance between cam and roller] mm Intake valve 0.09 − Exhaust valve 0.14 −

SEALANTS ENGINE MECHANICAL 11A-3 SEALANTS M1111000500956 Item Specified Sealant Remark Semi-circular packing 3M ATD Part No. 8660 or exact equivalent Semi-drying sealant Front left camshaft bearing cap Oil seal case assembly ThreeBond 1207F (Mitsubishi Genuine Part No. 1000A992) or exact equivalent Idle speed r/min Euro 5-M/T 600 ± 50 − Euro 5-A/T 650 ± 50 − Except Euro 5-2WD-except high rider 650 ± 50 − Except Euro 5-high rider and 4WD 700 ± 50 − Compression pressure (at engine speed of 250 r/min) kPa Euro 5 2,400 Minimum 1,650 Except Euro 5 2,500 Minimum 1,750 Compression pressure difference of all cylinder kPa − Maximum 300 Timing belt B tension mm 4 − 5 Timing belt auto tensioner rod protrusion amount mm 2.3 − 7.6 Item Standard value Limit

SPECIAL TOOLS ENGINE MECHANICAL 11A-4 SPECIAL TOOLS M1111000602799 Tool Number Name Use B992080 a b MB992080 a: MB992081 b: MB992082 Belt tension meter set a: Belt tension meter b: Microphone assembly Drive belt tension check MB991910 MB991826 MB991955 MB991911 MB991824 MB991827 MB991825 a b c d e f DO NOT USE MB991955 a: MB991824 b: MB991827 c: MB991910 d: MB991911 e: MB991825 f: MB991826 M.U.T.-III sub assembly a: Vehicle communication interface (V.C.I.) b: M.U.T.-III USB cable c: M.U.T.-III main harness A (Vehicles with CAN communication system) d: M.U.T.-III main harness B (Vehicles without CAN communication system) e: M.U.T.-III adapter harness f: M.U.T.-III trigger harness CAUTION For vehicles with CAN communication, use M.U.T.-III main harness A to send simulated vehicle speed. If you connect M.U.T.-III main harness B instead, the CAN communication does not function correctly. • Checking the idle speed • Erasing diagnosis code MB992046 MB992046 Valve adjusting socket Adjustment of valve clearance

MB991800 SPECIAL TOOLS ENGINE MECHANICAL 11A-5 MB991800 Pulley holder Holding the crankshaft pulley B992100 MB992100 Crank pulley holder • Holding the crankshaft pulley • Crankshaft pulley removal B992099 MB992099 Crank pulley puller Crankshaft pulley removal MD998772 MD998772 Valve spring compressor Compressing valve spring MB991999 Valve stem seal installer Valve stem seal installation D998713 MD998713 Camshaft oil seal installer Camshaft oil seal installation D998727 MD998727 Oil pan FIPG cutter Oil pan removal MB991883 MB991883 Flywheel stopper • Supporting the flywheel assembly <M/T> • Supporting the inertia ring assembly <A/T> Tool Number Name Use

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1991-2000 Mitsubishi Montero Service & Repair Manual

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