2006-2008 Mitsubishi Montero/Pajero/Shogun Service & Repair Manual
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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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$32.99
This is the Official Service and Repair Manual for the 2006-2008 Mitsubishi Montero/Pajero/Shogun. It covers all models and engines within this range, providing detailed instructions for repair, maintenance, rebuilding, and refurbishing. The manual includes diagnostic procedures, repair instructions, and troubleshooting techniques enhanced by illustrations, diagrams, wiring schematics, and detailed specifications. All pages are printable, ensuring easy reference in the garage or workshop. This cost-effective manual is ideal for both DIY enthusiasts and experienced mechanics.
The manual covers an extensive range of service and repair topics, including:
- Engine overhaul and performance testing
- Brake system diagnostics and servicing
- Sunroof and electrical system troubleshooting
- Timing belt replacement and maintenance procedures
- Trouble code analysis and resolution
- Wiring diagrams and vacuum schematic layouts
- Front end and alignment procedures
- Suspension repairs and adjustments
- Transmission removal, installation, and in-car servicing
- Air conditioning service and diagnostics
- Computer diagnostic codes and firing orders
- Detailed model specifications and factory maintenance schedules
- Serpentine belt routings and complete torque specifications
- U-joint and CV-joint service procedures
- Exploded diagrams, illustrations, and repair procedures
Model Specification: 2006-2008 Mitsubishi Montero/Pajero/Shogun
Language: English
File Format: PDF
Total Pages: More than 5000 pages
Requirements: Adobe Reader & Windows
Zoom In/Out: Yes
Instant Delivery: Yes
Specifications: Fully Printable & Bookmarked
Compatible: All Versions of Windows & Mac
This comprehensive manual is complete and intact, with no missing or corrupt pages or sections. It is bookmarked and searchable for easy navigation. Detailed illustrations, exploded diagrams, drawings, and photographs are included to clearly guide users through each service repair procedure. The manual is viewable on any computer, allowing for zooming and printing. Instant delivery eliminates shipping costs and waiting time, with immediate access provided upon payment via a secure processor. Major credit/debit cards and PayPal are accepted.
By utilizing this manual, individuals can perform repairs themselves and save money.
