Mitsubishi Montero Sport 1999–2002 Service Manual Set (P/N PWJE9812)

Use the model-year supplements with the base chapters: they describe changed systems and refer unchanged procedures back to earlier sections. This arrangement helps match the repair or diagnostic procedure to the installed configuration.

Scope before purchase: Engine and transmission coverage centers on on-vehicle inspection, adjustment, and major-unit removal and installation. Full off-vehicle engine and transmission overhaul requires separate manuals. Complete vehicle wiring belongs to PHJE9810, and structural collision repair belongs to PBJE9808; neither publication is included.

PDF Search, Bookmarks and File Layout

Search and diagram detail: Text search is partial because of character-encoding problems in the base chapters and nonsearchable antenna additions. All 32 section PDFs have bookmarks organized by model year and subject; the separate cover has none. Small connector-pin labels require zooming.

The ZIP contains 33 printable PDFs: 32 section files and a separate cover. The 1,523-page total includes the publications above, one cover page and 43 navigation pages; 24 notes pages are already included in the publication counts.

Engine Diagnosis, Drivetrain Repair and Chassis Service

These are selected coverage highlights, rather than a complete contents list. Other documented topics include stream-fording inspections and cruise-control diagnosis.

• Engine repair: Step-by-step procedures for timing belts and timing belt B, camshaft and crankshaft seals, cylinder-head gaskets, and engine-assembly removal and installation.

• Fuel and engine management: MUT-II diagnosis, code and symptom charts, ECU terminal checks, oscilloscope inspections, injector and throttle-body service, and diesel injection-nozzle and pump work.

• Transmission and 4WD: V5MT1 and V4A51 removal and installation, clutch controls, automatic-transmission hydraulic tests, shift/key interlocks, propeller shafts, and freewheel-clutch service.

• Brakes, steering and suspension: Basic brake and ABS diagnosis, hydraulic-unit and sensor service, parking brakes, power-steering gear and pump repair, steering linkage, and suspension work.

• Engine electrical systems: Charging-system tests, alternator and starter disassembly and reassembly, ignition-waveform diagnosis, and diesel glow-system checks.

• SRS and body electrical: SRS maintenance and post-collision diagnosis, front impact sensors, airbag modules, clock spring, immobilizer, instruments, lighting, and keyless entry.

• Heating and air conditioning: Manual and automatic A/C diagnosis, refrigerant-system testing, compressor and blower service, damper-motor checks, and A/C-ECU terminal data.

Written for service mechanics, the manual uses MUT-II diagnostics, electrical test equipment and system-specific workshop tools.

Model-Year and Control-System Differences

The model tables distinguish GLX/GLS, left- and right-hand drive, and standard- and wide-fender bodies. The V4A51 automatic appears on applicable 6G72 configurations from the 2000 model year; the listed diesel configurations use the manual transmission.

2001 MPI diagnosis: The revised material adds on-board diagnostics, freeze-frame data and readiness-test status. The drive-cycle bulletin supports checking monitor operation after a repair, rather than relying only on whether the warning lamp has gone out.

2002 Step III diesel: Dedicated sections address the electronically controlled injection pump, sensor and actuator diagnosis, variable-geometry boost control, EGR cooler and catalyst changes. Revised engine procedures cover injection timing, idle checks, the oil-pan cover, cylinder-head gasket and timing belts. Keeping these sections distinct prevents earlier mechanical-pump procedures from being confused with the electronic system.

The variable-geometry turbocharger is treated as a non-disassemblable unit; internal turbocharger rebuilding is outside that section’s scope.

Engine and Drivetrain Repair Depth

On-vehicle engine procedures include compression and intake-manifold vacuum checks, ignition and injection timing, belt adjustment, lash-adjuster checks, oil-pan and oil-screen work, and lubrication and cooling-system tests. Sealant locations, torque references and inspection limits accompany the procedures.

Special-tool references include MUT-II sub-assembly MB991502, cylinder-head-bolt wrench MD998051 and, for Step III head-bolt tightening, angle gauge MB991614.

Axle coverage reaches into front hubs, knuckles, drive shafts, inner shafts, axle shafts and differential carriers, with bearing preload, backlash and tooth-contact checks. Conventional differential repair is distinguished from the limited-slip differential case assembly, which must not be disassembled.

The automatic-transmission revisions also describe the reshaped 2002 oil pan, its sealing method and the associated fluid-capacity change.

Diagnostic Charts and Component Views

The MPI, Step III diesel, automatic-transmission, ABS, SRS, immobilizer and automatic-A/C sections combine fault charts with connector checks, terminal references, service data and actuator tests.

Representative illustrations include the Multipoint Fuel Injection System Diagram, Step III Control System Diagram, V4A51 Hydraulic Circuit, and A/T Control Component Location. The emission-control Vacuum Circuit Diagram and SRS-ECU connector/front-impact-sensor views provide additional system-specific orientation.

Chassis, Body and Safety-Related Service

Chassis procedures cover disc brakes, wheel-speed and G-sensors, power-steering pressure tests, torsion-bar front suspension and rear coil-spring suspension. The 2002 ABS revision introduces Electronic Brake Force Distribution (EBD) and discontinues the load-sensing proportioning valve on ABS-equipped vehicles.

Body and trim sections address doors, window glass and regulators, sunroof, seats, exterior hardware, wipers and washers. Wheel/tire diagnosis and the balancing bulletin supplement the suspension information.

Component-specific cautions: The integral-pan bulletin warns that oil-pan remover MD998727 can damage the aluminum 6G72 pan. The revised SRS-ECU connector instructions specify ultra-fine probe MB991222 because incorrect probing can damage the harness or strip terminal plating.

Follow the manual’s SRS isolation requirements before handling airbag components, use proper support equipment during engine, transmission, axle, or crossmember removal, and use approved recovery equipment for refrigerant service.

Step III Sensor and Solenoid Check Examples

For the 4D56 Step III coolant-temperature sensor, the resistance specifications are 2.1–2.7 kΩ at 20°C and 0.26–0.36 kΩ at 80°C.

The same engine’s injection-pump fuel-cut-solenoid check specifies 6.8–9.2 Ω between terminal 1 of the pump’s 12-pin connector and the pump body.