2003 GROUP INDEX Volume 1

Return to Group Selections

Volume 3

Alphabetic Index
Volume 4

MITSUBISHI Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . 13 B
MONTERO SPORT Engine Cooling . . . . . . . . . . . . . . . . . 14
SERVICE MANUAL
Intake and Exhaust . . . . . . . . . . . . . . 15
Volume 2 Engine Electrical. . . . . . . . . . . . . . . . 16
FOREWORD
This service manual is subdivided into various group Engine and Emission Control . . . . . 17
categories. Each section contains diagnostic,
disassembly, repair, and installation procedures, Automatic Transmission . . . . . . . . . 23
along with complete specifications and tightening
references. Use of this manual will aid in properly Alphabetical Index . . . . . . . . . . . . . .
performing any service necessary to maintain or
restore the high levels of performance and reliability NOTE:
designed into this Mitsubishi vehicle. For the information on all service manual
This manual is designed for use with the 2003 groups not listed above, please refer to
MONTERO SPORT Service Manual Volume 1, Volume 1, Volume 3 and Volume 4.
Volume 3 and Volume 4, and the 1997 MONTERO
SPORT Body Repair Manual to provide complete
service information for the 2003 MONTERO SPORT.
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.

2002 Mitsubishi Motors Corporation

All Rights, Reserved
2002 Printed in USA
MSSP-003B-2003 (2/4)
 WARNING

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.
CALIFORNIA PROPOSITION 65 WARNING

WARNING
• This product contains or emits 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

WARNING
• 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 the temperatures below in
baking or in drying after painting, remove the SRS components [air bag modules, SRS-ECU,
clock spring, front impact sensor, seat belt with pre-tensioner] beforehand.
• Air bag modules, SRS-ECU, clock spring, front impact sensor: 93°C (200°F) or more
• Seat belt with pre-tensioner: 90°C (194°F) or more
• 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.
 MITSUBISHI PUBLICATION COMMENT FORM

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Mail To: Mitsubishi Motor Sales of America, Inc. Fax to: Mitsubishi Motor Sales of America, Inc.
6400 Katella Avenue Technical Information Dept.
P.O. Box 6400 (714) 373-2347
Cypress, California 90630-0064
Attn: Technical Information Dept.