Montero Gen 2.5 (NL) Capacities, Part Numbers and Specialty Tools List

[jlocster]

Montero Gen 2.5 (NL) Capacities, Part Numbers, and Specialty Tools List

**If you've installed a part and can confirm that it fits the Gen 2.5, please post the brand, part #, and a description of the part so it can be added to the list**

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Subsections:

I. Capacities
II. Part Numbers
III. Specialty Tools
IV. Additional Resources

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I. CAPACITIES
*per 2000 Model Year North American Vehicle Owners Manual (Petrol Engine)

Automatic Transmission ATF Dexron II (8.9 qt)
***Some Gen 2.5s may require Mitsubishi Diamond SP III transmission fluid depending on build date***

Axle, Front API Class GL-5 (1.3 qt)
>-10 deg F SAE 90, 85W-90, 80W-90
-10 deg F to -30 deg F SAE 80W, 80W-90
<-30 deg F SAE 75W

Axle, Rear API Class GL-5 (3.3 qt)
>-10 deg F SAE 90, 85W-90, 80W-90
-10 deg F to -30 deg F SAE 80W, 80W-90
<-30 deg F SAE 75W

Brakes Brake Fluid Type DOT3 or DOT4 (as required)

Engine Coolant Ethylene Glycol (10 qt)
*includes .63 qt in overflow tank

Engine Oil API SJ or higher
Oil Pan (4.5 qt)
Oil Filter (.32 qt)
Oil Cooler (.32 qt)

Fuel (24 gal)

Power Steering ATF Dexron II (1.1 qt)

Refrigerant (Air Cond.) HFC-134a (27 oz)

Transfer Case API Class GL-4 (2.6 qt)
SAE 75W-90 or 75W-85W

Washer Fluid
Windshield (3.2 qt)
Rear Window (1.5 qt)
Headlights (3.9 qt)

Wheel Bearings, Front NLGI Grade 2 Multipurpose Grease (as required)

Door Hinges, Back Door Hinges Engine Oil (as required)

Hook Lock Catch, Door Lock Strikers, Seat Adjusters, Backdoor Lock, Parking Brake Cable Mechanism NLGI Grade 2 Multipurpose Grease (as required)

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II. PART NUMBERS
*The following parts are confirmed to fit the Gen 2.5 Montero

Axles
To fit 4.90 gearing in rear differential you will need:
MITSUBISHI MR124858 Gear Set, 4.90 Ring and Pinion (per grandpa)
MITSUBISHI MB837842 Spacer, Pinion (to set pinion rotating torque with correct shim, per grandpa)
MITSUBISHI MR580530 Oil Seal, Pinion (per grandpa)
MITSUBISHI MR569391 Shim Set, Pinion Bearing, Front (to set pinion rotating torque, per grandpa)
MITSUBISHI MR179440 Shim Set, Pinion Bearing, Rear (to set pinion depth, per grandpa)
MITSUBISHI MB393471 Bearing and Race, Pinion, Front (per grandpa)
MITSUBISHI MB837844 Bearing and Race, Pinion, Rear (per grandpa)

Battery
ODYSSEY 34/78-PC1500 Group 34/78 DT (AGM battery, top/side terminals)
ODYSSEY 65-PC1750 Group 65 (AGM battery)

Body/Exterior
ARB 3434040 Bullbar, 97-00 Montero (needs some modification to mount, per grandpa)
Kit# D12 (4crawler.com) 2" Lift Blocks, 2.5" dia. (set of 12, per eurosonic)
Kit# 120002-1-KIT (trail-gear.com) Rock Sliders, 67" (sold in pairs, per eurosonic)

TSMV33AA Snorkel (search eBay "pajero smv33a")

MITSUBISHI MR230032 Handle, Rear Exterior (per Clem)

GOODYEAR GY-WB765-20 Wiper Blade, Windshield, 20"
VALEO 900-19-1B Wiper Blade, Windshield, 19" (per snare)
GOODYEAR GY-WB765-16 Wiper Blade, Rear, 16"

Brakes/Wheels/Tires
WAGNER BD125515 Rotor, Front
WAGNER BD125262 Rotor, Rear

AKEBONO ACT530 Brake Pads, Front (ProAct Ultra-Premium, ceramic, per snare)
NAPA UP-7412-X Brake Pads, Front (ceramic)
RAYBESTOS PGD530C Brake Pads, Front **Despite RockAuto's Listing THESE DO NOT FIT Year 2000 Gen 2.5**

AKEBONO ACT567 Brake Pads, Rear (ProAct Ultra-Premium, ceramic, per snare)
RAYBESTOS PGD567C Brake Pads, Rear (ceramic)

TIMKEN SET47 Wheel Bearings, Front (sold individually, 2 per wheel)
MITSUBISHI MB526395 Inner Grease Seal, Front Wheel Hub (1 per wheel)

265/70 R15 Tire Size, Stock
33x10.5 R15 Tire Size, Aftermarket (up to and including this size fit stock rim, stock suspension, no rubbing)

Cooling
CSF 3050 Radiator (all metal, per TheMole)
MITSUBISHI MB660735 Radiator Cap (per TheMole)

GATES 22073 Radiator Hose, Upper
GATES 22146 Radiator Hose, Lower
MITSUBISHI MB890985 Radiator Hose, Lower (per TheMole)
DAYCO D87788 Universal Molded Heater Hose (1 needed, cut to fit)
DAYCO B87661 Universal Molded Heater Hose (1 needed, cut to fit)

MITSUBISHI MD030763 O-ring, Under Plenum Coolant Passage Tube to Rear Water Pump Housing
MITSUBISHI MD308723 Gasket, Water Pump Housing to Thermostat Housing
MITSUBISHI MD308724 Gasket, Thermostat Housing, Top

MITSUBISHI MD350415 Thermostat Kit (per twocommas)

Electrical/Lighting
PHILLIPS 9003 XPS2 Bulb, Headlight (X-treme Power, sold in pairs)
MITSUBISHI MR283314 Bulb, Compass Gauge (2 needed)

JDM Side Marker Lights, Front Fender (clear lens, sold in pairs, search eBay "93-05 mitsubishi proton side marker lights")
MITSUBISHI MB943607 Socket Connector Pigtail (fits JDM Side Marker Lights, per BEG)

MITSUBISHI MD350609 Alternator (100A, per twocommas)
GATES 36238 Pulley, Alternator Tensioner (per SlimPickins)

METRA 70-7003 Wiring Harness, Stereo (utilizes stock amplifier)

Emissions
DENSO 234-4738 O2 Sensor, Upstream Right
DENSO 234-4742 O2 Sensor, Upstream Left

FRAM FV350 PCV Valve (per twocommas)
MITSUBISHI MD183547 PCV Valve (per TheMole)

Engine
NGK 7005 Spark Plug Wires
DENSO 3174 Spark Plugs (Double-Platinum, per TheMole)
DENSO 3395 Spark Plugs (Iridium Long Life, per twocommas)
NGK 7994 Spark Plugs (Laser Iridium)
**NOTE** TO COMPLETE SPARK PLUG/WIRE JOB YOU WILL ALSO NEED:
MITSUBISHI MD 199282 Intake Plenum Gasket
MITSUBISHI MD 149764 EGR Tube Gasket

ACDELCO TCKWP287B Timing Belt Kit, No Water Pump Housing (per twocommas)
GATES TCKWP287B Timing Belt Kit, No Water Pump Housing
GATES TCKWP287B kit contains: Timing Belt, Timing Belt Hydraulic Tensioner, Tensioner Pulley, Idler, Water Pump, Water Pump to Water Pump Housing Gasket, Water Pump Housing to Engine Gasket, Upper Coolant Passage O-ring
**NOTE** TO COMPLETE TIMING BELT/WATER PUMP JOB YOU WILL ALSO NEED:
MITSUBISHI MD030763 O-ring, Under Plenum Coolant Passage Tube to Rear Water Pump Housing
MITSUBISHI MD308723 Gasket, Water Pump Housing to Thermostat Housing

MITSUBISHI MD372536 Camshaft Seal, Front (2 needed)
MITSUBISHI MN176208 Camshaft O-ring, Rear (2 needed)

MITSUBISHI 1100A141 Crankshaft Bolt, 3rd Version (earlier versions are obsolete, prone to failure and should be avoided)
MITSUBISHI MR994412 Crankshaft Bolt Washer
MITSUBISHI MD372249 Crankshaft Seal, Front

SMP INTERMOTOR PC96 Sensor, Camshaft Position
AIRTEX/WELLS 5S1858 Sensor, Crankshaft Position (per nwoods)
SMP INTERMOTOR PC191 Sensor, Crankshaft Position

MITSUBISHI MD303148 Valve Cover Gasket (2 needed)
MITSUBISHI MD198128 Valve Cover Spark Plug Tube Grommets (6 needed)

MITSUBISHI MD149764 EGR Tube Gasket
MITSUBISHI MD199282 Intake Plenum Gasket
FEL PRO MS95709 Intake Plenum Gasket (includes upper and lower, per TheMole)

PUROLATOR A35050 Air Filter
STP SA7605 Air Filter
WIX 46308 Air Filter (per TheMole)

FRAM XG9688 Oil Filter (Fram Ultra)
MOBIL M1-104 Oil Filter (Mobil 1 Extended Performance)
NAPA 7092 Oil Filter (Napa Gold)
PUROLATOR PL14459 Oil Filter (PureOne)
WIX 51334XP Oil Filter (Extended Performance, per snare)

NAPA 25-9365 Belt, Air Conditioner
NAPA 25-050446 Belt, Fan/Alternator
NAPA 25-040390 Belt, Fan/Power Steering

Fuel System
PUROLATOR F45057 Fuel Filter

MITSUBISHI MB571603 Fuel Gauge Sender, In-tank

Interior
CABELAS IK-521945 Seatcover, TrailGear Front Bucket (sold individually, per nwoods)

Steering
MOOG K9753 Ball Joint, Upper (right/left are same part #)
MOOG K9755 Ball Joint, Lower Right
MOOG K9754 Ball Joint, Lower Left

MOOG K750292 Sway Bar End Link, Front Right
DEEZA MSL127 Sway Bar End Link, Front Right (per TheMole)
MOOG K750291 Sway Bar End Link, Front Left
DEEZA MSL128 Sway Bar End Link, Front Left (per TheMole)
MOOG K9232 Sway Bar End Link, Rear (right/left are same part #, per TheMole)

MOOG K90635 Sway Bar Bushings, Front (non-adjustable suspension, sold in pairs, per TheMole)
MOOG K90631 Sway Bar Bushings, Rear (non-adjustable suspension, sold in pairs, per TheMole)

MOOG K9751 Idler Arm
MOOG K9752 Pitman Arm

MOOG ES3387RL Tie Rod End, Inner (right/left are same part #)
MOOG ES3386RL Tie Rod End, Outer (right/left are same part #)

MOOG SSD99 Steering Dampener Kit (per billygoats)

Suspension
KYB KG54302 Gas-A-Just Shock Absorber, Front
KYB KG54303 Gas-A-Just Shock Absorber, Rear

KYB 565024 MonoMax Shock Absorber, Front (per TheMole)
KYB 565025 MonoMax Shock Absorber, Rear (per TheMole)

OLD MAN EMU OME938 Rear Coil Springs, Expedition Duty (sold in pairs)

Transmission/Transfer Case
WIX 58884 Transmission Filter Kit, Automatic (includes transmission pan gasket, filter and filter gasket, per TheMole)

MITSUBISHI MD951858 Crush Washer, Automatic Transmission Drain Plug (per SlimPickins)

MITSUBISHI MB580253 Bushing, Gearshift (per KyleT)

MITSUBISHI MD701605 Bushing, Transfer Case Lever (red material, per All-Terrain)
MITSUBISHI MR110334 Lever Assembly, Transfer Case (per grandpa)


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III. SPECIALTY TOOLS
Spanner Wrench used to Remove/Replace Harmonic Balancer
Made from 1/4" bar stock, 5/16" bolts for pins, 3/8" bolt for the pivot
View attachment 147443

View attachment 147429

Spanner Socket used to Set Timing Belt Tensioner Pre-load (on eBay, search "mitsubishi timing belt tensioner tool")
View attachment 147444

Fits a 1/4" ratchet/torque wrench.
View attachment 147445

Spanner Socket used to Remove/Replace Front Hub Assembly/Wheel Bearings/Rotors
MITSUBISHI MB990954 Factory Tool (link, per SONICMASD)

Made from GM 3/4 ton 4wd front axle socket. Shave off four of the six pins.
PERFORMANCE TOOL W1270
View attachment 147446

View attachment 147447

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IV. ADDITIONAL RESOURCES

mitsubishilinks.com factory service manual, CAPS/ASA factory parts program ---> link

4x4Wire TrailTalk forum ---> Mitsubishi link , Mitsubishi Diesel link , Mitsubishi Archive link
Pajero 4wd Club of Victoria forum ---> link
Pajero Owners Club UK forum ---> link
Pajero Owners Club of South Africa forum ---> link

 

[nwoods]

Yeah okay, so this pretty much should be nominated as Post of the Year!

Wow man, this is awesome!

 

[nwoods]

So, for the total Timing Belt job, is this correct?:


TO COMPLETE TIMING BELT/WATER PUMP JOB YOU WILL ALSO NEED:
Gates TCKWP287B Timing Belt Kit, No Water Pump Housing
Kit contains: Timing Belt, Timing Belt Hydraulic Tensioner, Tensioner Pulley, Idler, Water Pump, Water Pump to Water Pump Housing Gasket, Water Pump Housing to Engine Gasket, Upper Coolant Passage O-ring
MITSUBISHI MD 030763 O-ring, Under Plenum Coolant Passage Tube to Rear Water Pump Housing
MITSUBISHI MD 308723 Gasket, Water Pump Housing to Thermostat Housing
MITSUBISHI MD 372536 Camshaft Seal, Front (2 needed)
MITSUBISHI MN 176208 Camshaft O-ring, Rear (2 needed)
MITSUBISHI MD 149764 EGR Tube Gasket
MITSUBISHI MD 303148 Valve Cover Gasket (2 needed)
MITSUBISHI MD 198128 Valve Cover Spark Plug Tube Grommets (6 needed)
MITSUBISHI MR 994412 Crankshaft Washer
MITSUBISHI 1100A141 Crankshaft Bolt, 3rd Version
MITSUBISHI MD 3772249 Crankshaft Seal, Front
MITSUBISHI MD 199282 Intake Plenum Gasket

 

[jlocster]

That looks good nwoods. Also, unless you've already bought spark plugs and wires, don't forget those!

In your case, think of what you're doing as 2 separate jobs.
1--Front of the engine includes: timing belt, water pump, front cam seals, crank seal/bolt
2--Top of the engine includes: valve cover gaskets, spark plugs/wires, spark plug tube grommets, rear cam seals

Now, since the top of the engine will be apart/accessible, I'd also strongly recommend you replace both rubber heater hoses and the rubber coolant crossover hose at the rear of the engine.

In that same vein, while the front of the engine is apart, I'd strongly recommend you replace your upper/lower radiator hoses, accessory drive belts, and thermostat.

Please note I had originally mistyped the front crankshaft seal part #, it should be MD 372249.

 

[eurosonic]

Ill be doing my front end soon.. thanks you sir

 

[Toasty]

Battery should be a group 27 though, a 34 is much smaller so might as well make the most out of having a big battery box. For AGM's you can get the marine deep cycle/starting combo batteries or for example the D27M.

Also i still have the dude's number from TJM, I should call him and get the part number for the Airtech snorkel kit.

 

[KIRK!]

Nice!

 

[twocommas]

Want to confirm some items since I had similar work done to my Montero this week. Some non-OEM parts are from different brands than what jlocster bought. New items in RED.

Spark Plug Job:
NGK 7005 wires + (6) Denso 3395 (Iridium Long Life) spark plugs
MD 199282 Intake Plenum Gasket
MD 149764 EGR Tube Gasket

Timing Belt Job:
ACDelco TCKWP287B Timing belt kit with water pump
MD 308723 Gasket Water Pump Housing to Thermostat Housing

Valve Cover Gasket Job:
MD 303148 Valve Cover Gasket (2)
MD 198128 Valve Cover Spark Plug Tube Grommets (6)

Other work you can do if you're doing the first 3 jobs:
1100A141 Crankshaft Bolt, 3rd Version (Note: this was recommended by Mitsubishi because the earlier ones are not as reliable)
MD 372249 Crankshaft Seal, Front
MD350415 Thermostat Kit
MD 372536 Camshaft Seal, Front (2)
MN 176208 Camshaft O-ring, Rear (2)
M350609D Mitsubishi Alternator (Note: according to the forums, if you get a non-oem alternator you may have 3 lights come on in the dash intermittently: Battery, Brake, and A/T lights)
FRAM 228 FV350 PCV Valve (2)

I paid about $700 for the parts and about $800 for all the labor. Time to go out there and break it!

 

[jlocster]

Thanks twocommas, added the following to the list:

ACDelco TCKWP287B Timing belt kit
MD350415 Thermostat Kit
M350609D Mitsubishi Alternator (changed to "MD 350609," correct?)
Denso 3395 (Iridium Long Life) spark plugs
FRAM 228 FV350 PCV Valve (changed to "FRAM FV350 PCV Valve," correct?)


sneakyninja, that'd be great if you could locate the Airtec snorkel part #

 

[twocommas]

Yup, you got it jlocster!

 

[Allrounder]

Found an interesting Mitsubishi parts page the other day...

http://mitsubishi.epc-data.com/pajero/

Think, most of the stuff up there is useful if you want to get dealership parts.

Best regards!

 

[nwoods]

thanks to TyTy on this forum I just ordered a fairly inexpensive Timing belt kit, that seems pretty complete.

http://www.ebay.com/itm/30093883146...iewitem=&sspagename=ADME:L:OU:US:1120&vxp=mtr

I also ordered the crankbolt and seal
http://www.ebay.com/itm/110985996424

 

[Mudrunner]

This post should also cross reference parts that were used on other vehicles. Like I just found out the PN for the fan shroud cross to Chrysler products. This is helpful if you are hunting for pick and pull parts because it gives you more vehicles to choose from. I am currently trying to find out what Chrysler vehicles for the fan shroud parts. Upon doing more research the P/N I had was just for the Sport. Apparently I thought I had clicked properly in the ASA but I didn't. But never a bad Idea to have options.

 

[raysobi]

Hello All,

I am planning to purchase the RTT, i would like to know about roof rack and maybe some of you can recommend?

I also do not wish to do any fabrication if i don't have to since my fabrication skill isn't so good, I am interested to purchase out right, plug n play rack....if there is one out there.

Thanks!

PS. I have Mitsu Montero 2.5 year 2000.

 

[Clem]

Handle, Back MR230032

I know I'm not the first to have their back handle ("lift gate handle") break. Some have MacGyvered solutions, but I oped for the OEM part (found it on eBay for ~$35). Part number took a little digging so here it is for the next guy MR230032.