The Mitsubishi Montero, also known as the Pajero in global markets, has a reputation as a durable SUV with legendary off-road capability. Models produced between 1982 and 2006 are still on the road today thanks to their rugged design, but even the toughest engines eventually wear out. If your Montero Pajero is showing signs of serious engine trouble, replacing the engine can bring it back to life for years of dependable driving. This guide breaks down the process step by step. At Power Engines, we provide OEM-quality, road-legal replacement engines designed for direct fitment and long-term reliability.
Preparation and Tools Required
Before beginning, gather the right equipment: an engine hoist, hydraulic jack, jack stands, socket and wrench sets, torque wrench, screwdrivers, pliers, and drain pans. You’ll also need replacement fluids such as coolant, oil, and transmission fluid. Make sure your vehicle is parked on a level surface, disconnect the battery, and allow the engine to cool completely before starting.
Step 1: Remove the Hood and Drain Fluids
Start by removing the hood for complete access to the engine bay. Drain the engine oil, coolant, and transmission fluid into proper containers. This step prevents spills and ensures a cleaner workspace.
Step 2: Disconnect Wiring and Fuel Lines
Label all wiring harnesses, vacuum hoses, and sensors before disconnecting them. Relieve pressure from the fuel system and detach the fuel lines. Documenting connections with labels or photos makes reassembly easier.
Step 3: Remove Accessories and Cooling Components
Detach the alternator, starter motor, A/C compressor, and power steering pump. If possible, secure the A/C and power steering systems aside without disconnecting their fluid lines. Remove the radiator, cooling fans, and hoses to create more space for engine removal.
Step 4: Disconnect Exhaust and Transmission
Unbolt the exhaust manifold from the engine and detach the downpipe. Support the transmission with a jack or stand, then remove the bolts connecting it to the engine block. Automatic transmissions require disconnecting torque converter bolts, while manual versions require clutch assembly removal.
Step 5: Unbolt Motor Mounts and Lift Out the Engine
Remove the bolts securing the motor mounts. Attach the hoist chains to the correct lifting points and carefully raise the engine out of the bay. Double-check that no wiring or hoses remain attached before fully extracting the engine.
Step 6: Prepare the Replacement Engine
Transfer necessary components from the old engine to the new one, including intake and exhaust manifolds, brackets, and sensors. Replace seals, gaskets, and belts while the engine is out for maximum reliability. At Power Engines, our replacement engines for the Mitsubishi Montero Pajero are built to OEM specifications, ensuring direct fitment and emissions compliance.
Step 7: Install the New Engine
Lower the replacement engine into the bay, aligning it with the motor mounts and transmission. Secure all bolts to factory torque specifications. Reconnect the exhaust, transmission, and all accessory components.
Step 8: Reconnect Wiring, Fuel, and Cooling Systems
Reattach all labeled wiring harnesses, vacuum hoses, and fuel lines. Reinstall the radiator, fans, and coolant hoses. Fill the vehicle with fresh oil, coolant, and transmission fluid.
Step 9: Test and Break-In
Reconnect the battery and switch the ignition to ON to prime the fuel system. Start the engine and let it idle, checking for leaks, unusual noises, or dashboard warning lights. Allow the engine to reach operating temperature. For the first 500 miles, avoid aggressive driving and high RPMs. Perform an oil change after the break-in period to ensure long-term performance.
Replacing the engine in a Mitsubishi Montero Pajero (1982–2006) is a detailed but rewarding process that can extend the life of this iconic SUV for many more years. With the right preparation and a step-by-step approach, the job can be completed successfully. Choosing a high-quality, road-legal replacement from Power Engines ensures your Montero Pajero maintains its strength, reliability, and off-road capability long into the future.
