**How to Install a Mitsubishi Montero (Pajero) Engine – Step-by-Step Guide**
Replacing the engine in your **Mitsubishi Montero (Pajero)** is a challenging task but can be done with the right tools and knowledge. This **step-by-step guide** will walk you through the process.
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### **Tools & Equipment Needed:**
- Engine hoist (cherry picker)
- Socket and wrench set
- Screwdrivers
- Jack and jack stands
- Torque wrench
- Engine mounting bolts
- Coolant, oil, and transmission fluid
- Service manual for torque specs
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## **Step 1: Preparation & Safety**
✅ Park the vehicle on a level surface and engage the parking brake.
✅ Disconnect the **battery terminals (negative first)** to prevent electrical issues.
✅ Jack up the car and secure it with **jack stands** for stability.
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## **Step 2: Drain Fluids**
1. Place a **drain pan** under the engine.
2. Remove the **engine oil drain plug** and let the oil drain completely.
3. Remove the **radiator cap** and drain the **coolant** from the radiator.
4. If your Pajero has an automatic transmission, drain the **transmission fluid** as well.
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## **Step 3: Remove the Hood & Accessories**
1. Unbolt and remove the **hood** for better access.
2. Remove the **air intake system** and air filter housing.
3. Disconnect the **coolant hoses** leading to the radiator.
4. Remove the **radiator and fan assembly** for more working space.
5. Disconnect the **fuel lines** and label them to avoid confusion.
6. Unbolt the **exhaust manifold** from the engine.
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## **Step 4: Disconnect Wiring & Hoses**
1. Unplug the **engine wiring harness** (ECU connections, ignition coils, sensors, etc.).
2. Label the disconnected wires for easier reinstallation.
3. Disconnect the **power steering pump** and **A/C compressor** (if reusing them, don’t remove the lines—just unbolt them and move aside).
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## **Step 5: Unbolt the Engine from Transmission & Mounts**
1. If manual, **disconnect the clutch** and flywheel. If automatic, remove the **torque converter bolts**.
2. Remove the **engine mounts** from the chassis.
3. Support the **transmission with a jack** so it doesn’t sag when the engine is removed.
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## **Step 6: Remove the Engine**
1. Attach an **engine hoist** to the engine lifting points.
2. Slowly lift the engine while checking for any still-connected components.
3. Carefully maneuver the engine out of the bay.
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## **Step 7: Install the New/Rebuilt Engine**
1. Lower the **new engine** into the bay slowly with the hoist.
2. Align the **engine mounts** and bolt them securely.
3. Attach the engine to the **transmission**, ensuring proper alignment.
4. Reinstall the **flywheel/clutch (manual) or torque converter (automatic)**.
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## **Step 8: Reconnect Wiring & Components**
1. Reconnect the **engine wiring harness**, sensors, and ignition components.
2. Reattach the **power steering pump** and **A/C compressor**.
3. Bolt the **exhaust manifold** back to the engine.
4. Reinstall the **radiator, coolant hoses, and air intake system**.
5. Connect the **fuel lines** securely.
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## **Step 9: Refill Fluids & Final Checks**
1. Refill with **fresh engine oil**.
2. Add **coolant** and bleed the cooling system properly.
3. If applicable, refill **transmission fluid**.
4. Reconnect the **battery terminals (positive first, then negative)**.
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## **Step 10: Start & Test the Engine**
✅ Double-check all connections and bolts.
✅ Turn the ignition **without starting** to let the fuel pump prime.
✅ Start the engine and **listen for any unusual noises**.
✅ Check for **leaks (oil, coolant, fuel, transmission fluid)**.
✅ Monitor **engine temperature and idle speed**.
✅ Take a short test drive to ensure proper performance.
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## **🚀 Conclusion**
Installing a Mitsubishi Montero (Pajero) engine requires patience and attention to detail. By following this **step-by-step guide**, you can successfully replace your engine and get back on the road with confidence! 🔧💨
💡 **Pro Tip:** Always **torque bolts to factory specifications** and double-check everything before starting the engine.