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Hi Don. Is a shop doing the gasket replacement or was it a D.I.Y. thing? I ask because the problem may very well be a warped/cracked exhaust manifold, or worse a cylinder head issue. If your doing this yourself, perhaps remove the exhaust manifold and take it to a shop to be checked for warpage or cracks, and simply repace it (along with a new gasket of course) if yours is found to be faulty. Also, use new hardware ( studs/bolts) to install the manifold and torque to proper torque specs. Proper torque is important.
Buy a gasket kit for the upper end. Remove the valve cover intake and exhaust manifolds. Remove the head bolts. Remove head and clean up block from old gasket material. Take the head to a machinist and make sure that it is not warped. If it is warped either replace the head with a new one or have it machined true. Install new gasket and get torque specs with new head bolts and follow torque sequence using the correct torque specs. Clean exhaust, intake and valve cover of old gaskets. install new gaskets and torque according to specifications.
Water pump is driven by timing chain idler and is mounted on the rear of the timing chain housing. Disconnect the neg. battery cable. Drain cooling system. Disconnect oxygen sensor connector.
Remove upper exhaust manifould heat sheild. Remove exhaust manifold brace. Remove lower exhaust manifold heat sheild. Loosen manifold to exhaust manifold spring loaded nuts. Remove radiator outlet pipe to water pump coverbolts. Disconnect exhaust pipe from manifold.
Pull down on the exhaust pipe to disconnect it from exhaust manifold bolts. Disconnect outlet pipe from oil pan and transaxle. If equipped with manual tranaxle, remove exhaust maifold brace. Leave lower radiator hose attached and pull down on radiator out look pipe to disengauge from water pump. Leave outlet pipe hanging.
Lower vehicle. Remove exhaustmanifold to cylinder head nuts. Remove exhaust manifold to cylinder head nuts. Remove manifould. Remove timing chain front cover. Remove timing chain tensioner. Remove bolts bolts securing water pump cover to cylinder block. Remove water pump to timing chain housing nuts. Remove water pump attaching nuts. Remove water pump and cover assembly. Separate componets as necessary.
WHEN INSTALLING WATER PUMP MAKE SURE YOU FOLLOW THE TIGHTENING SEQUENCES THAT AFFECT SEALING. My frist one I messed up and broke the pump so becarful.
If cover was separated from body during removal, join this componets with a new gasket and hand tighten bolts. Apply bearing grease to splines of water pump drive. Set body and assemble into position.
Install and hand tighten bolts securing cover to cylinder block. Install and hand tighten bolts securing cover to cylinder block. Installand hand tighten nuts securing body to timing chain housing. Lubracate outlet pipe "O" ring with antifreeze. (I use RTV) Connect outlet pipe. Install and hand tighten bolts. Tighten bolts and nuts to specification in the following sequence. I'll ad the torque spec. at the end but this is where if you tighten out of order something will break.
pump assembly to timing chain housing nuts.
pump cover to pump body bolts
pump cover to cylinder block bolts (Bottom Bolt First)
outlet pipe to cover bolts
To complete installation reverse removel procedure.
Torque specs are 19 in. or 26mm all except water pump cover bolts which are 124 in or 14Nm
I never torque the bolts just make sure there done in the right order.
According to the service literature I read, the 2003 Montero Sport with the 3.0 or 3.5 L engine does not have O2 sensors listed even in the maintenance schedule. The 2.4 L engine has it on the exhaust manifold though. --- However, the following lists the par, though for before or after the catalytic converter:
--- I think that $250 to $300 is reasonable if the Oxygen sensors are stuck in there with rust and the threads are preserved by the technician. Oxygen Sensor replacement can be tricky. --- Good luck on this repair.