Question about 2001 Mitsubishi Montero

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Mitsubishi Montero (Pajero in Australia) fan belt auto tensioner.

I have an Australian based Mitsubishi Pajero (Montero)NM model with 6G7 engine, serpentine belt and auto tensioner. The manual p11A-17 has tensioner removal instructions which indicate rotating the tensioner with a socket handle, locking it in position with an allen key and removing the holding bolt. I'm concerned that the tensioner is still under tension and that something will give when I undo the bolt. I also concerned about the replacement method?

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  • mads_borvin Sep 04, 2009

    Thanks, but I have tried this by locking the tensioner, removing the belt from that area, re-inserting the socket handle, taking the strain, removing the Allen key and then gently releasing the tensioner. The tensioner goes to maximum travel but there is still some tension in its spring. The concern is firstly doing some damage in taking it off under the remaining tension, but also how I will get it or a new one back on?

  • mads_borvin Sep 06, 2009

    Thank you very much. Tried this and the removal went well. I had to remove a second bolt that was part of the assembly, end the tensioner came off with no problems. Thanks again.

  • mads_borvin Sep 06, 2009

    Thank you very much. Tried this and the removal went well. I had to remove a second bolt that was part of the assembly, end the tensioner came off with no problems. Thanks again.

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Follow the directions, you will be fine, here is what you do, place the tool to back off tension to remove belt then release tension of tensioner pulley mounting bracket to relaxed position, then break loose mounting bolt that is in the center of the actual pulley itself , then remove pulley, follow the directions in reverse order to reinstall pulley, yes the bracket is under spring tension as long as belt is resting on pulley , but with belt off it is at rest with no tension therefore no danger...

Posted on Sep 03, 2009

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1 Answer

How to replace fan belt on a Mitsubishi pajero


Instructions
  1. 1 Open the bonnet of the Pajero, and turn the bolt on the centre of the tension pulley with a socket wrench two full rotations. The tension pulley is the pulley directly behind the fan in the upper portion of the front of the engine.
  2. 2 Loosen the adjuster bolt on the tension pulley bracket. This bolt is on the left-hand side, situated in a long horizontal groove.
  3. 3 Slip the fan belt off of the engine. Draw a diagram of the path of the fan belt if the factory printed sticker diagram is no longer in the front of your engine on your Pajero.
  4. 4 Insert the new fan belt, winding it through the various pulleys according to your diagram. Put it on the tensioner pulley last.
  5. 5 Place the tension belt tool on the tension pulley bolt and pull until the slack in the belt is gone. When there is no slack, keep the pressure on the pulley, and tighten the adjuster bolt with the wrench. Tighten the lock bolt on the pulley.

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I checked out the pajero forum, they don't mention the bottom tensioner as being the noise maker here but rather a sloppy chain, stretched beyond the tensioner and riding on the guides. The noise sounds like it comes from the fan area as a metallic chattering. They sell a chain that has a master link in it, and you don't have to tear down the entire engine again to get to it, just the top cover,, Cut the old chain, and use it to pull the new one through. Also, if your chain did jump its gear, it would only be a matter of 8 - 10 miles before the cam breaks. Hope this helps.

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How do you remove tension from power steering belt


Hi Jeremy, Over here in Australia the Montero is badged as a 'Pajero'. I have a 2003 model but I presume the serpentine belt or accesory drive belt would be similar in both models and drives the power steering.

The belt most likely has an automatic tensioner as mine does. The tensioner looks like two small pulleys about 21/2" in diameter. The top one should have a square hole cutout for inserting a square peg handle to rotate the tensioner clockwise to release tension on belt.

If you can't find it - start your engine and with the hood popped rev the engine a few times. You should see the belt flexing and the tensioner will be the unit which flexes up and down to maintain the tension - all other pulleys should be rotating in a fixed position only.

Just to the right of the afore mentioned square hole is a small 1/4" hole which lines up with another hole when you rotate the tensioner clockwise to release the tension. Line up the holes and put an allen key or small screw driver through the holes to keep the tension released.

Naturally, I didn't have a square pegged hadle to lever the tensioner so I used a small gemmy or crow bar (whatever you call them in the USA) and levered between the crank pulley and the tensioner to rotate the tensioner clockwise. Be gentle and remember to remove the allen key/screw driver when you have finished.

Good Luck.

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You'll need to remove/loosen one of the components (such as the alternator or power steering pump) to relieve tension on the belt before removing the tensioner as it should be spring loaded. Installation is going to be the reverse of the removal procedure.
Also, if the tensioner is noisy, replace it.

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First job is to remove the 4 bolts securing the Intercooler, Its not totaly necessary to remove, but makes it a lot easier to get to the pullies.

Remove the 4 Bolts and move the Intercooler to the left hand side of the engine

Loosen off the locking bolt on the centre of the pully and then loosen the adjuster bolt until belt slackens

Loosen off the forward facing locking bolt and then loosen the adjuster bolt (Hidden behind the top hose) until belt slackens

You should now be able to remove all the belts and replace as required.

On refitting the belts adjust as required and then do up the locking bolts, refit Intercooler and check all connections (you wouldn't like the intercooler fan to fail

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