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Function The original intercooler for the L200 is quite small. Because of this the cooling capacity is low and the pressure drop is considerable. When increasing the power output of the L200 engine the boost air temperature must be kept as low as possible, while it has a great influence in performance as well as engine durability. Charge air cooling also has a positive effect on exhaust emissions from diesel engines. The pressure drop through the charge air cooler lowers the air mass flow trough the engine. To maximize air mass flow is essential to increase performance. The sttemtec charge air cooler upgrade maximizes the cooling capacity and minimizes the pressure drop of the charge air cooler without any negative effects of the vehicle. List of content 1. Charge air cooler 2. Air hose 3. Bag, Brackets and rubber mountings for intercooler Installation Installation preparations 1. Perform test drive with verification of general engine functions. 2. Wash engine bay with special attention to radiator and intercooler (wash, compressed air). System installation Remove the radiator grille by first remove the four plastic clips and then the claws by pulling out and up.

WIRING INFORMATION: 1997 Mitsubishi Montero Sport WIRE WIRE COLOR WIRE LOCATION 12V CONSTANT WIRE WHITE Ignition Harness
STARTER WIRE BLACK/YELLOW or BLACK/BLUE Ignition Harness IGNITION WIRE BLACK/WHITE Ignition Harness ACCESSORY WIRE BLUE/RED Ignition Harness

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1. Remove tailgate cover 5. Slide bracket into tailgate over studs 9. Connect actuator to loom and use cable tie/clip to secure cable. 2. Remove nut 6. Replace both nuts 3. Remove nut 7. Remove cable cover 11. Run the cable along the chassis, taking care to ensure it is kept away from heat sources. 12. Bring the cable through the grommet located under the passen- ger seat. 13. Remove the door sill trim from the passenger side front door. 14. Connect the wires as follows. TruckLok Vehicle Red Blue 4. Slide bracket into tailgate 8. Feed cable through grommet 15. Close all doors and test using vehicle’s key. Do not test repeatedly as the actuator may overheat. 16. Replace all trim and tailgate cover.

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Valve timing procedures Valve timing procedures Ensure crankshaft at TDC on No.1 cylinder. Ensure crankshaft pulley timing mark aligned with 0° timing mark on chain cover [1]. Ensure notch on camshaft points upwards [2]. If notch not visible, turn crankshaft one more turn. Install timing gears as follows: Ensure crankshaft gear and intermediate shaft gear timing marks aligned [3]. Install LH balancer shaft [4]. Ensure timing marks on intermediate shaft gears and LH balancer shaft gear aligned [5] & [6]. Ensure RH balancer shaft gear and oil pump gear timing marks aligned [7]. Install oil pump housing complete with RH balancer shaft. Ensure timing marks on oil pump gear and crankshaft gear aligned [8]. Install injection pump as follows [9] : Ensure notch on injection pump gear aligned with mark ‘T’ on flange [10]. During installation of injection pump: Notch on gear moves in direction of arrow. Install timing chain as follows:

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1. Remove exhaust manifolds and inlet manifold thoroughly cleaning old gasket from head. 2. Remove oil plug from rear of cylinder head using a 6 mm Allen headed socket and fit 1/4 BSP oil fitting No. 34 and oil pipe No. 35. 3. Remove oil filter and then whole oil filter casting. Clean old gasket from both surfaces and make a holding jig for aluminium casting so as to be able to drill out the oil return. Drill a 15 mm hole right through to return gallery and tap out to 3/8 BSP. Thoroughly blow clean of metal and fit 3/8 x 16 mm hose fitting No. 42 and oil return hose No. 40. Now refit to block using new gasket No. 39. 4. Fit new manifold gasket No. 7 and Denco Diesel exhaust manifold No. 6. Now fit turbo to manifold making sure to engage oil return fitting. Tighten turbo to manifold using lock nuts .9. (NOTE: Make sure all openings on turbo and motor have been covered to prevent foreign material entering.) 5. Fit oil pipe No. 35 to turbo and tighten fittings. 6. Fit inlet manifold No. 26 to motor and connect to turbo using No. 30 casting and item No. 28 and 29 clamps and hoses. Secure oil pipe with clamp and bolt. 7. Fit heat shield No. 17 to exhaust manifold No. 6 using bolts No. 18. 8. Fit air cleaner to turbo 4D 003 Casting No. 21 or 22 to turbo using items No. 24-25 clamps and hoses and connect to air cleaner using original hoses. 9. Fit exhaust dump pipe No. 43 to turbo using V Clamp No. 16. 10. Connect engine breather pipe to fitting No. 23. 11. Increase Max fuel on fuel injection pump by one sixth of a turn, or 2 segments of the clock inwards. 12. Fit 2 1/4 inch or 55mm exhaust system and straight through muffler (not supplied). 13. Start engine and allow it to idle for 5 minutes whilst checking for air and oil leaks. Set max. boost under load to 50 KPA by adjusting actuator rod. ALL DENCO DIESEL SYSTEMS RUN AT 60 KPA BOOST MAXIMUM AND A MAXIMUM OF 550°C UNDER POWER LOAD UNLESS OTHERWISE STATED. 14. Recheck for leaks.