MitsubishiMontero Sport20023.5L/mitsubishi/montero-sport/2002/3-5l/

2002 Mitsubishi Montero Sport — 3.5L

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2002 Montero Sport 3.5L.

Body SUVEngine 3.5LTransmission Automatic 4-spd

The 2002 Mitsubishi Montero Sport 3.5L is an SUV pairing a 3.5L engine with a four-speed automatic, a combination that returned EPA fuel economy of 15 city / 20 highway / 17 combined mpg and required 4.9 quarts of 10W-30 or 5W-30 API oil for servicing. Coming one model year after the 2001 version logged the highest complaint volume in the nameplate's 1998–2009 history at 245 reports, the 2002 saw a steep drop to 61 owner complaints, with air bags leading the issue list and no recalls on record. That 61-complaint figure, however, still far exceeds the platform's quietest year (2009, with a single report), meaning the 2002 represents an early step down from peak trouble rather than the low-complaint tail end of the model run. For a researcher, this places the 2002 as a transitional year—clearly past the 2001 surge but not yet in the calm of the late production cycle.

Model year20042003200220001999

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity4.9 qtOEM · verified
Engine oil type10W-30 / 5W-30 APIOEM · verified
Lug nut torque72-87 ft-lbsOEM · verified
EPA fuel economy15/20/17 mpgEPA · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 24 · 585 CCA battery, OE oil filter MZ690116. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 24 · 585 CCAOEM · verified
Tail / brake / turnHEADOEM · verified
Tire size4WD:P225-75R15OEM · verified
Wheel / rim6-JJ inOEM · verified

OE service part numbers OEM · verified

Engine oil filterMZ690116
Engine air filterMR571471 alt MR571473
Fuel filterMR239580
Spark plugMD361067 alt MD372553
Front wiper bladesMR300876 alt MR300877
Serpentine beltMD199223 alt 7814A030
Thermostat1305A239

Full specifications

Engine, drivetrain, dimensions and economy.

Engine & drivetrain NHTSA vPIC

TransmissionAutomatic 4-spd

Dimensions & weight NHTSA vPIC

Overall length181.1 in
Overall width66.5 in
Overall height67.7 in
Wheelbase106.7 in
Curb weight3843 lb
Track (front / rear)57.9 / 58.3 in
Weight distribution (front / rear)55/45

Ratings & economy EPA / vPIC

EPA city / highway / combined15 / 20 / 17 mpg
DrivetrainRear-Wheel Drive
Recommended fuelRegular Gasoline

Performance & power Independent road tests

0–60 mph, quarter-mile, horsepower and torque from independent road tests.

No 2002 road test on record; the results below are same-engine tests from nearby model years, each shown under its own year.

10.1 sec0–60 mph (tested)quickest 10.10 sec — 2000 Limited
200 hpHorsepower (as tested)
230 lb-ftTorque (as tested)
YearTrim / engine0–60¼ mileHPDrivetrain
2000Limited 3.5L V610.10 sec17.50 sec200 hp4x4

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 4.9 qt of 10W-30 / 5W-30 API engine oil, DOT 3 · DOT 4 brake fluid. Torque lug nuts to 72-87 ft-lbs, the oil drain plug to 29.0 ft-lbs. The firing order is 1-2-3-4-5-6.

Lubricants & capacities

Brake FluidDOT 3 · DOT 4
Engine Oil10W-30 · API · 5W-30
Engine Oil Capacity4.9 qt
Power Steering FluidGenuine Mitsubishi PS fluid
Power Steering FluidUse Mitsubishi PS fluid

Engine torques

Camshaft Bearing/Carrier Cap Bolts or StudsTighten in 2
Crankshaft Pulley and/or Damper Bolts134 ft-lbs
Cylinder Head Steps3 steps in sequence: Final torque; 80 ft-lbs
Engine Flywheel Bolts54 ft-lbs
Intake Manifold to Engine Bolts16 ft-lbs
Exhaust Manifold to Cylinder Head Bolts33 ft-lbs
Main Bearings54 ft-lbs
Engine Oil Pan Drain Plug29.0 ft-lbs

Chassis torques

Lug Nuts72-87 ft-lbs
Transfer Case Fill Plug21.0-25.0 ft-lbs
Transfer Case Drain Plug21.0-25.0 ft-lbs

Ignition

Cylinder Firing Order1-2-3-4-5-6
Curb Idle Speed (No Load)700 rpm
Curb Idle Speed Variance (No Load)100 rpm
Spark Plug Gap0.039-0.0.043 in
Spark Plug Torque15.0-21.0 ft-lbs
Ignition Timing5, Not adjustable degrees
Ignition Timing Acceptable Variance3 degrees

Battery & A/C

RefrigerantR134a
Refrigerant Capacity1.44-1.50 lbs
Oil GroupPAG
Oil Type56
Oil Capacity5.70 oz
Standard BCI Group Number24
Standard BCI Cranking Performance585 cca

Service checks

Pressure Test23 psi
Radiator Cap Pressure Relief11-15 psi
Thermostat Opening Temperature187-193 °F
Regulated Fuel System Pressure (Without Vacuum)47.0-50.0 psi
Regulated Fuel System Pressure (With Vacuum)38.0 psi
Engine Compression171 minimum PSI. 14 maximum variation PSI.
Engine Compression127-171 psi
Engine Oil Pressure11.4-11.6 psi

Brakes

Brake ApplicationWITH REAR DISC / WITH STANDARD
Torque Caliper to Bracket32 ft-lbs / 55 ft-lbs
Torque to Knuckle93 ft-lbs / 65 ft-lbs
Minimum Pad ThicknessFront: 0.080; Rear: 0.080 in
Minimum Shoe Thickness0.039 in
Brake ApplicationWITH REAR DISC / WITH STANDARD
Rotor Runout Limit0.0031 in / 0.0024 in
Rotor Nominal Thickness From0.709 in / 0.945 in

Multi-step torque procedures OEM · verified

Connecting Rod (Large End) Bearings — tightening sequence 1 stages
125 ft. lbs., Step 2: 9025 ft. lbs

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 7,500 mi; spark plugs every 60,000 mi; coolant at 60,000 mi. The big-interval services (at 60,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

Every 7,500 miBrake Hydraulic System (inspect fluid level) · Clutch Master Cylinder (inspect fluid level) · Engine Oil (drain & refill) · Engine Oil Filter (replace) · Power Steering System (inspect) · Tire & Wheel Assembly (rotate)
Every 15,000 miAxle Shaft Oil Seal (inspect) · Brake Linings (inspect) · CV Joint Boot (inspect)
Every 30,000 miAccessory Drive Belt (inspect) · Brake Drum Assembly (inspect) · Brake System (inspect) · Differential (inspect fluid level) · Drive Axle Assembly (drain & refill) · Driveshaft U-Joint (inspect)
At 60,000 miEngine Coolant System (drain, flush & refill)
Every 60,000 miFuel Evaporative Emission Control System (inspect) · Fuel Line (inspect) · Fuel Tank (inspect) · Fuel Tank Filler Cap (inspect) · Spark Plug Wires (replace) · Timing Belt (replace)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

The 2002 Mitsubishi Montero Sport sits at a clear inflection point in the generation's reliability arc. After a dramatic spike to 245 complaints and 6 recalls in 2001, the 2002 model year shows a sharp decline to 61 complaints and zero recalls, suggesting that many of the prior year's quality issues were addressed. However, it is the only model year with a federal investigation on record, and its complaint count remains higher than the later 2004 model (just 5 complaints). The top complaint areas—air bags, engine and engine cooling, and service brakes—are consistent with the generation's recurring themes, but the data does not specify root causes. With no fire complaints and a moderate 15 crash complaints, the 2002 Montero Sport is a markedly better choice than the troubled 2001, but the open investigation and lingering complaints mean it does not represent the generation's most trouble-free option.

0
Open recalls
NHTSA campaigns
57
Service bulletins
Manufacturer communications
1
ODI investigations
Office of Defects Investigation
61
Owner complaints
15 involved a crash · 0 a fire
NHTSA crash-test rating federal NCAP · out of 5 stars
Rollover★★★★★
Owner complaints by model year NHTSA · this generation & adjacent

Owner complaints filed with NHTSA, by component

All 61 complaints on record, top 8 components.

Air Bags10
Engine & Engine Cooling9
Service Brakes, Hydraulic6
Structure5
Power Train4
Visibility3
Tires3
Service Brakes2

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

No recall campaigns on record with NHTSA for this vehicle as of the last data refresh.

Technical service bulletins NHTSA · verified

Showing 5 of 57 bulletins on record with NHTSA.

BulletinDateComponentSummary
DEALER LETTER2023-07-21EquipmentThis is a Dealer Letter sent to dealers informing that Mitsubishi Technical Training has…
TSB-23-00-0042023-04-24StructureThis Technical Service Bulletin provides instructions and material safety data sheets for…
TSB-23-00-0012023-04-24EquipmentThis Technical Service Bulletin reviews the regulations that require a label showing the…
DEALER LETTER2023-04-21EquipmentThis is a Dealer Letter sent to dealers informing that Mitsubishi Technical Training has…
TSB-22-54-0032022-04-07Exterior LightingThis Technical Service Bulletin was sent to dealers to explain the difference between…

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420
Catalyst system efficiency below threshold — Bank 1
P0300
Random / multiple cylinder misfire detected
P0171
System too lean — Bank 1
P0455
Evaporative emission system leak detected — large leak
P0128
Coolant thermostat below regulating temperature
P0442
Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN
Decode a VIN to confirm the transmission and build data for a specific Montero Sport. OEM
Build data
Plant, GVWR class, engine and body data for any 17-character VIN.
Recalls
Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Reference guides

Cross-vehicle references for the kinds of data on this page.

Frequently asked

How much oil does the 2002 Montero Sport 3.5L take?

4.9 qt of ABOVE 0 degreesF 10W-30 SL API, BELOW 100 degreesF 5W-30 SL API, per the factory manual.

Does the 2002 Montero Sport have open recalls?

NHTSA lists 0 recall campaign(s) for this model year. Check your specific vehicle by VIN.

What gas mileage does the 3.5L get?

EPA figures are 15 city / 20 highway / 17 combined mpg.