Mitsubishi Montero 1996 1997 1998 1999 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Model Generation: Second Generation (1991-1999) Model Code Platform: K90 Series Applicable Years: 1996, 1997, 1998, 1999 Codes Chassis Code: K94W, K96W, K97W, K99W Engine Codes Covered: 6G72 (3.0L V6 SOHC, SOHC MPI), 6G74 (3.5L V6 SOHC MPI, DOHC MPI) 👋 Introduction Market Position Vehicle Type: Mid-size SUV / Sport Utility Vehicle Key Market Segment: Rugged, capable off-road SUV with comfortable on-road manners, popular for families and outdoor enthusiasts. Competitive Analysis Key Competitors: Jeep Grand Cherokee, Toyota 4Runner, Ford Explorer, Chevrolet Blazer, Nissan Pathfinder, Land Rover Discovery. Key Features Unique Selling Points: Optional 3.5L V6 engine, advanced Super Select 4WD system, robust chassis, comfortable interior, strong off-road capability. Body Styles: 2-door (short-wheelbase), 4-door (long-wheelbase), Wagon, Hardtop Convertible (limited). 📋 Manual Details Coverage Areas Regional Coverage: Global (North America, Europe, Asia, Australia, etc.) - tailored to specific markets where applicable Trim Levels Covered: LS, SR, Sport, XLS, ES, Limited, Evolution (where applicable for specific markets and engine variants) Page Count Estimated Page Count: 1500-2000+ pages (comprehensive factory documentation) Manual Type Type: Factory Service Repair Manual (FSM) / Workshop Manual Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical (3.0L 6G72, 3.5L 6G74), fuel injection, ignition system, exhaust system, cooling system, lubrication system, engine control module (ECM). Transmission Drivetrain: Manual transmission (KM14x series), Automatic transmission (V4A51, W4A51), Transfer case (Super Select 4WD, Easy Select 4WD), drive shafts, axles, differential systems (front, rear, center). Chassis Suspension Steering: Independent front suspension (double wishbone), Multi-link rear suspension, shock absorbers, springs, control arms, stabilizer bars, power steering system, steering gear/rack. Braking System: Front disc brakes, rear disc or drum brakes, Anti-lock Braking System (ABS) with hydraulic control unit and sensors, parking brake. Electrical Electronics: Battery, charging system (alternator), starting system, lighting (headlights, taillights, interior), dashboard instruments, gauges, fuses, relays, wiring diagrams for all circuits, body control module (BCM). HVAC Body: Heating, Ventilation, and Air Conditioning (HVAC) system components (compressor, condenser, evaporator, blower motor), body panels, doors, windows, seats, interior trim, body sealing, wipers, mirrors. Procedures Included Maintenance: Scheduled maintenance, oil change procedures, fluid checks and replacements (coolant, brake fluid, power steering fluid, transmission fluid, differential fluid), filter replacements (oil, air, fuel), spark plug replacement, timing belt inspection/replacement (on applicable engines). Diagnostics Troubleshooting: Systematic diagnostic procedures for engine performance issues, transmission faults, electrical problems, brake system malfunctions, HVAC complaints, using diagnostic trouble codes (DTCs) and scan tools. Repair Overhaul: Detailed disassembly, inspection, repair, and reassembly procedures for all major components: engine rebuilds, transmission overhauls, differential repairs, brake caliper and rotor replacement, suspension component replacement, steering rack rebuild, AC system servicing. Electrical Diagnostics: Component testing, circuit diagnosis, wiring harness repair, ECM/PCM troubleshooting, ABS sensor testing, power window/lock diagnostics. Body Collision: Body panel alignment, door and latch repair, glass replacement, collision repair guidelines (structural components if specified). Technical Depth Depth Of Information: Comprehensive factory-level technical data, including detailed specifications, torque values, diagnostic charts, wiring schematics, repair sequences, and specifications for specialized tools. Diagnostic Capabilities: Includes specific diagnostic trouble codes (DTCs) and their meanings, diagnostic flowcharts, and recommended test procedures for common and uncommon faults. Special Tool Requirements: Lists and describes the use of specialized tools and equipment required for specific diagnostic and repair procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content for quick information retrieval. Printability: Printable pages for offline use and workshop reference. Print Quality Image Resolution: High-resolution images and diagrams for clarity. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code 1: 6G72 Engine Displacement 1: 3.0 Liters (2972 cc) Engine Configuration 1: V6 SOHC (Single Overhead Cam) Engine Type 1: Gasoline Multi-Point Fuel Injection (MPI) Horsepower 1: Approx. 150-175 HP (depending on market and specific tuning) Torque 1: Approx. 170-185 lb-ft (depending on market and specific tuning) Optional Engine Engine Code 2: 6G74 Engine Displacement 2: 3.5 Liters (3497 cc) Engine Configuration 2: V6 SOHC MPI / DOHC MPI (depending on trim and year) Horsepower 2: Approx. 195-215 HP (SOHC MPI), Approx. 230-244 HP (DOHC MPI - Montero Evolution/limited markets) Torque 2: Approx. 200-220 lb-ft (SOHC MPI), Approx. 230-240 lb-ft (DOHC MPI) Fuel System Fuel Delivery: Electronic Multi-Point Fuel Injection (MPI) / Sequential Fuel Injection (SFI) on later models. Fuel Type: Unleaded Gasoline (Regular Octane typically recommended, Premium for higher performance variants) Ignition System: Distributorless Ignition System (DIS) or Distributor type with Coil-on-Plug (COP) or Coil-Pack depending on specific engine and market. 🔧 Transmission Standard Transmission Type 1: 5-speed Manual Transmission (e.g., KM14x series) Optional Transmission Type 2: 4-speed Automatic Transmission with Electronic Control (e.g., V4A51, W4A51) Features Auto: Overdrive gear, sport mode, torque converter lock-up clutch. Drivetrain Options 4Wd System 1: Easy Select 4WD (Part-time, manually selectable 2WD/4H/4L) 4Wd System 2: Super Select 4WD (Full-time...

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Tipo: Car

Fabricante:

Sku: 476856

Coleções: ALL Mitsubishi

Disponibilidade: Em estoque

Tag: 1996 1997 1998 1999 Car Cars Misc Mitsubishi Montero

Variantes do produto

Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Montero

Model Generation:

Second Generation (1991-1999)

Model Code Platform:

K90 Series

Applicable Years:

1996, 1997, 1998, 1999

Codes

Chassis Code:

K94W, K96W, K97W, K99W

Engine Codes Covered:

6G72 (3.0L V6 SOHC, SOHC MPI), 6G74 (3.5L V6 SOHC MPI, DOHC MPI)

👋 Introduction

Market Position

Vehicle Type:

Mid-size SUV / Sport Utility Vehicle

Key Market Segment:

Rugged, capable off-road SUV with comfortable on-road manners, popular for families and outdoor enthusiasts.

Competitive Analysis

Key Competitors:

Jeep Grand Cherokee, Toyota 4Runner, Ford Explorer, Chevrolet Blazer, Nissan Pathfinder, Land Rover Discovery.

Key Features

Unique Selling Points:

Optional 3.5L V6 engine, advanced Super Select 4WD system, robust chassis, comfortable interior, strong off-road capability.

Body Styles:

2-door (short-wheelbase), 4-door (long-wheelbase), Wagon, Hardtop Convertible (limited).

📋 Manual Details

Coverage Areas

Regional Coverage:

Global (North America, Europe, Asia, Australia, etc.) - tailored to specific markets where applicable

Trim Levels Covered:

LS, SR, Sport, XLS, ES, Limited, Evolution (where applicable for specific markets and engine variants)

Page Count

Estimated Page Count:

1500-2000+ pages (comprehensive factory documentation)

Manual Type

Type:

Factory Service Repair Manual (FSM) / Workshop Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical (3.0L 6G72, 3.5L 6G74), fuel injection, ignition system, exhaust system, cooling system, lubrication system, engine control module (ECM).

Transmission Drivetrain:

Manual transmission (KM14x series), Automatic transmission (V4A51, W4A51), Transfer case (Super Select 4WD, Easy Select 4WD), drive shafts, axles, differential systems (front, rear, center).

Chassis Suspension Steering:

Independent front suspension (double wishbone), Multi-link rear suspension, shock absorbers, springs, control arms, stabilizer bars, power steering system, steering gear/rack.

Braking System:

Front disc brakes, rear disc or drum brakes, Anti-lock Braking System (ABS) with hydraulic control unit and sensors, parking brake.

Electrical Electronics:

Battery, charging system (alternator), starting system, lighting (headlights, taillights, interior), dashboard instruments, gauges, fuses, relays, wiring diagrams for all circuits, body control module (BCM).

HVAC Body:

Heating, Ventilation, and Air Conditioning (HVAC) system components (compressor, condenser, evaporator, blower motor), body panels, doors, windows, seats, interior trim, body sealing, wipers, mirrors.

Procedures Included

Maintenance:

Scheduled maintenance, oil change procedures, fluid checks and replacements (coolant, brake fluid, power steering fluid, transmission fluid, differential fluid), filter replacements (oil, air, fuel), spark plug replacement, timing belt inspection/replacement (on applicable engines).

Diagnostics Troubleshooting:

Systematic diagnostic procedures for engine performance issues, transmission faults, electrical problems, brake system malfunctions, HVAC complaints, using diagnostic trouble codes (DTCs) and scan tools.

Repair Overhaul:

Detailed disassembly, inspection, repair, and reassembly procedures for all major components: engine rebuilds, transmission overhauls, differential repairs, brake caliper and rotor replacement, suspension component replacement, steering rack rebuild, AC system servicing.

Electrical Diagnostics:

Component testing, circuit diagnosis, wiring harness repair, ECM/PCM troubleshooting, ABS sensor testing, power window/lock diagnostics.

Body Collision:

Body panel alignment, door and latch repair, glass replacement, collision repair guidelines (structural components if specified).

Technical Depth

Depth Of Information:

Comprehensive factory-level technical data, including detailed specifications, torque values, diagnostic charts, wiring schematics, repair sequences, and specifications for specialized tools.

Diagnostic Capabilities:

Includes specific diagnostic trouble codes (DTCs) and their meanings, diagnostic flowcharts, and recommended test procedures for common and uncommon faults.

Special Tool Requirements:

Lists and describes the use of specialized tools and equipment required for specific diagnostic and repair procedures.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content for quick information retrieval.

Printability:

Printable pages for offline use and workshop reference.

Print Quality

Image Resolution:

High-resolution images and diagrams for clarity.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

Engine Displacement 1:

3.0 Liters (2972 cc)

Engine Configuration 1:

V6 SOHC (Single Overhead Cam)

Engine Type 1:

Gasoline Multi-Point Fuel Injection (MPI)

Horsepower 1:

Approx. 150-175 HP (depending on market and specific tuning)

Torque 1:

Approx. 170-185 lb-ft (depending on market and specific tuning)

Optional Engine

Engine Code 2:

Engine Displacement 2:

3.5 Liters (3497 cc)

Engine Configuration 2:

V6 SOHC MPI / DOHC MPI (depending on trim and year)

Horsepower 2:

Approx. 195-215 HP (SOHC MPI), Approx. 230-244 HP (DOHC MPI - Montero Evolution/limited markets)

Torque 2:

Approx. 200-220 lb-ft (SOHC MPI), Approx. 230-240 lb-ft (DOHC MPI)

Fuel System

Fuel Delivery:

Electronic Multi-Point Fuel Injection (MPI) / Sequential Fuel Injection (SFI) on later models.

Fuel Type:

Unleaded Gasoline (Regular Octane typically recommended, Premium for higher performance variants)

Ignition System:

Distributorless Ignition System (DIS) or Distributor type with Coil-on-Plug (COP) or Coil-Pack depending on specific engine and market.

🔧 Transmission

Standard Transmission

Type 1:

5-speed Manual Transmission (e.g., KM14x series)

Optional Transmission

Type 2:

4-speed Automatic Transmission with Electronic Control (e.g., V4A51, W4A51)

Features Auto:

Overdrive gear, sport mode, torque converter lock-up clutch.

Drivetrain Options

4Wd System 1:

Easy Select 4WD (Part-time, manually selectable 2WD/4H/4L)

4Wd System 2:

Super Select 4WD (Full-time 4WD with 2H/4H/4HLc/4LLc modes, center differential lock, optional rear differential lock)

Fluid Specifications

Manual Transmission Fluid:

API GL-4 or GL-5, SAE 75W-90 Gear Oil. Consult manual for specific viscosity and capacity.

Automatic Transmission Fluid:

DIAQueen ATF-SP II M or equivalent (e.g., Dexron III/Mercon for some regions). Consult manual for exact specification and capacity.

Transfer Case Fluid:

API GL-5, SAE 75W-90 Gear Oil. Consult manual for specific viscosity and capacity.

Rear Differential Fluid:

API GL-5, SAE 75W-90 Gear Oil. Consult manual for specific viscosity and capacity. Limited Slip Differential (LSD) may require specific additive.

📐 Dimensions

Exterior Dimensions

Wheelbase Long Wb:

Approx. 109.4 inches (2780 mm)

Wheelbase Short Wb:

Approx. 100.2 inches (2545 mm)

Length Long Wb:

Approx. 186.8 inches (4745 mm)

Width:

Approx. 70.1 inches (1780 mm)

Height:

Approx. 66.5-69.7 inches (1690-1770 mm) (depending on suspension and roof rack)

Weights

Curb Weight:

Approx. 3900 - 4500 lbs (1770 - 2040 kg) (depending on configuration)

Gross Vehicle Weight Rating Gvw:

Approx. 5500 - 5900 lbs (2500 - 2675 kg)

Cargo Dimensions

Cargo Volume Behind Second Row:

Approx. 45.2 cu ft (1280 liters)

Cargo Volume With Second Row Folded:

Approx. 92.1 cu ft (2608 liters)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

4/5 Stars (for models with dual airbags, verify year)

NHTSA Front Impact Passenger:

4/5 Stars (for models with dual airbags, verify year)

IIHS Side Impact:

Acceptable/Good (varies by year and equipment, dual airbags enhance rating)

Active Features

Standard on most trims from 1997 onwards, optional on some earlier models. Four-wheel Anti-lock Braking System (ABS).

Traction Control:

Available on select higher trims, particularly with the 3.5L engine.

Passive Features

Airbags:

Driver and front passenger airbags standard on most models from 1997 onwards. Side-impact airbags not commonly available for this generation.

Seatbelts:

Three-point seatbelts with pretensioners for front occupants, three-point belts for rear passengers.

Rollover Protection:

Reinforced body structure, although SUVs of this era are inherently more prone to rollovers than sedans. Super Select 4WD with low-range gearing aids stability off-road.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/Cassette or CD player, with optional premium sound systems (e.g., Rockford Fosgate on some trims). Speaker configurations vary by trim.

Navigation:

Rarely available from the factory for this generation. Aftermarket solutions were common.

Driver Assistance

Cruise Control:

Available on most trims, speed-sensitive or standard. Controlled via steering wheel or stalk.

Parking Assist:

Not available from factory. Backup sensors or cameras were aftermarket additions.

Connectivity

Auxiliary Input:

Not standard. Aftermarket head unit upgrades or cassette adapters were used for modern audio connectivity.

Bluetooth:

Not available from factory. Aftermarket Bluetooth modules or integrated systems in aftermarket head units.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 miles (6,000 km) or 3-6 months, whichever comes first. Use synthetic or high-mileage oil for longer intervals. Consult manual for specific grades.

Engine Oil Filter Replacement:

With every oil change.

Air Filter Replacement:

Every 15,000 miles (24,000 km) or as needed based on driving conditions.

Fuel Filter Replacement:

Every 30,000 miles (48,000 km).

Spark Plug Replacement:

Every 60,000 miles (96,000 km) for standard spark plugs; platinum/iridium plugs may last longer.

Timing Belt Replacement:

Critical: Every 60,000 - 90,000 miles (96,000 - 144,000 km) or 5-7 years. Failure can cause catastrophic engine damage on interference engines.

Fluid Specifications

Engine Oil Capacity 3.0L:

Approx. 4.5 US quarts (4.3 liters) with filter. Refer to manual for exact capacity and oil type (e.g., 5W-30 or 5W-40).

Engine Oil Capacity 3.5L:

Approx. 4.8 US quarts (4.5 liters) with filter. Refer to manual for exact capacity and oil type (e.g., 5W-30 or 10W-30).

Coolant Type:

Mitsubishi Super Long Life Coolant (MS-LS) or equivalent ethylene glycol-based coolant. Do not mix coolant types.

Coolant Capacity:

Approx. 8.0 - 8.5 US quarts (7.6 - 8.0 liters). Check manual for exact capacity.

Known Issues

Common Issues Engine:

Timing belt failure (if not replaced on schedule), intake manifold gasket leaks, occasional valve cover gasket leaks, radiator leaks, thermostat failure.

Common Issues Transmission:

Automatic transmission fluid leaks, potential valve body issues in high-mileage units, clutch wear on manual transmissions.

Common Issues Suspension Steering:

Worn ball joints and control arm bushings, tie rod end wear, power steering pump leaks, rear differential mounts.

Common Issues Electrical:

Alternator failure, window motor/regulator issues, power door lock actuator problems, dashboard warning light illumination (e.g., ABS, SRS).

Common Issues Body Chassis:

Frame rust (especially in areas with road salt), tailgate struts, sunroof drain clogs (leading to interior water ingress).

📚 Vehicle History

Brand Heritage

Mitsubishi Motors:

Founded in 1970, Mitsubishi Motors is a Japanese multinational automotive manufacturer. Known for its technological innovation, particularly in four-wheel-drive systems and performance vehicles.

Model Evolution

Montero Second Gen:

Launched globally in 1991, the second generation Montero (also known as Pajero in many markets) represented a significant update with improved styling, interior comfort, and enhanced off-road capabilities. The 1996-1999 models represent the latter half of this generation, featuring updated engines and available features.

Montero Evolution:

Specialized 'Evolution' or 'Ralli Art' versions were produced for homologation purposes in rally racing (e.g., Pajero Evolution), featuring unique bodywork and advanced drivetrains, though rare in North American markets as a 'Montero'.

Production

Manufacturing Locations:

Primarily manufactured in Japan (Okazaki Plant). Some assembly may have occurred in other Mitsubishi global facilities.

Production Years Second Gen:

1991-1999

🏆 Awards & Recognition

Recognitions

Off Road Awards:

Consistently recognized for its off-road prowess, often winning comparisons against competitors in its class for its robust 4WD systems and suspension articulation.

Ratings

Consumer Reports Ratings:

Mixed to good reliability ratings over its lifecycle. Issues varied by year and powertrain, with specific emphasis on timing belt maintenance and early ABS system reliability.

Certifications

Emission Standards:

Compliant with EPA and CARB emission standards for the model years, with specific certifications varying by region and state.