Mitsubishi Montero 1998 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Montero Year: 1998 Codes Platform Code: Second Generation (K90 series) Chassis Code: K94W (SWB), K96W (LWB) 👋 Introduction Market Position Vehicle Segment: Mid-size SUV / Off-roader Key Selling Points: Ruggedness, off-road capability, spacious interior, reliable powertrain Competitive Analysis Key Competitors: Toyota 4Runner, Jeep Grand Cherokee, Ford Explorer, Nissan Pathfinder Key Features Vehicle Type: Body-on-frame SUV Drivetrain Options: 2WD (RWD), 4WD (Part-time and Full-time options with Super Select system) Body Styles: 2-door (short wheelbase, often referred to as Montero Sport in some markets, though this manual covers the larger Montero) and 4-door (long wheelbase) 📋 Manual Details Coverage Areas Engine: Yes Transmission: Yes Drivetrain: Yes Suspension: Yes Brakes: Yes Steering: Yes Electrical System: Yes Body And Trim: Yes HVAC: Yes Diagnostics And Troubleshooting: Yes Page Count Estimated Pages: 1500+ Manual Type Type: Factory Service Manual Completeness: Full factory service manual, covering all aspects of the vehicle Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Management: Fuel injection, ignition timing, emissions control, sensor testing, ECU diagnostics Cooling System: Radiator, water pump, thermostat, hoses, fan operation, coolant specifications Lubrication System: Oil pump, oil filter, oil pressure, oil specifications Fuel System: Fuel pump, injectors, fuel pressure regulator, fuel filter, tank capacity Exhaust System: Catalytic converter, mufflers, exhaust manifold, pipe routing Transmission Operation: Automatic transmission (4-speed) and manual transmission (5-speed) control, fluid types, torque converter Transfer Case And Differentials: Super Select 4WD system operation, front and rear differential service, fluid specifications Suspension Components: Front independent double-wishbone, rear multi-link, shock absorbers, springs, bushings, alignment specifications Steering System: Power steering pump, rack and pinion, tie rod ends, steering column, fluid type Brake System: Front disc brakes, rear drum or disc brakes (depending on trim), ABS operation, brake fluid type, bleeding procedures Electrical Distribution: Fuse box locations, relay functions, wiring diagrams for all circuits Lighting System: Headlights, taillights, interior lights, bulb types and replacement Instrument Panel: Gauge cluster, warning lights, sensor inputs Audio System: Radio, speaker wiring, antenna Comfort And Convenience: Power windows, power door locks, mirrors, cruise control, remote keyless entry HVAC Controls: Air conditioning system, heater core, blower motor, refrigerant type, operation Body Exterior: Body panels, doors, hoods, bumpers, glass, weatherstripping Body Interior: Seats, upholstery, dashboard, trim panels, carpeting Paint And Finishes: Paint codes, touch-up procedures Procedures Included Maintenance Tasks: Oil changes, filter replacements, spark plug replacement, fluid checks and changes, belt inspection and replacement Repair Procedures: Engine rebuilds, transmission overhaul, brake caliper replacement, suspension component replacement, radiator service, starter and alternator replacement Diagnostics Procedures: Using scan tools, interpreting DTCs (Diagnostic Trouble Codes), testing sensors and actuators, troubleshooting electrical faults Troubleshooting Charts: Symptom-based diagnostic guides for common problems Specifications And Tolerances: Torque values, clearances, fluid capacities, electrical specifications Wiring Diagrams: Comprehensive schematics for all electrical systems Component Removal And Installation: Step-by-step instructions for disassembling and reassembling major vehicle components Wheel Alignment: Camber, caster, toe adjustments Air Conditioning Service: Refrigerant handling, component testing, leak detection Technical Depth Depth Level: Comprehensive (from basic maintenance to complete engine/transmission rebuilds) Diagnostic Capabilities: Advanced diagnostic procedures, including sensor readings and system checks Repair Accuracy: Factory-level accuracy and detail for all repair procedures 📊 Manual Specifications File Format Digital Format: PDF (Searchable, Bookmarked, Printable) Print Quality Image Resolution: High-resolution, ensuring clarity of diagrams and text Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: 6G72 Engine Type: 3.0L SOHC V6 (Naturally Aspirated) Displacement: 2972 cc Bore X Stroke: 91.1 mm x 76.0 mm Compression Ratio: 8.9:1 Horsepower: 177 hp @ 5500 rpm Torque: 200 lb-ft @ 3500 rpm Valvetrain: SOHC (Single Overhead Camshaft), 2 valves per cylinder Engine Block Material: Cast Iron Cylinder Head Material: Aluminum Alloy Fuel System Fuel Delivery: Multi-point Electronic Fuel Injection (MPI) Recommended Fuel: 87 Octane Unleaded Gasoline Performance Engine Management System: MITEC Emissions Control: Catalytic Converter, EGR (Exhaust Gas Recirculation) 🔧 Transmission Standard Transmission Type Lwb: 4-speed Automatic (V4A51) Optional Transmission Type Swb: 5-speed Manual (M037) Features Automatic Transmission Features: Electronically controlled, Overdrive gear Manual Transmission Features: Close-ratio gearing for off-road performance Fluid Specifications Automatic Transmission Fluid: MITSUBISHI ATF-SPII or DEXRON-III (or equivalent) Manual Transmission Fluid: GL-4 SAE 75W-90 Gear Oil Capacities Automatic Transmission Fluid Capacity: Approx. 7.5 liters (including torque converter) Manual Transmission Fluid Capacity: Approx. 2.5 liters Drivetrain Control 4Wd System: Super Select II (Part-time 4WD with 2WD, 4H, 4HLC, 4LLC modes) 📐 Dimensions Exterior Wheelbase Swb: 2,500 mm (98.4 in) Wheelbase Lwb: 2,725 mm (107.3 in) Overall Length Swb: 4,470 mm (176.0 in) Overall Length Lwb: 4,715 mm (185.6 in) Overall Width: 1,780 mm (70.1 in) Overall Height: 1,800 mm (70.9 in) Ground Clearance: Approx. 210 mm (8.3 in) Weights Curb Weight Swb: Approx. 1,800 kg (3,968 lbs) Curb Weight Lwb: Approx. 1,950 kg (4,300 lbs) Gross Vehicle Weight Rating: Approx. 2,500...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Montero

Year:

Codes

Platform Code:

Second Generation (K90 series)

Chassis Code:

K94W (SWB), K96W (LWB)

👋 Introduction

Market Position

Vehicle Segment:

Mid-size SUV / Off-roader

Key Selling Points:

Ruggedness, off-road capability, spacious interior, reliable powertrain

Competitive Analysis

Key Competitors:

Toyota 4Runner, Jeep Grand Cherokee, Ford Explorer, Nissan Pathfinder

Key Features

Vehicle Type:

Body-on-frame SUV

Drivetrain Options:

2WD (RWD), 4WD (Part-time and Full-time options with Super Select system)

Body Styles:

2-door (short wheelbase, often referred to as Montero Sport in some markets, though this manual covers the larger Montero) and 4-door (long wheelbase)

📋 Manual Details

Coverage Areas

Engine:

Transmission:

Drivetrain:

Suspension:

Brakes:

Steering:

Electrical System:

Body And Trim:

HVAC:

Diagnostics And Troubleshooting:

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Factory Service Manual

Completeness:

Full factory service manual, covering all aspects of the vehicle

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Management:

Fuel injection, ignition timing, emissions control, sensor testing, ECU diagnostics

Cooling System:

Radiator, water pump, thermostat, hoses, fan operation, coolant specifications

Lubrication System:

Oil pump, oil filter, oil pressure, oil specifications

Fuel System:

Fuel pump, injectors, fuel pressure regulator, fuel filter, tank capacity

Exhaust System:

Catalytic converter, mufflers, exhaust manifold, pipe routing

Transmission Operation:

Automatic transmission (4-speed) and manual transmission (5-speed) control, fluid types, torque converter

Transfer Case And Differentials:

Super Select 4WD system operation, front and rear differential service, fluid specifications

Suspension Components:

Front independent double-wishbone, rear multi-link, shock absorbers, springs, bushings, alignment specifications

Steering System:

Power steering pump, rack and pinion, tie rod ends, steering column, fluid type

Brake System:

Front disc brakes, rear drum or disc brakes (depending on trim), ABS operation, brake fluid type, bleeding procedures

Electrical Distribution:

Fuse box locations, relay functions, wiring diagrams for all circuits

Lighting System:

Headlights, taillights, interior lights, bulb types and replacement

Instrument Panel:

Gauge cluster, warning lights, sensor inputs

Audio System:

Radio, speaker wiring, antenna

Comfort And Convenience:

Power windows, power door locks, mirrors, cruise control, remote keyless entry

HVAC Controls:

Air conditioning system, heater core, blower motor, refrigerant type, operation

Body Exterior:

Body panels, doors, hoods, bumpers, glass, weatherstripping

Body Interior:

Seats, upholstery, dashboard, trim panels, carpeting

Paint And Finishes:

Paint codes, touch-up procedures

Procedures Included

Maintenance Tasks:

Oil changes, filter replacements, spark plug replacement, fluid checks and changes, belt inspection and replacement

Repair Procedures:

Engine rebuilds, transmission overhaul, brake caliper replacement, suspension component replacement, radiator service, starter and alternator replacement

Diagnostics Procedures:

Using scan tools, interpreting DTCs (Diagnostic Trouble Codes), testing sensors and actuators, troubleshooting electrical faults

Troubleshooting Charts:

Symptom-based diagnostic guides for common problems

Specifications And Tolerances:

Torque values, clearances, fluid capacities, electrical specifications

Wiring Diagrams:

Comprehensive schematics for all electrical systems

Component Removal And Installation:

Step-by-step instructions for disassembling and reassembling major vehicle components

Wheel Alignment:

Camber, caster, toe adjustments

Air Conditioning Service:

Refrigerant handling, component testing, leak detection

Technical Depth

Depth Level:

Comprehensive (from basic maintenance to complete engine/transmission rebuilds)

Diagnostic Capabilities:

Advanced diagnostic procedures, including sensor readings and system checks

Repair Accuracy:

Factory-level accuracy and detail for all repair procedures

📊 Manual Specifications

File Format

Digital Format:

PDF (Searchable, Bookmarked, Printable)

Print Quality

Image Resolution:

High-resolution, ensuring clarity of diagrams and text

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Quality:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

Engine Type:

3.0L SOHC V6 (Naturally Aspirated)

Displacement:

2972 cc

Bore X Stroke:

91.1 mm x 76.0 mm

Compression Ratio:

8.9:1

Horsepower:

177 hp @ 5500 rpm

Torque:

200 lb-ft @ 3500 rpm

Valvetrain:

SOHC (Single Overhead Camshaft), 2 valves per cylinder

Engine Block Material:

Cast Iron

Cylinder Head Material:

Aluminum Alloy

Fuel System

Fuel Delivery:

Multi-point Electronic Fuel Injection (MPI)

Recommended Fuel:

87 Octane Unleaded Gasoline

Performance

Engine Management System:

MITEC

Emissions Control:

Catalytic Converter, EGR (Exhaust Gas Recirculation)

🔧 Transmission

Standard

Transmission Type Lwb:

4-speed Automatic (V4A51)

Optional

Transmission Type Swb:

5-speed Manual (M037)

Features

Automatic Transmission Features:

Electronically controlled, Overdrive gear

Manual Transmission Features:

Close-ratio gearing for off-road performance

Fluid Specifications

Automatic Transmission Fluid:

MITSUBISHI ATF-SPII or DEXRON-III (or equivalent)

Manual Transmission Fluid:

GL-4 SAE 75W-90 Gear Oil

Capacities

Automatic Transmission Fluid Capacity:

Approx. 7.5 liters (including torque converter)

Manual Transmission Fluid Capacity:

Approx. 2.5 liters

Drivetrain Control

4Wd System:

Super Select II (Part-time 4WD with 2WD, 4H, 4HLC, 4LLC modes)

📐 Dimensions

Exterior

Wheelbase Swb:

2,500 mm (98.4 in)

Wheelbase Lwb:

2,725 mm (107.3 in)

Overall Length Swb:

4,470 mm (176.0 in)

Overall Length Lwb:

4,715 mm (185.6 in)

Overall Width:

1,780 mm (70.1 in)

Overall Height:

1,800 mm (70.9 in)

Ground Clearance:

Approx. 210 mm (8.3 in)

Weights

Curb Weight Swb:

Approx. 1,800 kg (3,968 lbs)

Curb Weight Lwb:

Approx. 1,950 kg (4,300 lbs)

Gross Vehicle Weight Rating:

Approx. 2,500 kg (5,511 lbs)

Cargo

Cargo Volume Lwb:

Variable, with folding rear seats

Wheels And Tires

Standard Tire Size:

265/70R16

Wheel Bolt Pattern:

6x139.7 mm (6x5.5 inches)

Wheel Size:

16x7J

🛡️ Safety Features

Ratings

NHTSA Rollover Rating:

3-Star (for 1998 models)

Active Features

Anti-lock Braking System (Standard on most trims)

Traction Control:

Optional on some models

Passive Features

Airbags:

Driver and front passenger airbags

Seatbelts:

3-point seatbelts with pretensioners for front occupants

Body Construction:

Reinforced chassis with crumple zones

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/Cassette or CD player, often with 4-6 speakers. Optional premium audio available on higher trims.

Driver Assistance

Standard ABS system aids in maintaining steering control during hard braking.

Connectivity

Remote Keyless Entry:

Available on some higher trim levels.

Comfort Features

Cruise Control:

Standard on most models.

Climate Control

Automatic Climate Control:

Optional on top-tier trims, featuring automatic temperature regulation.

🔧 Maintenance

Service Intervals

Engine Oil And Filter:

Every 7,500 miles (12,000 km) or 6 months, whichever comes first (using synthetic blend or full synthetic)

Engine Air Filter:

Inspect every 7,500 miles (12,000 km), replace as needed or every 30,000 miles (48,000 km)

Transmission Fluid Change:

Every 30,000 miles (48,000 km) for automatic, 50,000 miles (80,000 km) for manual

Coolant Flush:

Every 30,000 miles (48,000 km) or 24 months

Spark Plugs:

Every 60,000 miles (96,000 km) (NGK Platinum recommended)

Drive Belts:

Inspect every 7,500 miles (12,000 km), replace if cracked or worn

Timing Belt:

Crucial: Replace every 60,000 miles (96,000 km) or 4 years. (This engine is an interference engine, failure can cause catastrophic engine damage)

Fluid Specifications

Engine Oil Type:

API SJ or higher, SAE 5W-30 (preferred) or 10W-30

Engine Oil Capacity:

4.5 liters (4.8 US quarts) with filter

Coolant Type:

Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors)

Brake Fluid Type:

DOT 3 or DOT 4

Power Steering Fluid Type:

MITSUBISHI PSF or DEXRON-II (or equivalent ATF)

Transfer Case Fluid:

API GL-4 SAE 75W-90 Gear Oil

Differential Fluid Front Rear:

API GL-5 SAE 80W-90 Gear Oil

Known Issues

Head Gaskets:

Some early 6G7x V6 engines could be prone to head gasket failure, especially if not properly maintained or if overheated. The manual will detail inspection and replacement procedures.

Timing Belt Tensioner:

Potential for premature failure of the timing belt tensioner, emphasizing the importance of timely replacement as per schedule.

Rear Main Seal:

Occasional leaks from the rear main crankshaft seal may occur with age and mileage.

ABS Sensors:

ABS wheel speed sensors can fail over time, leading to ABS warning lights. Manual provides diagnostic steps.

Radiator Plastic Tanks:

Plastic end tanks on the radiator can become brittle and crack with age, leading to coolant leaks.

📚 Vehicle History

Brand Heritage

Manufacturer Origin:

Japan

Mitsubishi Motors History:

A long-standing automotive manufacturer with a history dating back to the early 20th century.

Model Evolution

Montero History:

The Mitsubishi Pajero (marketed as Montero in North America and some other regions) debuted in 1982. The 1998 model represents the latter part of the second generation (1991-1999), which saw significant updates in styling, comfort, and technology.

Second Generation Updates:

Introduction of the Super Select 4WD system, improved independent front suspension, more powerful engines, and refined interior appointments.

Production

Manufacturing Location:

Japan (primary), also assembled in other countries

Production Period For Second Gen:

1991-1999

🏆 Awards & Recognition

Recognitions

Off Road Capability Recognition:

The Montero (Pajero) has a strong reputation for off-road prowess, often winning or placing well in international rally raids like the Dakar Rally, reflecting its inherent ruggedness and capability.

Ratings

Consumer Reports Rating:

Historically, second-generation Monteros received mixed reviews, with strong ratings for powertrain and off-road performance but variable ratings for reliability in certain areas. The manual is essential for addressing potential issues.

Certifications

Emission Standards:

Complies with U.S. EPA emission standards for the 1998 model year.