Segment:
Mid-size SUV / Off-road focused vehicle
Key Competitors:
Toyota 4Runner, Nissan Pathfinder, Ford Explorer, Jeep Grand Cherokee, Chevrolet Blazer (during its respective production years).
Strengths:
Renowned off-road capability (especially with Super Select 4WD-II), robust construction, reliable powertrains (particularly the V6), relatively affordable maintenance compared to some European counterparts.
Weaknesses:
Interior ergonomics and material quality can be dated, fuel economy is not a strong suit, third-row seating (where equipped) is often cramped.
Off Road Systems:
Available Super Select II 4WD system offering 2H, 4H, 4HLC (4WD High-Lock), 4LLC (4WD Low-Lock) modes; available rear differential lock.
Body Style:
Body-on-frame construction, offering superior durability and off-road articulation compared to unibody SUVs.
Applicable Years:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004
Regions Covered:
Global (models designated Montero Sport and Pajero Sport are generally identical in this generation)
Estimated Pages:
~1500-2000+ (typical for a comprehensive workshop manual covering multiple model years and engine options)
Type:
Workshop Service Repair Manual
Format:
Digital Download (PDF)
Powertrain:
Engine mechanical (including disassembly, inspection, assembly), engine electrical, fuel system, cooling system, exhaust system, ignition system, lubrication system, intake system, emission control systems.
Transmission:
Manual transmission (clutch, gearbox, transfer case), Automatic transmission (hydraulic control, torque converter, planetary gearsets, valve body, solenoids), differentials (front, rear, center if applicable).
Chassis:
Suspension (front independent, rear solid axle), steering system (power steering pump, rack and pinion/steering box), brake system (front discs, rear drums/discs, ABS), driveline components (propeller shafts, CV joints, universal joints).
Body & Electrical:
Body construction, exterior trim, interior trim, seats, HVAC system, body electrical systems (lighting, wipers, power windows, locks), wiring diagrams, fuses, relays, body control modules.
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection/replacement, brake pad/shoe inspection.
Component Repair:
Engine overhaul, cylinder head reconditioning, piston and ring replacement, crankshaft bearing replacement, transmission rebuild (manual and automatic), clutch replacement, brake caliper/master cylinder rebuild, suspension component replacement, steering rack/box overhaul.
Diagnostics & Troubleshooting:
Step-by-step troubleshooting guides for common problems, diagnostic trouble codes (DTCs) interpretation, electrical circuit testing, fuel system pressure testing, ignition system testing.
Specifications & Data:
Torque specifications for all fasteners, clearances and tolerances for engine and transmission components, fluid capacities, electrical specifications, wheel alignment parameters.
Depth:
Comprehensive: Covers from basic preventative maintenance and fluid changes to full engine and transmission rebuilds, complex electrical diagnostics, and chassis component overhauls. Includes detailed exploded views and diagrams.
Engine Code:
6G72 (SOHC V6), 6G74 (DOHC V6)
Displacement:
3.0L (6G72), 3.5L (6G74)
Configuration:
V6, SOHC or DOHC
Horsepower Range:
Approx. 175-200 hp (3.0L), 200-240 hp (3.5L)
Torque Range:
Approx. 180-190 lb-ft (3.0L), 220-240 lb-ft (3.5L)
Fuel System:
Electronic Fuel Injection (EFI), Multi-point fuel injection
Fuel Type:
Unleaded Gasoline
Engine Code 2:
4G64 (4-Cylinder)
Configuration 2:
Inline 4-Cylinder, SOHC
Horsepower 2:
Approx. 135-140 hp
Torque 2:
Approx. 145-150 lb-ft
Length:
Approx. 179.3 inches (4555 mm)
Width:
Approx. 69.5 inches (1765 mm)
Height:
Approx. 66.1 inches (1680 mm) (without roof rails)
Wheelbase:
Approx. 103.7 inches (2635 mm)
Curb Weight Range:
Approx. 4000-4500 lbs (1814-2041 kg), depending on configuration and engine.
Gross Vehicle Weight Rating Range:
Approx. 5500-6000 lbs (2495-2721 kg)
NHTSA Front Impact:
Likely rated 'Good' or 'Acceptable' in frontal crash tests by IIHS/NHTSA for its era, but specific data for all years/trims may vary. Body-on-frame construction offers inherent structural integrity.
ABS:
Available Anti-lock Braking System (ABS)
Traction Control:
Limited availability or basic form in some later models, not a prevalent feature across the entire range.
Airbags:
Driver and front passenger airbags standard.
Seatbelts:
Three-point seatbelts with pretensioners for front occupants, lap belts for rear passengers (depending on seating configuration).
Audio System:
Factory-installed AM/FM/Cassette/CD players, with varying speaker configurations. Optional premium sound systems available on higher trims.
Navigation:
Very limited or no factory navigation available for most of this generation. Aftermarket installations were common.
Cruise Control:
Standard on most models.
Parking Assist:
No factory rear parking sensors or cameras. Parking was aided by the vehicle's size and driver awareness.
Bluetooth:
Not available from the factory. Bluetooth integration would be an aftermarket addition.
Service Intervals Engine Oil
Interval Miles:
Every 3,750 to 7,500 miles (6,000 to 12,000 km), or 6 months, depending on driving conditions (severe vs. normal).
Interval Months:
6 months
Engine Oil Type V6:
API SG or higher, SAE 10W-30 or 5W-30 (check owner's manual for specific viscosity recommendations based on climate).
Engine Oil Type I4:
API SG or higher, SAE 5W-30
Transmission Fluid Manual:
API GL-4 or GL-5, SAE 75W-90 (transfer case may have separate specification).
Transmission Fluid Automatic:
Mitsubishi DiaQueen ATF-SP II M or equivalent.
Coolant:
Mitsubishi Genuine Super Long Life Coolant (SLLC) or equivalent (50/50 mix of ethylene glycol and distilled water).
Brake Fluid:
DOT 3 or DOT 4 Brake Fluid.
Common Wear Items:
Front suspension bushings and ball joints, rear main crankshaft seal leaks, catalytic converter failure, automatic transmission solenoid issues (particularly on older models).
Engine Specific Concerns:
6G74 DOHC engines can be sensitive to cooling system maintenance; head gasket failures have been reported if overheated. Timing belt replacement is critical for interference engines (6G72 SOHC, 6G74 DOHC, 4G64).
Maintenance Schedule Highlights
Timing Belt Replacement:
Crucial. Typically every 60,000-90,000 miles or 4-5 years for interference engines. Manual will specify exact interval and procedure.
Spark Plugs:
Replace every 30,000-60,000 miles depending on plug type (standard vs. platinum/iridium).
Filters:
Engine oil filter, air filter, fuel filter replacement intervals vary but are typically addressed during major services.
Mitsubishi 4X4 Legacy:
Mitsubishi has a long and distinguished history in off-road vehicles, stemming from its legendary Pajero (Montero in many markets) lineage, which began in 1982.
Generation Introduction:
The second generation (K90 series) Montero Sport/Pajero Sport was introduced for the 1996 model year, replacing the original Montero Sport (which was based on the Pajero II).
Key Changes Generation:
This generation saw a significant redesign, moving to a more modern SUV aesthetic, and incorporating more advanced drivetrain options like the Super Select II system. Engine offerings were expanded.
Manufacturing Location:
Primarily manufactured in Japan (Okazaki Plant), with some assembly occurring in other global locations for specific markets.
