Mitsubishi Montero 1998 Full Service Repair Manual

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Type: Car

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Sku: 57635

Tags: 1998 Car Cars Misc Mitsubishi Montero

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Description

The 1998 Mitsubishi Montero, part of the V40/V20 Series (Second Generation) built on the Pajero II Platform, is a robust mid-size SUV renowned for its rugged body-on-frame construction, advanced Super Select 4WD II system, and exceptional off-road capability. Offering a spacious interior and powered by either a 3.0L V6 (6G72) or a 3.5L V6 (6G74) engine, this vehicle was engineered for durability and versatility, making it a strong competitor in its segment against models like the Toyota 4Runner and Jeep Grand Cherokee. Its design prioritizes reliable performance in diverse conditions, appealing to enthusiasts and owners who value a capable and enduring vehicle. This comprehensive English-language manual provides full service, repair, rebuild, and refurbishment guidance for the 1998 Mitsubishi Montero. It covers all major vehicle systems, including engines, transmissions (automatic and manual), drivetrain, suspension, brakes, steering, electrical systems, body, HVAC, fuel, and cooling. The manual details scheduled maintenance, troubleshooting procedures, diagnostic techniques, and specific repair instructions with accompanying torque specifications and tolerances. With over 1500 pages of content, it serves as an essential resource for owners and technicians aiming to maintain, repair, or restore the vehicle to its optimal condition.

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Montero

Year:

Codes

Chassis Code Family:

V40/V20 Series (Second Generation)

Platform:

Pajero II Platform

👋 Introduction

Market Position

Vehicle Segment:

Mid-size SUV / Off-Road Vehicle

Target Audience:

Enthusiasts, off-roaders, owners seeking to perform their own maintenance and repairs

Competitive Analysis

Key Competitors 1998:

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

Key Features

Notable Features:

Rugged body-on-frame construction, advanced 4WD systems, robust off-road capability, spacious interior

📋 Manual Details

Coverage Areas

Coverage Scope:

Full Service, Repair, Rebuild, Refurbish, Restoration

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Full Service & Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

All engine types, diagnostics, repair, overhaul

Transmission:

Automatic and Manual transmissions, diagnostics, repair, overhaul

Drivetrain:

4WD systems (Super Select 4WD II), differentials, axles, driveshafts

Suspension:

Front and rear suspension systems, shock absorbers, springs, bushings

Brakes:

Front and rear brake systems (disc/drum), ABS, hydraulic components

Steering:

Power steering system, steering column, linkage

Electrical:

Wiring diagrams, starting and charging system, ignition, lighting, accessories, ECUs

Body:

Body panels, doors, windows, interior trim, chassis structural integrity

HVAC:

Heating, Ventilation, and Air Conditioning system

Fuel:

Fuel tank, lines, pump, injectors, fuel injection system

Cooling:

Radiator, coolant, water pump, thermostat, cooling fan

Exhaust:

Exhaust manifold, catalytic converter, muffler, pipes

Procedures Included

Maintenance:

Scheduled maintenance, oil changes, filter replacements, inspections

Troubleshooting:

Diagnostic procedures, symptom-based troubleshooting, fault code interpretation

Repair:

Step-by-step repair instructions for all major components and systems

Rebuild:

Detailed procedures for engine, transmission, and differential rebuilds

Refurbishment:

Guidance on restoring worn components and systems

Restoration:

Information relevant to bringing the vehicle back to original specifications

Diagnostics:

On-board diagnostics (OBD-I/II), scan tool usage, electrical testing

Specifications:

Torque specifications, clearances, tolerances for all repairs

Body And Frame:

Body panel alignment, door hinge repair, glass replacement, frame straightening (diagnostic approach).

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to complete engine and transmission overhauls

Engine Rebuild Detail:

Includes piston ring gap, bearing clearance, valve seat geometry, crankshaft specifications, cylinder head torque sequences.

Transmission Rebuild Detail:

Clutch pack clearances, valve body operation, torque converter specifications, gear train component tolerances.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable due to digital format

Print Quality

Print Recommendation:

Printable for workshop use

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

Completeness

Coverage Detail:

Extremely detailed, designed for professional technicians and serious DIYers, includes wiring diagrams, schematics, and specific torque values.

⚙️ Engine Specifications

Primary Engine

Engine Code Common:

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

Displacement 3.0L:

2972 cc (181.4 cu in)

Displacement 3.5L:

3497 cc (213.4 cu in)

Performance 3.0L

Horsepower 3.0L:

Approx. 143-153 hp (depending on market and spec)

Torque 3.0L:

Approx. 174-180 lb-ft (depending on market and spec)

Performance 3.5L

Horsepower 3.5L:

Approx. 195-215 hp (depending on market and spec)

Torque 3.5L:

Approx. 228-250 lb-ft (depending on market and spec)

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline

🔧 Transmission

Standard

Standard Transmission:

5-speed Manual

Optional

Optional Transmission:

4-speed Automatic (with electronic control)

Features

4Wd System:

Super Select 4WD II (with center differential, locking 4WD, low range)

📐 Dimensions

Exterior

Wheelbase:

Approx. 104.7 inches (2659 mm)

Length:

Approx. 179.1 inches (4550 mm)

Width:

Approx. 69.5 inches (1765 mm)

Height:

Approx. 70.1 inches (1780 mm)

Weights

Curb Weight:

Approx. 4,200 - 4,600 lbs (1905 - 2087 kg), varies by configuration

🛡️ Safety Features

Ratings

NHTSA Side Impact Rating:

Likely 4 stars for front occupants in side impact (based on similar period vehicles, requires specific manual verification)

Active Features

Available Anti-lock Braking System (ABS) on all four wheels

Passive Features

Airbags:

Driver and Passenger front airbags

Body Construction:

Body-on-frame construction for durability and off-road resilience

💡 Technology Features

Infotainment

Infotainment System:

Basic AM/FM/Cassette or CD player with limited speaker systems. May feature optional premium audio.

Driver Assistance

Driver Assistance Features:

Primarily ABS. Other advanced electronic aids were not common in this era.

Connectivity

Connectivity Features:

Limited to optional power accessories (windows, locks). No factory integrated Bluetooth or USB.

🔧 Maintenance

Service Intervals

Oil Change Interval Typical:

Every 3,750 - 7,500 miles (6,000 - 12,000 km) or 6-12 months, depending on driving conditions and oil type (refer to manual for specifics)

Transmission Fluid Interval Typical:

Every 30,000 - 60,000 miles (48,000 - 96,000 km) for automatic, consult manual for manual transmission

Coolant Flush Interval Typical:

Every 30,000 - 60,000 miles (48,000 - 96,000 km)

Timing Belt Replacement:

Critical for 6G7 series engines. Typically 60,000-90,000 miles (96,000-144,000 km) or 7-10 years. Failure causes severe engine damage. Manual will specify exact interval and recommended parts.

Fluid Specifications

Engine Oil Type Common:

API SG, SH, SJ; Viscosity 5W-30 or 10W-30 (check manual for exact specification and viscosity based on climate)

Engine Oil Capacity 3.0L:

Approx. 4.5 - 4.8 quarts (4.3 - 4.6 liters) with filter change

Engine Oil Capacity 3.5L:

Approx. 4.8 - 5.0 quarts (4.6 - 4.8 liters) with filter change

Transmission Fluid Automatic:

Dexron III or equivalent

Transmission Fluid Manual:

GL-4 Gear Oil, SAE 75W-90

Coolant Type:

Ethylene Glycol based, typically a 50/50 mix with distilled water

Known Issues

Common Wear Item 1:

Upper and lower ball joints and control arm bushings (due to weight and off-road use)

Common Wear Item 2:

Exhaust manifold leaks (cracking)

Common Wear Item 3:

Rear main seal leaks (on higher mileage vehicles)

Common Wear Item 4:

Power window regulators and motors

Common Wear Item 5:

HVAC blower motor resistors

Drivetrain Issue:

Front CV axle boots can tear, leading to joint failure

📚 Vehicle History

Brand Heritage

Mitsubishi Motors Heritage:

Long history in automotive manufacturing, with a strong reputation for robust and capable SUVs/off-road vehicles, building on the success of the Pajero/Montero line.

Model Evolution

Second Generation:

The 1998 Montero is part of the second generation (1991-1999), which saw significant updates including the introduction of the more advanced Super Select 4WD II system and more powerful V6 engines.

Production

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Industry Recognition:

While specific awards for the 1998 model might be elusive, the Montero line consistently received praise for its off-road prowess and durability throughout the second generation.