🏷️ Basic Information

Make:

Mitsubishi

Model:

Montero

Model Variant:

Pajero (Global Market Designation)

Chassis Code Series:

V-Series (e.g., V23W, V43W, V45W, V46W)

Engine Code Common:

6G72 (3.0L V6 SOHC/DOHC), 6G74 (3.5L V6 SOHC/DOHC), 4D56 (2.5L Turbo Diesel), 4M40 (2.8L Turbo Diesel)

Body Styles Covered:

Short Wheelbase (2-Door), Long Wheelbase (4-Door), Canvas Top, Hardtop

👋 Introduction

Segment:

Mid-size SUV, Body-on-frame construction, known for off-road capability and ruggedness

Competitors:

Jeep Cherokee, Toyota 4Runner, Ford Explorer, Chevrolet Blazer, Nissan Pathfinder

Value Proposition:

Offered a blend of off-road prowess, comfortable on-road manners, and robust construction for its era, often at a competitive price point.

Powertrain Options:

Available with reliable V6 gasoline engines and robust turbo-diesel engines (market dependent), coupled with robust 4WD systems (Super Select II 4WD was a notable feature).

Durability:

Renowned for its durable chassis and drivetrain, making it a popular choice for overland travel and off-roading.

Body On Frame:

The body-on-frame construction provided inherent strength and articulation for off-road use, and contributed to its longevity.

📋 Manual Details

Model Years:

1998, 1999, 2000, 2001, 2002

Geographic Markets:

North America (USA, Canada), with adaptations for global specifications

Estimated Page Count:

1500-2000+ (typically extensive for complete workshop manuals)

Type:

Complete Workshop Service Repair Manual

Language:

English

Format:

Downloadable PDF

📖 Manual Coverage

Engine:

Engine mechanical, lubrication, cooling, fuel delivery (MPI, diesel injection), exhaust, ignition, emissions control, engine management (ECU), turbocharging (if applicable)

Transmission:

Manual transmission (5-speed), Automatic transmission (4-speed), Transfer case, Drivetrain components (driveshafts, differentials)

Brakes:

Front disc brakes, Rear disc/drum brakes, ABS (Anti-lock Braking System), Parking brake system

Suspension Steering:

Front independent suspension (Double Wishbone), Rear multi-link suspension (Solid Axle), Power steering system, Steering gearbox/rack and pinion

Electrical:

Battery, Charging system (alternator), Starting system, Lighting (headlights, taillights, interior), Gauges and instruments, Wiper/washer system, Horn, Fuse box and wiring diagrams, ECU diagnostics

Body Chassis:

Frame and body construction, Doors, Hood, Tailgate, Bumpers, Exterior trim, Interior trim, Seats, HVAC system, Body sealing

Routine Maintenance:

Oil change, filter replacement, fluid checks and top-offs, spark plug replacement, air filter replacement, tire rotation

Repair Rebuild:

Engine overhaul, transmission overhaul, differential repair, brake caliper replacement, suspension component replacement, starter motor replacement, alternator replacement

Diagnostics Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting, electrical circuit testing, fuel system diagnostics, emissions diagnostics

Special Tools Procedures:

Use of specialized tools for engine timing, bearing removal/installation, fuel pressure testing, etc.

Depth:

Comprehensive (from basic maintenance to full engine and transmission rebuilds, detailed electrical schematics, torque specifications, component tolerances)

📊 Manual Specifications

Quality:

High-resolution, text-searchable PDF, allowing for easy navigation and printing of specific sections

Printability:

Designed for high-quality printing of individual pages or sections

Format For Print:

Digital (PDF), no physical binding type applies directly; user can print and bind as desired

Digital Format Consideration:

Optimized for clarity on screen and upon printing

⚙️ Engine Specifications

Engine Displacement Common:

3.0L (2972cc), 3.5L (3497cc)

Engine Type Common:

V6 SOHC (6G72, 6G74), V6 DOHC (6G74 MIVEC on later models, sometimes introduced for 2000 model year revisions)

Bore Stroke 3 0L:

86.1 mm x 86.0 mm (approx.)

Bore Stroke 3 5L:

91.1 mm x 86.1 mm (approx.)

Horsepower 3 0L Sohc:

180-197 HP @ 5500-6000 RPM (varies by market and configuration)

Torque 3 0L Sohc:

202-220 lb-ft @ 3000-4000 RPM (varies by market and configuration)

Horsepower 3 5L Sohc:

200-215 HP @ 5500-6000 RPM (varies by market and configuration)

Torque 3 5L Sohc:

230-235 lb-ft @ 3500-4000 RPM (varies by market and configuration)

Horsepower 3 5L DOHc Mivec:

235-274 HP @ 5500-6000 RPM (varies by market and configuration)

Torque 3 5L DOHc Mivec:

255-273 lb-ft @ 3000-4500 RPM (varies by market and configuration)

Induction Type:

Multi-Point Fuel Injection (MPI) for gasoline; Direct Injection for some diesel variants

Fuel Type:

Unleaded Gasoline (Octane 87 minimum recommended for most variants), Diesel for diesel variants

Coolant Type:

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

Engine Oil Viscosity:

SAE 5W-30, 10W-30, or 10W-40 depending on ambient temperature (refer to owner's manual for precise recommendations)

🔧 Transmission

Transmission Type:

5-Speed Manual Transmission (5MT)

Transmission Type:

4-Speed Automatic Transmission (4AT)

4Wd System:

Mitsubishi's 'Super Select II' 4WD system was a hallmark, offering 2H, 4H, 4HLC (Locked Center Differential), and 4LLC (Locked Low Range Center Differential).

Transfer Case:

Robust, gear-driven transfer case with a locking center differential and low-range gearing.

Automatic Transmission Fluid:

Mitsubishi Diamond ATF-SP II M or equivalent

Manual Transmission Fluid:

GL-4 or GL-5 gear oil (check specific manual for viscosity and specification)

Capacity Approx:

7.2 - 9.5 Liters (1.9 - 2.5 Gallons) depending on torque converter and cooler capacity

📐 Dimensions

Wheelbase Short Wheelbase:

Approx. 2,450 mm (96.5 in)

Wheelbase Long Wheelbase:

Approx. 2,725 mm (107.3 in)

Length Long Wheelbase:

Approx. 4,650 - 4,720 mm (183.1 - 185.8 in)

Width Long Wheelbase:

Approx. 1,775 - 1,830 mm (69.9 - 72.0 in)

Height Long Wheelbase:

Approx. 1,820 - 1,875 mm (71.7 - 73.8 in)

Curb Weight Approx:

4,200 - 4,700 lbs (1,905 - 2,132 kg) depending on configuration

Gross Vehicle Weight Rating Gvw:

Approximately 5,500 - 6,000 lbs (2,495 - 2,722 kg)

Towing Capacity:

Varies significantly by market and specific model, often around 5,000 lbs (2,268 kg) when properly equipped.

🛡️ Safety Features

NHTSA Front Crash Test:

The NHTSA ratings for this specific model year range varied; typically, it performed acceptably for its class and era, but modern standards are more stringent. Refer to specific VIN for exact ratings.

ABS:

Anti-lock Braking System (ABS) was standard or available on most models.

Traction Control:

Traction control systems were not commonly available on this generation during these years.

Airbags:

Driver and front passenger airbags were standard.

Seatbelts:

3-point seatbelts for all occupants, with pretensioners for front seats.

Body Structure:

Reinforced body structure with crumple zones to absorb impact energy.

💡 Technology Features

Audio System:

Factory AM/FM/CD/Cassette player with optional premium audio systems (e.g., Rockford Fosgate) on higher trims.

Navigation:

Optional factory-installed GPS navigation systems were available on select higher-trim models, though often rudimentary by modern standards.

Cruise Control:

Electronic cruise control was standard on most models.

Parking Sensors:

Rear parking sensors were not commonly available for this generation.

Usb Aux Ports:

No factory USB or auxiliary input ports available; aftermarket solutions would be required for modern device connectivity.

🔧 Maintenance

Oil Filter Change:

Every 5,000 - 7,500 miles or 6 months, whichever comes first. (Refer to manual for specific engine/oil type)

Engine Oil Change:

Every 5,000 - 7,500 miles or 6 months, whichever comes first. (Refer to manual for specific engine/oil type)

Air Filter Replacement:

Every 30,000 miles or 2 years.

Spark Plugs Replacement:

Every 60,000 - 100,000 miles, depending on spark plug type (e.g., Iridium).

Timing Belt Replacement:

For 6G72 and 6G74 engines, timing belt replacement is crucial around 60,000 - 90,000 miles. Failure can cause catastrophic engine damage. This is a critical item.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid

Power Steering Fluid:

ATF Dexron II or equivalent

Coolant Capacity:

Approx. 9.0 - 10.0 Liters (2.4 - 2.6 Gallons)

Common Wear Items:

Suspension bushings, ball joints, tie rod ends, wheel bearings, and brake components due to age and off-road use.

Engine Issues:

Head gasket leaks on some 6G74 V6 engines, oil leaks from valve cover gaskets and oil pan, thermostat failures, and starter motor issues. Timing belt replacement is critical.

Transmission Issues:

Automatic transmission issues can include solenoid failures, torque converter clutch problems, and general wear over time. Clutch wear on manual transmissions is typical.

Electrical Issues:

Aging wiring harnesses, sensor failures (e.g., crank/cam sensors), and HVAC blower motor resistor failures.

Rust Corrosion:

Frame rust and body corrosion can be significant issues in rust-prone climates, especially around suspension mounting points and rocker panels.

📚 Vehicle History

Mitsubishi Motors:

Mitsubishi Motors has a long history in automotive manufacturing, with its SUV lineage tracing back to the iconic Pajero (Montero in North America), first introduced in 1976.

Montero Second Generation Facelift:

The 1998-2002 models represent the latter half of the second generation Pajero/Montero (1991-2000) and the transition to the third generation (2001-2006). The manual likely covers the final updates and revisions of the second gen, and potentially early third gen aspects if it's a crossover manual. Given the product name, it specifically targets the '98-'02 range of the second generation.

Third Generation Introduction:

The third generation Montero (2001-2006) represented a significant shift with unibody construction and independent front suspension, a departure from the body-on-frame of the previous generations. This manual focuses on the earlier body-on-frame era.

Manufacturing Locations:

Primarily manufactured in Japan by Mitsubishi Motors.

Market Presence:

The Montero was a strong contender in the North American SUV market, celebrated for its off-road prowess and utility.

🏆 Awards & Recognition

Off Road Accolades:

The Mitsubishi Pajero/Montero has a strong rally heritage, including multiple victories in the Dakar Rally, showcasing its inherent off-road capabilities.

Consumer Reports Ratings:

Consumer Reports ratings varied; while praised for off-road capability and V6 power, reliability scores could be mixed, often reflecting the complexity of V6 engines and the challenges of body-on-frame SUVs.