Mitsubishi Pajero Sport / Montero Sport 1997–1999 Repair Manual Set

The repair reference and factory volume cover different market and drivetrain configurations. Match the engine and transmission before selecting a procedure; the older wiring supplement is separate from the Sport-specific diagrams in the repair reference.

Factory coverage limits: Engine and transmission chapters cover on-vehicle inspections, adjustments, and major-component removal and installation. Detailed off-vehicle overhaul uses separate manuals. The foreword also identifies companion electrical-wiring, structural body-repair, and parts publications that are not included here. Automatic-transmission diagnosis comes from the Montero Sport reference.

PDF Search, Bookmarks and File Condition

Search and diagram detail: The Montero Sport reference supports text search and section bookmarks, although some diagram pages have no searchable labels. All 26 factory PDFs have bookmarks, but their character encoding prevents reliable keyword searching. Small labels on the inspected wiring diagrams are readable with zoom, with some coarse raster lettering. The older wiring supplement has partially searchable headings and no bookmarks; page positions 4–25 render blank because of file errors.

The ZIP contains 28 printable PDFs: one repair reference, 26 factory files, and one older wiring supplement. The two main publications total 2,269 pages, including the two-page factory foreword and 14 notes pages. The nominal package count is 2,318, including the older supplement’s 49 page entries; its damaged structure causes different page counts in different PDF readers.

Engine, Drivetrain and Control-System Work

Selected coverage: These highlights show major workshop tasks rather than reproduce the complete contents. Other topics include rear-window defogger and power-sunroof testing.

• Engine repair: Step-by-step procedures for 6G72 and 4D56 timing belts, camshafts, cylinder-head gaskets, crankshaft oil seals, oil pans, and engine removal and installation.

• Drivetrain service: Clutch hydraulics, manual-transmission servicing, transfer-case work, propeller shafts, axle removal, differential overhaul, and freewheel-clutch service.

• Engine-control diagnosis: OBD fault testing, no-code symptom charts, sensor-range and pin-voltage data, and MUT-II diagnostic procedures.

• Brakes and chassis: Hydraulic bleeding, disc and drum service, load-sensing proportioning-valve checks, steering and suspension repair, and separate 2WD/4WD ABS diagnosis.

• Heating and air conditioning: Performance testing, control and sensor diagnosis, blower testing, and evaporator, heater-core, compressor, condenser, and refrigerant-line service.

• SRS diagnosis: Fault isolation for impact sensors, SRS-ECU, driver and passenger modules, and clockspring circuits, plus post-collision checks and module disposal.

• Workshop references: System wiring diagrams, connector and component-location views, diagnostic flowcharts, exploded assemblies, and component-specific torque, clearance, pressure-test, and adjustment data.

The factory volume is written for service mechanics; the diagnostic work calls for familiarity with electrical testing, scan equipment, and the specified workshop tools.

Engine Repair and Diesel Fuel Systems

6G72 repair depth: The Montero Sport reference includes cylinder-head overhaul, cylinder-block inspection, rocker-arm service, water-pump replacement, and lubrication-system work. Intake and exhaust procedures accompany the engine repair sections.

4G64 coverage: The 2.4L articles concentrate on adjustments, engine-control diagnosis, and fuel and ignition components. The general engine-overhaul article uses non-model-specific examples rather than providing a dedicated 4G64 internal-overhaul chapter.

4D56 diesel work: Factory procedures cover injection-nozzle inspection, injection-pump removal and installation, injection-timing checks and adjustment, turbocharger and intercooler service, and glow-system testing.

Transmission, Axles and Chassis Diagnosis

The R4AW3/V4AW3 diagnostic material provides TCM input/output terminal checks, speed- and temperature-sensor tests, shift and lock-up solenoid checks, and shift-lock adjustment. Its fault charts and harness tests help distinguish circuit and sensor problems from control-unit faults; internal transmission repair refers to separate overhaul articles.

Mechanical driveline sections add limited-slip differential setup, rear differential-lock testing, bearing adjustments, and gear-tooth contact checks. These references support differential setup beyond simple assembly removal.

ABS troubleshooting separates wheel-speed sensors, hydraulic units, solenoid circuits, G-sensor inputs, and 4WD detection circuits. Conventional brake procedures include booster and master-cylinder work alongside hydraulic and friction-component service.

The MAP inspection articles provide condition-based criteria for HVAC, brakes, steering, drivetrain, electrical, engine, exhaust, suspension, and restraint components. They support inspection reporting and repair recommendations, while the model-specific chapters supply the service procedures.

HVAC Controls and SRS Service

ACCU testing relates thermosensor, inlet-sensor, dual-pressure-switch, and coolant-temperature-switch inputs to compressor-clutch operation. Separate sections address rear heaters, diesel idle-up control, and gasoline-engine outside-temperature sensing.

General A/C servicing covers R-12/R-134a identification, oil compatibility, service valves, recovery and recycling, evacuation, charging, and leak testing. The refrigerant warnings explain how incompatible oils or contaminated service equipment can damage A/C components or the compressor.

SRS procedures include deployment, cleanup, and disposal guidance. Tool references include MUT-II MB991502, SRS Check Harness MB991613, and steering-wheel puller MB990803.

Incorrect clockspring centering can sever its internal flat cable, while hammering ABS sensor rings can demagnetize them and disrupt wheel-speed signals. The SRS warnings also address accidental deployment from squib-resistance testing.

Refrigerant recovery and SRS work require the specified equipment, electrical isolation, and the handling procedures contained in the manuals. The factory warning assigns SRS servicing to authorized Mitsubishi dealer personnel.

Wiring and Assembly References

Electrical examples include A/C control and condenser-fan circuits, 2WD/4WD ABS schematics, and R4AW3/V4AW3 TCM and solenoid circuits. Engine-management diagrams and SRS component-location views support circuit tracing; front and rear differential exploded views accompany tooth-contact references.

A Preview of Differential Setup Values

For the factory-covered 4WD axles, front final-drive gear backlash has a standard range of 0.11–0.16 mm, while rear drive-gear backlash is 0.13–0.18 mm. The axle chapters pair these settings with bearing adjustments and tooth-contact inspection procedures.