Mitsubishi Montero 1998 Service & Repair Manual Collection

Vehicle service articles supply application-specific procedures and data, while the general workshop references explain inspection, diagnostic, and overhaul methods. Shared Mitsubishi articles also cover other vehicles; use the Montero application headings to select the relevant information.

Coverage limits: The engine material provides specifications and assembly illustrations rather than a complete Montero-specific teardown sequence. Full internal transmission and transfer-case rebuild procedures are outside this collection’s scope.

PDF Search, Diagram Detail and File Contents

Search and diagram access: The PDFs contain searchable text, but lettering within image-based diagrams and some tables is not searchable. No embedded PDF bookmarks are provided. Small wiring labels require zooming.

The ZIP contains 81 printable PDFs totaling 1,501 pages, including two one-page recall bulletins and four blank or nearly blank end pages. An additional file named “gear tooth contact patterns.pdf” is damaged and cannot be opened; it is excluded from the usable PDF count and page total.

6G74 Service Data and Montero System Diagnosis

These selected coverage highlights summarize major workshop topics rather than the complete contents. Other articles address rear-window defogger faults and power-mirror testing.

• Engine reference: Crankshaft and bearing identification, cylinder-head and block specifications, timing-mark illustrations, inspection clearances, and component tightening data.

• Fuel-system repair: Step-by-step removal and installation procedures for the fuel pump, rails, injectors, and throttle body, with pressure-testing and ignition-check information.

• Automatic transmission: V4AW3 shift and lockup diagnosis, solenoid and TCM circuit testing, and transmission removal and installation procedures.

• Axles and differentials: Bearing replacement, differential overhaul, pinion-depth and preload adjustment, plus rear differential-lock pump and control-system tests.

• Brakes and ABS: Hydraulic brake service, wheel-speed-sensor checks, anti-lock fault diagnosis, and load-sensing proportioning valve pressure tests.

• Electrical references: Federal and California engine wiring, PCM terminal charts, connector identification, and vehicle system circuits.

• Starting and charging: Starter relay and bench tests, generator output and regulated-voltage checks, and component inspection information.

The diagnostic and overhaul material is suited to mechanics comfortable interpreting scan-tool data, tracing circuits, and making precision measurements.

Engine Inspection and Overhaul References

The 6G74 article distinguishes Montero and Diamante bearing-selection data. Its inspection tables cover cylinder bores, valve stem-to-guide clearances, valve seats, and camshaft lobe heights; on-vehicle adjustment material also addresses hydraulic lash adjusters.

Assembly figures show camshaft and crankshaft timing marks and tightening sequences for the cylinder heads, main bearing caps, and oil pans. The general engine overhaul guide explains cylinder-head reconditioning, piston and ring inspection, bearing-clearance measurement, cylinder honing, and oil-pump inspection.

Driveability Faults and PCM Circuit Checks

Engine-performance articles separate preliminary testing, code-based diagnosis, and symptoms without stored codes. They address no-start conditions, unstable idle, hesitation, misfires, and EGR or EVAP faults. Sensor-range charts also address signals that can affect driveability without triggering a trouble code.

PCM voltage charts, connector views, and known-good crankshaft and camshaft sensor waveforms support circuit-level checks when a fault has several possible causes. The procedures reference Mitsubishi’s MUT II scan tool; throttle-position-sensor adjustment specifies test harness MB991348.

The EVAP diagnostic material warns that excessive leak-test pressure can crack the fuel tank.

Transmission, Differentials and Chassis

Automatic-transmission articles cover fault-code retrieval, fail-safe operation, fluid service, shift-linkage adjustment, and speed-sensor testing. Separate shared articles address manual-transmission lubrication and hydraulic-clutch repair.

The rear-axle material distinguishes conventional, limited-slip, and locking differentials. It describes limited-slip clutch inspection and assembly checks, but provides exploded illustrations without a complete locking-differential disassembly and reassembly procedure. The rear-lock article explains the system’s interaction with ABS.

Steering procedures extend to recirculating-ball gear and pump overhaul, hydraulic pressure testing, and bleeding. Suspension coverage includes front torsion bars, control arms, ball joints, and wheel bearings, plus the Montero’s rear coil springs and lateral rod. Ride-height, camber, caster, and toe information supports alignment checks following chassis repairs.

Cabin Equipment, Cooling and Maintenance

A/C and heater material addresses compressor service, control-unit and blower tests, evaporator removal, and heater-core access. Body electrical articles cover cruise control, keyless-entry transmitter programming, power windows, seat motors, sunroof adjustment, and instrument-panel faults.

Vehicle wiring includes Power Distribution, Ground Distribution, Electronic Suspension, and Starting/Charging circuits. SRS coverage includes diagnosis and clockspring centering; incorrect centering can sever the internal flat cable and disable the restraint system. Fuel-system and SRS work requires the manual’s pressure-release and deactivation precautions.

Cooling references combine general thermostat and pressure-testing guidance with model-specific temperature and belt-routing data. Maintenance tables distinguish normal and severe service, with fluid specifications and wear limits. General inspection guidelines, symptom worksheets, and the injector-waveform tutorial supplement the vehicle articles.

Examples of Engine Clearances and Thermostat Data

For Montero piston inspection, the engine article lists piston-to-block clearance at .0012–.0020 in. (.030–.050 mm), with a separate entry for Diamante.

The cooling specifications list the 1998 Montero thermostat as starting to open at 190°F (88°C) and fully open at 212°F (100°C). These entries accompany the collection’s general thermostat-testing information.