1998 Mitsubishi Montero SUV Service & Repair Manual (P/N 809923)

• 6G74 engine reference: crankshaft and bearing identification, cylinder-head and block specifications, timing-mark illustrations, and component torque tables.
• Fuel-system repair procedures cover fuel pump, fuel rail, injector, and throttle-body removal and installation, supported by pressure testing and ignition checks.
• V4AW3 automatic transmission diagnostics cover shift and torque-converter lockup faults, solenoid testing, TCM electrical checks, and transmission removal and installation.
• Front and rear axle sections detail differential overhaul, bearing replacement, pinion-depth and preload adjustment, and testing of the rear differential lock's air pump and controls.
• Brake coverage combines hydraulic service with ABS diagnosis, wheel-speed-sensor checks, and load-sensing proportioning valve pressure tests.
• Electrical references include separate Federal and California engine wiring diagrams, PCM pin-voltage charts, connector identification, and vehicle system schematics.

This 1,501-page PDF reference set, organized into 81 documents, covers the 1998 Mitsubishi Montero with the 3.5L V6 6G74 SOHC engine, VIN code M. It combines 895 pages of vehicle service articles and maintenance information with 606 pages of general workshop references. The diagnostic and overhaul material is suited to mechanics comfortable interpreting scan-tool data, tracing circuits, and making precision measurements. Shared articles also contain material for other Mitsubishi models, with application headings distinguishing their procedures and specifications.

6G74 Mechanical Specifications and Engine Repair

The 18-page engine article concentrates on specifications and assembly illustrations. It lists crankshaft journal identifications, cylinder block bore specs, and piston-to-bore clearances. Valve stem-to-guide clearances, valve seat widths, and camshaft lobe heights are tabulated for bench inspection. Montero and Diamante bearing-selection entries are distinguished where applicable. On-vehicle checks also address hydraulic lash adjusters.

Detailed figures illustrate the proper bolt tightening sequences for cylinder heads, main bearing caps, and oil pans. A separate 40-page general engine overhaul guide explains cylinder-head reconditioning, piston and ring inspection, bearing-clearance measurement, cylinder honing, and oil-pump inspection. The 6G74 article supplies reference data; the general guide does not provide a complete Montero-specific teardown sequence.

PCM Diagnostics and Electrical Testing

The engine-performance articles separate basic testing, tests with codes, and symptom diagnosis without codes. Coverage addresses no-start conditions, unstable idle, hesitation, misfires, and EGR or EVAP faults. Sensor-range charts support diagnosis of calibration drift that may affect driveability without setting a trouble code.

Connector views identify PCM, ignition coil, and engine sensor terminals. Electrical test specifications cover ignition components and sensor signals, with known-good crankshaft and camshaft sensor waveforms for comparison. The procedures reference Mitsubishi's MUT II scan tool. On-vehicle adjustments cover basic idle speed and the throttle position sensor, with test harness MB991348 specified for sensor adjustment.

The EVAP leak-testing section warns that excessive test pressure can crack the fuel tank, an important limit when diagnosing vapor-system leaks.

Transmission, Axles, and Chassis

Automatic-transmission coverage includes fault-code retrieval, fail-safe operation, fluid service, shift-linkage adjustment, and speed-sensor testing. Manual-transmission lubrication and hydraulic-clutch repair articles are also included. Full internal transmission and transfer-case rebuild procedures are outside this set's coverage.

Rear axle information distinguishes conventional, limited-slip, and locking differentials. Limited-slip clutch inspection and assembly checks are described; locking-differential internals are illustrated without a complete disassembly and reassembly procedure. The rear-lock section also explains its interaction with ABS operation.

Chassis procedures cover recirculating-ball steering gear and pump overhaul, steering-system bleeding, and hydraulic pressure testing. Suspension work includes front torsion bars, control arms, ball joints, and wheel bearings, along with the Montero's rear coil springs and lateral rod. Ride-height checks and camber, caster, and toe adjustments support alignment work after repair.

Cabin Systems, Wiring, and Maintenance

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

The separate 45-page System Wiring Diagrams document includes power and ground distribution, electronic suspension, starting and charging, and lighting circuits. SRS procedures cover fault 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.

Technical data is structured into fast-reference tables covering fluid capacities, normal and severe service requirements, and wear limits. General inspection guidelines and an injector-waveform tutorial supplement the vehicle articles.