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Mitsubushi CHALLENGER 1998-2006 Workshop Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Challenger / Pajero Sport Generation Production Years: 1998-2006 Codes Chassis Code Common: K90 Series 👋 Introduction Market Position Segment: Mid-size SUV / Off-roader...
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Tipo: Car
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SKU: 198652
Mitsubushi CHALLENGER 1998-2006 Workshop Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Challenger / Pajero Sport
Generation
Production Years:
1998-2006
Codes
Chassis Code Common:
K90 Series
👋 Introduction
Market Position
Segment:
Mid-size SUV / Off-roader
Competitive Analysis
Key Competitors:
Toyota Land Cruiser Prado, Nissan Pathfinder, Ford Explorer, Isuzu Trooper
Key Features
Vehicle Attributes:
Body-on-frame construction, available 4WD (Super Select II on some models), robust engines, practical interior, off-road capability.
Manual Value Proposition
Benefits For Owner:
Empowers owners and DIY mechanics with professional-level repair and maintenance knowledge, reducing reliance on expensive dealership services and improving vehicle longevity.
📋 Manual Details
Coverage Areas
Vehicle Models Covered:
Mitsubishi Challenger, Mitsubishi Pajero Sport
Page Count
Estimated Pages:
900+
Manual Type
Type:
Workshop Repair Manual
Language
Language:
English
Format
Format:
PDF (Download)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (3.0L V6 6G72, 2.5L TD 4D56), Manual Transmission (V5MT1-4-BFG, V5MT1-4-AEG)
Drivetrain:
Front Axle, Rear Axle, Propeller Shaft
Suspension Steering:
Front Suspension, Rear Suspension, Steering System
Brakes:
Service Brakes, Parking Brakes
Electrical:
Chassis Electrical, Engine Electrical
Body Interior Exterior:
Body, Exterior, Interior and SRS (Supplemental Restraint System)
Comfort Climate:
HVAC (Heating, Ventilation, and Air Conditioning)
Fuel Exhaust:
Fuel System, Intake and Exhaust Systems
Procedures Included
Maintenance:
Scheduled Maintenance, Fluid Changes, Filter Replacements, General Servicing
Diagnostics:
Troubleshooting Guides, Fault Code Identification (Engine and Emission Control)
Repair:
Component Removal and Installation, Reassembly Procedures, Component Overhaul
Technical Adjustments:
Alignment Specifications, Clutch Adjustments, Brake Adjustments
Technical Depth
Depth:
Comprehensive, from basic maintenance to complex repairs, including detailed diagrams and exploded views.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Fully printable (selected pages or entire manual)
Binding Type
Binding Type:
Digital (N/A for PDF)
Paper Type
Paper Type:
Digital (N/A for PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
6G72
Engine Type 1:
V6 SOHC (Single Overhead Cam)
Displacement 1:
3.0 Liters (2972 cc)
Fuel Delivery 1:
Multi-point Fuel Injection (MPI)
Secondary Engine
Engine Code 2:
4D56 TD
Engine Type 2:
Inline 4-cylinder, SOHC, Turbocharged Diesel
Displacement 2:
2.5 Liters (2477 cc)
Performance
Horsepower 6G72 Typical:
Approx. 177-184 hp @ 5500-6000 rpm (depending on specific market tune)
Torque 6G72 Typical:
Approx. 245-260 Nm @ 4000-4500 rpm (depending on specific market tune)
Horsepower 4D56 Td Typical:
Approx. 114-132 hp @ 4000-4200 rpm (depending on specific market tune)
Torque 4D56 Td Typical:
Approx. 240-280 Nm @ 2000-2500 rpm (depending on specific market tune)
Fuel System
Fuel Type:
Unleaded Petrol (6G72), Diesel (4D56 TD)
Engine Management
ECU Type:
Electronic Control Unit (ECU) for fuel injection and ignition timing.
🔧 Transmission
Standard
Transmission Type Manual:
5-Speed Manual
Manual Transmission Codes:
V5MT1-4-BFG, V5MT1-4-AEG
Features
Transfer Case:
Part-time or Full-time 4WD systems, likely including low-range gearing.
Fluid Specifications
Manual Transmission Fluid Type:
API GL-4 (or GL-5 for some applications, consult manual for specifics). Viscosity SAE 75W-90 or SAE 80W-90 often recommended.
Capacity
Manual Transmission Fluid Capacity:
Approximately 2.0 - 2.5 Liters (consult manual for exact capacity).
📐 Dimensions
Exterior
Body Style:
5-door SUV
Wheelbase:
Approx. 2725 mm (107.3 inches)
Length:
Approx. 4660 mm (183.5 inches)
Width:
Approx. 1775 mm (69.9 inches)
Height:
Approx. 1715 mm (67.5 inches)
Weights
Curb Weight:
Approx. 1800 - 2000 kg (depending on engine and drivetrain)
Wheels Tires
Typical Tire Size:
235/75R15, 265/70R16 (varies by trim and market)
Bolt Pattern:
6x139.7 mm (6x5.5 inches)
Center Bore:
67.1 mm
🛡️ Safety Features
Ratings
Crash Test Results:
Information may vary by market. Early models may not have standardized ratings comparable to modern vehicles. Refer to specific market safety reports if available.
Active Features
Braking System:
Front: Ventilated Disc Brakes, Rear: Disc or Drum Brakes (depending on model and year). ABS (Anti-lock Braking System) available on many models.
Passive Features
Airbags:
Driver and Front Passenger Airbags standard on most models. SRS system covered in manual.
Chassis Structure:
Robust body-on-frame construction designed for durability and off-road use.
💡 Technology Features
Infotainment
Audio System:
Typically features AM/FM radio, CD player, and optional cassette player. Speaker configurations vary by trim. Manual provides wiring diagrams for potential upgrades.
Driver Assistance
ABS:
Anti-lock Braking System available on many models, providing enhanced braking control.
Connectivity
Lighting System:
Halogen headlamps. Manual details bulb types and replacement procedures.
🔧 Maintenance
Service Intervals
Oil Change Interval Petrol:
Typically every 5,000 - 10,000 km or 6-12 months (refer to manual for specific interval based on driving conditions).
Oil Change Interval Diesel:
Typically every 5,000 - 10,000 km or 6-12 months (refer to manual for specific interval based on driving conditions).
Timing Belt Replacement 6G72:
Crucial maintenance item. Recommended replacement interval is typically 90,000 - 100,000 km or 5-7 years. Failure can cause catastrophic engine damage.
Transmission Fluid Interval:
Every 40,000 - 60,000 km or as per manual recommendations, especially under heavy use or towing.
Fluid Specifications
Engine Oil Grade 6G72:
API SJ or higher, viscosity SAE 10W-30 or 10W-40 recommended. Check manual for exact specifications.
Engine Oil Grade 4D56 Td:
API CF-4 or CH-4, viscosity SAE 15W-40 or 10W-30 recommended. Check manual for exact specifications.
Coolant Type:
Ethylene Glycol based coolant, typically a 50/50 mix with distilled water. Green or Pink coolant types may be specified. Consult manual for correct type and capacity.
Known Issues
Common Wear Items:
Suspension components (bushings, ball joints, tie rods), exhaust system, clutch wear (manual transmission), radiator and cooling system components, glow plugs (diesel).
Common Issues
Engine Specific Concerns:
For 6G72: potential for oil leaks, intake manifold gaskets. For 4D56 TD: turbocharger health is critical, potential for injector issues.
📚 Vehicle History
Brand Heritage
Mitsubishi SUV Legacy:
Leverages Mitsubishi's long history in producing capable off-road vehicles, building upon the Pajero (Montero) lineage.
Model Evolution
Pajero Sport Introduction:
Launched as a more affordable and slightly less rugged alternative to the flagship Pajero, targeting families and adventurers. Often based on a shorter-wheelbase Pajero platform.
Production
Manufacturing Locations:
Primarily produced in Japan, with potential assembly in other global locations.
🏆 Awards & Recognition
Recognitions
Segment Popularity:
Popular in markets valuing ruggedness and off-road capability for recreational and utilitarian purposes. Specific awards are less common for this model compared to luxury SUVs.
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