Mitsubishi Challenger 2004 Workshop Service Repair Manual

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Tipo: Car

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SKU: 70421

Etiquetas: 2004 Car Cars Challenger Mitsubishi

Variantes de producto

Descripción

The 2004 Mitsubishi Challenger, also known as the Pajero Sport or Montero Sport II, represents a capable mid-size SUV built on a robust body-on-frame construction. This generation, identified by the K90 chassis code, offered a blend of everyday usability and off-road prowess, often competing with established players in its segment. Key features included available four-wheel drive systems, durable powertrains such as the 3.0L 6G72 V6 gasoline engine, and a spacious interior designed for individuals and families seeking versatility for both daily commuting and adventurous excursions. Its engineering prioritized reliability and off-road capability, making it a practical choice for those requiring a rugged yet accessible SUV. This comprehensive factory service repair manual provides in-depth guidance for maintaining and repairing the 2004 Mitsubishi Challenger. It covers a wide array of systems, including detailed procedures for engine service, transmission repair (both automatic and manual), brake systems, electrical components, suspension, steering, and the cooling and fuel systems. The manual also includes troubleshooting guides, diagnostic information, wiring diagrams, and specifications essential for accurate repairs. Whether you are a seasoned technician or a dedicated owner, this manual offers the necessary technical details and step-by-step instructions to ensure the optimal performance and longevity of your vehicle.

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Challenger

Year:

Generation

Generation:

Second Generation (Pajero Sport II / Montero Sport II)

Codes

Chassis Code:

K90 series (general)

👋 Introduction

Market Position

Market Position:

A capable mid-size SUV, often positioned as a more rugged and off-road oriented alternative in its segment.

Competitive Analysis

Competitors:

Competed with vehicles like the Toyota 4Runner, Nissan Pathfinder, Ford Explorer, and Jeep Grand Cherokee.

Key Features

Key Features:

Body-on-frame construction, available four-wheel drive, durable powertrains, spacious interior, and respectable off-road capability.

Target Audience

Target Audience:

Individuals and families seeking a versatile vehicle for everyday use and occasional off-road adventures or towing.

📋 Manual Details

Coverage Areas

Coverage:

Complete Workshop Service Repair Manual

Page Count

Page Count:

Hundreds of pages (specific number not provided, but implies comprehensive coverage)

Manual Type

Manual Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Service Repair:

In-depth coverage of engine maintenance, diagnostics, and repair for all engine variants.

Transmission Service Repair:

Comprehensive details on both automatic and manual transmission service, repair, and overhaul.

Brake System:

Detailed procedures for inspection, service, and repair of hydraulic and parking brake systems.

Wiring Diagram:

Includes detailed, high-resolution wiring diagrams for all electrical systems.

Electrical System:

Troubleshooting and repair of all electrical components, including lighting, ignition, charging, and accessories.

Suspension:

Coverage of front and rear suspension systems, including shock absorbers, springs, control arms, and alignment procedures.

Steering:

Detailed information on power steering system service, repair, and steering linkage components.

Cooling System:

Maintenance and repair of the radiator, water pump, thermostat, and cooling fan assembly.

Fuel Injection:

In-depth coverage of fuel injector service, fuel pump operation, and associated electronic controls.

Fuel System:

Service and repair for the fuel tank, fuel lines, and fuel filter.

Emission System:

Information on emissions control components, diagnosis, and service.

Heater Air Conditional:

Service and repair of the HVAC system, including refrigerant handling and component replacement.

Engine Control System:

Diagnosis and repair of the Engine Control Unit (ECU) and related sensors and actuators.

Chassis Body:

Body panel repair, structural components, and chassis alignment procedures.

Restraint System:

Information on airbags, seatbelts, and related safety restraint system components.

Interior:

Service and repair of interior trim, seats, and dashboard components.

Differential Drive:

Maintenance and repair of front and rear differentials, transfer case, and drive shafts.

Axle:

Service and repair of front and rear axle components, including CV joints.

Procedures Included

General Maintenance:

Covers routine checks, fluid changes, filter replacements, and inspection procedures.

Troubleshooting:

Extensive troubleshooting guides with symptoms, potential causes, and diagnostic steps for various issues.

Periodic Lubrication:

Specific lubrication points and recommended lubricant types and intervals.

Engine Tune Up:

Detailed steps for engine tune-ups, including spark plug replacement, ignition timing checks, and idle speed adjustments.

Brake Pad Replacement:

Step-by-step instructions for replacing front and rear brake pads and rotors.

Wheel Alignment Specifications:

Includes required alignment angles (camber, caster, toe) for proper handling and tire wear.

Torque Specifications:

Essential torque values for critical fasteners across all systems (engine, transmission, suspension, brakes, etc.).

Diagnostic Trouble Codes:

Guidance on reading and interpreting diagnostic trouble codes (DTCs) from the Engine Control Module (ECM) and potentially other modules.

Body And Trim Repair:

Information on removing and installing interior and exterior trim panels, bumpers, and fenders.

Fluid Capacities:

Precise fluid capacities for engine oil, transmission fluid, coolant, brake fluid, power steering fluid, and differential fluid.

Refrigerant Handling:

Procedures for handling refrigerant in the air conditioning system, including evacuation and recharging (requiring appropriate certifications and equipment).

Technical Depth

Depth:

Complete disassembly and reassembly procedures for major components, suitable for DIYers and professional mechanics.

Diagnostics:

Detailed diagnostic procedures for electrical and mechanical systems, including fault code interpretations where applicable.

Illustrations:

Hundreds of photos, drawings, and detailed illustrations to guide repair procedures.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

Printable without restriction, allowing users to print entire manual or selected pages.

Binding Type

Binding Type:

Digital Download (user printable)

Paper Type

Paper Type:

N/A (digital format)

⚙️ Engine Specifications

Primary Engine

Engine Options 2004:

Likely included the 3.0L 6G72 V6 gasoline engine and potentially a 2.5L 4D56 diesel engine in certain markets.

Performance

Horsepower Range:

For the 3.0L V6, typically in the range of 170-190 hp, with torque figures around 245-270 Nm. Diesel variants would differ.

Fuel System

Fuel System Type:

Multi-point Fuel Injection (MPI) for gasoline engines. Diesel likely used direct injection.

Engine Code Example

Example Gasoline Engine Code:

Example Diesel Engine Code:

4D56 (common for this era)

🔧 Transmission

Standard

Standard Transmission Type:

Likely a 5-speed manual transmission was available as standard on some trims.

Optional

Optional Transmission Type:

A 4-speed automatic transmission was a common option.

Features

Transfer Case:

Part-time 4WD system with a 2-speed transfer case (e.g., Super Select 4WD) likely available on higher trims, offering 2H, 4H, 4HLc, and 4LLc modes.

📐 Dimensions

Exterior

Body Styles:

5-door SUV

Wheelbase:

Approximately 2725 mm (107.3 inches) for the second generation.

Ground Clearance:

Typically around 200-220 mm (7.9-8.7 inches) depending on suspension setup and tire size, beneficial for off-road use.

Weights

Curb Weight Range:

Generally between 1800 kg to 2000 kg (3968 lbs to 4409 lbs) depending on engine, drivetrain, and trim level.

🛡️ Safety Features

Ratings

Safety Ratings:

Specific official crash test ratings for the 2004 model year from agencies like NHTSA or IIHS would need to be verified, but generally offered standard safety equipment for its era.

Active Features

Active Safety Features:

Anti-lock Braking System (ABS) was likely standard or optional. Electronic Brake-force Distribution (EBD) may have been available.

Passive Features

Passive Safety Features:

Front airbags for driver and passenger, three-point seatbelts, and reinforced safety cage construction.

💡 Technology Features

Infotainment

Infotainment Features:

Base models likely featured a standard AM/FM/CD player. Higher trims might have offered upgraded audio systems, potentially with a simple LCD display.

Driver Assistance

Driver Assistance Features:

Limited by modern standards; focus would be on ABS. No advanced driver-assistance systems (ADAS) expected.

Connectivity

Connectivity Options:

Basic; may include power windows, power locks, and potentially a pre-wiring for accessories. No integrated Bluetooth or USB ports typically found.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 7,500 to 10,000 miles (12,000 to 16,000 km) or 6-12 months, depending on driving conditions. Refer to manual for specifics.

Spark Plug Replacement:

Around 60,000 to 100,000 miles (96,000 to 160,000 km) for iridium or platinum plugs, but varies by plug type. Check manual.

Fluid Specifications

Engine Oil Specification:

Likely API SN or higher, with viscosity grades such as 5W-30 or 10W-40 depending on climate. Consult manual for exact specs (e.g., API SG or SH for older specs).

Transmission Fluid Type Automatic:

Likely ATF SP-III or equivalent.

Coolant Specification:

Typically a 50/50 mix of ethylene glycol-based coolant and distilled water. Ensure it's Asian vehicle compatible.

Known Issues

Common Issues:

Potential issues might include minor interior trim wear, occasional electrical connector corrosion, and standard wear-and-tear on suspension components and drivetrain elements common to SUVs of this age. Overheating if cooling system maintenance is neglected.

📚 Vehicle History

Brand Heritage

Brand Heritage:

Mitsubishi has a long history of producing robust and capable off-road vehicles, stemming from its Pajero lineage.

Model Evolution

Model Evolution:

The Challenger (known as Pajero Sport or Montero Sport in other markets) is based on the Pajero platform, offering a more compact and accessible option within Mitsubishi's SUV lineup.

Production

Production Regions:

Produced in various Mitsubishi plants globally, including Japan and Thailand.

🏆 Awards & Recognition

Recognitions

Awards Recognition:

While specific awards for the 2004 Challenger might not be widely publicized, Mitsubishi vehicles of this era were generally recognized for their durability and value in the SUV segment.