Segment:
Mid-size SUV (Sport Utility Vehicle) / Off-road capable
Competitors 2004:
Jeep Cherokee (KJ), Toyota 4Runner, Nissan Pathfinder, Ford Explorer, Land Rover Discovery
Body Style:
Body-on-frame construction, robust chassis for off-road capability
Drivetrain:
Available in 2WD and 4WD (Super Select 4WD-II)
Powertrain Options:
Known for reliable V6 gasoline and diesel engines, often with excellent torque
Coverage:
All Models, Engines, Trim, and Transmission Types
Estimated Page Count:
Hundreds of pages (specific number not provided, but described as extensive)
Type:
Workshop Repair Service Manual
Engine Service Repair:
Detailed procedures for engine overhaul, disassembly, assembly, and diagnostics.
Transmission Service Repair:
Comprehensive information on automatic and manual transmission servicing, repair, and diagnostics.
Brake System:
Maintenance, repair, and troubleshooting of brake components including ABS.
Electrical System:
Diagnosis and repair of all electrical circuits, components, and wiring.
Suspension:
Service and repair for front and rear suspension components, alignment.
Steering:
Maintenance and repair of the power steering system and steering linkage.
Cooling System:
Repair and maintenance of the radiator, thermostat, water pump, and cooling fans.
Fuel Injection Fuel System:
Diagnosis and service for fuel delivery, injectors, fuel pump, and fuel lines.
Emission System:
Information on emission control devices and troubleshooting.
Heater Air Conditioner:
Service and repair for the HVAC system, including refrigerant handling.
Engine Control System:
Detailed diagnostics and troubleshooting for the Engine Control Unit (ECU) and sensors.
Chassis Body:
Body panel repair, frame straightening, and chassis component servicing.
Restraint System:
Information on airbags and seatbelt systems.
Interior:
Service and repair for interior trim, seats, and dashboard components.
Differential Drive:
Maintenance and repair of front and rear differentials and drive shafts.
Axle:
Service and repair of front and rear axles and CV joints.
Wiring Diagram:
Complete and detailed wiring schematics for all vehicle systems.
General Maintenance:
Routine checks, fluid changes, filter replacements, and preventative care.
Troubleshooting:
Systematic diagnostic procedures for identifying and resolving common and complex issues.
Periodic Lubrication:
Specific lubrication points and recommended lubricants for various components.
Disassembly Assembly:
Step-by-step instructions for removing and reinstalling vehicle components.
Cleaning Reinstalling:
Guidelines for cleaning parts and proper reassembly techniques.
Depth:
Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics.
Engine Options:
Commonly featured 3.0L V6 (6G72), 3.5L V6 (6G74) gasoline engines, and 2.8L 4M40/4M41 diesel engines.
Horsepower Torque 3 0L V6:
Approx. 173-181 hp / 255-270 Nm (specific figures vary by market and tune)
Horsepower Torque 3 5L V6:
Approx. 200-225 hp / 300-343 Nm (specific figures vary by market and tune)
Horsepower Torque 2 8L Diesel:
Approx. 125-140 hp / 280-314 Nm (specific figures vary by market and tune)
Fuel Delivery:
Multi-point Fuel Injection (MPI) for gasoline engines, Direct Injection for diesel engines
Length:
Approx. 4,690 - 4,740 mm (varies by market/spec)
Width:
Approx. 1,775 - 1,815 mm (varies by market/spec)
Height:
Approx. 1,750 - 1,800 mm (varies by market/spec)
Curb Weight:
Approx. 1,800 - 2,000 kg (varies by engine and drivetrain)
Towing Capacity:
Typically rated around 2,500 kg (braked) depending on region and specifications.
Crash Test Results:
Safety ratings vary by region and specific testing body. Generally, vehicles of this era offered basic safety features.
ABS:
Anti-lock Braking System (ABS) typically standard or optional.
Traction Control:
Traction control systems may have been available on higher trims.
Airbags:
Driver and front passenger airbags commonly fitted.
Audio System:
Factory-fitted radios with AM/FM and CD player, typically 4-6 speakers. Higher trims might have upgraded audio systems.
Cruise Control:
Available on many models, typically as standard on higher trims.
Phone Integration:
Limited by modern standards. Some models may have provisions for aftermarket Bluetooth kits.
Oil Change:
Typically every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, depending on driving conditions and oil type. Refer to manual for precise intervals.
Air Filter Replacement:
Recommended every 15,000 - 30,000 miles (24,000 - 48,000 km).
Spark Plug Replacement:
Intervals vary significantly based on plug type (e.g., iridium plugs last longer). Consult manual for specifics.
Engine Oil Type:
API SG, SH, SJ, or SL classification. Viscosity typically 10W-30 or 5W-30 (check manual for exact specification).
Engine Oil Capacity:
Approx. 4.5 - 5.5 liters for V6 engines (check manual for exact capacity and filter).
Coolant Type:
Ethylene glycol-based antifreeze (e.g., Mitsubishi DiaQueen Super Long Life Coolant or equivalent). Typically a 50/50 mix with distilled water.
Transmission Fluid Type:
Automatic: ATF SP-II M, SP-III, or equivalent. Manual: GL-4 or GL-5 gear oil (check manual for specific viscosity and type).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Common Wear Items:
Suspension bushings, ball joints, CV joints, and wheel bearings due to its robust nature and off-road use.
Potential Engine Issues:
Carbon buildup in intake manifolds, especially with older gasoline engines. Diesel engines may require glow plug maintenance.
Transmission Longevity:
Automatics can be robust but benefit from regular fluid changes. Manuals are generally very durable.
Mitsubishi Motors:
Mitsubishi Motors has a long history in automotive manufacturing, known for ruggedness and off-road capabilities with models like the Pajero/Montero.
Challenger Lineage:
The Challenger (also known as Montero Sport in some markets) is based on the Pajero platform, offering a blend of family practicality and off-road prowess.
Manufacturing Locations:
Produced in various Mitsubishi plants globally, including Japan and Thailand.
