Vehicle Type:
Mid-size SUV (often based on the Mitsubishi Pajero/Montero platform).
Key Attributes:
Known for its off-road capability, durable construction, and comfortable ride. Often positioned as a capable family vehicle with adventuring potential.
Competitors:
Competed against vehicles such as the Toyota 4Runner, Nissan Pathfinder, Ford Explorer, and Jeep Grand Cherokee during its production run.
Manual Value Proposition:
Provides in-depth technical information essential for maintaining and repairing the Mitsubishi Challenger, saving owners and technicians time and money compared to dealership service.
Manual Type:
Full Workshop Repair Manual
Format:
Digital (Likely PDF)
Main Sections Covered:
General Information, Body, Chassis Electrical, Clutch, Engine and Emission Control, Engine Cooling, Engine Electrical, Engine Lubrication, Engine, Exterior, Front Axle, Front Suspension, Fuel, HVAC, Intake and Exhaust, Interior and SRS, Manual Transmission, Parking Brakes, Power Plant Mount, Propeller Shaft, Rear Axle, Rear Suspension, Service Brakes, Steering, Wheel and Tyre
Engine Systems:
All aspects of the 3.0L 6G72 V6 and 2.5L 4D56 TD engines, including component identification, diagnosis, disassembly, inspection, assembly, and adjustment. Covers fuel injection, ignition, lubrication, cooling, intake, exhaust, and emissions control systems.
Transmission Systems:
Detailed coverage of the 5-speed manual V5MT1-4-BFG/V5MT1-4-AEG transmission, including clutch operation, removal, disassembly, inspection, assembly, and installation. Includes torque specifications and troubleshooting for common issues.
Chassis And Suspension:
Comprehensive coverage of front and rear axles, suspension components (springs, shock absorbers, control arms, bushings), steering system, service brakes (hydraulic system, components, ABS if equipped), parking brake system, wheels, and tires.
Electrical And Body:
Includes chassis electrical systems (lighting, power accessories, wiring diagrams), engine electrical systems (starter, alternator, ignition), interior components, SRS (Supplemental Restraint System) safety features, HVAC (Heating, Ventilation, and Air Conditioning), fuel system components, and exterior body panels and trim.
Maintenance Procedures:
Routine maintenance tasks such as oil changes, filter replacements, fluid checks and top-ups, brake pad replacement, spark plug replacement, belt inspection and replacement, and general system inspections.
Repair Procedures:
Step-by-step repair instructions for all major mechanical and electrical components, including engine overhaul, transmission repair, brake caliper rebuild, suspension component replacement, steering rack repair, and electrical component diagnostics and replacement.
Diagnostic Procedures:
Troubleshooting guides, diagnostic flowcharts, and symptom-based diagnosis for common issues related to the engine, transmission, brakes, electrical systems, and HVAC. Includes diagnostic trouble codes (DTCs) where applicable.
Technical Specifications And Tolerances:
Detailed specifications for all components, including torque values, clearances, fluid capacities, electrical system voltages, and critical measurement tolerances required for proper assembly and function.
Depth Of Coverage:
Comprehensive, suitable for professional technicians and advanced DIY enthusiasts. Covers everything from basic maintenance to complete engine and transmission rebuilds, including in-depth diagnostics and electrical troubleshooting.
Engine 1 Displacement:
3.0 Liters
Engine 1 Configuration:
V6 SOHC (Single Overhead Camshaft)
Engine 1 Fuel System:
Multi-point Fuel Injection (MPI)
Engine 2 Displacement:
2.5 Liters
Engine 2 Configuration:
Inline 4-cylinder, Turbocharged Diesel (TD)
Engine 2 Fuel System:
Indirect Injection (IDI) or Direct Injection (DI) with Turbocharger
Engine 1 Horsepower Estimate:
Approximately 173-181 hp (depending on specific market and tuning)
Engine 1 Torque Estimate:
Approximately 194-200 lb-ft (depending on specific market and tuning)
Engine 2 Horsepower Estimate:
Approximately 103-114 hp (depending on specific market and tuning)
Engine 2 Torque Estimate:
Approximately 177-192 lb-ft (depending on specific market and tuning)
Fuel Type 6G72:
Unleaded Gasoline
Fuel Type 4D56 Td:
Diesel
Body Styles:
Typically 5-door SUV (Sport Utility Vehicle)
Wheelbase:
Approximately 2,725 mm (107.3 in) for the K90 series.
Curb Weight Estimate:
Varies by engine and trim, but generally around 1,800 - 2,000 kg (3,968 - 4,409 lbs).
Gross Vehicle Weight Rating Gvwr:
The manual would specify GVWR for different configurations.
Crash Test Ratings General:
Safety ratings varied by market and testing agency. Early models may have lower ratings than later ones. The manual will detail SRS system components.
Active Safety Features:
Four-wheel drive (4WD) system, Anti-lock Braking System (ABS) likely available on some trims.
Passive Safety Features:
Front airbags (driver and passenger), reinforced body structure, seatbelts with pretensioners. The manual covers SRS system diagnosis and repair.
Infotainment Features:
Basic audio systems with AM/FM radio, cassette player, and CD player depending on trim level and year. Manual covers audio system components and wiring.
Driver Assistance Features:
Limited by the era. ABS was an option. No advanced driver-assistance systems (ADAS) typical of modern vehicles.
Connectivity Features:
No integrated Bluetooth or smartphone connectivity as standard. Manual covers basic electrical connections for accessories.
Engine Oil Change:
Typically every 7,500 to 10,000 miles (12,000 to 16,000 km) or 6-12 months, depending on driving conditions. Manual will specify exact intervals.
Transmission Fluid Change:
Manual transmission fluid: every 30,000 to 60,000 miles (48,000 to 96,000 km). Manual will provide specific interval and fluid type.
Timing Belt Replacement:
For the 6G72 V6, timing belt replacement is critical, typically at 60,000 to 90,000 miles (96,000 to 144,000 km). The manual will detail the procedure and interval.
Engine Oil Viscosity 6G72:
Likely 10W-30 or 5W-30 API SG or higher (manual to confirm specific grade and API rating).
Engine Oil Capacity 6G72:
Approximately 4.5 - 5.0 liters (4.8 - 5.3 US quarts) with filter change (manual to confirm exact capacity).
Manual Transmission Fluid Type:
Likely GL-4 or GL-5 gear oil (manual will specify exact specification and viscosity, e.g., 75W-90).
Brake Fluid Type:
DOT 3 or DOT 4 (manual to confirm specific standard).
Engine 6G72 Common Problems:
Timing belt failure (if not replaced on schedule), radiator leaks, exhaust manifold cracks, potential head gasket issues on high-mileage examples.
Engine 4D56 Td Common Problems:
Turbocharger wear, glow plug issues, injector problems, potential for cylinder head cracking if overheated (especially early models).
Transmission Manual Common Problems:
Worn clutch components (pressure plate, friction disc), synchro ring wear leading to difficult shifting, potential bearing noise.
Suspension And Steering Common Problems:
Worn ball joints and tie rod ends, worn control arm bushings, power steering leaks.
