🏷️ Basic Information

Make:

Mitsubishi

Model:

Challenger

Year:

2004

Generation:

Second Generation (Pajero Sport II / Montero Sport II)

Chassis Code:

K90 series (general)

👋 Introduction

Market Position:

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

Competitors:

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

Key Features:

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

Target Audience:

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

📋 Manual Details

Coverage:

Complete Workshop Service Repair Manual

Page Count:

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

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

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.

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).

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:

PDF

Print Quality:

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

Binding Type:

Digital Download (user printable)

Paper Type:

N/A (digital format)

⚙️ Engine Specifications

Engine Options 2004:

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

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 Type:

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

Example Gasoline Engine Code:

6G72

Example Diesel Engine Code:

4D56 (common for this era)

🔧 Transmission

Standard Transmission Type:

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

Optional Transmission Type:

A 4-speed automatic transmission was a common option.

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

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.

Curb Weight Range:

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

🛡️ Safety Features

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 Safety Features:

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

Passive Safety Features:

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

💡 Technology Features

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 Features:

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

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

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.

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.

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:

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

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 Regions:

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

🏆 Awards & Recognition

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.