Model:
Challenger / Pajero Sport
Generation:
1st Generation (K90 Series)
Chassis Codes:
K94W, K96W, K97W, K99W
Engine Codes Primary:
6G72 (3.0L V6)
Engine Codes Secondary:
4D56 TD (2.5L Turbo Diesel)
Transmission Codes:
V5MT1-4-BFG, V5MT1-4-AEG (5-Speed Manual)
Vehicle Segment:
Compact/Mid-size SUV, Body-on-frame construction
Target Audience:
Off-road enthusiasts, families, general utility
Key Competitors:
Toyota 4Runner, Nissan Pathfinder, Isuzu Trooper, Jeep Cherokee (XJ/WJ), Ford Explorer
Drivetrain Options:
Available in 2WD and 4WD (part-time or full-time depending on market)
Body Styles:
Primarily 5-door SUV, some markets may have had 2-door variants
Cost Effectiveness:
Inexpensive way to perform routine maintenance and larger repairs, saving on labor costs
User Base:
Suitable for DIY enthusiasts and experienced mechanics alike
Applicable Years:
1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Covered Markets:
Global (Challenger and Pajero Sport variants)
Type:
Workshop Service Repair Manual
Primary Language:
English
Engine Systems:
Engine and Emission Control, Engine Cooling, Engine Electrical, Engine Lubrication, Engine Mechanical, Fuel System, Intake and Exhaust
Transmission Systems:
Clutch, Manual Transmission (V5MT1-4 series), Drivetrain (Propeller Shaft, Front Axle, Rear Axle)
Chassis Systems:
Chassis Electrical, Parking Brakes, Service Brakes, Steering, Suspension (Front & Rear), Wheels and Tyres
Body Systems:
Body Construction, Exterior Components, Interior Components, HVAC (Heating, Ventilation, and Air Conditioning), SRS (Supplemental Restraint System - Airbags)
Maintenance Procedures:
Scheduled maintenance, fluid changes, filter replacements, belt inspections, tune-ups
Repair Procedures:
Engine overhaul, transmission rebuild, brake system repair, suspension component replacement, electrical system troubleshooting, body panel repair
Diagnostic Procedures:
Troubleshooting guides, fault code interpretation (where applicable), symptom-based diagnostics
Wiring Information:
Comprehensive wiring diagrams for all major vehicle systems
Diagnostic Capability:
Advanced diagnostics, component-level testing, electrical troubleshooting with diagrams
Repair Scope:
From basic adjustments and fluid services to complete engine and transmission rebuilds
Illustrations:
Detailed illustrations, diagrams, and step-by-step instructions with pictures
Configuration:
3.0L (2972cc) SOHC V6
Bore X Stroke:
86.1 mm x 85.0 mm
Compression Ratio:
Approx. 8.9:1 (Varies slightly by sub-model)
Horsepower Range:
133-180 hp (depending on market and specific tune)
Torque Range:
175-203 lb-ft (depending on market and specific tune)
Induction:
Multi-point fuel injection (MPI)
Configuration:
2.5L (2477cc) SOHC 4-cylinder Turbo Diesel
Horsepower Range:
95-118 hp (depending on market and specific tune)
Torque Range:
152-177 lb-ft (depending on market and specific tune)
Engine Oil Type:
API SG/SH or ILSAC GF-1 rated, SAE 10W-30 or 10W-40 (Check manual for specific climate recommendations)
Engine Oil Capacity:
Approx. 4.5 Liters (V6), 5.5 Liters (4-cyl Diesel) - with filter change (Verify in manual)
Coolant Type:
Ethylene glycol-based coolant, 50/50 mix with distilled water
Type:
5-Speed Manual Transmission
Codes:
V5MT1-4-BFG, V5MT1-4-AEG
Drivetrain Configuration:
Part-time 4WD (Super Select 4WD or Easy Select 4WD depending on trim)
Manual Transmission Fluid Type:
API GL-4 SAE 75W-90 Gear Oil (Verify specific requirements in manual)
Manual Transmission Fluid Capacity:
Approx. 2.5 Liters (Verify in manual)
Length:
Approx. 4,600 - 4,650 mm (depending on market variant)
Width:
Approx. 1,775 - 1,820 mm
Height:
Approx. 1,700 - 1,750 mm
Wheelbase:
Approx. 2,725 mm
Curb Weight:
Approx. 1,800 - 1,950 kg (depending on engine and drivetrain)
Gross Vehicle Weight Rating Gvwr:
Approx. 2,400 - 2,550 kg (Verify in manual)
Airbags:
Driver and passenger airbags standard on most models, supplemental restraint system (SRS) covered in manual
Seatbelts:
3-point ELR seatbelts for all occupants, pre-tensioners (check specific market)
Braking System:
Front ventilated discs, Rear drums (standard); ABS often optional or standard on higher trims
Traction Control:
Not commonly equipped on base models of this era, but may be present on higher trims or later production years
Oil Change Interval:
Typically 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first (Refer to manual for exact schedule)
Engine Coolant Interval:
Initial change at 100,000 miles (160,000 km), then every 50,000 miles (80,000 km) or 2-4 years (Verify in manual)
Transmission Fluid Interval:
Manual: Typically 30,000-60,000 miles (48,000-96,000 km) (Verify in manual)
Spark Plug Replacement:
V6: Approx. 60,000-100,000 miles (depending on plug type, Iridium recommended) (Verify in manual)
Brake Fluid Type:
DOT 3 or DOT 4
Power Steering Fluid Type:
MS-54232 or equivalent ATF Dexron III (Verify in manual)
Common Problems:
Radiator leaks, fuel pump failures, power window motor issues, transmission synchronizer wear (manual), transfer case issues on high mileage units, front suspension wear (ball joints, bushings)
Diesel Specific Issues:
Glow plug failures, turbocharger issues, potential for injector pump problems
Mitsubishi Offroad Legacy:
Builds on Mitsubishi's strong heritage in off-road vehicles, including the Pajero/Montero lineage
Platform Sharing:
Based on the Pajero/Montero (NM/NP series) platform, adapted for different markets and naming conventions.
Manufacturing Location:
Primarily manufactured in Japan, with potential assembly in other regions for specific markets
Production Years Covered By Manual:
1998-2006
