1 1

Mitsubishi

Mitsubushi CHALLENGER 1998-2006 Workshop Repair Manual

Mitsubushi CHALLENGER 1998-2006 Workshop Repair Manual

$16.99
$16.99
Sale Sold out
Shipping calculated at checkout.
Vehicle data plateRef 198652
Brand
Mitsubishi
Vehicle
Cars
Models covered
CHALLENGER, Mitsubushi
Years
1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

What happens after you pay

  • Download link opens on the order page immediately
  • The same link is emailed to you โ€” re-download any time
  • Open on phone, tablet or PC; print only the pages you need
  • Not sure it covers your model year? Ask us before you buy
๐Ÿท๏ธ Basic Information
Identification
Make:
Mitsubishi
Model:
Challenger / Pajero Sport
Generation
Production Years:
1998-2006
Codes
Chassis Code Common:
K90 Series
๐Ÿ‘‹ Introduction
Market Position
Segment:
Mid-size SUV / Off-roader
Competitive Analysis
Key Competitors:
Toyota Land Cruiser Prado, Nissan Pathfinder, Ford Explorer, Isuzu Trooper
Key Features
Vehicle Attributes:
Body-on-frame construction, available 4WD (Super Select II on some models), robust engines, practical interior, off-road capability.
Manual Value Proposition
Benefits For Owner:
Empowers owners and DIY mechanics with professional-level repair and maintenance knowledge, reducing reliance on expensive dealership services and improving vehicle longevity.
๐Ÿ“‹ Manual Details
Coverage Areas
Vehicle Models Covered:
Mitsubishi Challenger, Mitsubishi Pajero Sport
Page Count
Estimated Pages:
900+
Manual Type
Type:
Workshop Repair Manual
Language
Language:
English
Format
Format:
PDF (Download)
๐Ÿ“– Manual Coverage
Systems Covered
Powertrain:
Engine (3.0L V6 6G72, 2.5L TD 4D56), Manual Transmission (V5MT1-4-BFG, V5MT1-4-AEG)
Drivetrain:
Front Axle, Rear Axle, Propeller Shaft
Suspension Steering:
Front Suspension, Rear Suspension, Steering System
Brakes:
Service Brakes, Parking Brakes
Electrical:
Chassis Electrical, Engine Electrical
Body Interior Exterior:
Body, Exterior, Interior and SRS (Supplemental Restraint System)
Comfort Climate:
HVAC (Heating, Ventilation, and Air Conditioning)
Fuel Exhaust:
Fuel System, Intake and Exhaust Systems
Procedures Included
Maintenance:
Scheduled Maintenance, Fluid Changes, Filter Replacements, General Servicing
Diagnostics:
Troubleshooting Guides, Fault Code Identification (Engine and Emission Control)
Repair:
Component Removal and Installation, Reassembly Procedures, Component Overhaul
Technical Adjustments:
Alignment Specifications, Clutch Adjustments, Brake Adjustments
Technical Depth
Depth:
Comprehensive, from basic maintenance to complex repairs, including detailed diagrams and exploded views.
๐Ÿ“Š Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Fully printable (selected pages or entire manual)
Binding Type
Binding Type:
Digital (N/A for PDF)
Paper Type
Paper Type:
Digital (N/A for PDF)
โš™๏ธ Engine Specifications
Primary Engine
Engine Code 1:
6G72
Engine Type 1:
V6 SOHC (Single Overhead Cam)
Displacement 1:
3.0 Liters (2972 cc)
Fuel Delivery 1:
Multi-point Fuel Injection (MPI)
Secondary Engine
Engine Code 2:
4D56 TD
Engine Type 2:
Inline 4-cylinder, SOHC, Turbocharged Diesel
Displacement 2:
2.5 Liters (2477 cc)
Performance
Horsepower 6G72 Typical:
Approx. 177-184 hp @ 5500-6000 rpm (depending on specific market tune)
Torque 6G72 Typical:
Approx. 245-260 Nm @ 4000-4500 rpm (depending on specific market tune)
Horsepower 4D56 Td Typical:
Approx. 114-132 hp @ 4000-4200 rpm (depending on specific market tune)
Torque 4D56 Td Typical:
Approx. 240-280 Nm @ 2000-2500 rpm (depending on specific market tune)
Fuel System
Fuel Type:
Unleaded Petrol (6G72), Diesel (4D56 TD)
Engine Management
ECU Type:
Electronic Control Unit (ECU) for fuel injection and ignition timing.
๐Ÿ”ง Transmission
Standard
Transmission Type Manual:
5-Speed Manual
Manual Transmission Codes:
V5MT1-4-BFG, V5MT1-4-AEG
Features
Transfer Case:
Part-time or Full-time 4WD systems, likely including low-range gearing.
Fluid Specifications
Manual Transmission Fluid Type:
API GL-4 (or GL-5 for some applications, consult manual for specifics). Viscosity SAE 75W-90 or SAE 80W-90 often recommended.
Capacity
Manual Transmission Fluid Capacity:
Approximately 2.0 - 2.5 Liters (consult manual for exact capacity).
๐Ÿ“ Dimensions
Exterior
Body Style:
5-door SUV
Wheelbase:
Approx. 2725 mm (107.3 inches)
Length:
Approx. 4660 mm (183.5 inches)
Width:
Approx. 1775 mm (69.9 inches)
Height:
Approx. 1715 mm (67.5 inches)
Weights
Curb Weight:
Approx. 1800 - 2000 kg (depending on engine and drivetrain)
Wheels Tires
Typical Tire Size:
235/75R15, 265/70R16 (varies by trim and market)
Bolt Pattern:
6x139.7 mm (6x5.5 inches)
Center Bore:
67.1 mm
๐Ÿ›ก๏ธ Safety Features
Ratings
Crash Test Results:
Information may vary by market. Early models may not have standardized ratings comparable to modern vehicles. Refer to specific market safety reports if available.
Active Features
Braking System:
Front: Ventilated Disc Brakes, Rear: Disc or Drum Brakes (depending on model and year). ABS (Anti-lock Braking System) available on many models.
Passive Features
Airbags:
Driver and Front Passenger Airbags standard on most models. SRS system covered in manual.
Chassis Structure:
Robust body-on-frame construction designed for durability and off-road use.
๐Ÿ’ก Technology Features
Infotainment
Audio System:
Typically features AM/FM radio, CD player, and optional cassette player. Speaker configurations vary by trim. Manual provides wiring diagrams for potential upgrades.
Driver Assistance
ABS:
Anti-lock Braking System available on many models, providing enhanced braking control.
Connectivity
Lighting System:
Halogen headlamps. Manual details bulb types and replacement procedures.
๐Ÿ”ง Maintenance
Service Intervals
Oil Change Interval Petrol:
Typically every 5,000 - 10,000 km or 6-12 months (refer to manual for specific interval based on driving conditions).
Oil Change Interval Diesel:
Typically every 5,000 - 10,000 km or 6-12 months (refer to manual for specific interval based on driving conditions).
Timing Belt Replacement 6G72:
Crucial maintenance item. Recommended replacement interval is typically 90,000 - 100,000 km or 5-7 years. Failure can cause catastrophic engine damage.
Transmission Fluid Interval:
Every 40,000 - 60,000 km or as per manual recommendations, especially under heavy use or towing.
Fluid Specifications
Engine Oil Grade 6G72:
API SJ or higher, viscosity SAE 10W-30 or 10W-40 recommended. Check manual for exact specifications.
Engine Oil Grade 4D56 Td:
API CF-4 or CH-4, viscosity SAE 15W-40 or 10W-30 recommended. Check manual for exact specifications.
Coolant Type:
Ethylene Glycol based coolant, typically a 50/50 mix with distilled water. Green or Pink coolant types may be specified. Consult manual for correct type and capacity.
Known Issues
Common Wear Items:
Suspension components (bushings, ball joints, tie rods), exhaust system, clutch wear (manual transmission), radiator and cooling system components, glow plugs (diesel).
Common Issues
Engine Specific Concerns:
For 6G72: potential for oil leaks, intake manifold gaskets. For 4D56 TD: turbocharger health is critical, potential for injector issues.
๐Ÿ“š Vehicle History
Brand Heritage
Mitsubishi SUV Legacy:
Leverages Mitsubishi's long history in producing capable off-road vehicles, building upon the Pajero (Montero) lineage.
Model Evolution
Pajero Sport Introduction:
Launched as a more affordable and slightly less rugged alternative to the flagship Pajero, targeting families and adventurers. Often based on a shorter-wheelbase Pajero platform.
Production
Manufacturing Locations:
Primarily produced in Japan, with potential assembly in other global locations.
๐Ÿ† Awards & Recognition
Recognitions
Segment Popularity:
Popular in markets valuing ruggedness and off-road capability for recreational and utilitarian purposes. Specific awards are less common for this model compared to luxury SUVs.

Delivery & file format

This is a digital PDF download, not a printed book. After payment the download link appears on your order confirmation page and is emailed to the address you entered. Files open in any PDF reader on phone, tablet or computer and can be printed.

Check the model year and engine before you buy

Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.

View full details
  • Instant download Link on the order page and in your inbox within a minute.
  • Secure checkout Encrypted Shopify payments โ€” card, PayPal, Apple Pay, Google Pay.
  • Print-ready PDF Searchable text; print only the pages you take to the bench.
  • Coverage check Not sure it fits? Send the model and VIN before you buy.