🏷️ Basic Information Identification Make: Mitsubishi Model: Challenger Year: 2004 Platform: Second Generation (Pajero Sport/Montero Sport) Codes Chassis Code: K90 series (specifically K94W/K96W depending on engine/drivetrain) 👋 Introduction Market Position Target Audience: Owners, DIY enthusiasts, Independent Repair Shops seeking comprehensive factory repair data for the 2004 Mitsubishi Challenger. Competitive Analysis Manual Uniqueness: Actual genuine factory service manual, not a third-party aftermarket guide. Provides the same information as authorized service centers. Key Features User Experience: Easy to navigate with numbered instructions, notes, cautions, warnings, and detailed illustrations/diagrams. Searchable functionality within the PDF. Value Proposition Cost Savings: Enables owners to perform servicing and repairs themselves, potentially saving $50-$60 per hour in labor costs. 📋 Manual Details Coverage Areas Manual Scope: Complete factory service and repair coverage for all styles of the 2004 Mitsubishi Challenger. Page Count Estimated Page Count: Hundreds of pages (actual count not specified, but implies comprehensive) Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format File Format: PDF (Downloadable) 📖 Manual Coverage Systems Covered Powertrain: Engine, Transmission, Differential, Drive Axles Chassis And Suspension: Brake System, Suspension, Steering, Chassis/Body Electrical System, Wiring Diagrams, Heater/Air Conditioning, Restraint System, Interior: electrical_and_comfort Engine And Emissions: Engine Service/Repair, Cooling System, Fuel Injection/Fuel System, Emission System, Engine Control System Body And Interior: Includes body panel removal/installation, interior trim, seats, dashboard, and related components. Also covers chassis and frame inspection/repair. Brake System Details: Detailed procedures for brake pad replacement, caliper service, rotor resurfacing/replacement, brake fluid bleeding, and ABS system diagnostics. Cooling System Service: Covers radiator, coolant hoses, water pump, thermostat, and cooling fan diagnostics and replacement procedures. Fuel System Diagnostics: Includes fuel pump testing, fuel injector cleaning/replacement, fuel filter replacement, and fuel pressure checks. HVAC Service: Covers refrigerant system, compressor, condenser, evaporator, heater core, and blower motor diagnostics and repair. Suspension And Steering Repair: Detailed instructions for servicing control arms, shock absorbers, struts, steering rack, power steering pump, and tie rods. Procedures Included Maintenance: General Maintenance, Periodic Lubrication, Scheduled Servicing Diagnostics And Repair: Troubleshooting, Step-by-step repair procedures, Advanced troubleshooting guide Component Rebuilding: Engine Rebuild, Transmission Rebuild, Component Overhaul Wiring Diagrams: Comprehensive wiring diagrams for all electrical systems, including engine control, lighting, power accessories, and chassis electronics, facilitating electrical troubleshooting. Wheel Alignment And Tires: Covers wheel alignment specifications (camber, caster, toe), tire pressure recommendations, and balancing/rotation procedures. Troubleshooting Guides: Systematic troubleshooting flowcharts and guides for common and complex issues across all vehicle systems. Technical Depth Depth Of Coverage: Factory-level technical information, covering fundamentals to advanced diagnostics and repair procedures. Comparable to information used by professional technicians. Illustrations And Diagrams: Contains numerous detailed illustrations, diagrams, and photographic aids to visually guide users through each procedure. Specifications And Tolerances: Provides critical torque specifications, measurements, clearances, and diagnostic parameters for accurate repairs. 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: Fully printable without restriction; individual pages or entire manual. High resolution. Binding Type Binding Method: N/A (Digital PDF download) Paper Type Paper Quality: N/A (Digital PDF download) Software Requirements Reader Requirement: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Options 2004: Likely to include the 6G72 3.0L V6 SOHC MPI and potentially the 4D56T 2.5L 4-cylinder Turbo-Diesel (depending on market). Detailed specifications for each engine variant covered. Performance Engine Performance Data: Includes horsepower, torque figures, and power delivery characteristics for applicable engines. Fuel System Fuel System Type: Multi-Point Fuel Injection (MPI) for gasoline engines, likely Direct Injection or Indirect Injection for diesel variants. Covers fuel pump, injectors, pressure regulation, and sensors. Engine Management ECU And Sensors: Covers Engine Control Unit (ECU) operation, sensor data (MAP, MAF, TPS, O2, Crankshaft/Camshaft Position), ignition timing, and emission control systems. 🔧 Transmission Standard Transmission Type Standard: Likely a 5-speed manual or 4-speed automatic transmission (depending on engine and trim). Optional Transmission Type Optional: May include a Super Select 4WD system with an automatic transmission or a more basic 2WD setup. Features Transmission Features: Covers gear ratios, clutch operation (manual), torque converter function (automatic), shift control, and transmission fluid specifications. 📐 Dimensions Exterior Body Styles: Primarily a 5-door SUV. Specific exterior dimensions (length, width, height) may vary slightly by market or trim but are comprehensively detailed in the manual. Weights Curb Weight Range: Typical curb weights range from approximately 1800 kg to 2100 kg, depending on engine, drivetrain, and equipment. Manual will provide exact figures. Gross Vehicle Weight Rating: GVWR specifications for payload capacity will be detailed. 🛡️ Safety Features Ratings Crash Test Data: While specific official ratings (like NHTSA/Euro NCAP) for the 2004 model may not be in the manual itself, the manual details all safety-critical systems like airbags, seatbelt pre-tensioners, and ABS. Active Features Active Safety Systems: Anti-lock Braking System (ABS), Electronic Brakeforce Distribution (EBD) if equipped. Passive Features Passive Safety Systems: Front airbags, potentially side airbags, seatbelt pretensioners, and reinforced body structure components. 💡 Technology...