The Mitsubishi Challenger, produced in 2004 as part of the Second Generation (K90 Series), is a mid-size SUV renowned for its robust body-on-frame construction and impressive off-road capability. Building on a heritage of rugged vehicles, this model offers a blend of family practicality and dependable performance, making it a strong competitor in its segment. It was available with reliable V6 gasoline engines, such as the 3.0L (6G72) and 3.5L (6G74), and efficient 2.8L diesel options, often paired with a Super Select 4WD-II system for versatile drivetrain control. Its design prioritizes durability and a commanding presence, suitable for both daily commuting and adventurous excursions. This comprehensive workshop repair service manual provides detailed guidance for all models, engines, trims, and transmission types of the Mitsubishi Challenger. It covers a wide array of essential maintenance and repair procedures, including in-depth engine and transmission servicing, brake system diagnostics, electrical system troubleshooting, and suspension and steering repairs. The manual also details general maintenance, periodic lubrication, disassembly and assembly instructions, and cleaning techniques. With extensive technical information, this resource is an invaluable tool for owners, mechanics, and technicians seeking to maintain, repair, and optimize the performance and longevity of their 2004 Mitsubishi Challenger. 🏷️ Basic Information Identification Make: Mitsubishi Model: Challenger Year: 2004 Generation Generation: Second Generation (K90 Series) Codes Chassis Code: K90 Series 👋 Introduction Market Position Segment: Mid-size SUV (Sport Utility Vehicle) / Off-road capable Competitive Analysis Competitors 2004: Jeep Cherokee (KJ), Toyota 4Runner, Nissan Pathfinder, Ford Explorer, Land Rover Discovery Key Features Body Style: Body-on-frame construction, robust chassis for off-road capability Drivetrain: Available in 2WD and 4WD (Super Select 4WD-II) Powertrain Options: Known for reliable V6 gasoline and diesel engines, often with excellent torque 📋 Manual Details Coverage Areas Coverage: All Models, Engines, Trim, and Transmission Types Page Count Estimated Page Count: Hundreds of pages (specific number not provided, but described as extensive) Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Service Repair: Detailed procedures for engine overhaul, disassembly, assembly, and diagnostics. Transmission Service Repair: Comprehensive information on automatic and manual transmission servicing, repair, and diagnostics. Brake System: Maintenance, repair, and troubleshooting of brake components including ABS. Electrical System: Diagnosis and repair of all electrical circuits, components, and wiring. Suspension: Service and repair for front and rear suspension components, alignment. Steering: Maintenance and repair of the power steering system and steering linkage. Cooling System: Repair and maintenance of the radiator, thermostat, water pump, and cooling fans. Fuel Injection Fuel System: Diagnosis and service for fuel delivery, injectors, fuel pump, and fuel lines. Emission System: Information on emission control devices and troubleshooting. Heater Air Conditioner: Service and repair for the HVAC system, including refrigerant handling. Engine Control System: Detailed diagnostics and troubleshooting for the Engine Control Unit (ECU) and sensors. Chassis Body: Body panel repair, frame straightening, and chassis component servicing. Restraint System: Information on airbags and seatbelt systems. Interior: Service and repair for interior trim, seats, and dashboard components. Differential Drive: Maintenance and repair of front and rear differentials and drive shafts. Axle: Service and repair of front and rear axles and CV joints. Wiring Diagram: Complete and detailed wiring schematics for all vehicle systems. Procedures Included General Maintenance: Routine checks, fluid changes, filter replacements, and preventative care. Troubleshooting: Systematic diagnostic procedures for identifying and resolving common and complex issues. Periodic Lubrication: Specific lubrication points and recommended lubricants for various components. Disassembly Assembly: Step-by-step instructions for removing and reinstalling vehicle components. Cleaning Reinstalling: Guidelines for cleaning parts and proper reassembly techniques. Technical Depth Depth: Comprehensive: Covers everything from basic maintenance to complete engine and transmission rebuilds, including advanced electrical diagnostics. 📊 Manual Specifications File Format File Format: PDF Print Quality Printability: Full Printable Zoom Functionality Zoom: Zoom IN/OUT Enabled Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader & WinZip Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Options: Commonly featured 3.0L V6 (6G72), 3.5L V6 (6G74) gasoline engines, and 2.8L 4M40/4M41 diesel engines. Performance Horsepower Torque 3 0L V6: Approx. 173-181 hp / 255-270 Nm (specific figures vary by market and tune) Horsepower Torque 3 5L V6: Approx. 200-225 hp / 300-343 Nm (specific figures vary by market and tune) Horsepower Torque 2 8L Diesel: Approx. 125-140 hp / 280-314 Nm (specific figures vary by market and tune) Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) for gasoline engines, Direct Injection for diesel engines 🔧 Transmission Standard Transmission Options: Often paired with 4-speed or 5-speed automatic transmissions. A 5-speed manual transmission was also available on some variants. Features Transfer Case: Super Select 4WD-II system (on applicable models) allowing for on-the-fly shifting between 2WD, 4WD High, 4WD Low, and Locked 4WD High. 📐 Dimensions Exterior Length: Approx. 4,690 - 4,740 mm (varies...