1998-2006 Mitsubishi Challenger Service and Repair Manual

This 1998–2006 Mitsubishi Challenger Service & Repair Manual Covers

Engine & Drivetrain

• 2.4L 4G64 SOHC petrol engine
• 3.0L 6G72 SOHC V6 petrol engine
• 3.5L 6G74 DOHC V6 petrol engine
• 2.8L 4M40 Turbo Diesel engine
• Multi-Point Fuel Injection (MPI) diagnostics
• Electronic diesel fuel injection diagnostics
• Turbocharger servicing (4M40)
• Engine cooling and lubrication system repairs
• Timing belt inspection and replacement procedures
• Fuel delivery and emissions control system servicing
• Exhaust system repairs
• 5-speed manual transmission servicing
• INVECS-II 4-speed automatic transmission servicing
• Easy Select 4WD system diagnostics
• Super Select 4WD system servicing (where equipped)
• Transfer case overhaul and adjustments
• Front and rear differential servicing
• Front axle, CV joint, and driveshaft repairs

Suspension & Steering

• Independent front suspension servicing
• Rear live axle with coil spring suspension
• Torsion bar adjustment procedures (where applicable)
• Recirculating ball power steering system diagnostics
• Steering gearbox servicing
• Wheel hub and bearing replacement
• Suspension bush, ball joint, and control arm servicing
• Wheel alignment specifications

Braking Systems

• Anti-lock Braking System (ABS)
• Front disc brake servicing
• Rear drum or rear disc brake servicing (model dependent)
• Brake master cylinder overhaul
• Brake booster diagnostics
• Parking brake adjustment
• Hydraulic brake system bleeding procedures

Electrical & Wiring

• Complete factory wiring diagrams
• Mitsubishi MUT-II and MUT-III diagnostic procedures
• Engine Control Module (ECM) diagnostics
• Automatic Transmission Control Module diagnostics
• ABS control module diagnostics
• Charging and starting system repairs
• Glow plug system diagnostics (diesel models)
• Fuse, relay, and power distribution diagrams
• Exterior and interior lighting diagnostics
• Instrument cluster servicing
• Power window, mirror, and central locking diagnostics

Air Conditioning & HVAC

• Manual and automatic climate control systems
• Air conditioning compressor servicing
• Refrigerant recovery and recharge procedures
• HVAC control system diagnostics
• Heater core replacement
• Blend door and blower motor servicing

Body & Interior

• Power windows, door locks, and mirrors
• Central locking system servicing
• Airbag (SRS) system diagnostics
• Seat and seatbelt repairs
• Dashboard and instrument panel removal
• Interior trim servicing
• Tailgate and rear door adjustments
• Roof rack servicing
• Exterior body repair procedures

Diagnostics & Troubleshooting

• Mitsubishi MUT-II and MUT-III diagnostic procedures
• Diagnostic Trouble Code (DTC) troubleshooting
• ECU testing and replacement procedures
• Electrical circuit testing
• Sensor and actuator diagnostics
• Component activation procedures
• Factory maintenance schedules
• Complete factory service specifications

Common Error Codes Covered

This manual provides diagnostic and repair procedures for common Mitsubishi Diagnostic Trouble Codes (DTCs), including:

Engine Codes

• P0100 – Mass Air Flow (MAF) Sensor Circuit Malfunction
• P0115 – Engine Coolant Temperature Sensor Circuit
• P0120 – Throttle Position Sensor Circuit Malfunction
• P0170 – Fuel Trim Malfunction
• P0300 – Random/Multiple Cylinder Misfire Detected
• P0335 – Crankshaft Position Sensor Circuit Malfunction
• P0400 – Exhaust Gas Recirculation Flow Malfunction
• P0505 – Idle Air Control System Malfunction

Transmission & Drivetrain Codes

• P0700 – Automatic Transmission Control System Malfunction
• P0715 – Input/Turbine Speed Sensor Circuit
• P0733 – Incorrect Third Gear Ratio
• P1766 – Transfer Case Position Switch Fault

ABS & Chassis Codes

• C1000 – ABS Electronic Control Unit Fault
• C1210 – Wheel Speed Sensor Circuit Malfunction
• C1215 – Hydraulic Unit Fault
• C1235 – Rear Wheel Speed Sensor Fault

Body & Electrical Codes

• B1206 – Ignition Switch Circuit Malfunction
• B1610 – Immobilizer Communication Fault
• U1100 – CAN Bus Communication Error
• U1111 – ECM Communication Fault

The manual also includes hundreds of additional Mitsubishi-specific diagnostic trouble codes, complete electrical wiring diagrams, troubleshooting flowcharts, MUT-II/MUT-III diagnostic procedures, ECU testing, and factory repair specifications.

Who Is This Manual For?

• Mitsubishi dealership technicians
• Independent repair workshops
• Fleet maintenance professionals
• Off-road and 4WD specialists
• Mitsubishi Challenger owners
• Experienced DIY mechanics

If you are servicing, maintaining, diagnosing, or repairing a 1998–2006 Mitsubishi Challenger, this factory workshop manual provides the complete procedures and technical information required to perform repairs to Mitsubishi factory standards.