Mitsubushi OUTLAndER 2003-2008 Full Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Outlander Generation: First Generation Model Years Covered: 2003, 2004, 2005, 2006, 2007, 2008 Codes Chassis Code: CU_W 👋 Introduction Market Position Segment: Compact Crossover SUV Target Audience: Families, individuals seeking a versatile and practical vehicle for urban and light off-road use Competitive Analysis Key Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Subaru Forester Key Features Versatility: Practicality of an SUV with a more car-like driving experience AWD Option: Availability of Mitsubishi's AWC (All-Wheel Control) system for enhanced traction and stability Design: Distinctive styling, comfortable interior with good passenger space 📋 Manual Details Coverage Areas Content Scope: Comprehensive service, maintenance, and repair for all vehicle systems Page Count Estimated Pages: Over 2000 (typical for comprehensive service manuals of this era) Manual Type Type: Full Service and Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, crankshaft, pistons, connecting rods, timing system (belt/chain), lubrication, cooling, fuel delivery, emission controls Engine Electrical: Ignition system, starting system, charging system, fuel injection system, engine control module (ECM/ECU) diagnostics and wiring diagrams Transmission Manual: Clutch, gearbox assembly, internal components, shift mechanism, lubrication Transmission Automatic: Automatic transmission assembly, valve body, torque converter, planetary gear sets, hydraulic control, electronic controls, cooling, fluid specifications Drivetrain: Front-wheel drive (FWD) and All-Wheel Drive (AWD) systems, driveshafts, CV joints, differentials, transfer case (if applicable) Brakes: Front and rear brake systems (disc/drum), ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), hydraulic circuits, parking brake Suspension: Front suspension (MacPherson strut, control arms), rear suspension (multi-link, trailing arm), shock absorbers, springs, bushings, alignment specifications Steering: Power steering system (hydraulic), steering rack, tie rods, steering column, linkage Electrical Body: Lighting system (headlights, taillights, interior), power windows, power door locks, mirrors, wipers, horn, central locking, fuse box diagrams, relays Climate Control: HVAC (Heating, Ventilation, and Air Conditioning) system, refrigerant, compressor, condenser, evaporator, blower motor, climate control panel Body Exterior: Body panels, doors, hood, tailgate, bumpers, glass, seals, trim, chassis structure Body Interior: Dashboard, seats, upholstery, airbags, seat belts, interior trim, sound insulation Diagnostics: On-Board Diagnostics (OBD-II) system, diagnostic trouble codes (DTCs), scan tool procedures, troubleshooting flowcharts Procedures Included Routine Maintenance: Oil changes, filter replacements, fluid checks and top-offs, tire rotations, brake inspections, spark plug replacement Major Repairs: Engine overhaul, transmission rebuild, suspension component replacement, brake caliper replacement, exhaust system repair Troubleshooting: Systematic diagnostic procedures for common and complex issues, fault finding guides Wiring Diagrams: Detailed electrical system wiring schematics for all major components and circuits Special Tools: Identification and usage of any specialized tools required for specific repair procedures Technical Depth Depth: Full vehicle disassembly and reassembly procedures, component specifications, torque values, clearances, diagnostic parameters 📊 Manual Specifications File Format Format Details: PDF (Portable Document Format) Print Quality Printability: Fully printable, allowing users to print specific pages or the entire manual Binding Type Binding: Digital (N/A for PDF, but printable for physical binding) Paper Type Paper Quality: N/A (Digital format, but designed for clear printing on standard paper) Features Searchability: Searchable text within the PDF document for quick information retrieval Zoom Capability: Zoom IN/OUT functionality for detailed examination of diagrams and text Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader, WinZip (for potential archive extraction if applicable) Compatibility Operating Systems: Compatible with all versions of Windows and Mac ⚙️ Engine Specifications Primary Engine Engine Code 2 4L: 4G64 (2.4L SOHC Inline-4) Displacement 2 4L: 2351 cc (2.4 Liters) Bore X Stroke 2 4L: 86.5 mm x 100.0 mm Compression Ratio 2 4L: 9.0:1 Horsepower 2 4L Approx: 140-145 hp @ 5500-5700 rpm Torque 2 4L Approx: 145-150 lb-ft @ 3500-4000 rpm Engine Code 3 0L V6: 6G72 (3.0L SOHC V6 - available in later models/markets) Displacement 3 0L V6: 2972 cc (3.0 Liters) Horsepower 3 0L V6 Approx: 165-200 hp (depending on market and specific engine variant) Torque 3 0L V6 Approx: 180-200 lb-ft (depending on market and specific engine variant) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Recommended Octane: 87 Octane (Minimum) 🔧 Transmission Standard Transmission Type Std: 4-speed Automatic Transmission (FWD) Optional Transmission Type Opt: 5-speed Manual Transmission (FWD, typically for 2.4L models) Transmission Type AWD: 4-speed Automatic Transmission with AWC (All-Wheel Control) System (available for AWD models) Features Awc System: Active All-Wheel Control system with selectable modes (e.g., 2WD, 4WD Auto, 4WD Lock) 📐 Dimensions Exterior Length Approx: 4535-4570 mm (178.5-179.9 inches) Width Approx: 1780-1800 mm (70.1-70.9 inches) Height Approx: 1655-1670 mm (65.2-65.7 inches) Wheelbase Approx: 2625 mm (103.3 inches) Weights Curb Weight Approx: 1480-1650 kg (3260-3640 lbs) - varies by drivetrain and trim Cargo Cargo Volume Approx: Around 30-35 cubic feet (behind rear seats), expandable with seats folded 🛡️ Safety Features Ratings NHTSA Front Driver Side: 5-Star (for models equipped with side airbags) NHTSA Front...
Systematic diagnostic procedures for common and complex issues, fault finding guides
Wiring Diagrams:
Detailed electrical system wiring schematics for all major components and circuits
Special Tools:
Identification and usage of any specialized tools required for specific repair procedures
Technical Depth
Depth:
Full vehicle disassembly and reassembly procedures, component specifications, torque values, clearances, diagnostic parameters
📊 Manual Specifications
File Format
Format Details:
PDF (Portable Document Format)
Print Quality
Printability:
Fully printable, allowing users to print specific pages or the entire manual
Binding Type
Binding:
Digital (N/A for PDF, but printable for physical binding)
Paper Type
Paper Quality:
N/A (Digital format, but designed for clear printing on standard paper)
Features
Searchability:
Searchable text within the PDF document for quick information retrieval
Zoom Capability:
Zoom IN/OUT functionality for detailed examination of diagrams and text
Delivery
Delivery Method:
Instant Download
Requirements
Software Requirements:
Adobe PDF Reader, WinZip (for potential archive extraction if applicable)
Compatibility
Operating Systems:
Compatible with all versions of Windows and Mac
⚙️ Engine Specifications
Primary Engine
Engine Code 2 4L:
4G64 (2.4L SOHC Inline-4)
Displacement 2 4L:
2351 cc (2.4 Liters)
Bore X Stroke 2 4L:
86.5 mm x 100.0 mm
Compression Ratio 2 4L:
9.0:1
Horsepower 2 4L Approx:
140-145 hp @ 5500-5700 rpm
Torque 2 4L Approx:
145-150 lb-ft @ 3500-4000 rpm
Engine Code 3 0L V6:
6G72 (3.0L SOHC V6 - available in later models/markets)
Displacement 3 0L V6:
2972 cc (3.0 Liters)
Horsepower 3 0L V6 Approx:
165-200 hp (depending on market and specific engine variant)
Torque 3 0L V6 Approx:
180-200 lb-ft (depending on market and specific engine variant)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Recommended Octane:
87 Octane (Minimum)
🔧 Transmission
Standard
Transmission Type Std:
4-speed Automatic Transmission (FWD)
Optional
Transmission Type Opt:
5-speed Manual Transmission (FWD, typically for 2.4L models)
Transmission Type AWD:
4-speed Automatic Transmission with AWC (All-Wheel Control) System (available for AWD models)
Features
Awc System:
Active All-Wheel Control system with selectable modes (e.g., 2WD, 4WD Auto, 4WD Lock)
📐 Dimensions
Exterior
Length Approx:
4535-4570 mm (178.5-179.9 inches)
Width Approx:
1780-1800 mm (70.1-70.9 inches)
Height Approx:
1655-1670 mm (65.2-65.7 inches)
Wheelbase Approx:
2625 mm (103.3 inches)
Weights
Curb Weight Approx:
1480-1650 kg (3260-3640 lbs) - varies by drivetrain and trim
Cargo
Cargo Volume Approx:
Around 30-35 cubic feet (behind rear seats), expandable with seats folded
🛡️ Safety Features
Ratings
NHTSA Front Driver Side:
5-Star (for models equipped with side airbags)
NHTSA Front Passenger Side:
5-Star (for models equipped with side airbags)
IIHS Side Impact:
Good (for models with side airbags)
Active Features
ABS:
Standard Anti-lock Braking System
Ebd:
Standard Electronic Brakeforce Distribution
Traction Control:
Optional Traction Control System (TCS) depending on trim and drivetrain
Passive Features
Airbags Std:
Front airbags
Airbags Opt:
Optional front side-impact airbags and side curtain airbags
Seatbelts:
3-point seat belts with pretensioners and load limiters
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD player, optional premium audio with subwoofer, satellite radio capability on some trims.
Display:
Basic digital display for climate and audio, no advanced infotainment screens in early models.
Driver Assistance
Cruise Control:
Standard on most trims.
Keyless Entry:
Available on higher trim levels.
Connectivity
Auxiliary Input:
Rare for this era, generally not equipped with standard aux inputs.
Bluetooth:
Not available from the factory for this model year range.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 7,500 miles or 6 months, whichever comes first (using synthetic blend or full synthetic oil)
Engine Oil Filter:
Replace with engine oil change
Engine Air Filter:
Inspect every 15,000 miles, replace as needed or every 30,000 miles
Cabin Air Filter:
Inspect every 15,000 miles, replace as needed or every 20,000 miles
Spark Plugs:
Replace every 60,000 - 100,000 miles (depending on plug type specified - platinum or iridium)
Timing Belt:
Crucial: Inspect and replace every 60,000 to 90,000 miles or 5-7 years for the 4G64 engine. Failure can cause catastrophic engine damage. The manual will specify exact interval and potential replacement of tensioner/water pump.
Fluid Specifications
Engine Oil:
SAE 5W-30 or 5W-40 (API SJ or higher classification)
Engine Coolant:
Mitsubishi DiaQueen Super Long Life Coolant (SLLC) or equivalent (ethylene glycol based, 50/50 mix with distilled water)
Transmission Fluid Auto:
Mitsubishi DiaQueen ATF-J2 or equivalent (specific to the transmission)
Transmission Fluid Manual:
API GL-4 SAE 75W-85 or 75W-90 gear oil
Power Steering Fluid:
Dexron III/Mercon ATF or equivalent
Brake Fluid:
DOT 3 or DOT 4 brake fluid
Differential Fluid AWD:
API GL-5 SAE 75W-90 hypoid gear oil (for center differential/transfer case if applicable)
Known Issues
Timing Belt Failure:
A known risk if not replaced at recommended intervals, leading to severe engine damage.
Suspension Wear:
Front control arm bushings and rear suspension bushings can wear over time, leading to clunking noises and alignment issues.
Power Steering Leaks:
Some owners have reported leaks from the power steering pump or hoses.
ABS/Traction Control Lamp:
Intermittent illumination of ABS or traction control warning lights can be due to faulty wheel speed sensors.
HVAC Blower Motor:
Blower motor failure or intermittent operation can occur.
📚 Vehicle History
Brand Heritage
Manufacturer:
Mitsubishi Motors Corporation (MMC)
Model Evolution
Introduction:
The first generation Outlander was launched in Japan in 2001 and globally in 2003 as Mitsubishi's entry into the compact SUV segment.
Platform:
Built on the Mitsubishi GS platform, shared with other Mitsubishi and related Chrysler/Dodge/Plymouth models of the era.
Facelift:
A significant facelift occurred for the 2007 model year, introducing updated styling, interior refinements, and enhanced features.
Production
Manufacturing Location:
Primarily produced at Mitsubishi's plant in Mizushima, Japan.
🏆 Awards & Recognition
Recognitions
IIHS Top Safety Pick:
Achieved 'Good' ratings in IIHS front and side impact tests for models equipped with side airbags, contributing to its safety reputation.
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