Mitsubishi Outlander 2004 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Outlander Year: 2004 Codes Chassis Code: CU2W Generation: First Generation (2001-2006) 👋 Introduction Market Position Segment: Compact Crossover SUV Positioning: Offered as a practical, versatile, and often value-oriented option in the growing SUV market. Competitive Analysis Key Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Subaru Forester. Key Features Utility: Practical cargo space, available all-wheel drive (AWD) for enhanced traction in various conditions. Versatility: Suitable for daily commuting, family hauling, and light off-road use. 📋 Manual Details Coverage Areas Primary Coverage: North America Secondary Coverage: Global markets with similar specifications Page Count Estimated Page Count: Approx. 2000-2500 pages (typical for comprehensive factory service manuals) Manual Type Type: Factory Service Repair Manual Language Language: English Format Format: Likely PDF or Digital Format (as per typical modern sales) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, engine electrical systems. Drivetrain: Transmission (automatic & manual), transfer case (if applicable), drive shafts, differentials, axles, wheel hub assemblies. Chassis: Suspension systems (front and rear), steering system, brake system (hydraulic, ABS, parking brake), wheels, tires. Body And Interior: Body construction, exterior panels, doors, glass, seats, interior trim, HVAC system, SRS (airbag) system. Electrical And Electronics: Battery, charging system, starting system, lighting system, wipers, horn, power accessories (windows, mirrors, locks), instrument cluster, audio system, wiring diagrams. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, component inspections. Diagnostics: Troubleshooting guides, symptom-based diagnostics, DTC (Diagnostic Trouble Code) explanations and procedures. Repair: Component removal, disassembly, reassembly, installation, adjustment procedures for all major systems. Technical Specifications: Torque specifications, clearances, tolerances, component measurements, fluid capacities, electrical values. Technical Depth Depth: Comprehensive from basic adjustments and fluid checks to complete engine and transmission rebuilds, including electrical system troubleshooting and wiring diagrams. 📊 Manual Specifications File Format Digital Format Features: Searchable text, hyperlinked sections, zoomable diagrams, printable pages. Print Quality Print Quality: High-resolution diagrams and text, designed for clarity during repairs. Binding Type Binding: Spiral-bound or perfect-bound (if printed), allowing pages to lay flat for easier use in a workshop. Paper Type Paper Quality: Durable, often coated paper to withstand workshop environments. ⚙️ Engine Specifications Primary Engine Engine Code And Type: 4G63 (2.4L SOHC Inline-4) - This engine family is well-regarded for its durability, though variants differ. Displacement: 2351 cc (2.4 Liters) Performance Horsepower: Approximately 140-148 hp @ 5500-5750 RPM (depending on market and specific tuning) Torque: Approximately 145-150 lb-ft @ 3500-4000 RPM (depending on market and specific tuning) Fuel System Induction: Electronic Fuel Injection (EFI) with multi-point injection (MPI) Fuel Type: Unleaded Gasoline Other Engines Optional Engine: For some markets, a 3.0L V6 (6G72) engine was also available, offering higher performance. 🔧 Transmission Standard Transmission Type: 4-speed Automatic Transmission (INVECS-II) Optional Transmission Type: 5-speed Manual Transmission (for some variants/markets) Features AWD System: Available on many models, often featuring Mitsubishi's 'Active-Sport' or similar electronically controlled AWD system for optimized traction and handling. 📐 Dimensions Exterior Length: Approx. 4545 mm (179.0 in) Width: Approx. 1775 mm (69.9 in) Height: Approx. 1660 mm (65.4 in) Wheelbase: Approx. 2630 mm (103.5 in) Weights Curb Weight: Approx. 1500-1650 kg (3307-3638 lbs) depending on configuration 🛡️ Safety Features Ratings NHTSA Front Crash Test: Likely 4-star rating for driver and front passenger (typical for vehicles of this era and class) IIHS Side Impact Test: Likely Acceptable or Good rating (as per IIHS testing during this period) Active Features ABS: Anti-lock Braking System (ABS) - standard on most trims Traction Control: Electronic Traction Control System (TCS) - often paired with AWD systems Passive Features Airbags: Front dual-stage airbags, side-impact airbags (optional on some trims), available curtain airbags. Seatbelts: 3-point seatbelts with pretensioners and load limiters for front occupants. 💡 Technology Features Infotainment Audio System: Standard AM/FM/CD audio system, with optional premium Rockford Fosgate audio system available on higher trims. Auxiliary input or satellite radio may be options. Navigation: Optional factory-installed GPS navigation system was available. Driver Assistance Cruise Control: Standard cruise control for highway driving. Connectivity Power Accessories: Power windows, power door locks, power side mirrors were standard or optional depending on trim level. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 miles (8,000 km) or 6 months, whichever comes first (typical for this era, check manual for specific conditions). Major Service Interval: Timing belt replacement typically at 60,000-90,000 miles (96,000-145,000 km) for the 4G63 engine (crucial to verify in manual). Fluid Specifications Engine Oil Type: SAE 5W-30 API SG or higher (consult manual for precise specification and capacity). Transmission Fluid Automatic: DIA QUEEN ATF-SPII or equivalent (specific for Mitsubishi transmissions, consult manual). Coolant: Mitsubishi Super Long Life Coolant (LLC) Green or equivalent Ethylene Glycol based, 50/50 mix with distilled water. Known Issues Engine Mounts: Premature wear of engine and transmission mounts can lead to increased vibration and noise. Cv Axles:...
Comprehensive from basic adjustments and fluid checks to complete engine and transmission rebuilds, including electrical system troubleshooting and wiring diagrams.
High-resolution diagrams and text, designed for clarity during repairs.
Binding Type
Binding:
Spiral-bound or perfect-bound (if printed), allowing pages to lay flat for easier use in a workshop.
Paper Type
Paper Quality:
Durable, often coated paper to withstand workshop environments.
⚙️ Engine Specifications
Primary Engine
Engine Code And Type:
4G63 (2.4L SOHC Inline-4) - This engine family is well-regarded for its durability, though variants differ.
Displacement:
2351 cc (2.4 Liters)
Performance
Horsepower:
Approximately 140-148 hp @ 5500-5750 RPM (depending on market and specific tuning)
Torque:
Approximately 145-150 lb-ft @ 3500-4000 RPM (depending on market and specific tuning)
Fuel System
Induction:
Electronic Fuel Injection (EFI) with multi-point injection (MPI)
Fuel Type:
Unleaded Gasoline
Other Engines
Optional Engine:
For some markets, a 3.0L V6 (6G72) engine was also available, offering higher performance.
🔧 Transmission
Standard
Transmission Type:
4-speed Automatic Transmission (INVECS-II)
Optional
Transmission Type:
5-speed Manual Transmission (for some variants/markets)
Features
AWD System:
Available on many models, often featuring Mitsubishi's 'Active-Sport' or similar electronically controlled AWD system for optimized traction and handling.
📐 Dimensions
Exterior
Length:
Approx. 4545 mm (179.0 in)
Width:
Approx. 1775 mm (69.9 in)
Height:
Approx. 1660 mm (65.4 in)
Wheelbase:
Approx. 2630 mm (103.5 in)
Weights
Curb Weight:
Approx. 1500-1650 kg (3307-3638 lbs) depending on configuration
🛡️ Safety Features
Ratings
NHTSA Front Crash Test:
Likely 4-star rating for driver and front passenger (typical for vehicles of this era and class)
IIHS Side Impact Test:
Likely Acceptable or Good rating (as per IIHS testing during this period)
Active Features
ABS:
Anti-lock Braking System (ABS) - standard on most trims
Traction Control:
Electronic Traction Control System (TCS) - often paired with AWD systems
Passive Features
Airbags:
Front dual-stage airbags, side-impact airbags (optional on some trims), available curtain airbags.
Seatbelts:
3-point seatbelts with pretensioners and load limiters for front occupants.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD audio system, with optional premium Rockford Fosgate audio system available on higher trims. Auxiliary input or satellite radio may be options.
Navigation:
Optional factory-installed GPS navigation system was available.
Driver Assistance
Cruise Control:
Standard cruise control for highway driving.
Connectivity
Power Accessories:
Power windows, power door locks, power side mirrors were standard or optional depending on trim level.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 miles (8,000 km) or 6 months, whichever comes first (typical for this era, check manual for specific conditions).
Major Service Interval:
Timing belt replacement typically at 60,000-90,000 miles (96,000-145,000 km) for the 4G63 engine (crucial to verify in manual).
Fluid Specifications
Engine Oil Type:
SAE 5W-30 API SG or higher (consult manual for precise specification and capacity).
Transmission Fluid Automatic:
DIA QUEEN ATF-SPII or equivalent (specific for Mitsubishi transmissions, consult manual).
Coolant:
Mitsubishi Super Long Life Coolant (LLC) Green or equivalent Ethylene Glycol based, 50/50 mix with distilled water.
Known Issues
Engine Mounts:
Premature wear of engine and transmission mounts can lead to increased vibration and noise.
Cv Axles:
Wear on front Constant Velocity (CV) joints and boots, especially if abused or neglected, can lead to clicking noises during turns.
Exhaust System:
Corrosion and leaks in the exhaust system, particularly in rust-prone climates.
Automatic Transmission:
Occasional issues with shifting harshness or delayed engagement, often resolvable with fluid changes and adaptations.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors:
Mitsubishi Motors Corporation has a long history of automotive manufacturing, known for robust engineering and rally-inspired performance in some models.
Model Evolution
First Generation Launch:
The first generation Outlander debuted globally in 2001 as the Mitsubishi Airtrek in Japan, rebadged as Outlander for export markets in 2003 for the 2004 model year.
Platform:
Built on Mitsubishi's GS platform, shared with models like the Lancer and Grandis.
Production
Manufacturing Locations:
Primarily manufactured in Japan.
🏆 Awards & Recognition
Recognitions
Segment Performance:
While not a recipient of major individual awards, the Outlander 2004 was recognized for its competitive value and practicality within the compact SUV segment.
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