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Mitsubushi OUTLAndER Service Repair Manual 2005-2010

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๐Ÿท๏ธ Basic Information Identification Make: Mitsubishi Model: Outlander Generation: Second Generation (CW/ZJ) Codes Chassis Codes: CW5W, CW6W, CW4W ๐Ÿ‘‹ Introduction Market Position Vehicle Segment: Compact Crossover SUV Competitive Analysis Key Competitors: Honda CR-V, Toyota RAV4, Nissan X-Trail (Rogue), Ford Escape, Subaru Forester Key Features Platform Sharing: Built on the Mitsubishi GS platform, shared with the Mitsubishi Lancer and related to the Mitsubishi Outlander XL (PSA Peugeot Citroรซn C-Crosser/Citroรซn C4/Peugeot 4007). Drivetrain Options: Available with front-wheel drive (FWD) and Mitsubishi's AWC (All-Wheel Control) system. ๐Ÿ“‹ Manual Details Coverage Areas Markets Covered: Global (specific to regions and engine variants as outlined in the manual) Page Count Estimated Page Count: Likely 1500+ pages (typical for comprehensive factory service manuals of this era) Manual Type Manual Type: Factory Service Manual / Workshop Repair Manual Language Language: English Format Format: PDF ๐Ÿ“– Manual Coverage Systems Covered Powertrain Components: Engine mechanical, fuel system, exhaust system, cooling system, lubrication system, ignition system, starter system, charging system Drivetrain Components: Clutch, manual transmission, automatic transmission, sub-transmission (if applicable), transfer case, drive shafts, axles, differentials Suspension Steering Brakes: Front suspension, rear suspension, steering system, hydraulic brake system, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution) Electrical Electronics: Battery, charging system, starting system, ignition system, lighting system, instrumentation, switches, power windows, power locks, HVAC controls, audio system, SRS (Supplemental Restraint System) / Airbag system, body control module (BCM) Body Chassis Comfort: Body construction, exterior trim, interior trim, seats, HVAC system, doors, windows, wipers, locks Procedures Included Maintenance Tasks: Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements (oil, air, fuel), spark plug replacement, belt inspection/replacement Diagnostic Procedures: Troubleshooting guides, diagnostic trouble codes (DTCs), wiring diagrams for electrical systems, component testing procedures Repair Rebuild Procedures: Engine removal/installation, cylinder head repair, piston/ring replacement, crankshaft inspection, transmission overhaul, brake caliper overhaul, suspension component replacement, steering rack replacement Adjustment Calibration: Valve lash adjustment, parking brake adjustment, wheel alignment specifications, headlight aiming Technical Depth Depth Of Coverage: Comprehensive: from basic fluid checks and routine maintenance to in-depth component diagnostics, repair, and complete rebuilds of major systems. ๐Ÿ“Š Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, printable pages with clear diagrams and text. Searchable functionality likely present. Binding Type Binding Type: Digital Download (not a physical book) Paper Type Paper Type: Not Applicable (Digital) โš™๏ธ Engine Specifications Primary Engine Engine Displacement And Code: 2.4L 4G69 MIVEC I4 (common in many markets) Engine Horsepower Approx: 160-170 hp @ 6000 rpm (may vary slightly by region) Engine Torque Approx: 162-165 lb-ft @ 4000 rpm (may vary slightly by region) Optional Engine Optional Engine Displacement And Code: 3.0L 6B31 MIVEC V6 (in some markets, particularly North America) Optional Engine Horsepower Approx: 220-230 hp @ 6250 rpm Optional Engine Torque Approx: 200-205 lb-ft @ 3750 rpm Fuel System Fuel Delivery System: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (Octane rating as specified by Mitsubishi) ๐Ÿ”ง Transmission Standard Standard Transmission: 5-speed Manual Transmission (less common in some markets) Optional Optional Transmission: 6-speed INVECS-III Continuously Variable Transmission (CVT) with Paddle Shifters (most common) Optional Transmission V6: 6-speed Automatic Transmission (typically paired with the 3.0L V6) Features Awc System: All-Wheel Control (AWC) system with selectable modes (e.g., Normal, Snow, Lock) for enhanced traction and stability. ๐Ÿ“ Dimensions Exterior Length Approx: 4570 mm (179.9 in) Width Approx: 1800 mm (70.9 in) Height Approx: 1690 mm (66.5 in) (without roof rails) Wheelbase Approx: 2670 mm (105.1 in) Weights Curb Weight Approx: 1550 - 1750 kg (3417 - 3858 lbs) (depending on engine and drivetrain) ๐Ÿ›ก๏ธ Safety Features Ratings NHTSA Ratings: Generally received good ratings, with 4 or 5 stars in frontal and side impact tests in applicable years/regions. IIHS Ratings: Received 'Good' ratings in frontal offset and side impact tests for certain model years. Active Features Active Safety Features: Anti-lock Braking System (ABS), Electronic Brakeforce Distribution (EBD), Brake Assist (BA), Traction Control System (TCS), Active Stability Control (ASC)/Electronic Stability Control (ESC), All-Wheel Control (AWC) Passive Features Passive Safety Features: Front airbags, front side-impact airbags, side curtain airbags, three-point seatbelts with pretensioners, LATCH (Lower Anchors and Tethers for Children) system. ๐Ÿ’ก Technology Features Infotainment Infotainment System: Base models featured a standard AM/FM/CD audio system. Higher trims offered optional Rockford Fosgate premium audio, in-dash CD changer, and navigation systems. Connectivity Options: Auxiliary input jack for audio devices was available on many models. Bluetooth hands-free calling was an option on later models or higher trims. Driver Assistance Driver Assistance Features: Traction Control, Stability Control, ABS, EBD, Brake Assist were standard or widely available. Advanced driver assistance systems (like adaptive cruise control, lane departure warning) were not common on this generation. ๐Ÿ”ง Maintenance Service Intervals Engine Oil Change Interval: Typically every 7,500 miles (12,000 km) or 6 months, whichever comes first, under normal driving conditions. Refer to manual for severe conditions. Transmission...
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Mitsubushi OUTLAndER Service Repair Manual 2005-2010
๐Ÿท๏ธ Basic Information
Identification
Make:
Mitsubishi
Model:
Outlander
Generation:
Second Generation (CW/ZJ)
Codes
Chassis Codes:
CW5W, CW6W, CW4W
๐Ÿ‘‹ Introduction
Market Position
Vehicle Segment:
Compact Crossover SUV
Competitive Analysis
Key Competitors:
Honda CR-V, Toyota RAV4, Nissan X-Trail (Rogue), Ford Escape, Subaru Forester
Key Features
Platform Sharing:
Built on the Mitsubishi GS platform, shared with the Mitsubishi Lancer and related to the Mitsubishi Outlander XL (PSA Peugeot Citroรซn C-Crosser/Citroรซn C4/Peugeot 4007).
Drivetrain Options:
Available with front-wheel drive (FWD) and Mitsubishi's AWC (All-Wheel Control) system.
๐Ÿ“‹ Manual Details
Coverage Areas
Markets Covered:
Global (specific to regions and engine variants as outlined in the manual)
Page Count
Estimated Page Count:
Likely 1500+ pages (typical for comprehensive factory service manuals of this era)
Manual Type
Manual Type:
Factory Service Manual / Workshop Repair Manual
Language
Language:
English
Format
Format:
PDF
๐Ÿ“– Manual Coverage
Systems Covered
Powertrain Components:
Engine mechanical, fuel system, exhaust system, cooling system, lubrication system, ignition system, starter system, charging system
Drivetrain Components:
Clutch, manual transmission, automatic transmission, sub-transmission (if applicable), transfer case, drive shafts, axles, differentials
Suspension Steering Brakes:
Front suspension, rear suspension, steering system, hydraulic brake system, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution)
Electrical Electronics:
Battery, charging system, starting system, ignition system, lighting system, instrumentation, switches, power windows, power locks, HVAC controls, audio system, SRS (Supplemental Restraint System) / Airbag system, body control module (BCM)
Body Chassis Comfort:
Body construction, exterior trim, interior trim, seats, HVAC system, doors, windows, wipers, locks
Procedures Included
Maintenance Tasks:
Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements (oil, air, fuel), spark plug replacement, belt inspection/replacement
Diagnostic Procedures:
Troubleshooting guides, diagnostic trouble codes (DTCs), wiring diagrams for electrical systems, component testing procedures
Repair Rebuild Procedures:
Engine removal/installation, cylinder head repair, piston/ring replacement, crankshaft inspection, transmission overhaul, brake caliper overhaul, suspension component replacement, steering rack replacement
Adjustment Calibration:
Valve lash adjustment, parking brake adjustment, wheel alignment specifications, headlight aiming
Technical Depth
Depth Of Coverage:
Comprehensive: from basic fluid checks and routine maintenance to in-depth component diagnostics, repair, and complete rebuilds of major systems.
๐Ÿ“Š Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution, printable pages with clear diagrams and text. Searchable functionality likely present.
Binding Type
Binding Type:
Digital Download (not a physical book)
Paper Type
Paper Type:
Not Applicable (Digital)
โš™๏ธ Engine Specifications
Primary Engine
Engine Displacement And Code:
2.4L 4G69 MIVEC I4 (common in many markets)
Engine Horsepower Approx:
160-170 hp @ 6000 rpm (may vary slightly by region)
Engine Torque Approx:
162-165 lb-ft @ 4000 rpm (may vary slightly by region)
Optional Engine
Optional Engine Displacement And Code:
3.0L 6B31 MIVEC V6 (in some markets, particularly North America)
Optional Engine Horsepower Approx:
220-230 hp @ 6250 rpm
Optional Engine Torque Approx:
200-205 lb-ft @ 3750 rpm
Fuel System
Fuel Delivery System:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (Octane rating as specified by Mitsubishi)
๐Ÿ”ง Transmission
Standard
Standard Transmission:
5-speed Manual Transmission (less common in some markets)
Optional
Optional Transmission:
6-speed INVECS-III Continuously Variable Transmission (CVT) with Paddle Shifters (most common)
Optional Transmission V6:
6-speed Automatic Transmission (typically paired with the 3.0L V6)
Features
Awc System:
All-Wheel Control (AWC) system with selectable modes (e.g., Normal, Snow, Lock) for enhanced traction and stability.
๐Ÿ“ Dimensions
Exterior
Length Approx:
4570 mm (179.9 in)
Width Approx:
1800 mm (70.9 in)
Height Approx:
1690 mm (66.5 in) (without roof rails)
Wheelbase Approx:
2670 mm (105.1 in)
Weights
Curb Weight Approx:
1550 - 1750 kg (3417 - 3858 lbs) (depending on engine and drivetrain)
๐Ÿ›ก๏ธ Safety Features
Ratings
NHTSA Ratings:
Generally received good ratings, with 4 or 5 stars in frontal and side impact tests in applicable years/regions.
IIHS Ratings:
Received 'Good' ratings in frontal offset and side impact tests for certain model years.
Active Features
Active Safety Features:
Anti-lock Braking System (ABS), Electronic Brakeforce Distribution (EBD), Brake Assist (BA), Traction Control System (TCS), Active Stability Control (ASC)/Electronic Stability Control (ESC), All-Wheel Control (AWC)
Passive Features
Passive Safety Features:
Front airbags, front side-impact airbags, side curtain airbags, three-point seatbelts with pretensioners, LATCH (Lower Anchors and Tethers for Children) system.
๐Ÿ’ก Technology Features
Infotainment
Infotainment System:
Base models featured a standard AM/FM/CD audio system. Higher trims offered optional Rockford Fosgate premium audio, in-dash CD changer, and navigation systems.
Connectivity Options:
Auxiliary input jack for audio devices was available on many models. Bluetooth hands-free calling was an option on later models or higher trims.
Driver Assistance
Driver Assistance Features:
Traction Control, Stability Control, ABS, EBD, Brake Assist were standard or widely available. Advanced driver assistance systems (like adaptive cruise control, lane departure warning) were not common on this generation.
๐Ÿ”ง Maintenance
Service Intervals
Engine Oil Change Interval:
Typically every 7,500 miles (12,000 km) or 6 months, whichever comes first, under normal driving conditions. Refer to manual for severe conditions.
Transmission Fluid Change Interval Cvt:
Crucial for CVT longevity. Often recommended around 30,000-60,000 miles (48,000-96,000 km), but check manual for specific fluid type and interval as CVTs can be sensitive.
Coolant Replacement Interval:
Initial replacement at a higher mileage (e.g., 100,000 miles/10 years), then every 50,000 miles/5 years. Use specified Long Life Coolant.
Fluid Specifications
Engine Oil Specification:
SAE 5W-30 API SM or higher, ILSAC GF-4 or higher (confirm with manual for specific viscosity and certification)
Transmission Fluid Specification Cvt:
Specific Mitsubishi CVT Fluid J4 (or equivalent approved fluid). Do not use generic ATF.
Brake Fluid Specification:
DOT 3 or DOT 4
Power Steering Fluid Type:
Use Genuine Mitsubishi Power Steering Fluid or a DEXRON-III (H) or equivalent ATF.
Known Issues
Cvt Durability:
Some models, particularly early ones with CVTs, may experience CVT wear or failure if maintenance intervals are not strictly followed, especially fluid changes.
Engine Misfires:
Potential for ignition coil issues or spark plug wear, leading to misfires, especially on the 4G69 engine.
Suspension Noise:
Worn sway bar links or bushings can lead to knocking or clunking noises, particularly over uneven surfaces.
Ac System Performance:
Occasional reports of AC compressor or clutch issues, or refrigerant leaks.
๐Ÿ“š Vehicle History
Brand Heritage
Mitsubishi SUV History:
Mitsubishi has a long history of producing capable SUVs, including the Pajero (Montero) and the Outlander line, known for their durability and off-road prowess in earlier generations.
Model Evolution
Outlander Second Generation:
This generation (2005-2010) marked a significant redesign, featuring a more car-like monocoque construction, a smoother exterior design, and increased refinement. It also saw the introduction of the optional third-row seating in some configurations and the development of the AWC system.
Production
Manufacturing Locations:
Primary production in Japan. Some variants or related models were also produced in other Mitsubishi facilities globally.
๐Ÿ† Awards & Recognition
Recognitions
IIHS Top Safety Pick:
Received IIHS Top Safety Pick awards for certain model years, indicating good performance in crash safety tests.
Other Awards:
Varies by market; often praised for its value proposition, available AWD system, and practicality.
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