Mitsubushi OUTLAndER 2003-2008 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Outlander Generation: First Generation (CU/CT Series) Production Years: 2003-2008 👋 Introduction Market Position Vehicle Segment: Compact Crossover SUV Competitive Analysis Key Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra Key Features Design Philosophy: Practicality, comfort, and Mitsubishi's signature 'Dynamic Shield' design language (for later generations, but design cues are present) All Wheel Drive: Available All-Wheel Control (AWC) system offering enhanced traction and stability 📋 Manual Details Coverage Areas Coverage Scope: Complete vehicle service and repair Page Count Estimated Page Count: Extensive (typical for comprehensive service manuals, likely 1000+ pages) Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed overhaul and repair procedures for all engine variants Engine Management: Ignition system, fuel system, emissions control, ECU diagnosis and repair Transmission: Automatic (INVECS-II) and Manual transmission repair, overhaul, and diagnosis Drivetrain: Front-wheel drive, All-Wheel Control (AWC) system service, driveshafts, differentials Suspension: Front and rear suspension systems, components, and alignment specifications Steering: Power steering system diagnosis and repair, steering column components Brakes: Front and rear brake systems (disc), ABS operation and troubleshooting, parking brake Electrical: Wiring diagrams, component location, diagnosis of power distribution, lighting, and accessories Body And Chassis: Body panel repair, glass replacement, interior trim removal and installation Heating Ventilation Air Conditioning HVAC: HVAC system diagnosis, refrigerant handling, component replacement Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, inspections Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting guides for various systems Repair: Step-by-step instructions for component removal, installation, and repair Overhaul: Complete disassembly and reassembly procedures for major components like engines and transmissions Wiring Diagrams: Comprehensive electrical circuit diagrams for all vehicle systems Technical Depth Depth Of Coverage: Comprehensive, suitable for both novice DIYers and professional mechanics 📊 Manual Specifications File Format Printability: Full Printable Zoom Capability: YES (Zoom IN/OUT) Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader & WinZip Compatibility: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Code 2003-2004: 4G64 (2.4L SOHC) Engine Code 2005-2006: 4G69 (2.4L SOHC MIVEC) Engine Code 2004-2006 Optional: 6G72 (3.0L SOHC V6) Engine Code 2007-2008: 4B12 (2.4L DOHC MIVEC) Displacement 2.4L: 2378 cc (145.1 cu in) Displacement 3.0L: 2972 cc (181.4 cu in) Performance Horsepower 2.4L 4G64: 135 hp @ 5500 rpm Torque 2.4L 4G64: 140 lb-ft @ 3750 rpm Horsepower 2.4L 4G69: 160 hp @ 6000 rpm Torque 2.4L 4G69: 162 lb-ft @ 4000 rpm Horsepower 3.0L V6: 200 hp @ 5500 rpm Torque 3.0L V6: 205 lb-ft @ 4000 rpm Horsepower 2.4L 4B12: 165 hp @ 6000 rpm Torque 2.4L 4B12: 162 lb-ft @ 4000 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (87 octane minimum recommended) 🔧 Transmission Standard Transmission 2.4L: 4-Speed Automatic (INVECS-II Sports Mode) Transmission 3.0L V6: 4-Speed Automatic (INVECS-II Sports Mode) Optional Transmission 2.4L Manual: 5-Speed Manual Transmission (available on select trims/years) Features Awc System: Available All-Wheel Control (AWC) system with selectable modes (e.g., 2WD, 4WD Auto, 4WD Lock) 📐 Dimensions Exterior Length: Approx. 178.0 - 181.7 inches (4520 - 4615 mm) Width: Approx. 70.1 - 70.3 inches (1780 - 1785 mm) Height: Approx. 65.0 - 65.4 inches (1650 - 1660 mm) Wheelbase Wheelbase: Approx. 103.3 inches (2625 mm) Weights Curb Weight: Approx. 3400 - 3700 lbs (1542 - 1678 kg), depending on configuration Cargo Cargo Volume Behind 2Nd Row: Approx. 32.0 - 36.0 cu ft (906 - 1019 L) Cargo Volume With 2Nd Row Folded: Approx. 63.4 - 66.0 cu ft (1795 - 1869 L) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 5-Star (for models tested) NHTSA Front Impact Passenger: 5-Star (for models tested) NHTSA Side Impact Front Seat: 5-Star (for models tested) NHTSA Side Impact Rear Seat: 4-Star (for models tested) IIHS Front Crash Rating: Good (for models tested) IIHS Side Impact Rating: Good (for models tested) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Available Traction Control System (TCS) Electronic Stability Control: Available Active Stability Control (ASC) or Electronic Stability Control (ESC) Passive Features Airbags: Standard front airbags, optional front-side airbags and side-curtain airbags Seatbelts: 3-point seatbelts with pretensioners and load limiters 💡 Technology Features Infotainment Audio System: Standard AM/FM/CD player, with optional Rockford Fosgate premium audio system on higher trims. Navigation: Optional factory-installed navigation system available on select models/trims. Driver Assistance Cruise Control: Standard on most trims. Keyless Entry: Available keyless entry and alarm system. Connectivity Power Windows Locks: Standard power windows and door locks. 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 3,750 to 7,500 miles (6,000 to 12,000 km) or 6-12 months, depending on driving conditions and oil type (consult manual for specific recommendations). Engine Coolant Replacement: Typically every 30,000 miles (48,000 km) or 2 years. Transmission Fluid Change: Automatic transmission fluid typically every 40,000 to...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Outlander

Generation:

First Generation (CU/CT Series)

Production Years:

2003-2008

👋 Introduction

Market Position

Vehicle Segment:

Compact Crossover SUV

Competitive Analysis

Key Competitors:

Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra

Key Features

Design Philosophy:

Practicality, comfort, and Mitsubishi's signature 'Dynamic Shield' design language (for later generations, but design cues are present)

All Wheel Drive:

Available All-Wheel Control (AWC) system offering enhanced traction and stability

📋 Manual Details

Coverage Areas

Coverage Scope:

Complete vehicle service and repair

Page Count

Estimated Page Count:

Extensive (typical for comprehensive service manuals, likely 1000+ pages)

Manual Type

Manual Type:

Workshop Service Repair Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Detailed overhaul and repair procedures for all engine variants

Engine Management:

Ignition system, fuel system, emissions control, ECU diagnosis and repair

Transmission:

Automatic (INVECS-II) and Manual transmission repair, overhaul, and diagnosis

Drivetrain:

Front-wheel drive, All-Wheel Control (AWC) system service, driveshafts, differentials

Suspension:

Front and rear suspension systems, components, and alignment specifications

Steering:

Power steering system diagnosis and repair, steering column components

Brakes:

Front and rear brake systems (disc), ABS operation and troubleshooting, parking brake

Electrical:

Wiring diagrams, component location, diagnosis of power distribution, lighting, and accessories

Body And Chassis:

Body panel repair, glass replacement, interior trim removal and installation

Heating Ventilation Air Conditioning HVAC:

HVAC system diagnosis, refrigerant handling, component replacement

Procedures Included

Maintenance:

Scheduled maintenance, fluid changes, filter replacements, inspections

Troubleshooting:

Diagnostic flowcharts and symptom-based troubleshooting guides for various systems

Repair:

Step-by-step instructions for component removal, installation, and repair

Overhaul:

Complete disassembly and reassembly procedures for major components like engines and transmissions

Wiring Diagrams:

Comprehensive electrical circuit diagrams for all vehicle systems

Technical Depth

Depth Of Coverage:

Comprehensive, suitable for both novice DIYers and professional mechanics

📊 Manual Specifications

File Format

Printability:

Full Printable

Zoom Capability:

YES (Zoom IN/OUT)

Delivery

Delivery Method:

Instant Download

Requirements

Software Requirements:

Adobe PDF Reader & WinZip

Compatibility:

All Versions of Windows & Mac

⚙️ Engine Specifications

Primary Engine

Engine Code 2003-2004:

4G64 (2.4L SOHC)

Engine Code 2005-2006:

4G69 (2.4L SOHC MIVEC)

Engine Code 2004-2006 Optional:

6G72 (3.0L SOHC V6)

Engine Code 2007-2008:

4B12 (2.4L DOHC MIVEC)

Displacement 2.4L:

2378 cc (145.1 cu in)

Displacement 3.0L:

2972 cc (181.4 cu in)

Performance

Horsepower 2.4L 4G64:

135 hp @ 5500 rpm

Torque 2.4L 4G64:

140 lb-ft @ 3750 rpm

Horsepower 2.4L 4G69:

160 hp @ 6000 rpm

Torque 2.4L 4G69:

162 lb-ft @ 4000 rpm

Horsepower 3.0L V6:

200 hp @ 5500 rpm

Torque 3.0L V6:

205 lb-ft @ 4000 rpm

Horsepower 2.4L 4B12:

165 hp @ 6000 rpm

Torque 2.4L 4B12:

162 lb-ft @ 4000 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline (87 octane minimum recommended)

🔧 Transmission

Standard

Transmission 2.4L:

4-Speed Automatic (INVECS-II Sports Mode)

Transmission 3.0L V6:

4-Speed Automatic (INVECS-II Sports Mode)

Optional

Transmission 2.4L Manual:

5-Speed Manual Transmission (available on select trims/years)

Features

Awc System:

Available All-Wheel Control (AWC) system with selectable modes (e.g., 2WD, 4WD Auto, 4WD Lock)

📐 Dimensions

Exterior

Length:

Approx. 178.0 - 181.7 inches (4520 - 4615 mm)

Width:

Approx. 70.1 - 70.3 inches (1780 - 1785 mm)

Height:

Approx. 65.0 - 65.4 inches (1650 - 1660 mm)

Wheelbase

Wheelbase:

Approx. 103.3 inches (2625 mm)

Weights

Curb Weight:

Approx. 3400 - 3700 lbs (1542 - 1678 kg), depending on configuration

Cargo

Cargo Volume Behind 2Nd Row:

Approx. 32.0 - 36.0 cu ft (906 - 1019 L)

Cargo Volume With 2Nd Row Folded:

Approx. 63.4 - 66.0 cu ft (1795 - 1869 L)

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

5-Star (for models tested)

NHTSA Front Impact Passenger:

5-Star (for models tested)

NHTSA Side Impact Front Seat:

5-Star (for models tested)

NHTSA Side Impact Rear Seat:

4-Star (for models tested)

IIHS Front Crash Rating:

Good (for models tested)

IIHS Side Impact Rating:

Good (for models tested)

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Available Traction Control System (TCS)

Electronic Stability Control:

Available Active Stability Control (ASC) or Electronic Stability Control (ESC)

Passive Features

Airbags:

Standard front airbags, optional front-side airbags and side-curtain airbags

Seatbelts:

3-point seatbelts with pretensioners and load limiters

💡 Technology Features

Infotainment

Audio System:

Standard AM/FM/CD player, with optional Rockford Fosgate premium audio system on higher trims.

Navigation:

Optional factory-installed navigation system available on select models/trims.

Driver Assistance

Cruise Control:

Standard on most trims.

Keyless Entry:

Available keyless entry and alarm system.

Connectivity

Power Windows Locks:

Standard power windows and door locks.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,750 to 7,500 miles (6,000 to 12,000 km) or 6-12 months, depending on driving conditions and oil type (consult manual for specific recommendations).

Engine Coolant Replacement:

Typically every 30,000 miles (48,000 km) or 2 years.

Transmission Fluid Change:

Automatic transmission fluid typically every 40,000 to 60,000 miles (64,000 to 96,000 km). Manual transmission fluid inspection and potential change at similar intervals.

Spark Plug Replacement:

Approximately 60,000 to 100,000 miles (96,000 to 160,000 km) for iridium-tipped plugs, depending on engine.

Fluid Specifications

Engine Oil Type 2.4L:

API Service SN or newer, SAE 5W-30 (check manual for exact specification and viscosity).

Engine Oil Type 3.0L V6:

API Service SN or newer, SAE 5W-30 or 10W-30 (check manual for exact specification and viscosity).

Transmission Fluid Automatic:

Diamond SP-III or equivalent ATF (refer to manual for specific part number/specification).

Transmission Fluid Manual:

API GL-4 or GL-5 gear oil (viscosity specified in manual, e.g., 75W-90).

Coolant:

Mitsubishi Genuine Super Long Life Coolant (SLLC) or equivalent, usually a pink/red ethylene glycol-based type.

Known Issues

Oxygen Sensor Failure:

Can lead to poor fuel economy and check engine light illumination.

Cv Joint Wear:

Especially on AWD models, may result in clicking noises during turns.

Rear Hatch Struts:

May weaken over time, leading to difficulty holding the rear hatch open.

Radiator Leaks:

Some reports of early radiator failure or leaks.

📚 Vehicle History

Brand Heritage

Mitsubishi Motors:

Japanese automaker with a history dating back to 1917, known for its resilient and off-road capable vehicles (like the Pajero/Montero Sport) and performance models (like the Lancer Evolution).

Model Evolution

First Generation Launch:

Introduced in Japan in 2000, globally launched in 2001. The 2003-2008 period represents its first generation (CU/CT body style) in most major markets, including North America.

Mid-Cycle Refresh:

Received a significant facelift for the 2007 model year, featuring updated styling, interior enhancements, and revised powertrain options (notably the introduction of the 4B12 engine).

Production

Manufacturing Location:

Primarily manufactured in Japan, with some production also occurring in other global facilities.

🏆 Awards & Recognition

Recognitions

IIHS Top Safety Pick:

While not consistently receiving 'Top Safety Pick' awards across its entire run, it generally performed well in IIHS and NHTSA crash tests for its era, reflecting its safety focus.