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Mitsubishi Outlander 2003 2004 2005 2006 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Outlander Model Years Covered: 2003, 2004, 2005, 2006 Codes Chassis Code: CU2W 👋 Introduction Market Position Segment: Compact Crossover SUV Target Audience: Owners seeking to perform DIY maintenance, repairs, and diagnostics; independent repair shops. Competitive Analysis Key Competitors: Honda CR-V, Toyota RAV4, Subaru Forester, Ford Escape, Nissan Xterra. Key Features Vehicle Platform: Shared platform with Mitsubishi Airtrek (JDM market). Differentiators: Available AWD system, sporty styling for its class, often noted for good handling. 📋 Manual Details Coverage Areas Engine Coverage: 2.4L 4G64 (MPI) Transmission Coverage: 4-speed Automatic (F4A42), 5-speed Manual Drivetrain Coverage: Front-Wheel Drive (FWD), All-Wheel Drive (AWD) with Active-Front Differential (AFD) Page Count Estimated Page Count: 1500+ Manual Type Type: Factory Workshop Service Repair Manual Language Language: English Format Format: Digital (likely PDF), downloadable 📖 Manual Coverage Systems Covered Engine: Engine mechanical, lubrication, cooling, fuel, ignition, exhaust, emissions control, engine management Transmission: Automatic transmission (AT) overhaul, manual transmission (MT) overhaul, transaxle, clutch Drivetrain: Front suspension, rear suspension, steering system, drive shafts, differentials Brakes: Brake system hydraulics, parking brake, ABS (Anti-lock Braking System), brake inspections and repairs Electrical: Battery, charging system, starting system, lighting, instruments, gauges, power accessories, wiring diagrams Body: Body panels, doors, windows, interior trim, exterior trim, bumpers, glass, chassis frame HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system service and repair Restraints: Airbag system, seat belts Procedures Included Maintenance: Routine checks, oil changes, filter replacements, fluid level checks and top-offs, spark plug replacement Troubleshooting: Diagnostic procedures, common fault finding, error code interpretation Repair: Component removal and installation, rebuilding procedures, system adjustments Diagnostics: On-board diagnostics (OBD-II) system, sensor testing, actuator testing Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including electrical system diagnostics and wiring diagrams. 📊 Manual Specifications File Format File Type: PDF Print Quality Illustration Quality: High Resolution Image Quality: Clear photos and diagrams Binding Type Binding: Not Applicable (Digital Format) Paper Type Paper Quality: Not Applicable (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: 4G64 Configuration: Inline 4-cylinder, DOHC, 16-valve Displacement: 2.4 Liters (2351 cc) Performance Horsepower: 135-145 hp @ 5500-5800 rpm (varies slightly by year/market) Torque: 140-150 lb-ft @ 4000-4500 rpm (varies slightly by year/market) Fuel System Fuel Delivery: Multi-Point Fuel Injection (MPI) Fuel Type: Unleaded gasoline Recommended Octane: 87 Octane (R.O.N. 91) Cooling System Coolant Type: Mitsubishi DiaQueen Super Long Life Coolant (or equivalent OAT coolant, typically blue or green) Lubrication Oil Type: SAE 5W-30 API Service SL or SM Oil Capacity: Approx. 4.5 US quarts (4.3 liters) with filter change Ignition Spark Plugs: NGK BKR5EGP (Platinum) or Iridium equivalent 🔧 Transmission Standard Transmission Type: 4-speed Automatic (F4A42) Optional Transmission Type: 5-speed Manual Features Automatic Transmission Features: Electronically controlled, Lock-up torque converter AWD System: VISCOUS COUPLING 4WD (on AWD models), Active-Front Differential (AFD) Fluid Specifications Automatic Transmission Fluid Type: DIA QUEEN ATF SP-III (or equivalent MERCON V / ATF+4 approved) Manual Transmission Fluid Type: GL-3 or GL-4 75W-90 gear oil Fluid Capacities Automatic Transmission Fluid Capacity: Approx. 7.8 US quarts (7.4 liters) for refill Manual Transmission Fluid Capacity: Approx. 2.3 US quarts (2.2 liters) 📐 Dimensions Exterior Length: Approx. 177.4 inches (4506 mm) Width: Approx. 70.1 inches (1781 mm) Height: Approx. 65.7 inches (1669 mm) Wheelbase: Approx. 103.0 inches (2616 mm) Ground Clearance: Approx. 7.9 inches (200 mm) Weights Curb Weight: Approx. 3263 - 3527 lbs (1480 - 1600 kg) depending on FWD/AWD and trim Cargo Cargo Volume Behind Rear Seat: Approx. 27.7 cubic feet (784 liters) Cargo Volume With Rear Seat Folded: Approx. 64.5 cubic feet (1827 liters) Tires Wheels Standard Tire Size: 215/60R16 Optional Tire Size: 225/55R18 Wheel Bolt Pattern: 5x114.3 mm (5x4.5 inches) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 4 Stars (for 2004 model) NHTSA Front Impact Passenger: 4 Stars (for 2004 model) NHTSA Side Impact Front Driver: 5 Stars (for 2004 model) NHTSA Side Impact Front Passenger: 5 Stars (for 2004 model) NHTSA Side Impact Rear Driver: 4 Stars (for 2004 model) NHTSA Side Impact Rear Passenger: 4 Stars (for 2004 model) IIHS Frontal Offset: Good (for 2004 model) Active Features ABS: Standard on most trims (4-wheel disc brakes with ABS) Traction Control: Optional on some models, often integrated with AWD system. Passive Features Airbags: Dual front airbags, optional front side-impact airbags. Seatbelts: 3-point height-adjustable front seatbelts with pretensioners, rear 3-point seatbelts. 💡 Technology Features Infotainment Audio System: AM/FM CD player with optional Rockford Fosgate premium audio system. Auxiliary input jack may be present on later models or aftermarket. Navigation: Optional factory navigation system available on higher trim levels. Driver Assistance Cruise Control: Standard on most trims. Connectivity Keyless Entry: Available on many trims. 🔧 Maintenance Service Intervals Oil Change Interval: Every 7,500 miles (12,000 km) or 6 months, whichever comes first. Air Filter Replacement Interval: Every 15,000 miles (24,000 km) or 12 months....
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Mitsubishi Outlander 2003 2004 2005 2006 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Outlander
Model Years Covered:
2003, 2004, 2005, 2006
Codes
Chassis Code:
CU2W
👋 Introduction
Market Position
Segment:
Compact Crossover SUV
Target Audience:
Owners seeking to perform DIY maintenance, repairs, and diagnostics; independent repair shops.
Competitive Analysis
Key Competitors:
Honda CR-V, Toyota RAV4, Subaru Forester, Ford Escape, Nissan Xterra.
Key Features
Vehicle Platform:
Shared platform with Mitsubishi Airtrek (JDM market).
Differentiators:
Available AWD system, sporty styling for its class, often noted for good handling.
📋 Manual Details
Coverage Areas
Engine Coverage:
2.4L 4G64 (MPI)
Transmission Coverage:
4-speed Automatic (F4A42), 5-speed Manual
Drivetrain Coverage:
Front-Wheel Drive (FWD), All-Wheel Drive (AWD) with Active-Front Differential (AFD)
Page Count
Estimated Page Count:
1500+
Manual Type
Type:
Factory Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF), downloadable
📖 Manual Coverage
Systems Covered
Engine:
Engine mechanical, lubrication, cooling, fuel, ignition, exhaust, emissions control, engine management
Transmission:
Automatic transmission (AT) overhaul, manual transmission (MT) overhaul, transaxle, clutch
Drivetrain:
Front suspension, rear suspension, steering system, drive shafts, differentials
Brakes:
Brake system hydraulics, parking brake, ABS (Anti-lock Braking System), brake inspections and repairs
Electrical:
Battery, charging system, starting system, lighting, instruments, gauges, power accessories, wiring diagrams
Body:
Body panels, doors, windows, interior trim, exterior trim, bumpers, glass, chassis frame
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system service and repair
Restraints:
Airbag system, seat belts
Procedures Included
Maintenance:
Routine checks, oil changes, filter replacements, fluid level checks and top-offs, spark plug replacement
Troubleshooting:
Diagnostic procedures, common fault finding, error code interpretation
Repair:
Component removal and installation, rebuilding procedures, system adjustments
Diagnostics:
On-board diagnostics (OBD-II) system, sensor testing, actuator testing
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including electrical system diagnostics and wiring diagrams.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Illustration Quality:
High Resolution
Image Quality:
Clear photos and diagrams
Binding Type
Binding:
Not Applicable (Digital Format)
Paper Type
Paper Quality:
Not Applicable (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G64
Configuration:
Inline 4-cylinder, DOHC, 16-valve
Displacement:
2.4 Liters (2351 cc)
Performance
Horsepower:
135-145 hp @ 5500-5800 rpm (varies slightly by year/market)
Torque:
140-150 lb-ft @ 4000-4500 rpm (varies slightly by year/market)
Fuel System
Fuel Delivery:
Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline
Recommended Octane:
87 Octane (R.O.N. 91)
Cooling System
Coolant Type:
Mitsubishi DiaQueen Super Long Life Coolant (or equivalent OAT coolant, typically blue or green)
Lubrication
Oil Type:
SAE 5W-30 API Service SL or SM
Oil Capacity:
Approx. 4.5 US quarts (4.3 liters) with filter change
Ignition
Spark Plugs:
NGK BKR5EGP (Platinum) or Iridium equivalent
🔧 Transmission
Standard
Transmission Type:
4-speed Automatic (F4A42)
Optional
Transmission Type:
5-speed Manual
Features
Automatic Transmission Features:
Electronically controlled, Lock-up torque converter
AWD System:
VISCOUS COUPLING 4WD (on AWD models), Active-Front Differential (AFD)
Fluid Specifications
Automatic Transmission Fluid Type:
DIA QUEEN ATF SP-III (or equivalent MERCON V / ATF+4 approved)
Manual Transmission Fluid Type:
GL-3 or GL-4 75W-90 gear oil
Fluid Capacities
Automatic Transmission Fluid Capacity:
Approx. 7.8 US quarts (7.4 liters) for refill
Manual Transmission Fluid Capacity:
Approx. 2.3 US quarts (2.2 liters)
📐 Dimensions
Exterior
Length:
Approx. 177.4 inches (4506 mm)
Width:
Approx. 70.1 inches (1781 mm)
Height:
Approx. 65.7 inches (1669 mm)
Wheelbase:
Approx. 103.0 inches (2616 mm)
Ground Clearance:
Approx. 7.9 inches (200 mm)
Weights
Curb Weight:
Approx. 3263 - 3527 lbs (1480 - 1600 kg) depending on FWD/AWD and trim
Cargo
Cargo Volume Behind Rear Seat:
Approx. 27.7 cubic feet (784 liters)
Cargo Volume With Rear Seat Folded:
Approx. 64.5 cubic feet (1827 liters)
Tires Wheels
Standard Tire Size:
215/60R16
Optional Tire Size:
225/55R18
Wheel Bolt Pattern:
5x114.3 mm (5x4.5 inches)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
4 Stars (for 2004 model)
NHTSA Front Impact Passenger:
4 Stars (for 2004 model)
NHTSA Side Impact Front Driver:
5 Stars (for 2004 model)
NHTSA Side Impact Front Passenger:
5 Stars (for 2004 model)
NHTSA Side Impact Rear Driver:
4 Stars (for 2004 model)
NHTSA Side Impact Rear Passenger:
4 Stars (for 2004 model)
IIHS Frontal Offset:
Good (for 2004 model)
Active Features
ABS:
Standard on most trims (4-wheel disc brakes with ABS)
Traction Control:
Optional on some models, often integrated with AWD system.
Passive Features
Airbags:
Dual front airbags, optional front side-impact airbags.
Seatbelts:
3-point height-adjustable front seatbelts with pretensioners, rear 3-point seatbelts.
💡 Technology Features
Infotainment
Audio System:
AM/FM CD player with optional Rockford Fosgate premium audio system. Auxiliary input jack may be present on later models or aftermarket.
Navigation:
Optional factory navigation system available on higher trim levels.
Driver Assistance
Cruise Control:
Standard on most trims.
Connectivity
Keyless Entry:
Available on many trims.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first.
Air Filter Replacement Interval:
Every 15,000 miles (24,000 km) or 12 months.
Cabin Air Filter Replacement Interval:
Every 15,000 miles (24,000 km) or 12 months.
Spark Plug Replacement Interval:
Platinum: 105,000 miles (168,000 km); Iridium: 120,000 miles (192,000 km).
Coolant Flush Interval:
First at 105,000 miles (168,000 km), then every 60,000 miles (96,000 km) or 4 years.
Transmission Fluid Change Interval Automatic:
Every 45,000 miles (72,000 km) under normal conditions, or more frequently under severe driving conditions (towing, stop-and-go).
Transmission Fluid Change Interval Manual:
Every 60,000 miles (96,000 km) or 4 years.
Fluid Specifications
Brake Fluid Type:
DOT 3 (or DOT 4 equivalent)
Power Steering Fluid Type:
Dexron III ATF or equivalent power steering fluid
Known Issues
Common Wear Item:
Front struts and shock absorbers, sway bar links, A/C compressor clutch, rear wheel bearings.
Engine Reliability:
Generally reliable, but oil sludge can be an issue if maintenance is neglected. Check for timing belt condition (if applicable, though 4G64 is chain-driven). Intake manifold gaskets can sometimes leak.
Transmission Issues:
Automatic transmission can occasionally exhibit harsh shifting or slipping; regular fluid changes are critical.
Electrical Quirks:
Power window regulators can fail, sometimes issues with blower motor resistors for HVAC.
📚 Vehicle History
Brand Heritage
Manufacturer History:
Mitsubishi Motors Corporation is a Japanese automotive manufacturer with a long history of producing robust and capable vehicles, including SUVs and performance cars.
Model Evolution
Generation Start Year:
2001 (JDM Airtrek), 2003 (Global Outlander)
Generation End Year:
2006
Facelift:
Minor styling updates in 2005.
Production
Manufacturing Location:
Okazaki Plant, Aichi Prefecture, Japan.
🏆 Awards & Recognition
Recognitions
IIHS Top Safety Pick:
Earned 'Good' rating in IIHS frontal offset crash test.
Ratings
Consumer Reports Reliability:
Varied by year; generally rated average to above average for this era of Mitsubishi.
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