Mitsubishi Outlander Complete Workshop Service Repair Manual 2005 2006 2007 2008 2009 2010

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🏷️ Basic Information Identification Make: Mitsubishi Model: Outlander Codes Platform Code: CW_series Engine Codes: 4G63 (2.4L Turbocharged I4), 4G69 (2.4L Naturally Aspirated I4), 6B31 (3.0L SOHC V6) 👋 Introduction Market Position Segment: Compact Crossover SUV Target Audience: Families, individuals seeking a versatile and practical vehicle with available AWD. Competitive Analysis Key Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Subaru Forester, Mazda CX-7. Key Features Engine Options: Available with a 2.4L inline-4 and a 3.0L V6 engine, offering a balance of efficiency and performance. Drivetrain Options: Offered in both Front-Wheel Drive (FWD) and All-Wheel Drive (AWD) configurations. Seating Capacity: Typically offered with 5-passenger seating, with some configurations potentially having optional 3rd-row seating in earlier generations (though less common for this specific range). Design Philosophy: Practicality, versatility, and a focus on providing a comfortable and functional interior for daily use. 📋 Manual Details Coverage Areas Years Covered: 2005, 2006, 2007, 2008, 2009, 2010 Page Count Estimated Pages: Approximately 2500-3000 (typical for comprehensive workshop manuals of this era) Manual Type Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Downloadable Digital Format (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication system, cooling system, fuel injection, ignition system, emissions control Engine Performance: Engine tuning, diagnostics, power output, torque curves, emissions data Transmission Manual: Manual transmission (if applicable for specific trims), clutch system, gear shift mechanism, maintenance, repair, overhaul Transmission Automatic: Automatic transmission (INVECS-II/INVECS-III), torque converter, valve body, electronic control unit (TCU), maintenance, repair, overhaul, fluid specifications Drivetrain: Front-wheel drive (FWD), All-wheel drive (AWD/4WD) system (Active Center Differential - ACD), drive shafts, CV joints, differential, transfer case, rear differential (if applicable) Suspension: Front suspension (MacPherson strut), rear suspension (Multi-link beam axle or independent), shock absorbers, springs, bushings, alignment specifications, troubleshooting Steering: Power steering system (hydraulic or electric assist), steering rack, tie rods, steering column, column lock, troubleshooting Brakes: Front disc brakes, rear disc brakes, Anti-lock Braking System (ABS), Electronic Brakeforce Distribution (EBD), brake fluid specifications, master cylinder, calipers, pads, rotors, bleeding procedures Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior), fuses, relays, wiring diagrams, power distribution Body And Chassis: Body construction, frame, doors, hood, trunk, bumpers, interior trim, glass, rust prevention, repair procedures, torque specifications for body panels HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, compressor, condenser, evaporator, blower motor, refrigerant, troubleshooting Interior: Seats, dashboard, instrumentation, airbags, seat belts, interior trim removal and installation, sound deadening Exterior: Body panels, trim, mirrors, wipers, washer system, exterior lighting, paint and body repair basics Safety Systems: Airbag system (SRS), seat belt pre-tensioners, occupant classification system, troubleshooting and repair of SRS components Electronics And Control: Engine Control Unit (ECU), Transmission Control Unit (TCU), Body Control Module (BCM), Anti-lock Brake System (ABS) module, power distribution, diagnostic trouble codes (DTCs), CAN bus communication Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, fluid checks and top-offs, tire rotation Scheduled Maintenance: Timing belt/chain replacement (based on model year and engine), coolant flush, brake fluid flush, transmission fluid change, differential fluid change Engine Repair: Cylinder head gasket replacement, piston ring replacement, bearing replacement, crankshaft seal replacement, valve adjustment Transmission Repair: Transmission fluid and filter replacement, valve body overhaul, clutch replacement (manual), seal replacement Brake Service: Brake pad and rotor replacement, caliper rebuilding, brake line replacement, ABS component testing and replacement Suspension And Steering Repair: Strut and shock replacement, ball joint replacement, tie rod end replacement, power steering pump replacement, rack and pinion repair Electrical Diagnostics: Wiring diagram interpretation, component testing (sensors, actuators), fault code retrieval and clearing, circuit diagnosis Troubleshooting Guides: Step-by-step diagnostic procedures for common symptoms (e.g., starting problems, engine misfires, transmission shifting issues, brake noise) Body And Trim Repair: Door panel removal, dashboard disassembly, interior trim replacement, minor body panel repair and adjustment HVAC Repair: Evacuation and recharge of AC system, blower motor replacement, heater core replacement, AC compressor replacement Airbag System Repair: Airbag module replacement, sensor replacement, airbag warning light diagnosis Technical Depth Diagnostic Capabilities: Covers OBD-II diagnostic trouble codes (DTCs), live data stream interpretation, and sensor data analysis for advanced troubleshooting. Repair Depth: Detailed step-by-step instructions for component removal, installation, adjustment, and overhaul, suitable for both DIY enthusiasts and professional mechanics. Wiring Diagrams: Comprehensive electrical wiring diagrams for all vehicle systems, including power distribution, engine management, chassis controls, and comfort systems. Torque Specifications: Precise torque values for all critical fasteners, ensuring proper assembly and preventing damage during repairs. Special Tools: Identification of any specific tools or equipment required for certain procedures, along with descriptions or part numbers where available. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text for easy navigation and information retrieval. Print Quality Readability: High-resolution digital format ensuring clear text and diagrams, suitable for...

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Type: Car

Verkoper:

Sku: 410710

Collecties: ALL Mitsubishi

Beschikbaarheid: Op voorraad

Labels: 2005 2006 2007 2008 2009 2010 Car Cars Misc Mitsubishi Outlander

Productvarianten

Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Outlander

Codes

Platform Code:

CW_series

Engine Codes:

4G63 (2.4L Turbocharged I4), 4G69 (2.4L Naturally Aspirated I4), 6B31 (3.0L SOHC V6)

👋 Introduction

Market Position

Segment:

Compact Crossover SUV

Target Audience:

Families, individuals seeking a versatile and practical vehicle with available AWD.

Competitive Analysis

Key Competitors:

Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Subaru Forester, Mazda CX-7.

Key Features

Engine Options:

Available with a 2.4L inline-4 and a 3.0L V6 engine, offering a balance of efficiency and performance.

Drivetrain Options:

Offered in both Front-Wheel Drive (FWD) and All-Wheel Drive (AWD) configurations.

Seating Capacity:

Typically offered with 5-passenger seating, with some configurations potentially having optional 3rd-row seating in earlier generations (though less common for this specific range).

Design Philosophy:

Practicality, versatility, and a focus on providing a comfortable and functional interior for daily use.

📋 Manual Details

Coverage Areas

Years Covered:

2005, 2006, 2007, 2008, 2009, 2010

Page Count

Estimated Pages:

Approximately 2500-3000 (typical for comprehensive workshop manuals of this era)

Manual Type

Type:

Complete Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable Digital Format (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication system, cooling system, fuel injection, ignition system, emissions control

Engine Performance:

Engine tuning, diagnostics, power output, torque curves, emissions data

Transmission Manual:

Manual transmission (if applicable for specific trims), clutch system, gear shift mechanism, maintenance, repair, overhaul

Transmission Automatic:

Automatic transmission (INVECS-II/INVECS-III), torque converter, valve body, electronic control unit (TCU), maintenance, repair, overhaul, fluid specifications

Drivetrain:

Front-wheel drive (FWD), All-wheel drive (AWD/4WD) system (Active Center Differential - ACD), drive shafts, CV joints, differential, transfer case, rear differential (if applicable)

Suspension:

Front suspension (MacPherson strut), rear suspension (Multi-link beam axle or independent), shock absorbers, springs, bushings, alignment specifications, troubleshooting

Steering:

Power steering system (hydraulic or electric assist), steering rack, tie rods, steering column, column lock, troubleshooting

Brakes:

Front disc brakes, rear disc brakes, Anti-lock Braking System (ABS), Electronic Brakeforce Distribution (EBD), brake fluid specifications, master cylinder, calipers, pads, rotors, bleeding procedures

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior), fuses, relays, wiring diagrams, power distribution

Body And Chassis:

Body construction, frame, doors, hood, trunk, bumpers, interior trim, glass, rust prevention, repair procedures, torque specifications for body panels

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system, compressor, condenser, evaporator, blower motor, refrigerant, troubleshooting

Interior:

Seats, dashboard, instrumentation, airbags, seat belts, interior trim removal and installation, sound deadening

Exterior:

Body panels, trim, mirrors, wipers, washer system, exterior lighting, paint and body repair basics

Safety Systems:

Airbag system (SRS), seat belt pre-tensioners, occupant classification system, troubleshooting and repair of SRS components

Electronics And Control:

Engine Control Unit (ECU), Transmission Control Unit (TCU), Body Control Module (BCM), Anti-lock Brake System (ABS) module, power distribution, diagnostic trouble codes (DTCs), CAN bus communication

Procedures Included

Routine Maintenance:

Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, fluid checks and top-offs, tire rotation

Scheduled Maintenance:

Timing belt/chain replacement (based on model year and engine), coolant flush, brake fluid flush, transmission fluid change, differential fluid change

Engine Repair:

Cylinder head gasket replacement, piston ring replacement, bearing replacement, crankshaft seal replacement, valve adjustment

Transmission Repair:

Transmission fluid and filter replacement, valve body overhaul, clutch replacement (manual), seal replacement

Brake Service:

Brake pad and rotor replacement, caliper rebuilding, brake line replacement, ABS component testing and replacement

Suspension And Steering Repair:

Strut and shock replacement, ball joint replacement, tie rod end replacement, power steering pump replacement, rack and pinion repair

Electrical Diagnostics:

Wiring diagram interpretation, component testing (sensors, actuators), fault code retrieval and clearing, circuit diagnosis

Troubleshooting Guides:

Step-by-step diagnostic procedures for common symptoms (e.g., starting problems, engine misfires, transmission shifting issues, brake noise)

Body And Trim Repair:

Door panel removal, dashboard disassembly, interior trim replacement, minor body panel repair and adjustment

HVAC Repair:

Evacuation and recharge of AC system, blower motor replacement, heater core replacement, AC compressor replacement

Airbag System Repair:

Airbag module replacement, sensor replacement, airbag warning light diagnosis

Technical Depth

Diagnostic Capabilities:

Covers OBD-II diagnostic trouble codes (DTCs), live data stream interpretation, and sensor data analysis for advanced troubleshooting.

Repair Depth:

Detailed step-by-step instructions for component removal, installation, adjustment, and overhaul, suitable for both DIY enthusiasts and professional mechanics.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all vehicle systems, including power distribution, engine management, chassis controls, and comfort systems.

Torque Specifications:

Precise torque values for all critical fasteners, ensuring proper assembly and preventing damage during repairs.

Special Tools:

Identification of any specific tools or equipment required for certain procedures, along with descriptions or part numbers where available.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text for easy navigation and information retrieval.

Print Quality

Readability:

High-resolution digital format ensuring clear text and diagrams, suitable for printing individual pages or the entire manual.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine 1 Displacement:

2.4 Liters

Engine 1 Type:

Inline-4 Cylinder (I4)

Engine 1 Aspiration:

Naturally Aspirated (4G69), Turbocharged (4G63 for Outlander GT variants in certain markets/years).

Engine 1 Horsepower:

Approximately 160-170 hp (4G69), ~200-220 hp (4G63 Turbo - varies by specific tuning).

Engine 1 Torque:

Approximately 160-175 lb-ft (4G69), ~250-280 lb-ft (4G63 Turbo).

Engine 1 Valvetrain:

SOHC (Single Overhead Camshaft) or DOHC (Double Overhead Camshaft) with MIVEC (Mitsubishi Innovative Valve timing Electronic Control) on some variants.

Optional Engine

Engine 2 Displacement:

3.0 Liters

Engine 2 Type:

V6 SOHC

Engine 2 Aspiration:

Naturally Aspirated (6B31)

Engine 2 Horsepower:

Approximately 220-230 hp

Engine 2 Torque:

Approximately 200-215 lb-ft

Engine 2 Valvetrain:

SOHC with MIVEC

Fuel System

Fuel Type:

Unleaded Gasoline

Fuel Delivery:

Electronic Fuel Injection (EFI)

Recommended Octane:

87 Octane (check specific vehicle manual for premium fuel recommendations for V6 or turbo models)

🔧 Transmission

Standard

Transmission Type Std:

5-speed Manual Transmission (primarily for 2.4L models in base trims) / 6-speed INVECS-II Automatic Transmission (more common)

Optional

Transmission Type Opt:

Continuously Variable Transmission (CVT) - Introduced in later years of this generation for some markets, but automatic is more prevalent in the early part of this range.

Features

AWD System:

Active Center Differential (ACD) with Sport/Snow/Normal modes for AWD variants.

Transmission Fluid Spec Auto:

DIAQueen SPIII (or equivalent specification as per Mitsubishi).

Transmission Fluid Capacity Auto:

Approximately 6.7 Liters (14.2 US pints) for a dry fill, but significantly less for a fluid and filter change.

📐 Dimensions

Exterior

Length:

Approx. 177.2 - 182.5 inches (4498 - 4635 mm)

Width:

Approx. 70.1 - 70.5 inches (1781 - 1791 mm)

Height:

Approx. 65.6 - 66.1 inches (1666 - 1680 mm)

Wheelbase:

Approx. 103.7 inches (2634 mm)

Weights

Curb Weight:

Approx. 3,400 - 3,800 lbs (1542 - 1724 kg)

Cargo

Cargo Volume Behind Rear Seats:

Approx. 45.7 cu ft (1294 liters)

Cargo Volume With Rear Seats Folded:

Approx. 77.0 cu ft (2179 liters)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

5-Star (for driver and passenger in many configurations)

NHTSA Side Impact:

5-Star (for front and rear passengers in many configurations)

IIHS Crash Test Results:

Good to Acceptable ratings in various categories depending on the specific test and model year.

Active Features

Standard Anti-lock Braking System (ABS)

Standard Electronic Brakeforce Distribution (EBD)

Traction Control:

Optional Traction Control System (TCS) and Electronic Stability Control (ESC)/Active Stability Control (ASC) on some trims/years.

Passive Features

Airbags:

Frontal airbags (driver and passenger), front side-impact airbags, and available side-curtain airbags for front and rear occupants.

Seatbelts:

Three-point seatbelts with pretensioners and force limiters for front occupants.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system.

💡 Technology Features

Infotainment

Audio System:

AM/FM/CD player with available MP3 playback, SiriusXM satellite radio, and premium Rockford Fosgate audio system on higher trims.

Display Screen:

Available touchscreen infotainment system with navigation, rearview camera integration (on later models).

Connectivity:

Auxiliary audio input jack, available Bluetooth hands-free calling and audio streaming (depending on trim and year).

Driver Assistance

Cruise Control:

Standard cruise control on most trims.

Keyless Entry:

Available keyless entry and ignition system.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first (check owner's manual for specific engine and oil type recommendations).

Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on driving conditions.

Cabin Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or annually.

Spark Plug Replacement:

100,000 miles (160,000 km) for iridium-tipped spark plugs (check specific plug type and recommendation).

Coolant Flush:

Every 30,000-60,000 miles (48,000-96,000 km) or 2-4 years, depending on coolant type.

Fluid Specifications

Engine Oil Spec:

API SN or higher, SAE 0W-20 or 5W-30 (check owner's manual for specific viscosity and API rating required for engine and climate).

Brake Fluid Spec:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid Spec:

Genuine Mitsubishi power steering fluid or a compatible Dexron III/Mercon ATF (verify specific requirements).

Known Issues

Common Issues Engine:

Occasional oil consumption in higher mileage 4G69 engines, potential for radiator leaks, and the importance of regular timing belt inspection/replacement if equipped.

Common Issues Transmission:

Some reports of transmission shudder or harsh shifting with the automatic transmission, often related to fluid condition or valve body issues. Regular fluid changes are crucial.

Common Issues Suspension:

Wear in control arm bushings and ball joints, leading to clunking noises or alignment issues. Struts can also wear over time.

Common Issues Electrical:

Failing window regulators, occasional issues with power door locks, and potential for ABS sensor failures. Ensure battery terminals are clean and secure.

📚 Vehicle History

Brand Heritage

Manufacturer:

Mitsubishi Motors Corporation (Japan)

Model Evolution

Generation:

This period (2005-2010) represents the second generation of the Mitsubishi Outlander, codenamed CW_series. It was a significant redesign from the first generation, moving to a more car-like unibody construction.

Redesign Timeline:

The second-generation Outlander debuted in Japan in late 2005 and subsequently launched in North America for the 2007 model year. It received a facelift and minor updates for the 2010 model year.

Production

Manufacturing Location:

Primarily manufactured at Mitsubishi's Okazaki Plant in Japan. Assembly also occurred in other global locations for different markets.

🏆 Awards & Recognition

Recognitions

Safety Awards:

Received good safety ratings from IIHS and NHTSA, contributing to its market appeal.

Practicality Awards:

Often cited for its practical cargo space and versatile interior for its class.