Mitsubishi Outlander 2003 to 2008 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Outlander Generation: First Generation Model Years Covered: 2003, 2004, 2005, 2006, 2007, 2008 Codes Platform Code: CSA (shared with Mitsubishi Airtrek) Chassis Code: CU2W 👋 Introduction Market Position Segment: Compact Crossover SUV Positioning: Offered a more car-like driving experience than traditional SUVs, with available all-wheel drive and a focus on practicality and value. Competitive Analysis Key Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Subaru Forester. Key Features Body Style: 5-door compact SUV Drivetrain Options: Front-Wheel Drive (FWD) and available All-Wheel Drive (AWD - Mitsubishi's AWC system). Interior Versatility: Foldable rear seats for increased cargo space. 📋 Manual Details Coverage Areas Primary Coverage: Repair, maintenance, diagnostics, troubleshooting, and technical specifications for the Mitsubishi Outlander (2003-2008). Component Coverage: Engine, drivetrain, transmission, suspension, steering, brakes, electrical systems, HVAC, bodywork, interior, chassis. Page Count Estimated Page Count: Over 1500 pages (typical for comprehensive service manuals of this era). Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanical, fuel injection, ignition, cooling, lubrication, emission control, starting and charging. Drivetrain Systems: Front-wheel drive (FWD) and All-wheel drive (AWD) systems, differentials, drive shafts, CV joints. Transmission Systems: Automatic Transmission (INVECS-II) and Manual Transmission (if applicable to specific markets/trims). Suspension Steering: Front suspension (MacPherson strut), rear suspension (multi-link), power steering system, steering column, wheel alignment. Brake Systems: Front and rear brakes (disc brakes, potentially with ABS), parking brake, brake fluid specifications. Electrical Systems: Battery, charging system, starting system, lighting, wipers, power windows, central locking, fuses, relays, wiring diagrams. HVAC Systems: Air conditioning, heating, ventilation, climate control unit. Body Interior: Body panels, doors, hood, tailgate, interior trim, seats, safety restraints. Procedures Included Maintenance Procedures: Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, brake pad replacement, tire rotation. Repair Procedures: Engine component overhaul (e.g., cylinder head, pistons), transmission rebuild, suspension component replacement, brake caliper overhaul, electrical component testing and replacement. Diagnostic Procedures: Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs) and their interpretations, sensor testing, actuator testing. Installation Procedures: Component replacement and installation guidelines (e.g., alternator, starter motor, water pump). Technical Depth Depth: Comprehensive. Covers basic maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and wiring diagrams. 📊 Manual Specifications File Format File Type: PDF Searchable Text: Yes (typically, depending on PDF creation). Print Quality Printability: High quality, suitable for home printing. Allows for zooming into diagrams and text. Binding Type Binding: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code: 4G64 (2.4L SOHC I4) Displacement: 2351 cc Bore X Stroke: 86.5 mm x 100.0 mm Compression Ratio: 9.5:1 Horsepower: 137 hp @ 5,500 rpm (2003-2004), 160 hp @ 5,500 rpm (2005-2006), 156 hp @ 5,500 rpm (2007-2008) Torque: 140 lb-ft @ 3,500 rpm (2003-2004), 162 lb-ft @ 3,500 rpm (2005-2006), 162 lb-ft @ 3,500 rpm (2007-2008) Engine Block Material: Cast Iron Cylinder Head Material: Aluminum Alloy Valvetrain: SOHC (Single Overhead Camshaft), 16 valves Performance Engine Option 2 Code: 6B31 (3.0L SOHC V6 - introduced in 2007) Engine Option 2 Displacement: 2998 cc Engine Option 2 Horsepower: 220 hp @ 6,000 rpm Engine Option 2 Torque: 200 lb-ft @ 3,750 rpm Fuel System Fuel Delivery: Electronic Fuel Injection (MPI - Multi-Point Injection) Fuel Type: Unleaded Gasoline (87 octane recommended) Fuel Tank Capacity: 62.0 liters (16.4 US gallons) 🔧 Transmission Standard Transmission Type: 4-speed Automatic (INVECS-II) Optional Transmission Type: 5-speed Manual (Available on some 2.4L trims in certain markets). Features AWD System: Mitsubishi All-Wheel Control (AWC) system, featuring electronically controlled coupling for torque distribution. Transmission Fluid Type: DIAQUEEN SP-II (or equivalent Dexron III/Mercon) 📐 Dimensions Exterior Length: 4,580 mm (179.9 in) (2003-2006), 4,625 mm (182.1 in) (2007-2008) Width: 1,775 mm (69.9 in) Height: 1,670 mm (65.7 in) (FWD), 1,675 mm (65.9 in) (AWD) Wheelbase: 2,625 mm (103.3 in) Ground Clearance: 205 mm (8.1 in) (FWD), 195 mm (7.7 in) (AWD) Front Track: 1,515 mm (59.6 in) Rear Track: 1,510 mm (59.4 in) Wheel Bolt Pattern: 5x114.3 mm (5x4.5 inches) Wheel Size: 16x6.5, 17x6.5 Tire Size Standard: 215/70R16 Tire Size Optional: 215/60R17 Weights Curb Weight 2.4L: 1,500 - 1,600 kg (3,300 - 3,530 lbs) depending on FWD/AWD and trim Curb Weight 3.0L V6: 1,650 - 1,750 kg (3,640 - 3,860 lbs) depending on AWD and trim Gross Vehicle Weight Rating Gvwr: Approx. 2,000 - 2,150 kg (4,410 - 4,740 lbs) Cargo Cargo Volume Seats Up: Approx. 0.45 m³ (16 cu ft) Cargo Volume Seats Down: Approx. 1.45 m³ (51 cu ft) 🛡️ Safety Features Ratings NHTSA Frontal Driver: 4 Stars (2003) NHTSA Frontal Passenger: 4 Stars (2003) NHTSA Side Driver: 5 Stars (2003) NHTSA Side Rear Passenger: 5 Stars (2003) IIHS Frontal Offset: Good (2003-2006 models) IIHS Side Impact: Good (2003-2006 models) Active...

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Tipo: Car

Fabricante:

Sku: 264390

Coleções: ALL Mitsubishi

Disponibilidade: Em estoque

Tag: 2003 2004 2005 2006 2007 2008 Car Cars Mitsubishi Outlander

Variantes do produto

Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Outlander

Generation:

First Generation

Model Years Covered:

2003, 2004, 2005, 2006, 2007, 2008

Codes

Platform Code:

CSA (shared with Mitsubishi Airtrek)

Chassis Code:

👋 Introduction

Market Position

Segment:

Compact Crossover SUV

Positioning:

Offered a more car-like driving experience than traditional SUVs, with available all-wheel drive and a focus on practicality and value.

Competitive Analysis

Key Competitors:

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

Key Features

Body Style:

5-door compact SUV

Drivetrain Options:

Front-Wheel Drive (FWD) and available All-Wheel Drive (AWD - Mitsubishi's AWC system).

Interior Versatility:

Foldable rear seats for increased cargo space.

📋 Manual Details

Coverage Areas

Primary Coverage:

Repair, maintenance, diagnostics, troubleshooting, and technical specifications for the Mitsubishi Outlander (2003-2008).

Component Coverage:

Engine, drivetrain, transmission, suspension, steering, brakes, electrical systems, HVAC, bodywork, interior, chassis.

Page Count

Estimated Page Count:

Over 1500 pages (typical for comprehensive service manuals of this era).

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Systems:

Engine mechanical, fuel injection, ignition, cooling, lubrication, emission control, starting and charging.

Drivetrain Systems:

Front-wheel drive (FWD) and All-wheel drive (AWD) systems, differentials, drive shafts, CV joints.

Transmission Systems:

Automatic Transmission (INVECS-II) and Manual Transmission (if applicable to specific markets/trims).

Suspension Steering:

Front suspension (MacPherson strut), rear suspension (multi-link), power steering system, steering column, wheel alignment.

Brake Systems:

Front and rear brakes (disc brakes, potentially with ABS), parking brake, brake fluid specifications.

Electrical Systems:

Battery, charging system, starting system, lighting, wipers, power windows, central locking, fuses, relays, wiring diagrams.

HVAC Systems:

Air conditioning, heating, ventilation, climate control unit.

Body Interior:

Body panels, doors, hood, tailgate, interior trim, seats, safety restraints.

Procedures Included

Maintenance Procedures:

Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, brake pad replacement, tire rotation.

Repair Procedures:

Engine component overhaul (e.g., cylinder head, pistons), transmission rebuild, suspension component replacement, brake caliper overhaul, electrical component testing and replacement.

Diagnostic Procedures:

Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs) and their interpretations, sensor testing, actuator testing.

Installation Procedures:

Component replacement and installation guidelines (e.g., alternator, starter motor, water pump).

Technical Depth

Depth:

Comprehensive. Covers basic maintenance to full engine and transmission rebuilds, including detailed diagnostic procedures and wiring diagrams.

📊 Manual Specifications

File Format

File Type:

Searchable Text:

Yes (typically, depending on PDF creation).

Print Quality

Printability:

High quality, suitable for home printing. Allows for zooming into diagrams and text.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Code:

4G64 (2.4L SOHC I4)

Displacement:

2351 cc

Bore X Stroke:

86.5 mm x 100.0 mm

Compression Ratio:

9.5:1

Horsepower:

137 hp @ 5,500 rpm (2003-2004), 160 hp @ 5,500 rpm (2005-2006), 156 hp @ 5,500 rpm (2007-2008)

Torque:

140 lb-ft @ 3,500 rpm (2003-2004), 162 lb-ft @ 3,500 rpm (2005-2006), 162 lb-ft @ 3,500 rpm (2007-2008)

Engine Block Material:

Cast Iron

Cylinder Head Material:

Aluminum Alloy

Valvetrain:

SOHC (Single Overhead Camshaft), 16 valves

Performance

Engine Option 2 Code:

6B31 (3.0L SOHC V6 - introduced in 2007)

Engine Option 2 Displacement:

2998 cc

Engine Option 2 Horsepower:

220 hp @ 6,000 rpm

Engine Option 2 Torque:

200 lb-ft @ 3,750 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (MPI - Multi-Point Injection)

Fuel Type:

Unleaded Gasoline (87 octane recommended)

Fuel Tank Capacity:

62.0 liters (16.4 US gallons)

🔧 Transmission

Standard

Transmission Type:

4-speed Automatic (INVECS-II)

Optional

Transmission Type:

5-speed Manual (Available on some 2.4L trims in certain markets).

Features

AWD System:

Mitsubishi All-Wheel Control (AWC) system, featuring electronically controlled coupling for torque distribution.

Transmission Fluid Type:

DIAQUEEN SP-II (or equivalent Dexron III/Mercon)

📐 Dimensions

Exterior

Length:

4,580 mm (179.9 in) (2003-2006), 4,625 mm (182.1 in) (2007-2008)

Width:

1,775 mm (69.9 in)

Height:

1,670 mm (65.7 in) (FWD), 1,675 mm (65.9 in) (AWD)

Wheelbase:

2,625 mm (103.3 in)

Ground Clearance:

205 mm (8.1 in) (FWD), 195 mm (7.7 in) (AWD)

Front Track:

1,515 mm (59.6 in)

Rear Track:

1,510 mm (59.4 in)

Wheel Bolt Pattern:

5x114.3 mm (5x4.5 inches)

Wheel Size:

16x6.5, 17x6.5

Tire Size Standard:

215/70R16

Tire Size Optional:

215/60R17

Weights

Curb Weight 2.4L:

1,500 - 1,600 kg (3,300 - 3,530 lbs) depending on FWD/AWD and trim

Curb Weight 3.0L V6:

1,650 - 1,750 kg (3,640 - 3,860 lbs) depending on AWD and trim

Gross Vehicle Weight Rating Gvwr:

Approx. 2,000 - 2,150 kg (4,410 - 4,740 lbs)

Cargo

Cargo Volume Seats Up:

Approx. 0.45 m³ (16 cu ft)

Cargo Volume Seats Down:

Approx. 1.45 m³ (51 cu ft)

🛡️ Safety Features

Ratings

NHTSA Frontal Driver:

4 Stars (2003)

NHTSA Frontal Passenger:

4 Stars (2003)

NHTSA Side Driver:

5 Stars (2003)

NHTSA Side Rear Passenger:

5 Stars (2003)

IIHS Frontal Offset:

Good (2003-2006 models)

IIHS Side Impact:

Good (2003-2006 models)

Active Features

Standard on most trims, available on others.

Traction Control:

Available on AWD models.

Electronic Stability Control Esc:

Introduced on later models, typically with V6 engine.

Passive Features

Airbags Front:

Standard driver and front passenger airbags.

Airbags Side Curtain:

Available as an option or standard on higher trims (side curtain airbags with rollover sensors).

Seatbelts:

3-point front and rear seatbelts with pretensioners and force limiters (front).

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with CD player (single-disc or 6-disc changer on higher trims), optional Rockford Fosgate premium audio system.

Display:

Basic LCD display for audio information; optional navigation system on some models.

Driver Assistance

Cruise Control:

Standard on most trims.

Keyless Entry:

Available on most trims.

Connectivity

Auxiliary Input:

Not typically standard, but some aftermarket head units or adapters may exist.

Bluetooth:

Not available on factory systems for this generation.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 miles (12,000 km) or 6 months, whichever comes first (under normal driving conditions).

Engine Oil Filter Interval:

Replace with every oil change.

Air Filter Replacement:

Every 30,000 miles (48,000 km) or 24 months.

Spark Plug Replacement 2.4L:

Platinum-tipped spark plugs: Every 105,000 miles (168,000 km).

Spark Plug Replacement 3.0L V6:

Iridium-tipped spark plugs: Every 105,000 miles (168,000 km).

Transmission Fluid Change:

Every 60,000 miles (96,000 km) or 48 months (under normal conditions). Consider more frequent changes under severe conditions (towing, frequent short trips, etc.).

Coolant Flush Replacement:

Every 60,000 miles (96,000 km) or 48 months. Use Mitsubishi Super Long Life Coolant (SLLC) or equivalent. Use P-HOAT (Phosphated Hybrid Organic Acid Technology) coolant.

Brake Fluid Replacement:

Every 30,000 miles (48,000 km) or 24 months.

Fluid Specifications

Engine Oil Type 2.4L:

API SN or newer, ILSAC GF-5 or newer, SAE 5W-30 (preferred) or 10W-30.

Engine Oil Type 3.0L V6:

API SN or newer, ILSAC GF-5 or newer, SAE 5W-30.

Engine Oil Capacity 2.4L:

4.5 Liters (4.8 US Quarts) with filter change.

Engine Oil Capacity 3.0L V6:

4.8 Liters (5.1 US Quarts) with filter change.

Power Steering Fluid:

Mitsubishi Genuine Power Steering Fluid or equivalent Dexron III automatic transmission fluid.

Brake Fluid:

DOT 3 or DOT 4.

Known Issues

Engine Mounts:

Premature wear and failure of engine mounts leading to vibration and noise.

Cv Joints:

Wear on front CV joints, particularly on AWD models, causing clicking noises during turns.

Oxygen Sensors:

Failure of oxygen sensors can lead to poor fuel economy and check engine light illumination.

Rear Wheel Bearings:

Premature wear of rear wheel bearings, causing humming or grinding noises.

Evaporative Emissions Control Evap System:

Faulty purge solenoid or vent valve can trigger check engine lights (P0442, P0455).

Radiator And Hoses:

Plastic end tanks on radiators can become brittle and crack over time. Coolant hoses may degrade.

📚 Vehicle History

Brand Heritage

Parent Company:

Mitsubishi Motors Corporation (Japan)

Model Evolution

First Generation Launch:

Introduced in Japan as the Mitsubishi Airtrek in 2001, rebadged as Outlander for export markets in 2003.

Facelift:

Received a significant facelift for the 2007 model year, including revised exterior styling, updated interior, and the introduction of the 3.0L V6 engine option.

Production

Manufacturing Plant:

Mizushima Plant, Kurashiki, Okayama, Japan

Production Period:

2003 - 2006 (First generation phase 1), 2007 - 2008 (First generation phase 2)

🏆 Awards & Recognition

Recognitions

IIHS Top Safety Pick:

Received 'Good' ratings in frontal and side impact tests from the IIHS for early models, indicating strong safety performance for its class and era.

Consumer Reports:

Varied reliability ratings over the years, with some common issues noted (as listed in 'known_issues'). Consult specific year reviews.