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...
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.