Mitsubishi Outlander 2004-2005 Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Outlander Generation: First Generation (CU/CS/ZA/ZB) Model Years Covered: 2004-2005 Codes Chassis Codes: CU2W, CU5W 👋 Introduction Market Position Segment: Compact Crossover SUV Target Audience: Families, individuals seeking versatile utility and comfortable ride. Competitive Analysis Key Competitors: Honda CR-V, Toyota RAV4, Ford Escape, Subaru Forester. Key Features Versatility: Offers a blend of car-like handling with SUV practicality and optional all-wheel drive. Value Proposition: Known for its robust engineering and relatively affordable pricing compared to some rivals. 📋 Manual Details Coverage Areas All Models Engines Trims Transmissions: True Page Count Estimated Page Count: Refer to actual manual for exact count. Typically 1000+ pages for a comprehensive factory service manual. Manual Type Type: Service and Repair Manual Language Language: English Format File Format: HTML Delivery Method: Electronic (Email) Printability: Printable Compatibility Operating Systems: Windows, Mac, Linux OS 📖 Manual Coverage Systems Covered Engine: Includes maintenance, troubleshooting, repair of gasoline engines (4G6X series). Transmission: Covers automatic and manual transmissions, including operation, diagnosis, and repair. Chassis: Includes suspension, steering, braking systems (ABS, EBD), wheels, and tires. Electrical: Comprehensive coverage of wiring diagrams, electrical components, charging system, starting system, lighting, instruments, and accessories. Bodywork: Includes body panel repair, interior trim, and exterior components. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, inspections. Troubleshooting: Diagnostic procedures, symptom-based troubleshooting, fault code interpretation. Repair: Step-by-step repair instructions for all major vehicle systems, including engine overhauls, transmission rebuilds, brake component replacement, and electrical system diagnostics. Diagnostics: OBD-II diagnostic information, scan tool usage, component testing. Technical Depth Depth: Comprehensive, covering basic maintenance to advanced diagnostics and complete overhauls, suitable for professional technicians and advanced DIYers. 📊 Manual Specifications File Format Quality: High-quality, professional technical manual format. Print Quality Print Capability: All pages are printable for garage/workshop use. Binding Type Binding: Digital PDF (HTML format) Paper Type Paper Type: Not Applicable (Digital Format) Completeness Condition: Complete and intact, no missing or corrupt parts/pages. ⚙️ Engine Specifications Primary Engine Engine Code And Type: 4G64 (2.4L SOHC Inline-4) and 6G72 (3.0L SOHC V6) Performance 2.4L Horsepower: Approx. 135-141 hp (varies slightly by market/spec) 2.4L Torque: Approx. 142-147 lb-ft (varies slightly by market/spec) 3.0L Horsepower: Approx. 165-170 hp 3.0L Torque: Approx. 186-190 lb-ft Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Engine Management ECU Type: Proprietary Mitsubishi Engine Control Unit (ECU) Emission Control Catalytic Converter: Standard, integrated catalytic converter system 🔧 Transmission Standard Transmission Type: 4-Speed Automatic Transmission (F4A42, F4A4B, W4A4B) Optional Manual Transmission: 5-Speed Manual Transmission (W5M51) Features AWD System: Available with Mitsubishi's All-Wheel Control (AWC) system, often featuring viscous coupling center differential and electronically controlled clutch packs. Fluid Type Automatic Transmission Fluid: Diamond ATF SP-II or SP-III (refer to manual for exact specification) Manual Transmission Fluid: API GL-4 or GL-5 SAE 75W-90 gear oil (refer to manual for exact specification) 📐 Dimensions Exterior Length: Approx. 177.4 inches (4505 mm) Width: Approx. 70.1 inches (1780 mm) Height: Approx. 65.7 inches (1670 mm) Wheelbase Wheelbase: Approx. 103.0 inches (2615 mm) Weights Curb Weight: Approx. 3,300 - 3,700 lbs (1497 - 1678 kg) depending on configuration Cargo Cargo Volume Seats Up: Approx. 25.4 cu ft (720 L) Cargo Volume Seats Down: Approx. 67.7 cu ft (1917 L) 🛡️ Safety Features Ratings NHTSA Front Impact: 4/5 stars (driver/passenger) for 2004 IIHS Side Impact: Acceptable for 2004 Active Features ABS: Anti-lock Braking System (ABS) standard on most models. Ebd: Electronic Brake-force Distribution (EBD) often paired with ABS. Traction Control: Traction Control System (TCS) available on some models, especially AWD variants. Passive Features Airbags: Front airbags standard; side airbags and curtain airbags available on some trims. Seatbelts: 3-point seatbelts with pre-tensioners and load limiters. 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD player with optional premium sound system. Aux input or Bluetooth typically not standard. Driver Assistance Cruise Control: Standard on most trims for highway driving comfort. Connectivity Telematics: Limited compared to modern vehicles; no integrated smartphone connectivity features like Apple CarPlay or Android Auto. 🔧 Maintenance Service Intervals Oil Change: Typically every 3,750 to 7,500 miles (6,000 to 12,000 km) or 6 months, depending on driving conditions and oil type (refer to manual for precise intervals). Spark Plugs: Replacement interval varies by plug type; iridium plugs can last up to 100,000 miles. Timing Belt: The 4G64 engine uses a timing belt that typically requires replacement every 60,000 to 90,000 miles. The 6G72 V6 engine also uses a timing belt with a similar interval. Crucial to follow manual's recommendation to prevent engine damage. Fluid Specifications Engine Oil: SAE 5W-30 or 10W-30 viscosity grade, API SJ or SL certified (refer to manual for specific capacity and type). Coolant: Mitsubishi Super Long Life Coolant (SLLC) or equivalent with specified ethylene glycol/water mixture. Brake Fluid: DOT 3 or DOT 4 brake fluid (refer to manual for exact specification). Known Issues Engine Mounts: Can degrade...
Step-by-step repair instructions for all major vehicle systems, including engine overhauls, transmission rebuilds, brake component replacement, and electrical system diagnostics.
Available with Mitsubishi's All-Wheel Control (AWC) system, often featuring viscous coupling center differential and electronically controlled clutch packs.
Fluid Type
Automatic Transmission Fluid:
Diamond ATF SP-II or SP-III (refer to manual for exact specification)
Manual Transmission Fluid:
API GL-4 or GL-5 SAE 75W-90 gear oil (refer to manual for exact specification)
📐 Dimensions
Exterior
Length:
Approx. 177.4 inches (4505 mm)
Width:
Approx. 70.1 inches (1780 mm)
Height:
Approx. 65.7 inches (1670 mm)
Wheelbase
Wheelbase:
Approx. 103.0 inches (2615 mm)
Weights
Curb Weight:
Approx. 3,300 - 3,700 lbs (1497 - 1678 kg) depending on configuration
Cargo
Cargo Volume Seats Up:
Approx. 25.4 cu ft (720 L)
Cargo Volume Seats Down:
Approx. 67.7 cu ft (1917 L)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
4/5 stars (driver/passenger) for 2004
IIHS Side Impact:
Acceptable for 2004
Active Features
ABS:
Anti-lock Braking System (ABS) standard on most models.
Ebd:
Electronic Brake-force Distribution (EBD) often paired with ABS.
Traction Control:
Traction Control System (TCS) available on some models, especially AWD variants.
Passive Features
Airbags:
Front airbags standard; side airbags and curtain airbags available on some trims.
Seatbelts:
3-point seatbelts with pre-tensioners and load limiters.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD player with optional premium sound system. Aux input or Bluetooth typically not standard.
Driver Assistance
Cruise Control:
Standard on most trims for highway driving comfort.
Connectivity
Telematics:
Limited compared to modern vehicles; no integrated smartphone connectivity features like Apple CarPlay or Android Auto.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 3,750 to 7,500 miles (6,000 to 12,000 km) or 6 months, depending on driving conditions and oil type (refer to manual for precise intervals).
Spark Plugs:
Replacement interval varies by plug type; iridium plugs can last up to 100,000 miles.
Timing Belt:
The 4G64 engine uses a timing belt that typically requires replacement every 60,000 to 90,000 miles. The 6G72 V6 engine also uses a timing belt with a similar interval. Crucial to follow manual's recommendation to prevent engine damage.
Fluid Specifications
Engine Oil:
SAE 5W-30 or 10W-30 viscosity grade, API SJ or SL certified (refer to manual for specific capacity and type).
Coolant:
Mitsubishi Super Long Life Coolant (SLLC) or equivalent with specified ethylene glycol/water mixture.
Brake Fluid:
DOT 3 or DOT 4 brake fluid (refer to manual for exact specification).
Known Issues
Engine Mounts:
Can degrade over time, leading to increased vibration and noise, especially during acceleration or deceleration.
Automatic Transmission Slipping:
Early models might experience occasional hesitation or slipping; proper fluid maintenance is key.
Rear Suspension Noise:
Occasional reports of knocking or rattling from the rear suspension, potentially related to bushings or shock absorbers.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors:
Long history of automotive manufacturing, known for rally-bred performance (Lancer Evolution) and reliable engineering.
Model Evolution
First Generation:
Launched in 2000 globally, heavily revised for the 2004 model year with updated styling, interior, and powertrain options. This manual specifically covers the post-facelift models.
Production
Manufacturing Location:
Primarily produced in Japan, with some assembly in other regions depending on market.
🏆 Awards & Recognition
Recognitions
Safety Ratings:
Good overall safety ratings for its time, with positive marks from NHTSA and IIHS.