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2004 Mitsubishi Outlander Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Outlander Year: 2004 👋 Introduction Market Position Vehicle Segment: Compact Crossover SUV Competitive Analysis Key Competitors 2004: Honda CR-V, Toyota RAV4, Ford Escape, Subaru Forester, Nissan Xterra Key Features Manual Value Proposition: Provides factory-level diagnostic and repair information, enabling DIY maintenance and reducing reliance on costly dealership services. Manual Usefulness Benefit To Owner: Empowers owners to understand their vehicle's systems, perform routine maintenance, and troubleshoot common issues, thereby extending vehicle life and saving money. 📋 Manual Details Coverage Areas Primary Coverage: Complete Service, Repair, and Maintenance Page Count Estimated Page Count: Over 1500 pages (estimated based on typical factory manuals of this era and scope) Manual Type Type: Factory Service Manual (FSM) / Workshop Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine, Engine Lubrication, Fuel System, Engine Cooling System, Intake and Exhaust Systems, Engine Electrical, Engine and Emission Control, Clutch, Manual Transmission, Automatic Transmission, Propeller Shaft, Front Axle, Rear Axle, Power Plant Mount Chassis And Suspension: Wheel and Tyre, Front Suspension, Rear Suspension, Service Brakes, Parking Brakes, Steering System Body And Electrical: Body, Exterior, Interior, Supplement Restraint System (SRS), Chassis Electrical, Heater, Air Conditioner and Ventilation Drive Systems: Front-Wheel Drive (FWD) and All-Wheel Drive (AWD) systems including differentials, driveshafts, and couplings. Braking System: Front disc brakes, rear drum or disc brakes (depending on trim), ABS system components, and parking brake mechanisms. Steering System: Power assisted rack and pinion steering system, including steering column and linkage components. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, inspections, lubrication Repair And Rebuild: Engine overhaul, transmission repair, brake system overhaul, suspension component replacement, electrical component diagnosis and repair, body panel repair Diagnostics: Troubleshooting guides, diagnostic procedures for all major systems, electrical circuit diagrams, OBD-II diagnostic codes interpretation Wheel Alignment Specs: Detailed specifications for wheel alignment (camber, caster, toe) for front and rear suspensions. Technical Depth Depth: Comprehensive from basic maintenance to in-depth component overhauls and diagnostic procedures, including detailed torque specifications and repair sequences. Wiring Diagrams: Includes comprehensive electrical wiring diagrams for all vehicle systems, aiding in complex electrical diagnostics. 📊 Manual Specifications File Format Compatibility: All Versions of Windows & Mac Requirements: Adobe PDF Reader & WinZip Print Quality Printability: All pages are printable, allowing for physical use during repairs. Binding Type Binding Description: N/A (Digital PDF Format) Paper Type Paper Description: N/A (Digital PDF Format) Diagram Quality Diagrams And Illustrations: High quality, clear, and detailed diagrams and illustrations for easy comprehension of repair procedures. ⚙️ Engine Specifications Primary Engine Engine Code: 4G64 (SOHC Inline-4) Engine Code Engine Configuration: Inline 4-Cylinder, SOHC (Single Overhead Camshaft) Displacement Displacement Liters: 2.4 L Displacement Cc: 2351 cc Performance Horsepower Hp: 135 hp @ 5200 rpm (approximate) Torque Lb Ft: 145 lb-ft @ 4000 rpm (approximate) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) / Multi-Point Fuel Injection (MPFI) Fuel Type Fuel Type: Unleaded Gasoline Ignition System Ignition Type: Distributorless Ignition System (DIS) with coil-on-plug or coil-pack ignition. Engine Lubrication Oil Type Recommendation: API Service SL or SM, ILSAC GF-3 or GF-4, SAE 5W-30 (refer to manual for specific grade based on climate). Engine Cooling Coolant Type Recommendation: Ethylene glycol-based coolant, 50/50 mix with distilled water. Mitsubishi Super Long Life Coolant (MS-4) or equivalent. 🔧 Transmission Standard Transmission Type Standard: 5-Speed Manual Transmission Optional Transmission Type Optional: 4-Speed Automatic Transmission (INVECS-II) Features Manual Transmission Features: Standard front-wheel drive (FWD) or optional all-wheel drive (AWD) configurations. Automatic Transmission Features: INVECS-II (Intelligent & Innovative Vehicle Electronic Control system) with 'Sport Mode' and 'Snow Mode' on some AWD models. Fluid Specifications Manual Transmission Fluid Type: GL-4 SAE 75W-90 Gear Oil (refer to manual for specific Mitsubishi specifications). Automatic Transmission Fluid Type: DIA-Queen ATF-III or equivalent. Refer to manual for precise fluid type and capacity. 📐 Dimensions Exterior Wheelbase Inches: 103.3 inches (2624 mm) Length Inches: 177.2 inches (4498 mm) Width Inches: 69.9 inches (1775 mm) Height Inches: 66.1 inches (1679 mm) Weights Curb Weight Lbs: Approx. 3300-3550 lbs (depending on FWD/AWD and transmission) Cargo Cargo Volume Cu Ft: Approx. 31.5 cu ft (behind rear seats), expandable to 63.4 cu ft (with rear seats folded). 🛡️ Safety Features Ratings NHTSA Front Impact Driver: Good (refer to NHTSA records for specific 2004 model year ratings as they can vary) NHTSA Front Impact Passenger: Good (refer to NHTSA records for specific 2004 model year ratings as they can vary) IIHS Front Offset Crash Rating: Acceptable (refer to IIHS records for specific 2004 model year ratings) Passive Features Airbags: Front dual-stage airbags, optional front side-impact airbags. Seatbelts: 3-point height-adjustable front seatbelts with pretensioners and load limiters, 3-point rear seatbelts. Child Safety: LATCH (Lower Anchors and Tethers for CHildren) system in rear seats. Active Features ABS: Anti-lock Braking System (ABS) standard on most trims. Traction Control: Optional Traction Control System...
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2004 Mitsubishi Outlander Service Repair Workshop Manual2004 Mitsubishi Outlander Service Repair Workshop Manual2004 Mitsubishi Outlander Service Repair Workshop Manual2004 Mitsubishi Outlander Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Outlander
Year:
2004
👋 Introduction
Market Position
Vehicle Segment:
Compact Crossover SUV
Competitive Analysis
Key Competitors 2004:
Honda CR-V, Toyota RAV4, Ford Escape, Subaru Forester, Nissan Xterra
Key Features
Manual Value Proposition:
Provides factory-level diagnostic and repair information, enabling DIY maintenance and reducing reliance on costly dealership services.
Manual Usefulness
Benefit To Owner:
Empowers owners to understand their vehicle's systems, perform routine maintenance, and troubleshoot common issues, thereby extending vehicle life and saving money.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Service, Repair, and Maintenance
Page Count
Estimated Page Count:
Over 1500 pages (estimated based on typical factory manuals of this era and scope)
Manual Type
Type:
Factory Service Manual (FSM) / Workshop Manual
Language
Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Engine Lubrication, Fuel System, Engine Cooling System, Intake and Exhaust Systems, Engine Electrical, Engine and Emission Control, Clutch, Manual Transmission, Automatic Transmission, Propeller Shaft, Front Axle, Rear Axle, Power Plant Mount
Chassis And Suspension:
Wheel and Tyre, Front Suspension, Rear Suspension, Service Brakes, Parking Brakes, Steering System
Body And Electrical:
Body, Exterior, Interior, Supplement Restraint System (SRS), Chassis Electrical, Heater, Air Conditioner and Ventilation
Drive Systems:
Front-Wheel Drive (FWD) and All-Wheel Drive (AWD) systems including differentials, driveshafts, and couplings.
Braking System:
Front disc brakes, rear drum or disc brakes (depending on trim), ABS system components, and parking brake mechanisms.
Steering System:
Power assisted rack and pinion steering system, including steering column and linkage components.
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, inspections, lubrication
Repair And Rebuild:
Engine overhaul, transmission repair, brake system overhaul, suspension component replacement, electrical component diagnosis and repair, body panel repair
Diagnostics:
Troubleshooting guides, diagnostic procedures for all major systems, electrical circuit diagrams, OBD-II diagnostic codes interpretation
Wheel Alignment Specs:
Detailed specifications for wheel alignment (camber, caster, toe) for front and rear suspensions.
Technical Depth
Depth:
Comprehensive from basic maintenance to in-depth component overhauls and diagnostic procedures, including detailed torque specifications and repair sequences.
Wiring Diagrams:
Includes comprehensive electrical wiring diagrams for all vehicle systems, aiding in complex electrical diagnostics.
📊 Manual Specifications
File Format
Compatibility:
All Versions of Windows & Mac
Requirements:
Adobe PDF Reader & WinZip
Print Quality
Printability:
All pages are printable, allowing for physical use during repairs.
Binding Type
Binding Description:
N/A (Digital PDF Format)
Paper Type
Paper Description:
N/A (Digital PDF Format)
Diagram Quality
Diagrams And Illustrations:
High quality, clear, and detailed diagrams and illustrations for easy comprehension of repair procedures.
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G64 (SOHC Inline-4)
Engine Code
Engine Configuration:
Inline 4-Cylinder, SOHC (Single Overhead Camshaft)
Displacement
Displacement Liters:
2.4 L
Displacement Cc:
2351 cc
Performance
Horsepower Hp:
135 hp @ 5200 rpm (approximate)
Torque Lb Ft:
145 lb-ft @ 4000 rpm (approximate)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) / Multi-Point Fuel Injection (MPFI)
Fuel Type
Fuel Type:
Unleaded Gasoline
Ignition System
Ignition Type:
Distributorless Ignition System (DIS) with coil-on-plug or coil-pack ignition.
Engine Lubrication
Oil Type Recommendation:
API Service SL or SM, ILSAC GF-3 or GF-4, SAE 5W-30 (refer to manual for specific grade based on climate).
Engine Cooling
Coolant Type Recommendation:
Ethylene glycol-based coolant, 50/50 mix with distilled water. Mitsubishi Super Long Life Coolant (MS-4) or equivalent.
🔧 Transmission
Standard
Transmission Type Standard:
5-Speed Manual Transmission
Optional
Transmission Type Optional:
4-Speed Automatic Transmission (INVECS-II)
Features
Manual Transmission Features:
Standard front-wheel drive (FWD) or optional all-wheel drive (AWD) configurations.
Automatic Transmission Features:
INVECS-II (Intelligent & Innovative Vehicle Electronic Control system) with 'Sport Mode' and 'Snow Mode' on some AWD models.
Fluid Specifications
Manual Transmission Fluid Type:
GL-4 SAE 75W-90 Gear Oil (refer to manual for specific Mitsubishi specifications).
Automatic Transmission Fluid Type:
DIA-Queen ATF-III or equivalent. Refer to manual for precise fluid type and capacity.
📐 Dimensions
Exterior
Wheelbase Inches:
103.3 inches (2624 mm)
Length Inches:
177.2 inches (4498 mm)
Width Inches:
69.9 inches (1775 mm)
Height Inches:
66.1 inches (1679 mm)
Weights
Curb Weight Lbs:
Approx. 3300-3550 lbs (depending on FWD/AWD and transmission)
Cargo
Cargo Volume Cu Ft:
Approx. 31.5 cu ft (behind rear seats), expandable to 63.4 cu ft (with rear seats folded).
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
Good (refer to NHTSA records for specific 2004 model year ratings as they can vary)
NHTSA Front Impact Passenger:
Good (refer to NHTSA records for specific 2004 model year ratings as they can vary)
IIHS Front Offset Crash Rating:
Acceptable (refer to IIHS records for specific 2004 model year ratings)
Passive Features
Airbags:
Front dual-stage airbags, optional front side-impact airbags.
Seatbelts:
3-point height-adjustable front seatbelts with pretensioners and load limiters, 3-point rear seatbelts.
Child Safety:
LATCH (Lower Anchors and Tethers for CHildren) system in rear seats.
Active Features
ABS:
Anti-lock Braking System (ABS) standard on most trims.
Traction Control:
Optional Traction Control System (TCS) on some AWD models.
Stability Control:
Electronic Stability Control (ESC) not commonly available on this model year, but check specific trim details.
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player, optional Rockford Fosgate premium audio system with subwoofer on higher trims.
Climate Control:
Manual or optional Automatic Climate Control (ACC).
Driver Assistance
Cruise Control:
Standard on most trims.
Connectivity
Connectivity Features:
Limited connectivity options for the era; primarily audio auxiliary inputs if equipped.
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Every 3,750 miles (6,000 km) or 3 months, or 7,500 miles (12,000 km) or 6 months with synthetic oil (consult manual for exact intervals and severe service conditions).
Engine Air Filter:
Inspect every 15,000 miles (24,000 km), replace as needed. Recommended replacement every 30,000 miles (48,000 km).
Spark Plugs:
Replace every 60,000 miles (96,000 km) for standard spark plugs. Platinum or Iridium plugs may have longer intervals (consult manual).
Transmission Fluid Change Automatic:
Recommended every 30,000 miles (48,000 km) or as per severe service schedule.
Coolant Flush:
First flush at 105,000 miles (168,000 km) or 7 years, then every 52,500 miles (84,000 km) or 4 years thereafter.
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4.
Power Steering Fluid Type:
Mitsubishi Power Steering Fluid or Dexron III ATF.
Known Issues
Common Wear Item Suspension:
Front control arm bushings, sway bar links, and ball joints can wear over time, leading to clunking noises or poor handling.
Common Wear Item Engine:
Timing belt replacement is critical. If it breaks, it can cause severe engine damage. Inspect serpentine belt for cracks.
Common Issue Transmission:
Some models may experience occasional transmission hesitation or rough shifts, especially the automatic transmission. Regular fluid changes are key.
Common Issue Electrical:
Rear wiper motor failure, power window regulator issues, and occasional HVAC blower motor problems have been reported.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors Legacy:
Mitsubishi Motors has a long history in automotive manufacturing, known for robust engineering and rally-bred vehicles.
Model Evolution
Outlander First Generation Launch:
The first-generation Outlander (codenamed CU) debuted in 2001 in Japan and was released globally for the 2003 model year. The 2004 model is part of this initial generation.
Production
Manufacturing Location:
Japan (primarily for North American market).
🏆 Awards & Recognition
Recognitions
General Recognition:
The Outlander was generally well-received for its value, practicality, and available AWD system, though it didn't typically win major awards compared to more established competitors.
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