Mitsubushi OUTLAndER Service Repair Manual 2005-2010
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🏷️ Basic Information Identification Make: Mitsubishi Model: Outlander Generation: Second Generation (CW/ZJ) Codes Chassis Codes: CW5W, CW6W, CW4W 👋 Introduction Market Position Vehicle Segment: Compact Crossover SUV Competitive Analysis Key Competitors: Honda CR-V, Toyota RAV4, Nissan X-Trail (Rogue), Ford Escape, Subaru Forester Key Features Platform Sharing: Built on the Mitsubishi GS platform, shared with the Mitsubishi Lancer and related to the Mitsubishi Outlander XL (PSA Peugeot Citroën C-Crosser/Citroën C4/Peugeot 4007). Drivetrain Options: Available with front-wheel drive (FWD) and Mitsubishi's AWC (All-Wheel Control) system. 📋 Manual Details Coverage Areas Markets Covered: Global (specific to regions and engine variants as outlined in the manual) Page Count Estimated Page Count: Likely 1500+ pages (typical for comprehensive factory service manuals of this era) Manual Type Manual Type: Factory Service Manual / Workshop Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Powertrain Components: Engine mechanical, fuel system, exhaust system, cooling system, lubrication system, ignition system, starter system, charging system Drivetrain Components: Clutch, manual transmission, automatic transmission, sub-transmission (if applicable), transfer case, drive shafts, axles, differentials Suspension Steering Brakes: Front suspension, rear suspension, steering system, hydraulic brake system, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution) Electrical Electronics: Battery, charging system, starting system, ignition system, lighting system, instrumentation, switches, power windows, power locks, HVAC controls, audio system, SRS (Supplemental Restraint System) / Airbag system, body control module (BCM) Body Chassis Comfort: Body construction, exterior trim, interior trim, seats, HVAC system, doors, windows, wipers, locks Procedures Included Maintenance Tasks: Scheduled maintenance, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements (oil, air, fuel), spark plug replacement, belt inspection/replacement Diagnostic Procedures: Troubleshooting guides, diagnostic trouble codes (DTCs), wiring diagrams for electrical systems, component testing procedures Repair Rebuild Procedures: Engine removal/installation, cylinder head repair, piston/ring replacement, crankshaft inspection, transmission overhaul, brake caliper overhaul, suspension component replacement, steering rack replacement Adjustment Calibration: Valve lash adjustment, parking brake adjustment, wheel alignment specifications, headlight aiming Technical Depth Depth Of Coverage: Comprehensive: from basic fluid checks and routine maintenance to in-depth component diagnostics, repair, and complete rebuilds of major systems. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, printable pages with clear diagrams and text. Searchable functionality likely present. Binding Type Binding Type: Digital Download (not a physical book) Paper Type Paper Type: Not Applicable (Digital) ⚙️ Engine Specifications Primary Engine Engine Displacement And Code: 2.4L 4G69 MIVEC I4 (common in many markets) Engine Horsepower Approx: 160-170 hp @ 6000 rpm (may vary slightly by region) Engine Torque Approx: 162-165 lb-ft @ 4000 rpm (may vary slightly by region) Optional Engine Optional Engine Displacement And Code: 3.0L 6B31 MIVEC V6 (in some markets, particularly North America) Optional Engine Horsepower Approx: 220-230 hp @ 6250 rpm Optional Engine Torque Approx: 200-205 lb-ft @ 3750 rpm Fuel System Fuel Delivery System: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline (Octane rating as specified by Mitsubishi) 🔧 Transmission Standard Standard Transmission: 5-speed Manual Transmission (less common in some markets) Optional Optional Transmission: 6-speed INVECS-III Continuously Variable Transmission (CVT) with Paddle Shifters (most common) Optional Transmission V6: 6-speed Automatic Transmission (typically paired with the 3.0L V6) Features Awc System: All-Wheel Control (AWC) system with selectable modes (e.g., Normal, Snow, Lock) for enhanced traction and stability. 📐 Dimensions Exterior Length Approx: 4570 mm (179.9 in) Width Approx: 1800 mm (70.9 in) Height Approx: 1690 mm (66.5 in) (without roof rails) Wheelbase Approx: 2670 mm (105.1 in) Weights Curb Weight Approx: 1550 - 1750 kg (3417 - 3858 lbs) (depending on engine and drivetrain) 🛡️ Safety Features Ratings NHTSA Ratings: Generally received good ratings, with 4 or 5 stars in frontal and side impact tests in applicable years/regions. IIHS Ratings: Received 'Good' ratings in frontal offset and side impact tests for certain model years. Active Features Active Safety Features: Anti-lock Braking System (ABS), Electronic Brakeforce Distribution (EBD), Brake Assist (BA), Traction Control System (TCS), Active Stability Control (ASC)/Electronic Stability Control (ESC), All-Wheel Control (AWC) Passive Features Passive Safety Features: Front airbags, front side-impact airbags, side curtain airbags, three-point seatbelts with pretensioners, LATCH (Lower Anchors and Tethers for Children) system. 💡 Technology Features Infotainment Infotainment System: Base models featured a standard AM/FM/CD audio system. Higher trims offered optional Rockford Fosgate premium audio, in-dash CD changer, and navigation systems. Connectivity Options: Auxiliary input jack for audio devices was available on many models. Bluetooth hands-free calling was an option on later models or higher trims. Driver Assistance Driver Assistance Features: Traction Control, Stability Control, ABS, EBD, Brake Assist were standard or widely available. Advanced driver assistance systems (like adaptive cruise control, lane departure warning) were not common on this generation. 🔧 Maintenance Service Intervals Engine Oil Change Interval: Typically every 7,500 miles (12,000 km) or 6 months, whichever comes first, under normal driving conditions. Refer to manual for severe conditions. Transmission...
Honda CR-V, Toyota RAV4, Nissan X-Trail (Rogue), Ford Escape, Subaru Forester
Key Features
Platform Sharing:
Built on the Mitsubishi GS platform, shared with the Mitsubishi Lancer and related to the Mitsubishi Outlander XL (PSA Peugeot Citroën C-Crosser/Citroën C4/Peugeot 4007).
Drivetrain Options:
Available with front-wheel drive (FWD) and Mitsubishi's AWC (All-Wheel Control) system.
📋 Manual Details
Coverage Areas
Markets Covered:
Global (specific to regions and engine variants as outlined in the manual)
Page Count
Estimated Page Count:
Likely 1500+ pages (typical for comprehensive factory service manuals of this era)
6-speed Automatic Transmission (typically paired with the 3.0L V6)
Features
Awc System:
All-Wheel Control (AWC) system with selectable modes (e.g., Normal, Snow, Lock) for enhanced traction and stability.
📐 Dimensions
Exterior
Length Approx:
4570 mm (179.9 in)
Width Approx:
1800 mm (70.9 in)
Height Approx:
1690 mm (66.5 in) (without roof rails)
Wheelbase Approx:
2670 mm (105.1 in)
Weights
Curb Weight Approx:
1550 - 1750 kg (3417 - 3858 lbs) (depending on engine and drivetrain)
🛡️ Safety Features
Ratings
NHTSA Ratings:
Generally received good ratings, with 4 or 5 stars in frontal and side impact tests in applicable years/regions.
IIHS Ratings:
Received 'Good' ratings in frontal offset and side impact tests for certain model years.
Active Features
Active Safety Features:
Anti-lock Braking System (ABS), Electronic Brakeforce Distribution (EBD), Brake Assist (BA), Traction Control System (TCS), Active Stability Control (ASC)/Electronic Stability Control (ESC), All-Wheel Control (AWC)
Passive Features
Passive Safety Features:
Front airbags, front side-impact airbags, side curtain airbags, three-point seatbelts with pretensioners, LATCH (Lower Anchors and Tethers for Children) system.
💡 Technology Features
Infotainment
Infotainment System:
Base models featured a standard AM/FM/CD audio system. Higher trims offered optional Rockford Fosgate premium audio, in-dash CD changer, and navigation systems.
Connectivity Options:
Auxiliary input jack for audio devices was available on many models. Bluetooth hands-free calling was an option on later models or higher trims.
Driver Assistance
Driver Assistance Features:
Traction Control, Stability Control, ABS, EBD, Brake Assist were standard or widely available. Advanced driver assistance systems (like adaptive cruise control, lane departure warning) were not common on this generation.
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Typically every 7,500 miles (12,000 km) or 6 months, whichever comes first, under normal driving conditions. Refer to manual for severe conditions.
Transmission Fluid Change Interval Cvt:
Crucial for CVT longevity. Often recommended around 30,000-60,000 miles (48,000-96,000 km), but check manual for specific fluid type and interval as CVTs can be sensitive.
Coolant Replacement Interval:
Initial replacement at a higher mileage (e.g., 100,000 miles/10 years), then every 50,000 miles/5 years. Use specified Long Life Coolant.
Fluid Specifications
Engine Oil Specification:
SAE 5W-30 API SM or higher, ILSAC GF-4 or higher (confirm with manual for specific viscosity and certification)
Transmission Fluid Specification Cvt:
Specific Mitsubishi CVT Fluid J4 (or equivalent approved fluid). Do not use generic ATF.
Brake Fluid Specification:
DOT 3 or DOT 4
Power Steering Fluid Type:
Use Genuine Mitsubishi Power Steering Fluid or a DEXRON-III (H) or equivalent ATF.
Known Issues
Cvt Durability:
Some models, particularly early ones with CVTs, may experience CVT wear or failure if maintenance intervals are not strictly followed, especially fluid changes.
Engine Misfires:
Potential for ignition coil issues or spark plug wear, leading to misfires, especially on the 4G69 engine.
Suspension Noise:
Worn sway bar links or bushings can lead to knocking or clunking noises, particularly over uneven surfaces.
Ac System Performance:
Occasional reports of AC compressor or clutch issues, or refrigerant leaks.
📚 Vehicle History
Brand Heritage
Mitsubishi SUV History:
Mitsubishi has a long history of producing capable SUVs, including the Pajero (Montero) and the Outlander line, known for their durability and off-road prowess in earlier generations.
Model Evolution
Outlander Second Generation:
This generation (2005-2010) marked a significant redesign, featuring a more car-like monocoque construction, a smoother exterior design, and increased refinement. It also saw the introduction of the optional third-row seating in some configurations and the development of the AWC system.
Production
Manufacturing Locations:
Primary production in Japan. Some variants or related models were also produced in other Mitsubishi facilities globally.
🏆 Awards & Recognition
Recognitions
IIHS Top Safety Pick:
Received IIHS Top Safety Pick awards for certain model years, indicating good performance in crash safety tests.
Other Awards:
Varies by market; often praised for its value proposition, available AWD system, and practicality.
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