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Mitsubishi Outlander 2004 2005 2006 Body Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Outlander Year: 2004-2006 Codes Chassis Code: CU/CF Series 👋 Introduction Market Position Segment: Compact Crossover SUV Competitive Analysis Key Competitors: Honda CR-V, Toyota...
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Mitsubishi Outlander 2004 2005 2006 Body Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Outlander
Year:
2004-2006
Codes
Chassis Code:
CU/CF Series
👋 Introduction
Market Position
Segment:
Compact Crossover SUV
Competitive Analysis
Key Competitors:
Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra
Key Features
Design Philosophy:
Sporty styling, practical interior, available all-wheel drive, car-like handling
Target Audience:
Families, individuals seeking a versatile and stylish SUV with car-like driving dynamics
📋 Manual Details
Coverage Areas
General Scope:
Body Repair
Page Count
Estimated Pages:
Approximately 500-700 pages (typical for comprehensive body repair manuals, exact count not provided in product description)
Manual Type
Type:
Body Repair Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Body Structure:
Unibody construction, chassis components, frame straightening, structural repair procedures
Exterior Panels:
Front and rear bumper systems, fenders, hoods, doors, quarter panels, rocker panels, roof panel, tailgate, mirrors
Glass And Seals:
Windshield, rear window, side glass, sunroof, seals and weatherstripping installation and replacement
Paint And Finishing:
Surface preparation, dent repair, filler application, primer, base coat, clear coat procedures, touch-up techniques
Collision Repair:
Damage assessment, structural alignment, welding procedures (MIG, TIG), bonding techniques, panel replacement
Procedures Included
Panel Alignment:
Door, hood, and tailgate gap and flush alignment specifications
Welding Techniques:
Specific welding parameters, joint types, and material compatibility for chassis and body components
Adhesives And Sealants:
Application of body adhesives, seam sealers, and sound deadening materials
Underbody And Undercoating:
Repair and application of undercoating, rust proofing, and corrosion protection
Disassembly And Assembly:
Step-by-step instructions for removing and installing body panels and related components
Technical Depth
Detail Level:
Comprehensive, suitable for professional body shop technicians and advanced DIYers
Diagnostic Focus:
Diagnosis of structural damage, panel fitment issues, and common collision-related problems
Repair Methodology:
Detailed repair procedures for various types of impact damage, including minor cosmetic and major structural repairs
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely searchable text (common for professionally produced digital manuals)
Print Quality
Image Resolution:
High-resolution diagrams and illustrations suitable for printing
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G64 (2.4L)
Displacement:
2.4 Liters (2351 cc)
Configuration:
Inline 4-Cylinder, DOHC, 16-Valve
Horsepower:
Approx. 160 hp @ 6000 rpm
Torque:
Approx. 165 lb-ft @ 4000 rpm
Performance
Fuel Type:
Unleaded Gasoline
Fuel System
Injection Type:
Electronic Fuel Injection (EFI)
Emission Control:
Catalytic Converter, On-Board Diagnostics (OBD-II)
🔧 Transmission
Standard
Transmission Type:
4-Speed Automatic Transmission (INVECS-II)
Optional
Transmission Type:
5-Speed Manual Transmission (less common)
Features
Drivetrain:
Front-Wheel Drive (FWD) or All-Wheel Drive (AWD - Active). AWD system featured a viscous coupling center differential.
📐 Dimensions
Exterior
Length:
Approx. 178.4 inches (4531 mm)
Width:
Approx. 70.1 inches (1780 mm)
Height:
Approx. 65.4 inches (1661 mm)
Wheelbase:
Approx. 103.3 inches (2624 mm)
Interior
Seating Capacity:
5 Passengers
Cargo
Cargo Volume:
Approx. 33.5 cu ft (behind rear seats)
Weights
Curb Weight:
Approx. 3350-3600 lbs (depending on drivetrain and trim)
🛡️ Safety Features
Ratings
NHTSA Front Crash Test:
5-Star (Driver), 4-Star (Passenger) for 2004 model year (typical for this era, check specific year for exact results)
IIHS Side Impact Rating:
Good (for models equipped with side airbags)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Available Traction Control System (TCS)
Electronic Stability Control:
Available Electronic Stability Control (ESC) - often branded as Active Stability Control
Passive Features
Airbags:
Frontal airbags (driver and passenger), available front side-impact airbags, available side curtain airbags
Seatbelts:
3-point height-adjustable front seat belts with pretensioners, rear 3-point seat belts
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player, optional Rockford Fosgate premium audio system with subwoofer
Navigation:
Optional factory-installed GPS navigation system
Driver Assistance
Cruise Control:
Standard cruise control
Parking Assist:
Rear parking sensors were an available option on higher trims.
Connectivity
Auxiliary Input:
Likely an optional auxiliary audio input jack on later models or aftermarket integration.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles (6,000 km) or 6 months, whichever comes first, for severe driving conditions. 7,500 miles (12,000 km) or 12 months for normal driving.
Air Filter Replacement:
Every 30,000 miles (48,000 km) or as needed based on inspection.
Spark Plug Replacement:
Iridium spark plugs recommended for 105,000 miles (168,000 km) replacement interval.
Fluid Specifications
Engine Oil Type:
API SM or SN, SAE 5W-30 or 5W-20 (check owner's manual for specific recommendation)
Engine Oil Capacity:
Approx. 4.4 US quarts (4.2 liters) with filter change
Coolant Type:
Mitsubishi Super Long Life Coolant (or equivalent OAT coolant, typically pink or orange)
Transmission Fluid Type:
Diamond ATF SP-III (for automatic transmission)
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid
Known Issues
Common Problems:
Catalytic converter failure, O2 sensor issues, occasional ABS sensor faults, window regulator failures, minor interior trim rattles
Body Specific Concerns:
Corrosion on rocker panels and wheel arches in rust-prone climates, potential for minor paint chipping on front fascia
📚 Vehicle History
Brand Heritage
Manufacturer:
Mitsubishi Motors Corporation (Japan)
Model Evolution
First Generation:
Launched in 2001 globally, North American debut for the 2003 model year. The 2004-2006 models represent the first generation (CU/CF).
Facelift:
A minor facelift occurred for the 2006 model year, including revised front grille, bumper, and interior trim.
Production
Manufacturing Plant:
Primarily produced in Japan.
🏆 Awards & Recognition
Recognitions
Safety Awards:
Received good safety ratings from NHTSA and IIHS for its time, contributing to its appeal as a family vehicle.
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