Mitsubishi Outlander 2004 Repair Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Outlander Year: 2004 Codes Chassis Code: CU2W (specific to this generation) Engine Code: 4G63 (common for 2.4L variant) 👋 Introduction Market Position Segment:...

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Taper: Car

Distributeur:

UGS: 391056

Mots clés: 2004 Car Cars Misc Mitsubishi Outlander

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Outlander

Year:

Codes

Chassis Code:

CU2W (specific to this generation)

Engine Code:

4G63 (common for 2.4L variant)

👋 Introduction

Market Position

Segment:

Compact Crossover SUV

Target Audience:

Families, individuals seeking versatility and practicality, all-weather capability.

Competitive Analysis

Key Competitors:

Honda CR-V, Toyota RAV4, Subaru Forester, Ford Escape, Mazda CX-5.

Key Features

Design:

Distinctive 'jet-fighter' grille inspired by Lancer Evolution, available third-row seating (optional).

Performance:

Capable engine options, available Super All-Wheel Control (S-AWC) for enhanced traction.

Utility:

Practical cargo space, towing capability, versatile interior configurations.

📋 Manual Details

Coverage Areas

Covered Regions:

Global (primarily North American and European specifications)

Page Count

Estimated Pages:

1500+

Manual Type

Type:

Factory Service Manual (FSM) / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, cylinder head, block, pistons, crankshaft, camshafts, timing belt/chain, lubrication system, cooling system.

Engine Management:

Fuel injection, ignition system, sensors (MAP, MAF, O2, knock, etc.), actuators, ECU diagnostics, emission control systems.

Transmission:

Automatic and Manual Transmission service, repair, fluid changes, torque converter, internal components, clutch service.

Drivetrain:

Front-wheel drive (FWD), All-wheel drive (AWD) system service, differentials, drive shafts, CV joints, transfer case (if applicable).

Suspension:

Front and rear suspension, struts, shock absorbers, springs, control arms, ball joints, bushings, wheel alignment specifications.

Brakes:

Front and rear brake systems, discs, pads, calipers, hydraulic lines, master cylinder, ABS (Anti-lock Braking System) diagnostics and repair.

Steering:

Power steering system, pump, rack and pinion, tie rods, steering column, wheel alignment.

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting, power windows, power locks, wipers, horn.

HVAC:

Heating, Ventilation, and Air Conditioning (HVAC) system service, refrigerant, compressor, evaporator, condenser, heater core.

Body And Frame:

Body panel repair, door mechanisms, hinges, latches, bumpers, glass replacement, structural repair procedures.

Interior:

Seat removal and installation, dashboard components, trim panels, headliner.

Diagnostics:

On-Board Diagnostics (OBD-II) system, diagnostic trouble codes (DTCs), troubleshooting flowcharts.

Procedures Included

Maintenance:

Routine maintenance procedures, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection.

Repair:

Step-by-step repair procedures for all major mechanical and electrical components, including engine rebuilds and transmission overhauls.

Troubleshooting:

Detailed troubleshooting guides and flowcharts for diagnosing and resolving common and uncommon issues.

Diagnostics:

Procedures for using diagnostic tools, interpreting sensor data, and identifying fault codes.

Specifications:

Torque specifications, clearances, fluid capacities, diagnostic values, alignment angles.

Technical Depth

Depth:

Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures.

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable

Print Quality

Resolution:

High-resolution, suitable for printing individual pages or the entire manual.

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

2.4L 4-cylinder, SOHC, 16-valve, MIVEC (Mitsubishi Innovative Valve timing Electronic Control)

Engine Displacement:

2378 cc (2.4 Liters)

Engine Code Variant:

4G64 (for 2.4L, may differ slightly from 4G63 designation depending on specific variant)

Bore X Stroke:

86.5 mm x 100.0 mm

Compression Ratio:

9.5:1

Performance

Horsepower:

160 hp @ 5500 rpm (approx.)

Torque:

162 lb-ft @ 3500 rpm (approx.)

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline, 87 octane (recommended)

Emission Control:

Catalytic converter, EGR system, PCV system.

🔧 Transmission

Standard

Type:

4-speed Automatic (INVECS-II)

Optional

Type:

5-speed Manual

Features

AWD System:

Available electronically controlled All-Wheel Drive (AWC), including optional 'Sport' mode for enhanced performance (often referred to as S-AWC in later models, though the system evolved).

Fluid Specifications

Automatic Transmission Fluid:

Diamond ATF SP-II M or equivalent (refer to owner's manual for specific part number)

📐 Dimensions

Exterior

Length:

4590 mm (180.7 in)

Width:

1770 mm (69.7 in)

Height:

1640 mm (64.6 in)

Wheelbase:

2625 mm (103.3 in)

Front Track:

1515 mm (59.6 in)

Rear Track:

1515 mm (59.6 in)

Weights

Curb Weight FWD:

1570 kg (3461 lbs) (approx.)

Curb Weight AWD:

1670 kg (3682 lbs) (approx.)

Gross Vehicle Weight Rating:

2200 kg (4850 lbs) (approx.)

Towing Capacity:

1000 kg (2205 lbs) (braked trailer) (refer to owner's manual for specific regulations)

🛡️ Safety Features

Ratings

NHTSA Front Crash Test:

5-Star Rating

NHTSA Side Impact Test:

4-Star Rating

IIHS Front Offset Crash Test:

Good (for vehicles of this era, check specific IIHS reports)

Active Features

Standard Anti-lock Braking System (ABS)

E Brake Force Distribution:

Electronic Brake-force Distribution (EBD)

Traction Control:

Available Traction Control System (TCS)

Passive Features

Airbags Front:

Driver and front passenger airbags

Airbags Side:

Available front seat-mounted side airbags, optional front and rear side curtain airbags.

Seatbelts:

Three-point seatbelts with pretensioners and load limiters (front seats), three-point seatbelts (rear seats).

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system

💡 Technology Features

Infotainment

Audio System:

AM/FM stereo with CD player, optional premium audio system (e.g., Rockford Fosgate).

Display:

Basic LCD display for radio and climate controls.

Driver Assistance

Cruise Control:

Standard cruise control.

Keyless Entry:

Available keyless entry system.

Connectivity

Auxiliary Input:

Limited connectivity features typical for the era; no standard Bluetooth or USB inputs.

🔧 Maintenance

Service Intervals

Oil Change:

Every 7,500 miles (12,000 km) or 6 months, whichever comes first.

Engine Air Filter:

Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).

Cabin Air Filter:

Inspect every 15,000 miles (24,000 km), replace as needed or every 15,000-30,000 miles (24,000-48,000 km) depending on environment.

Spark Plugs:

Replace every 105,000 miles (168,000 km) (if using Iridium type plugs).

Transmission Fluid Change:

Inspect every 30,000 miles (48,000 km), change as needed or every 60,000 miles (96,000 km) (refer to manual for severe usage). Note: This is an estimate; consult manual for exact intervals.

Timing Belt Replacement:

If applicable (some engines used timing chains), refer to manual. Typically around 60,000-100,000 miles for belts.

Fluid Specifications

Engine Oil:

SAE 5W-30, API SJ or higher, ILSAC GF-3 (refer to manual for exact specification and capacity).

Engine Coolant:

Long-life coolant (Mitsubishi Super Long Life Coolant or equivalent), typically a 50/50 mix with distilled water. Capacity ~6.2 Liters.

Brake Fluid:

DOT 3 or DOT 4 brake fluid.

Power Steering Fluid:

Mitsubishi Genuine Power Steering Fluid or equivalent (ATF DEXRON II or III may be acceptable, verify with manual).

Known Issues

Engine Mounts:

Premature wear and failure of engine mounts leading to vibrations.

ABS Sensor Failure:

ABS wheel speed sensor failures can trigger ABS and traction control warning lights.

Suspension Bushings:

Wear in suspension bushings (e.g., control arm bushings) can lead to knocking noises and poor handling.

Automatic Transmission:

Some reports of rough shifting or delayed engagement in automatic transmissions, especially with high mileage.

Exhaust Manifold Cracks:

Cracking of the exhaust manifold can lead to exhaust leaks and a ticking sound.

📚 Vehicle History

Brand Heritage

Mitsubishi History:

Mitsubishi Motors Corporation is a Japanese multinational automotive manufacturer, part of the Mitsubishi keiretsu. Known for innovative technologies and robust vehicles.

Model Evolution

Generation Details:

First generation Outlander (CU#W series), launched in 2001. This 2004 model represents an early iteration of the Outlander's development.

Platform:

Built on Mitsubishi's GS platform, shared with the Mitsubishi Airtrek (Japan-market version) and later the Lancer sedan.

Production

Manufacturing Location:

Japan (primarily Okazaki Plant)

Production Years:

2001-2006 (First Generation)

🏆 Awards & Recognition

Recognitions

Crash Test Performance:

Received 5-star ratings from NHTSA for front impact safety.

Ratings

Consumer Reports Reliability:

Variable reliability ratings for this generation; specific year ratings should be consulted.