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Mitsubishi Outlander Service Repair Workshop Manual 05 Onwards

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🏷️ Basic Information Identification Make: Mitsubishi Model: Outlander Generation: Second Generation (CY/ZJ/ZK/ZL) Production Start Year: 2005 Codes Chassis Code Range: CY0, ZJ, ZK, ZL 👋 Introduction Market Position Segment: Compact...
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Type: Car
Vendor:
Sku: 257087
Mitsubishi Outlander Service Repair Workshop Manual 05 Onwards
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Outlander
Generation:
Second Generation (CY/ZJ/ZK/ZL)
Production Start Year:
2005
Codes
Chassis Code Range:
CY0, ZJ, ZK, ZL
👋 Introduction
Market Position
Segment:
Compact Crossover SUV
Key Selling Points:
Practicality, available All-Wheel Drive (AWC), comfortable ride, versatile interior.
Competitive Analysis
Direct Competitors:
Honda CR-V, Toyota RAV4, Nissan X-Trail (Rogue), Ford Escape, Subaru Forester.
Key Features
Standout Features 2Nd Gen:
Optional third-row seating on some configurations, 'RISE' body construction for safety, Sportronic® continuously variable automatic transmission (CVT) available on certain models.
📋 Manual Details
Coverage Areas
Regional Coverage:
Global (specific to engine/transmission variants common to 2005 onwards models)
Model Variants Covered:
All trim levels and configurations for the specified model years.
Page Count
Estimated Page Count:
1000+
Manual Type
Type:
Service and Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital (PDF - Instant Download)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (mechanical and electrical), Fuel System, Exhaust System, Transmission (Automatic & Manual), Drivetrain (FWD, AWD)
Chassis:
Suspension (front & rear), Steering System, Braking System (ABS, EBD), Wheels & Tires
Body:
Exterior Body Panels, Interior Trim, Doors, Windows, Seats, HVAC System, Body Electrical
Electrical Electronics:
Engine Control Module (ECM), Body Control Module (BCM), Lighting, Instrumentation, Audio System, SRS Airbag System, Power Accessories
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement, brake pad/rotor replacement.
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, DTC (Diagnostic Trouble Code) interpretation and resolution.
Repair Rebuild:
Engine disassembly and reassembly, transmission repair, suspension component replacement, brake caliper overhaul, electrical component repair/replacement.
Technical Specifications:
Torque specifications, fluid capacities, component dimensions, electrical schematics, wiring diagrams.
Technical Depth
Depth:
Comprehensive from basic adjustments to full component overhauls and advanced diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable for quick information retrieval.
Print Quality
Resolution:
High-resolution, suitable for printing individual pages or sections.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
4G69 (2.4L SOHC MIVEC)
Displacement 1:
2.4 Liters (2378cc)
Bore X Stroke 1:
87.0 mm x 96.0 mm
Compression Ratio 1:
9.5:1
Horsepower 1:
162 hp @ 6000 rpm (approx.)
Torque 1:
161 lb-ft @ 4000 rpm (approx.)
Engine Variants
Engine Code 2:
6B31 (3.0L SOHC MIVEC V6)
Displacement 2:
3.0 Liters (2998cc)
Horsepower 2:
220 hp @ 6250 rpm (approx.)
Torque 2:
202 lb-ft @ 3750 rpm (approx.)
Performance
Fuel Type:
Unleaded gasoline
Fuel System
Injection Type:
Multi-point Fuel Injection (MPI) or Electronic Fuel Injection (EFI)
Emission Controls:
Catalytic Converter, Oxygen Sensors (O2S), Evaporative Emission Control (EVAP) System
🔧 Transmission
Standard
Transmission Type 1:
5-Speed Manual Transmission (on select 2.4L models)
Optional
Transmission Type 2:
6-Speed Sportronic® Continuously Variable Transmission (CVT) with Paddle Shifters (on select 2.4L models)
Transmission Type 3:
6-Speed INVECS-II Automatic Transmission with Sportronic® (on 3.0L V6 models)
Features
Drive System:
Front-Wheel Drive (FWD) or All-Wheel Control (AWC) system (electronically controlled)
📐 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)
Ground Clearance:
Approx. 195 mm (7.7 in)
Interior
Seating Capacity:
5 or 7 passengers (depending on configuration)
Cargo
Cargo Volume Behind 2Nd Row:
Approx. 357 Liters (12.6 cu ft) (5-seater configuration)
Cargo Volume Max:
Approx. 1592 Liters (56.2 cu ft) (5-seater, seats folded)
Weights
Curb Weight Min:
Approx. 1500 kg (3307 lbs)
Curb Weight Max:
Approx. 1800 kg (3968 lbs)
Gross Vehicle Weight Rating Gvwr:
Approx. 2250 kg (4960 lbs)
🛡️ Safety Features
Ratings
NHTSA Front Crash Rating:
4-Star (for driver and front passenger, varies by model year and testing methodology)
IIHS Side Impact Rating:
Good (for models tested)
Active Features
ABS:
Standard Anti-lock Braking System
Ebd:
Standard Electronic Brakeforce Distribution
Traction Control:
Available Traction Control System (TCS)
Stability Control:
Available Electronic Stability Control (ESC)
Passive Features
Airbags:
Front airbags, front side-impact airbags, available side curtain airbags (for first and second rows).
Seatbelts:
3-point seatbelts with pre-tensioners and load limiters (front seats), LATCH child seat anchor system.
Body Structure:
RISE (Reinforced Impact Safety Evolution) body construction for enhanced crashworthiness.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD player, optional Rockford Fosgate premium audio system, available navigation system.
Connectivity:
Auxiliary audio input jack, available Bluetooth hands-free calling (on later models/trims).
Driver Assistance
Cruise Control:
Standard cruise control.
Keyless Entry:
Available keyless entry and push-button start.
Parking Sensors:
Available rear parking sensors.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, depending on driving conditions and oil type used.
Air Filter Replacement:
Every 30,000 miles (48,000 km) or as needed based on inspection.
Cabin Air Filter Replacement:
Every 15,000 - 30,000 miles (24,000 - 48,000 km) or annually.
Spark Plug Replacement 2.4L:
Iridium-tipped spark plugs: 105,000 miles (169,000 km).
Transmission Fluid Change Cvt:
Refer to manual, typically around 60,000 miles (96,000 km) for severe use. Use Genuine Mitsubishi CVT Fluid J1.
Transmission Fluid Change Automatic:
Refer to manual, typically around 60,000 miles (96,000 km). Use Genuine Mitsubishi ATF J2 or equivalent.
Fluid Specifications
Engine Oil Type:
SAE 5W-30, API SN or ILSAC GF-5 certified (check manual for specific regional requirements).
Engine Oil Capacity:
Approx. 4.5 Liters (4.8 US Quarts) with filter change for 2.4L.
Coolant Type:
Mitsubishi Long Life Coolant (LLC) Green, or equivalent HOAT (Hybrid Organic Acid Technology).
Brake Fluid Type:
DOT 3 or DOT 4.
Power Steering Fluid Type:
Refer to manual, often Dexron III or equivalent ATF.
Known Issues
Common Problems 2.4L:
CVT issues (hesitation, judder), occasional oil consumption, catalytic converter failure, ignition coil failure.
Common Problems 3.0L V6:
Less common issues reported; potential for exhaust manifold leaks, some transmission concerns.
Suspension Wear:
Front sway bar links and bushings can wear over time, leading to clunking noises.
HVAC System:
Blend door actuator failure causing incorrect temperature control.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Japan
Key Brand Attributes:
Reliability, value for money, often incorporating innovative technology.
Model Evolution
First Generation Start:
2000
Second Generation Introduction:
2005
Second Generation Facelift:
2007
Production
Manufacturing Locations:
Japan, North America (Illinois, USA), Netherlands, China.
Target Market:
Global SUV market, particularly appealing to families and individuals seeking versatile transport.
🏆 Awards & Recognition
Recognitions
IIHS Top Safety Pick:
Selected models received Top Safety Pick awards from IIHS in various years.
Consumer Reports Reliability:
Mixed reliability ratings over its lifecycle, with specific model years and powertrains performing better than others.
Ratings
Kbb Consumer Rating:
Generally positive consumer feedback regarding utility and value, though powertrain specific reliability can vary.
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