Mitsubishi Outlander 2003 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Outlander Year: 2003 Codes Chassis Code: CU/2W/4W Series Engine Codes: 4G63 (2.0L DOHC MPI), 4G64 (2.4L SOHC MPI) 👋 Introduction Market Position Segment:...

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Type: Car

Vendor:

Sku: 428071

Tags: 2003 Car Cars Misc Mitsubishi Outlander

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Outlander

Year:

Codes

Chassis Code:

CU/2W/4W Series

Engine Codes:

4G63 (2.0L DOHC MPI), 4G64 (2.4L SOHC MPI)

👋 Introduction

Market Position

Segment:

Compact Crossover SUV

Target Audience:

Families, individuals seeking versatile and capable compact SUV

Competitive Analysis

Key Competitors:

Honda CR-V, Toyota RAV4, Ford Escape, Nissan X-Trail (Rogue in some markets), Subaru Forester

Key Features

Design Philosophy:

Sporty styling, practical interior, available All-Wheel Drive (AWC)

Powertrain Options:

Choice of 2.0L or 2.4L inline-four engines, front-wheel drive or all-wheel drive

Interior Versatility:

Fold-flat rear seating, decent cargo space for its class

📋 Manual Details

Coverage Areas

Markets Covered:

Global (specific regional variations may exist)

Page Count

Estimated Page Count:

Approximately 1500-2000 pages (typical for comprehensive workshop manuals)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical (4G63, 4G64), engine electrical, fuel system, ignition system, exhaust system, engine management (ECU), cooling system, lubrication system, turbocharger (if applicable)

Transmission:

Manual Transmission (5-speed F5M42), Automatic Transmission (4-speed F4A42, INVECS-II), driveline, axles, differentials, transfer case (4WD models)

Chassis And Suspension:

Front suspension (MacPherson struts), rear suspension (Multi-link), steering system, brake system (ABS, front discs, rear discs/drums), wheels and tires

Electrical And Electronics:

Body electricals, lighting, wipers, horn, power windows, power mirrors, central locking, audio system, instrument cluster, warning lights, immobilizer, ECU diagnostics, wiring diagrams

Body And Interior:

Body panels, doors, hoods, fenders, bumpers, interior trim, seats, airbags, HVAC system, climate control

Procedures Included

Maintenance:

Scheduled maintenance (oil changes, filter replacements, tune-ups), fluid level checks and changes, belt inspection and replacement, spark plug replacement, battery maintenance

Repair And Overhaul:

Engine disassembly and reassembly, transmission repair, brake caliper overhaul, suspension component replacement, steering rack repair, electrical component diagnosis and repair, bodywork repair

Diagnostics And Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, component testing procedures, wiring diagram interpretation for fault finding

Specifications And Data:

Torque specifications, fluid capacities and types, diagnostic data (e.g., sensor readings), component dimensions, tolerances

Technical Depth

Depth:

Comprehensive (from basic maintenance and inspections to complete engine and transmission overhauls, including detailed electrical schematics and diagnostic procedures)

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text (OCR processed for efficient content retrieval)

Print Quality

Resolution:

High-resolution scans suitable for printing

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine 1 Displacement:

1997 cc

Engine 1 Type:

4G63, Inline-4, DOHC, 16-valve, MPI

Engine 1 Bore X Stroke:

85.0 mm x 88.0 mm

Engine 1 Compression Ratio:

9.5:1

Engine 1 Power Output:

130 hp (97 kW) @ 6000 rpm (approx.)

Engine 1 Torque Output:

135 lb-ft (183 Nm) @ 3500 rpm (approx.)

Optional Engine

Engine 2 Displacement:

2351 cc

Engine 2 Type:

4G64, Inline-4, SOHC, 16-valve, MPI

Engine 2 Bore X Stroke:

86.5 mm x 90.7 mm

Engine 2 Compression Ratio:

9.5:1

Engine 2 Power Output:

145 hp (108 kW) @ 5500 rpm (approx.)

Engine 2 Torque Output:

150 lb-ft (203 Nm) @ 3000 rpm (approx.)

Performance

Fuel Type:

Unleaded Gasoline

Fuel System

Fuel Delivery:

Multi-Point Fuel Injection (MPI)

Engine Management

ECU Type:

Proprietary Mitsubishi ECU (specific model varies)

🔧 Transmission

Standard

Transmission Type:

5-Speed Manual F5M42

Optional

Transmission Type:

4-Speed Automatic INVECS-II F4A42

Features

AWD System:

Mitsubishi All-Wheel Control (AWC) with selectable modes (e.g., 2WD, 4WD Auto, 4WD Lock) on some models

Fluid Specifications

Manual Transmission Fluid:

API GL-4, SAE 75W-90 (refer to manual for exact specification and capacity)

Automatic Transmission Fluid:

DIAQueen ATF-SPII or equivalent (refer to manual for exact specification and capacity)

📐 Dimensions

Exterior

Length:

Approx. 4575 mm (179.9 in)

Width:

Approx. 1775 mm (69.9 in)

Height:

Approx. 1670 mm (65.7 in)

Wheelbase:

Approx. 2625 mm (103.3 in)

Weights

Curb Weight:

Approx. 1450-1650 kg (depending on configuration)

Gross Vehicle Weight:

Approx. 2000-2100 kg

Cargo

Cargo Volume:

Approx. 450-850 Liters (behind rear seats, expandable with seats folded)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

4-star driver, 4-star passenger (for 2003 model year in US)

IIHS Side Impact:

Good (for models equipped with side airbags)

Active Features

Standard on most trims (Anti-lock Braking System)

Traction Control:

Optional on some models

Passive Features

Airbags:

Front driver and passenger airbags standard, optional side airbags and curtain airbags on select trims

Seatbelts:

3-point ELR seatbelts with pretensioners and load limiters

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player with optional premium audio system (speaker count and amplifier vary by trim)

Display:

Basic dashboard displays for climate control and audio, digital odometer

Driver Assistance

Cruise Control:

Standard on most trims

Connectivity

Power Accessories:

Power windows, power locks, power mirrors standard on higher trims, optional on base models

Keyless Entry:

Optional on select trims

🔧 Maintenance

Service Intervals

Engine Oil And Filter:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first (severe service: shorter intervals)

Air Filter:

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

Spark Plugs:

Replace every 60,000 miles (96,000 km) for iridium type, 30,000 miles (48,000 km) for standard

Timing Belt:

Inspect every 30,000 miles (48,000 km), replace every 60,000 miles (96,000 km) for the 4G63 engine (crucial maintenance item)

Fluid Specifications

Engine Coolant:

Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based coolant with demineralized water)

Engine Oil Capacity:

Approx. 4.0-4.5 liters (4.2-4.8 US quarts) for 4G63/4G64 engines (refer to manual for exact capacity)

Brake Fluid:

DOT 3 or DOT 4

Known Issues

Engine Timing Belt:

Potential for premature wear or failure if not replaced at recommended intervals (especially on 4G63), leading to catastrophic engine damage.

Suspension Components:

Worn ball joints, tie rod ends, and control arm bushings can lead to steering looseness and premature tire wear.

Exhaust Manifold:

Cracking of the exhaust manifold can occur due to thermal stress, leading to exhaust leaks and noise.

Transmission Shifts:

Some automatic transmission models may exhibit rough shifting or delayed engagement over time, often related to fluid condition or solenoid issues.

Power Steering Pump:

Occasional reports of power steering pump leaks or noise.

📚 Vehicle History

Brand Heritage

Manufacturer:

Mitsubishi Motors Corporation, Japan

Model Evolution

Generation Start:

First Generation (2000-2006)

Design Inspiration:

Developed to compete in the growing compact SUV market, blending car-like handling with SUV practicality

Production

Manufacturing Plant:

Okazaki Plant, Aichi Prefecture, Japan

Global Sales:

Sold globally under various names (e.g., Mitsubishi Outlander, Mitsubishi Airtrek in Japan)

🏆 Awards & Recognition

Recognitions

Safety Awards:

Received good safety ratings from IIHS and NHTSA for its time, reflecting a focus on occupant protection.

Market Reception:

Generally well-received for its styling, practicality, and available AWD system, though it faced stiff competition.