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Mitsubishi Outlander 2003-2008 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Outlander Generation: First Generation Codes Chassis Code: CU2W 👋 Introduction Market Position Segment: Compact Crossover SUV Target Audience: Families, individuals seeking versatile and...
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Type: Car
Vendor:
Sku: 263992
Mitsubishi Outlander 2003-2008 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Outlander
Generation:
First Generation
Codes
Chassis Code:
CU2W
👋 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 Xterra
Key Features
Design:
Distinctive styling, available third-row seating (optional on some trims), spacious interior
Powertrain:
Reliable 4-cylinder engines, optional AWD system for enhanced traction
Utility:
Practical cargo space, comfortable ride, suitable for daily commuting and light off-road excursions
📋 Manual Details
Coverage Areas
Years Covered:
2003, 2004, 2005, 2006, 2007, 2008
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Engine:
2.4L 4G64 SOHC/DOHC, 2.4L 4G69 MIVEC SOHC
Transmission:
4-speed Automatic (F4A42), 5-speed Manual
Drivetrain:
Front-Wheel Drive (FWD), All-Wheel Drive (AWD) - electronically controlled viscous coupling
Suspension:
Front: MacPherson Strut, Rear: Multi-link
Brakes:
Front: Ventilated Disc, Rear: Disc (ABS optional)
Steering:
Power Rack and Pinion
Electrical:
Battery, Charging System, Starting System, Ignition System, Lighting, Fuses, Relays, Body Control Modules (BCM), Power Windows, Locks, Mirrors, Wiper/Washer System, HVAC Controls
Body And Chassis:
Body Panels, Doors, Hood, Tailgate, Bumpers, Interior Trim, Unibody Structure
HVAC:
Air Conditioning, Heating, Ventilation, Blower Motor, Evaporator, Condenser, Refrigerant System
Safety Systems:
Airbags, Seatbelts, ABS (Anti-lock Braking System)
Procedures Included
General Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tire rotations, spark plug replacement, brake pad replacement
Engine Repair:
Timing belt replacement, cylinder head removal/installation, piston/ring replacement, valve adjustment, component diagnostics and repair
Transmission Service:
Fluid changes, filter replacement, torque converter service, transmission overhaul (major/minor repairs)
Brake Service:
Brake pad/rotor replacement, caliper service, bleeding procedure, ABS component testing
Electrical Diagnostics:
Wiring diagrams, troubleshooting guides for starting, charging, ignition, lighting, and accessories
Suspension And Steering:
Component replacement (shocks, struts, ball joints, tie rods), alignment procedures, power steering system repair
HVAC Service:
Refrigerant system diagnostics, component replacement, blower motor service, heater core service
Bodywork:
Panel alignment, door/tailgate adjustment, trim removal/installation
Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults
Technical Depth
Depth:
Comprehensive; from basic maintenance to full engine and transmission rebuilds, detailed electrical schematics and troubleshooting
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content
Printable:
Printable pages
Print Quality
Quality:
High-resolution scans of original factory documentation
Binding Type
Binding:
N/A (Digital)
Paper Type
Paper:
N/A (Digital)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G64
Displacement:
2.4 Liters (2351 cc)
Configuration:
Inline 4-Cylinder
Valvetrain:
SOHC 16-valve or DOHC 16-valve (depending on sub-model/year)
Bore X Stroke:
86.5 mm x 100.0 mm
Compression Ratio:
9.5:1 (typical)
Performance
Horsepower:
135-157 hp @ 5500-5750 rpm (depending on variant)
Torque:
140-159 lb-ft @ 2500-4000 rpm (depending on variant)
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 octane recommended)
Engine Codes
Engine Variant Codes:
4G64, 4G69 (MIVEC)
🔧 Transmission
Standard
Transmission Type:
4-speed Automatic (F4A42)
Optional
Transmission Type:
5-speed Manual
Features
AWD Coupling:
Electronically controlled viscous coupling (AWC - All Wheel Control system)
Fluid Specifications
Automatic Transmission Fluid:
DIA Queen ATF-SP-II M or equivalent DEXRON III/MERCON
Fluid Capacity
Automatic Transmission Fluid Capacity:
Approx. 7.4 Liters (Pan Drop)
Manual Transmission Fluid
Manual Transmission Fluid Type:
API GL-4, SAE 75W-90
📐 Dimensions
Exterior
Length:
Approx. 4555 mm (179.3 in)
Width:
Approx. 1775 mm (69.9 in)
Height:
Approx. 1650 mm (65.0 in)
Wheelbase:
Approx. 2670 mm (105.1 in)
Track Width Front:
Approx. 1515 mm (59.6 in)
Track Width Rear:
Approx. 1510 mm (59.4 in)
Weights
Curb Weight:
Approx. 1500-1650 kg (3300-3640 lbs) depending on configuration
Gross Vehicle Weight Rating:
Approx. 2050-2150 kg (4520-4740 lbs)
Cargo
Cargo Volume Behind 2Nd Row:
Approx. 850 Liters (30 cu ft)
Cargo Volume With 2Nd Row Folded:
Approx. 1700 Liters (60 cu ft)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact Driver:
4 Stars (2005 model year)
NHTSA Frontal Impact Passenger:
4 Stars (2005 model year)
NHTSA Side Impact Driver:
5 Stars (2005 model year)
NHTSA Side Impact Rear Passenger:
5 Stars (2005 model year)
IIHS Frontal Offset Score:
Good (2005 model year)
IIHS Side Impact Score:
Good (2005 model year)
Active Features
ABS:
Standard or Optional depending on trim and year
Traction Control:
Optional on some models
Passive Features
Airbags:
Front driver and passenger airbags standard, side curtain airbags optional on some models
Seatbelts:
3-point ELR seatbelts with pretensioners for front seats
💡 Technology Features
Infotainment
Audio System:
AM/FM/CD player with optional Rockford Fosgate premium audio system, steering wheel audio controls (on higher trims)
Navigation:
Optional factory navigation system on select models.
Driver Assistance
Cruise Control:
Standard on most models
Keyless Entry:
Standard or optional depending on trim
Connectivity
Power Outlets:
12V accessory power outlets
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,750 miles (6,000 km) or 3 months (severe service) / 7,500 miles (12,000 km) or 6 months (normal service)
Air Filter Replacement:
Every 15,000 miles (24,000 km) or 12 months
Engine Oil Filter:
Replace with every oil change
Spark Plugs:
Every 60,000 miles (96,000 km) (Iridium type)
Timing Belt:
Crucial: Every 90,000 miles (144,000 km) or 7 years. Failure can cause catastrophic engine damage.
Fluid Specifications
Engine Oil Type:
API SM/SN or ILSAC GF-4/GF-5, SAE 5W-30 (or 5W-20 if specified for specific climates/models)
Engine Oil Capacity:
Approx. 4.5 Liters (4.8 US Quarts) with filter
Coolant:
Mitsubishi Super Long Life Coolant (SLLC) - Blue (or equivalent HOAT)
Coolant Capacity:
Approx. 7.4 Liters (7.8 US Quarts)
Brake Fluid:
DOT 3 or DOT 4
Power Steering Fluid:
MITSUBISHI PSF or equivalent ATF Dexron II/III
Known Issues
Timing Belt Wear:
Crucial to follow replacement schedule; premature wear or breakage can occur if neglected.
Rear Suspension Noise:
Squeaks or rattles from rear multi-link suspension components can occur with age and mileage.
Cv Joint Boots:
Tearing of front CV joint boots can lead to premature joint failure.
Oxygen Sensor:
Failure of O2 sensors can impact fuel economy and emissions.
📚 Vehicle History
Brand Heritage
Parent Company:
Mitsubishi Motors Corporation
Notable Models:
Lancer Evolution, Pajero/Montero, Eclipse
Model Evolution
First Generation Launch:
Introduced for the 2001 model year in Japan, North American debut for 2003 model year
Major Refresh:
Facelift for the 2004 model year with updated styling and features
Production End First Gen:
Concluded with the 2006 model year in some markets, continued to 2008 for North America
Production
Manufacturing Location:
Mizushima Plant, Kurashiki, Okayama, Japan
🏆 Awards & Recognition
Recognitions
IIHS Top Safety Pick:
Achieved 'Good' ratings in IIHS frontal and side impact tests for 2005 model year.
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