Mitsubishi Outlander 2003-2006 Workshop Service Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Outlander Generation: First Generation Model Years Covered: 2003, 2004, 2005, 2006 Codes Chassis Code Prefix: CU 👋 Introduction Market Position Vehicle Segment: Compact...

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类型: Car

斯库: 56468

标签: 2003 2004 2005 2006 Car Cars Mitsubishi Outlander

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Outlander

Generation:

First Generation

Model Years Covered:

2003, 2004, 2005, 2006

Codes

Chassis Code Prefix:

👋 Introduction

Market Position

Vehicle Segment:

Compact Crossover SUV

Target Audience:

Families, individuals seeking practical and versatile transportation, capable of light off-road use.

Competitive Analysis

Key Competitors:

Honda CR-V, Toyota RAV4, Ford Escape, Subaru Forester, Nissan X-Trail (depending on market).

Key Features

Powertrain Options:

Available with 4-cylinder and V6 engines, FWD and AWD drivetrain options.

Practicality:

Spacious interior for its class, versatile cargo space, higher driving position.

Design:

Distinctive styling for its era, aiming for a balance between SUV ruggedness and car-like comfort.

📋 Manual Details

Coverage Areas

Regions Covered:

Global (specifications may vary slightly by market)

Page Count

Estimated Page Count:

1500+

Manual Type

Type:

Workshop Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Full overhaul, diagnostics, timing belt replacement, cooling system, lubrication system, fuel delivery, emissions control.

Engine Electrical:

Ignition system, starting and charging system, engine control unit (ECU) diagnostics, sensor operations.

Transmission Manual:

Removal, installation, internal components, fluid specifications, clutch operation.

Transmission Automatic:

Removal, installation, torque converter, internal components, fluid specifications, electronic control.

Drivetrain:

Front-wheel drive (FWD) and All-wheel drive (AWD) systems, front and rear differentials, driveshafts, CV joints.

Suspension:

Front and rear suspension components, shock absorbers, struts, bushings, alignment specifications.

Steering:

Power steering system, steering rack, tie rods, steering column, alignment.

Brakes:

Front and rear brake systems (disc/drum or disc/disc), ABS (Anti-lock Braking System) diagnostics, hydraulic components, parking brake.

Electrical System:

Battery, charging system, lighting, instruments, power accessories, fuse box diagrams, relay functions.

Body And Interior:

Body panels, doors, windows, seats, trim, HVAC (Heating, Ventilation, and Air Conditioning) system, interior components.

Body Electrical:

Wiper system, horn, mirrors, door locks, power windows, interior lighting, sound system wiring.

Chassis And Frame:

Frame construction, body mounting, exhaust system routing.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, brake inspections.

Troubleshooting:

Diagnostic flowcharts, common problem identification and solutions for engine, transmission, electrical, and other systems.

Repair Instructions:

Step-by-step procedures for component removal, installation, and repair, with detailed diagrams.

Overhaul Procedures:

Complete engine and transmission rebuild procedures, including part specifications and tolerances.

Diagnostics:

OBD-II (On-Board Diagnostics) information, diagnostic trouble codes (DTCs), sensor data interpretation.

Wiring Diagrams:

Comprehensive electrical wiring schematics for all major systems.

Technical Depth

Depth:

Professional-level diagnostics, repair, and overhaul procedures, suitable for experienced DIYers and professional technicians.

📊 Manual Specifications

File Format

Format:

Print Quality

Printability:

Full printable

Zoom Capability:

Yes (allows for detailed viewing of diagrams and text)

Binding Type

Binding:

Digital (Downloadable PDF)

Paper Type

Paper Type:

Not Applicable (Digital Format)

Delivery

Delivery Method:

Instant Download

Requirements

Software Requirements:

Adobe PDF Reader, WinRAR

Compatibility

Operating Systems:

All Versions of Windows & Mac

⚙️ Engine Specifications

Primary Engine

Engine Code Common:

4G6x series (e.g., 4G64, 4G69) - 2.4L Inline-4; 6G7x series (e.g., 6G72) - 3.0L V6

Displacement 2.4L:

2378 cc (145 cu. in.)

Displacement 3.0L:

2972 cc (181 cu. in.)

Performance 2.4L

Horsepower:

Approx. 140-145 hp @ 5500-5700 rpm

Torque:

Approx. 145-150 lb-ft @ 3500-4000 rpm

Performance 3.0L

Horsepower:

Approx. 165-170 hp @ 5500-5750 rpm

Torque:

Approx. 175-180 lb-ft @ 4000-4500 rpm

Fuel System

Fuel Delivery:

Electronic Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Engine Features

Timing System 2.4L:

SOHC (Single Overhead Camshaft) with timing belt

Timing System 3.0L:

SOHC (Single Overhead Camshaft) with timing belt

🔧 Transmission

Standard

Type:

5-speed Manual Transmission (typically on 2.4L FWD models)

Optional

Type:

4-speed Automatic Transmission (INVECS-II, common on both 2.4L and 3.0L, FWD and AWD)

Features

AWD System:

Mitsubishi's Active-Trac AWD system (electronically controlled coupling, often with driver-selectable modes).

📐 Dimensions

Exterior

Length:

Approx. 178.5 inches (4535 mm)

Width:

Approx. 70.9 inches (1800 mm)

Height:

Approx. 65.0 inches (1650 mm)

Wheelbase:

Approx. 103.3 inches (2625 mm)

Weights

Curb Weight Approx FWD:

3300-3500 lbs (1497-1588 kg)

Curb Weight Approx AWD:

3500-3700 lbs (1588-1678 kg)

Cargo

Cargo Volume Behind Rear Seats:

Approx. 14.8 - 20.8 cubic feet (depending on configuration)

Cargo Volume With Rear Seats Folded:

Approx. 63.4 cubic feet

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

4 Stars (2003 model, depending on specific configuration and testing)

NHTSA Front Impact Passenger:

4 Stars (2003 model, depending on specific configuration and testing)

IIHS Front Offset Crash Rating:

Good (2003-2006 models)

Active Features

Standard on most models, optional on base models.

Traction Control:

Available on AWD models, optional on FWD.

Passive Features

Airbags Front:

Standard dual front airbags.

Airbags Side:

Optional front side-impact airbags on some trims.

Seatbelts:

3-point seatbelts with pretensioners for front occupants.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, optional premium audio systems with more speakers available on higher trims.

Navigation:

Optional factory navigation system available on select higher-trim models.

Driver Assistance

Cruise Control:

Standard on most models.

Keyless Entry:

Available on most trims, often with remote key fob.

Connectivity

Auxiliary Input:

Typically not standard; aftermarket solutions may be required for audio device connectivity.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,750 to 7,500 miles (6,000 to 12,000 km) or 6 months, whichever comes first (refer to manual for exact recommendation based on driving conditions).

Timing Belt Replacement:

Crucial for 4G6x engines. Generally recommended every 60,000 miles (96,000 km) or 4-5 years. Failure can cause severe engine damage.

Transmission Fluid Change:

Every 30,000 to 60,000 miles (48,000 to 96,000 km), depending on automatic or manual and driving conditions.

Fluid Specifications

Engine Oil Type:

API SG, SH, SJ or higher, viscosity typically 5W-30 or 5W-40.

Engine Oil Capacity 2.4L:

Approx. 4.5 quarts (4.3 liters) with filter change.

Engine Oil Capacity 3.0L:

Approx. 4.5 quarts (4.3 liters) with filter change.

Coolant Type:

Ethylene glycol based antifreeze (Mitsubishi Diaqueen Super Long Life Coolant recommended or equivalent).

Transmission Fluid Automatic:

Mitsubishi Diaqueen ATF-SP II M or equivalent DEXRON-III/MERCON compatible fluid.

Transmission Fluid Manual:

API GL-4 or GL-5 gear oil, viscosity typically 75W-90.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Known Issues

Timing Belt Wear:

Critical maintenance item; premature wear or failure can cause catastrophic engine damage. Regular replacement is vital.

Cv Joint Boots:

Tears in front CV joint boots can lead to premature wear and failure of the CV joints, especially in AWD models.

Radiator Leaks:

Some owners have reported premature radiator failure or leaks, particularly in higher mileage vehicles.

Power Steering Pump:

Occasional reports of power steering pump noise or leaks.

Window Regulators:

Potential for power window regulator failures over time.

📚 Vehicle History

Brand Heritage

Parent Company:

Mitsubishi Motors Corporation

Design Philosophy:

Known for robust engineering, reliable powertrains, and often competitive pricing.

Model Evolution

Introduction:

The first generation Outlander was introduced for the 2003 model year, replacing the Mitsubishi Montero Sport in some markets as a more car-based SUV.

Platform:

Built on Mitsubishi's GS platform, shared with the Lancer sedan.

Production

Manufacturing Location:

Japan (and potentially other Mitsubishi assembly plants).

🏆 Awards & Recognition

Recognitions

IIHS Top Safety Pick:

Achieved 'Good' rating in the IIHS front offset crash test, indicating good structural integrity.

Consumer Reports Reliability:

Reliability ratings varied by model year and specific engine/transmission combination; consultation of historical data is recommended.

Ratings

Fuel Economy Estimates 2.4L FWD Auto:

Approx. 20-22 MPG city / 25-27 MPG highway.

Fuel Economy Estimates 3.0L AWD Auto:

Approx. 17-19 MPG city / 21-23 MPG highway.