🏷️ Basic Information

Make:

Mitsubishi

Model:

Outlander

Generation:

First Generation (CU)

Model Years Covered:

2003, 2004, 2005, 2006

Platform Code:

CU

👋 Introduction

Segment:

Compact Crossover SUV

Target Audience:

Families, individuals seeking versatility and practicality, light off-road capability.

Key Competitors:

Honda CR-V, Toyota RAV4, Ford Escape, Nissan Xterra, Subaru Forester.

Design Philosophy:

Car-like handling with SUV practicality, advanced all-wheel-drive system (AWC/S-AWC on later models, but the first gen had a capable AWD). Blending practicality, comfort, and a touch of sporty styling.

Differentiators:

Available All-Wheel Drive system, relatively sporty handling for its class, practical interior with flexible seating.

📋 Manual Details

Market:

North America, Global (specific to regions where this generation was sold)

Trim Levels Covered:

All available trim levels for the specified model years

Estimated Pages:

2000+

Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine Management:

Detailed diagnosis and repair of ECU, sensors (MAF, O2, TPS, CKP, CMP), ignition system, fuel injection system, emission control systems.

Powertrain:

Complete coverage of engine mechanicals, including cylinder head, pistons, crankshaft, timing system, and lubrication system. Transmission (automatic and manual) overhaul, troubleshooting, and fluid service.

Drivetrain:

Front-wheel drive and all-wheel drive (AWD) systems, including differentials, drive shafts, CV joints, and transfer case (if applicable to specific models covered).

Suspension And Steering:

Front and rear suspension components (struts, shock absorbers, control arms, bushings), steering rack, power steering system, wheel alignment procedures.

Brakes:

Front and rear brake systems (disc/drum configuration), hydraulic system, ABS (Anti-lock Braking System) diagnosis and repair, brake pad/rotor replacement, brake fluid service.

Electrical System:

Comprehensive wiring diagrams, fuse box locations, component testing, starter, alternator, battery service, lighting systems, power windows, door locks, and accessories.

HVAC:

Air conditioning system diagnosis, refrigerant handling, compressor, evaporator, condenser service, heater core replacement, climate control operation.

Body And Interior:

Exterior body panels, doors, hood, tailgate, interior trim removal and installation, seat adjustment mechanisms, glass replacement.

Routine Maintenance:

Oil and filter changes, air filter replacement, spark plug replacement, coolant flush and fill, transmission fluid service, brake fluid replacement, power steering fluid service.

Diagnostic Troubleshooting:

Step-by-step troubleshooting guides for common and complex issues, DTC (Diagnostic Trouble Code) interpretation and resolution, circuit testing.

Component Replacement:

Detailed instructions for replacing major and minor components across all vehicle systems.

Rebuilding Procedures:

Complete disassembly and reassembly procedures for engine, transmission, and other major mechanical units.

Specifications And Torques:

Essential torque specifications for all critical fasteners, fluid capacities, and engine/transmission tolerances.

Depth:

Comprehensive from basic owner maintenance to advanced engine and transmission rebuilds, including electrical diagnostics.

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchable Text:

Yes (typically OCR'd for searchable text)

Printability:

Printable (suitable for home or professional printing)

Binding:

N/A (Digital PDF)

Paper Quality:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Code:

4G64 (2.4L)

Engine Type:

Inline 4-cylinder, SOHC (Single Overhead Camshaft), 16-valve

Displacement:

2351 cc (2.4 Liters)

Bore X Stroke:

86.5 mm x 100.0 mm

Compression Ratio:

8.5:1

Horsepower:

135-145 hp @ 5500-5700 rpm (depending on year and market)

Torque:

145-155 lb-ft @ 3500-4000 rpm (depending on year and market)

Fuel Delivery:

Electronic Multi-Point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline (87 Octane Recommended)

Fuel Tank Capacity:

15.3 gallons (58 Liters)

Coolant Type:

Mitsubishi DiaQueen Super Long Life Coolant (or equivalent silicate-free, OAT antifreeze)

Recommended Oil Viscosity:

SAE 5W-30 (API Service SN/SN PLUS or ILSAC GF-6A)

Oil Capacity:

4.0 quarts (3.8 Liters) with filter change

🔧 Transmission

Type:

4-Speed Automatic Transmission (INVECS-II)

Type:

5-Speed Manual Transmission

AWD System:

Available 'SEMI-ALL WHEEL CONTROL' (S-AWC) or 'ALL WHEEL CONTROL' (AWC) system for enhanced traction and handling. Modes typically include 2WD, 4WD Auto, 4WD Lock.

Automatic Transmission Fluid:

DiaQueen SPIII or equivalent ATF (Dexron III compatible, but SPIII is preferred)

Automatic Transmission Capacity:

Approx. 2.6 quarts (2.5 Liters) for drain and fill

Gear Oil Type:

API GL-4 or GL-5, SAE 75W-90 synthetic gear oil recommended

📐 Dimensions

Length:

174.0 inches (4420 mm)

Width:

69.1 inches (1755 mm)

Height:

64.8 inches (1645 mm)

Wheelbase:

103.3 inches (2625 mm)

Ground Clearance:

7.9 inches (200 mm)

Curb Weight FWD:

3450 lbs (1565 kg)

Curb Weight AWD:

3572 lbs (1620 kg)

Cargo Volume Behind Rear Seat:

27.7 cu ft (784 Liters)

Cargo Volume With Rear Seat Folded:

63.7 cu ft (1804 Liters)

🛡️ Safety Features

NHTSA Frontal Crash Test:

5-Star (driver and passenger side, 2003 model year tested)

IIHS Side Impact Test:

Good (2003 model year tested)

ABS:

Standard on all models (4-wheel Anti-lock Braking System)

Traction Control:

Available (TCL) on some models, integrated with AWD system.

Airbags:

Front occupant airbags (driver and passenger), available front side-impact airbags.

Seatbelts:

3-point seatbelts with pretensioners for front occupants, 3-point seatbelts for rear occupants.

Child Seat Anchors:

LATCH (Lower Anchors and Tethers for Children) system

💡 Technology Features

Audio System:

Standard AM/FM/CD player. Higher trims may feature premium audio systems with more speakers.

Navigation:

Optional factory-installed navigation system on higher trim levels.

Cruise Control:

Standard on most models.

Auxiliary Input:

Rare for this era; typically requires aftermarket adapter.

Climate Control:

Manual or automatic climate control depending on trim level.

🔧 Maintenance

Oil And Filter Change:

Every 3,750 miles (6,000 km) or 6 months, whichever comes first (under severe driving conditions); 7,500 miles (12,000 km) or 12 months (under normal driving conditions).

Air Filter Replacement:

Every 30,000 miles (48,000 km) or as needed based on inspection.

Spark Plug Replacement:

Platinum-tipped spark plugs: 105,000 miles (168,000 km).

Coolant Replacement:

Initial replacement at 105,000 miles (168,000 km), then every 52,500 miles (84,000 km) or 3 years thereafter.

Automatic Transmission Fluid Change:

Recommended every 30,000 miles (48,000 km) or 24 months, especially with towing or severe use.

Brake Fluid Replacement:

Every 24 months or 30,000 miles (48,000 km), regardless of mileage.

Power Steering Fluid:

Mitsubishi Genuine Power Steering Fluid or Dexron III/Mercon compatible ATF.

Catalytic Converter:

Can become clogged or fail prematurely, often due to engine misfires or oil consumption issues. Symptoms include reduced power, poor fuel economy, and check engine light.

Engine Oil Consumption:

Some 4G64 engines may exhibit higher than normal oil consumption. Regular oil level checks are crucial. This can be exacerbated by worn piston rings or valve seals.

Oxygen Sensors:

Oxygen sensors can degrade over time, leading to check engine lights, poor fuel economy, and emissions issues. Replacement is straightforward.

Cvt Transmission Issues:

While this generation primarily used traditional automatics or manuals, some markets might have had CVT variants. Early CVTs could be prone to issues if not properly maintained. (Note: This generation predominantly used conventional automatic transmissions, not CVTs).

Suspension Components:

Worn ball joints, tie rod ends, and control arm bushings can lead to noise, poor handling, and alignment issues. Regular inspection is recommended.

Power Window Motors:

Window regulators and motors can fail over time, causing windows to stop working.

📚 Vehicle History

Mitsubishi Motors:

A Japanese automaker with a long history dating back to 1917, known for its diverse range of vehicles from compact cars to SUVs and performance vehicles.

First Generation Launch:

The Mitsubishi Outlander (CU platform) debuted in Japan in 2001 and was introduced to North America for the 2003 model year. It was designed as a compact SUV positioned below the larger Montero Sport.

Facelift:

A minor facelift occurred for the 2005 model year, which included updated exterior styling (front grille, headlights, bumpers) and interior refinements. Engine output was also slightly increased for some variants.

Manufacturing Location:

Mizushima Plant, Kurashiki, Okayama, Japan.

Production Period:

2001-2006 (for the first generation)

🏆 Awards & Recognition

NHTSA Safety:

Received top safety ratings (5-star frontal) from NHTSA, indicating a well-engineered safety structure for its time.

IIHS Safety:

Achieved 'Good' ratings in IIHS frontal and side impact tests, further validating its safety credentials.