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Outlander 1 (2003-2008)

Repair manual Mitsubishi Outlander 1 2003-2008

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  • 1 (2003-2008)

Here is a repair and maintenance manual for the Japanese crossover "Mitsubishi Outlander 1" (first generation), which was produced from 2003 to 2008. This manual only covers the repair of 2.0 liter (4G63) and 2.4 liter (4G69) four-cylinder petrol engines. You will also find step-by-step guides for removing / installing other Mitsubishi Outlander 1 units and assemblies, such as automatic and manual transmission, wheels and suspension, steering, brakes, body parts and repair of on-board electrical equipment.

See this manual on: russian, bulgarian, belarusian, ukrainian, serbian, croatian, romanian, polish, slovak, hungarian
General information
User manual
Exterior of the car
Technical data and characteristics of the car
Vehicle identification data
Loading the roof rack
The entire list of articles in this category »
Governing bodies
Controls and instrumentation
Odometer «trip meter/trip meter»
Instrument panel indicators
Indicator and control lamps
The entire list of articles in this category »
Salon equipment
Interior lighting lamps
Local lighting lamps
Interior rear view mirror
Antenna on the roof
The entire list of articles in this category »
Driving and maintenance
Recommendations for running in a car
Fuel selection
Towing a trailer
Ignition switch
The entire list of articles in this category »
Power unit
Engine repair
Recommendations for engine maintenance and repair
Operations in the engine compartment
Periodic maintenance regulations
Periodic maintenance (operations in the engine compartment on a cold engine)
The entire list of articles in this category »
Cooling and lubrication system
Checking for leaks in the cooling system
Checking the opening pressure of the radiator cap valve
Replacing the coolant
Checking the electronic unit of the electric fan
The entire list of articles in this category »
Fuel injection system (MPI)
General information about the fuel supply and injection system
Fuel injection system diagnostics
Technical operations on the car
Removal and installation injectors
The entire list of articles in this category »
Transmission
Clutch
Recommended precautions
Checking the level of working fluid in the clutch hydraulic drive
Checking the clutch
Checking the free travel of the clutch pedal
The entire list of articles in this category »
Mechanical gearbox
Checking the transmission performance in all ranges
Checking the oil level in the gearbox and transfer case (4WD)
Checking the oil level in a manual transmission
Checking the oil level in the transfer case (4WD)
The entire list of articles in this category »
Automatic gearbox
Checking the selector lever
Checking the fluid level in the automatic transmission (cold engine)
Checking the fluid level in the automatic transmission (hot engine)
Automatic transmission fluid replacement
The entire list of articles in this category »
Drive shafts and cardan
Checking the oil level in the front and rear axle differentials
Checking the drive shaft boots for damage
Changing the oil in the differential of the front and rear axles
Removal and installation the propeller shaft (4WD)
The entire list of articles in this category »
Chassis and running gear
Wheels and tires
Checking the air pressure in the tires (including the spare tire)
Checking for uneven tire wear
Technical characteristics of tires and wheels
Possible malfunctions, their causes and methods of elimination
The entire list of articles in this category »
Front suspension
Checking the vehicle's suspension for damage and loose fasteners
Description and design of the front axle
Removal and installation the front wheel hub assembly
Disassembly and assembly of the front wheel hub assembly
The entire list of articles in this category »
Rear suspension
Rear suspension specifications and testing
Removal and installation suspension arms
Installing the Upper Control Arm/Steering Rod Assembly
Removal and installation the trailing arm assembly
The entire list of articles in this category »
Steering
Technical characteristics of the steering system
Possible malfunctions, their causes and methods of elimination
Checking free play and checking the steering wheel angle
Checking the moment of the beginning of rotation of the ball joint of the steering rod end
The entire list of articles in this category »
Brake system
General information about the braking system
Possible malfunctions, their causes and methods of elimination
Checking the level of working fluid in the brake hydraulic drive
Checking the free and working travel of the parking brake lever
The entire list of articles in this category »
Body and interior
Exterior (external elements)
Features of the car body design
Removal and installation the front bumper
Disassembling and assembling the front bumper
Removal and installation the rear bumper
The entire list of articles in this category »
Doors, locks and windows
Removal and installation protective film on the side door glass frame
Adjusting the front and rear side doors
Adjusting the side door glass
Checking the travel of the outside handle of the side door
The entire list of articles in this category »
Electrical equipment
Equipment and devices
Checking the wiring harnesses
General information about on-board electrical equipment
Preliminary operations for checking electrical equipment
Periodic maintenance of electrical equipment
The entire list of articles in this category »
Headlights and lighting
Removal and installation headlights
Removal and installation the headlight corrector switch
Removal and installation front fog lights
Removal and installation front fog light switches and rear fog light switches
The entire list of articles in this category »
Power devices
Checking the condition of the battery and its terminals
General information about the power supply system
Checking the voltage drop on the generator wire with the battery
Checking the generator output current
The entire list of articles in this category »
Ignition system
General information about the ignition system
Maintenance operations performed directly on the vehicle
Taking high voltage waveforms using an oscilloscope
Examples of high voltage oscillograms of a faulty ignition system
The entire list of articles in this category »
Electrical circuits
Location of wiring harnesses, marking of wires and connectors
Starter wiring diagram
Electrical diagram of the ignition system
Electrical diagram of the charging system
The entire list of articles in this category »
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Outlander 1 (2003-2008) 
  • General information
  • User manual
  • Governing bodies
  • Salon equipment
  • Driving and maintenance
  • Power unit
  • Engine repair
  • Cooling and lubrication system
  • Fuel injection system (MPI)
  • Transmission
  • Clutch
  • Mechanical gearbox
  • Automatic gearbox
  • Drive shafts and cardan
  • Chassis and running gear
  • Wheels and tires
  • Front suspension
  • Rear suspension
  • Steering
  • Brake system
  • Body and interior
  • Exterior (external elements)
  • Doors, locks and windows
  • Electrical equipment
  • Equipment and devices
  • Headlights and lighting
  • Power devices
  • Ignition system
  • Electrical circuits
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