2005-2012 Mitsubishi Outlander XL Service and Repair Manual

GROUP 00 GENERAL <BODY AND CHASSIS> CONTENTS HOW TO USE THIS MANUAL..........00-3 TROUBLESHOOTING GUIDELINES......00-6 HOW TO USE TROUBLESHOOTING/ INSPECTION SERVICE POINTS.......00-6 TROUBLESHOOTING CONTENTS........00-6 HOW TO USE THE INSPECTION PROCEDURES ................................00-9 CONNECTOR MEASUREMENT SERVICE POINTS ...............................00-12 CONNECTOR INSPECTION SERVICE POINTS ...............................00-14 HOW TO COPE WITH INTERMITTENT MALFUNCTIONS...................00-15 HOW TO TREAT PAST TROUBLE......00-17 INSPECTION SERVICE POINTS FOR A BLOWN FUSE...........................00-18 VEHICLE IDENTIFICATION.........00-18 VEHICLE IDENTIFICATION CODE PLATE ...............................00-20 PRECAUTIONS BEFORE SERVICE.....00-26 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ...............................00-26 HOW TO PERFORM VEHICLE IDENTIFICATION NUMBER (VIN) WRITING...........00-26 INITIALIZATION PROCEDURE FOR LEARNING VALUE IN MFI ENGINE............00-30 ENGINE IDLING LEARNING PROCEDURE ...............................00-31 SERVICING ELECTRICAL SYSTEM....00-32 VEHICLE WASHING................00-33 APPLICATION OF ANTI-CORROSION AGENTS AND UNDERCOATS.................00-33 SCAN TOOL (MULTI USE TESTER { M.U.T.- III } SUB ASSEMBLY)............00-33 CODING LIST....................00-34 TOWING AND HOISTING............00-42 GENERAL DATA AND SPECIFICATIONS ...............................00-46 TIGHTENING TORQUE..............00-48 LUBRICATION AND MAINTENANCE....00-49 RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE...............00-51 SCHEDULED MAINTENANCE TABLE....00-53 MAINTENANCE SERVICE............00-56 1. FUEL SYSTEM (TANK, PIPE LINE AND CONNECTION, AND FUEL TANK FILLER TUBE CAP) (CHECK FOR LEAKS).........00-56 00-1 Continued on next page

2. FUEL HOSES (CHECK CONDITION) ...............................00-56 3. AIR CLEANER ELEMENT (REPLACE) ...............................00-56 4. EVAPORATIVE EMISSION SYSTEM (EXCEPT EVAPORATIVE EMISSION CANISTER) (CHECK FOR CLOGGING) ...............................00-57 5. SPARK PLUGS (REPLACE).......00-57 6. INTAKE AND EXHAUST VALVE CLEARANCE <INTAKE SIDE ONLY> (INSPECT AND ADJUST)........................00-57 7. TIMING BELT (REPLACE).......00-58 8. DRIVE BELT (FOR GENERATOR, WATER PUMP, POWER STEERING OIL PUMP) (CHECK CONDITION).....................00-58 9. EXHAUST SYSTEM (CONNECTIONS PORTION OF MUFFLER, MUFFLER PIPES AND CONVERTER HEAT SHIELDS) (CHECK AND SERVICE AS REQUIRED)...........00-61 10. ENGINE OIL (CHANGE)........00-62 11. ENGINE OIL FILTER (REPLACE) ...............................00-63 12. TRANSMISSION FLUID.........00-64 13. TRANSFER OIL...............00-67 14. ENGINE COOLANT (CHANGE)....00-67 15. COOLANT HOSES (RADIATOR HOSE, HEATER HOSE) (INSPECT).........00-69 16. DISC BRAKE PADS (INSPECT FOR WEAR) ...............................00-69 17. BRAKE HOSES (CHECK FOR DETERIORATION OR LEAKS)........00-69 18. BALL JOINT AND STEERING LINKAGE SEALS (INSPECT FOR GREASE LEAKS AND DAMAGE)........................00-69 19. DRIVE SHAFT BOOTS (INSPECT FOR GREASE LEAKS AND DAMAGE).......00-70 20. SUSPENSION SYSTEM (INSPECT FOR LOOSENESS AND DAMAGE)..........00-70 21. REAR AXLE OIL (CHECK OIL LEVEL) ...............................00-70 22. TIRES (ROTATE).............00-71 23. AIR FILTER (REPLACE).......00-71 MAIN SEALANT AND ADHESIVE TABLE ...............................00-71 00-2

HOW TO USE THIS MANUAL M10001000001USA0000010001 MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair and servicing of the subject model. Unless otherwise specified, each service procedure covers all models. Procedures covering specific models are identified by the model codes, or similar designation (engine type, transaxle type, etc.). A description of these designations is covered in this manual under "VEHICLE IDENTIFICATION." ON-VEHICLE SERVICE The "ON-VEHICLE SERVICE" section has procedures for performing inspections and adjustments of particularly important components. These procedures are done with regard to maintenance and servicing, but other inspections (looseness, play, cracking, damage, etc.) must also be performed. SERVICE PROCEDURES The service steps are arranged in numerical order. Attention to be paid in performing vehicle service are described in detail in SERVICE POINTS. DEFINITION OF TERMS STANDARD VALUE Indicates the value used as the standard for judging whether or not a part or adjustment is correct. LIMIT Shows the maximum or minimum value for judging whether or not a part or adjustment is acceptable. REFERENCE VALUE Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly and adjustment procedures, and so they can be completed in a shorter time). DANGER, WARNING, AND CAUTION DANGER, WARNING, and CAUTION call special attention to a necessary action or to an action that must be avoided. The differences among DANGER, WARNING, and CAUTION are as follows: ｠ If a DANGER is not followed, the result is severe bodily harm or even death. ｠ If a WARNING is not followed, the result could be bodily injury. ｠ If a CAUTION is not followed, the result could be damage to the vehicle, vehicle components or service equipment. TIGHTENING TORQUE INDICATION The tightening torque indicates a median and its tolerance by a unit of N·m (in-lb) or N·m (ft-lb). For fasteners with no assigned torque value, refer to P. 00-48. SPECIAL TOOL NOTE Only MMC special tool part numbers are called out in the repair sections of this manual. Please refer to the special tool cross-reference chart located at the beginning of each group, for the special tool number that is available in your market. ABBREVIATIONS The following abbreviations are used in this manual for classification of model types: NOTE: ｠ A/T: Automatic transaxle, or models equipped with automatic transaxle. ｠ MFI: Multiport fuel injection, or engines equipped with multiport fuel injection. ｠ FWD: 2-wheel drive vehicles. ｠ AWD: 4-wheel drive vehicles. ｠ A/C: Air conditioning. ｠ 3.0L Engine: 2.998 liter 6B31 engine, or a model equipped with such an engine. ｠ PCM: Powertrain control module ｠ SWS: Simplified wiring system ｠ Keyless Operation System (KOS): Free-hand Advanced Security Transmitter (F.A.S.T.-key) GENERAL <BODY AND CHASSIS> 00-3 HOW TO USE THIS MANUAL

EXPLANATION OF MANUAL CONTENTS N Denotes tightening torque. If there is no indication of tightening torque, refer to tightening torque. Indicates the group title. Indicates the section title. Indicates the group number. Indicates the page number. Indicates procedures to be performed before the work in that section is started, and procedures to be performed after the work in that section is finished. Component diagram A diagram of the component parts is provided near the front of each section in order to give the reader a better understanding of the installed condition of component parts. Mark denotes non-reusable part. Repair kit or parts sets are shown. (Only very frequently used parts are shown.) Removal steps : The part designation number corresponds to the number in the illustration to indicate removal steps. Disassembly steps : The part designation number corresponds to the number in the illustration to indicate disassembly steps. Maintenance and servicing procedures The numbers provided within the diagram indicate the sequence for maintenance and servicing procedures. Installation steps : Specified in case installation is impossible in reverse order of removal steps. Omitted if installation is possible in reverse order of removal steps. Assembly steps : Specified in case installation is impossible in reverse order of removal steps. Omitted if assembly is possible in reverse order of disassembly steps. Brake caliper kit Pad set Shim kit Seal and boot kit ZC6012870000 00-4 GENERAL <BODY AND CHASSIS> HOW TO USE THIS MANUAL

Classifications of major maintenance / service points When there are major points relative to maintenance and servicing procedures (such as essential maintenance and service points, maintenance and service standard values, information regarding the use of special tools, etc.). These are arranged together as major maintenance and service points and explained in detail. <<A>> : Indicates that there are essential points for removal or disassembly. >>A<< : Indicates that there are essential points for installation or assembly. Operating procedures, cautions, etc. on removal, installation, disassembly and assembly are described The title of the page (following the page on which the diagram of component parts is presented) indicating the locations of lubrication and sealing procedures. Indicates (by symbols) where lubrication is necessary. Symbols for lubrication, sealants and adhesives Symbols are used to show the locations for lubrication and for application of sealants and adhesives. These symbols are included in the diagram of component parts or on the page following the component parts page. The symbols do not always have accompanying text to support that symbol. Adhesive tape or butyl rubber tape Grease (Multi-purpose grease unless there is a brand or type specified) Sealant or adhesive Brake fluid or automatic transmission fluid Engine oil, gear oil or air conditioning compressor oil Grease: repair kit grease ZC6012880000 GENERAL <BODY AND CHASSIS> 00-5 HOW TO USE THIS MANUAL

TROUBLESHOOTING GUIDELINES M10001000088USA0000010001 VERIFY THE COMPLAINT ｠ Make sure the customer's complaint and the service writer's work order description are understood before starting work. ｠ Make sure the correct operation of the system is understood. Read the service manual description to verify normal system operation. ｠ Operate the system to see the symptoms. Look for other symptoms that were not reported by the customer, or on the work order, that may be related to the problem. DETERMINE POSSIBLE CAUSES Compare the confirmed symptoms to the diagnostic symptom indexes to find the right diagnosis procedure. If the confirmed symptoms cannot be found on any symptom index, determine other possible causes. ｠ Analyze the system diagrams and list all possible causes for the problem symptoms. ｠ Rank all these possible causes in order of probability, based on how much of the system they cover, how likely they are to be the cause, and how easy they will be to check. Be sure to take experience into account. Consider the causes of similar problems seen in the past. The list of causes should be ranked in order from general to specific, from most-likely to least-likely, and from easy-to- check to hard-to-check. FIND THE PROBLEM After the symptoms have been confirmed, and probable causes have been identified, the next step is to make step-by-step checks of the suspected system components, junctions, and links in logical order. Use the diagnostic procedures in the service manual whenever possible. Follow these procedures carefully to avoid missing an important step in the diagnosis sequence. It might be the skipped step that leads to the solution of the problem. If the service manual doesn't have step-by-step procedures to help diagnose the problem, make a series of checks based on the ranked list of probable causes. Troubleshooting checks should be made in the order that the list of causes was ranked: ｠ general to specific ｠ most-likely to least-likely ｠ easy-to-check to hard-to-check REPAIR THE PROBLEM When the step-by-step troubleshooting checks find a fault, perform the proper repairs. Make sure to fix the root cause of the problem, not just the symptom. Just fixing the symptom, without fixing the root cause, will cause the symptom to eventually return. VERIFY THE REPAIR After repairs are made, recheck the operation of the system to confirm that the problem is eliminated. Be sure to check the system thoroughly. Sometimes new problems are revealed after repairs have been made. HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS TROUBLESHOOTING CONTENTS M10001000133USA0000010001 The SRS-ECU adopts the rollover specification that the curtain airbag and seat belt pre-tensioner operate at the occurrence of rollover. Therefore, do not tilt the vehicle to the right and left with the IG ON or tilt the SRS-ECU to the right and left with the IG ON and the harness installed. During diagnosis, a diagnostic trouble code associated with other system may be set when the 00-6 GENERAL <BODY AND CHASSIS> TROUBLESHOOTING GUIDELINES

ignition switch is turned "ON" with connector(s) disconnected. On completion, confirm all systems for diagnostic trouble code(s). If diagnostic trouble code(s) are set, erase them all. Since the radiator fan rotates during CAN bus line diagnostics, make sure that no one is servicing the engine compartment before diagnosing the CAN bus line. Since the CAN communication stops when diagnosing the CAN bus line, the ETACS-ECU detects the time-out of the engine control module, and activates the radiator fan to prevent overheating as fail-safe. Troubleshooting of electronic control systems for which scan tool MB991958 can be used follows the basic outline described below. Even in systems for which scan tool MB991958 cannot be used, some of these systems still follow this outline. 1. STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING Troubleshooting sections are based on the diagnostic flow as below. If the diagnostic flow is different from that given below, or if additional explanation is required, the details of such differences or additions will also be listed. Diagnostic method ZC604018 Gathering information from the customer. Check trouble symptom. Reoccurs Does not reoccur CAN bus diagnosis chart* CAN bus diagnosis* Read the diagnosis code. Read the diagnosis code. After taking note of the malfunction code, erase the diagnosis code memory. Recheck trouble symptom. Read the diagnosis codes. How to treat past trouble* Refer to the INSPECTION CHA RT FOR DI AGNOSIS CODES (Re fer to applica ble g roup) . How to treat past trouble* Refer to the INSPECTION CHA RT FOR T ROUBLE SYMP TOMS (Re fer to applica ble g roup) . INTERMITTENT MALFUNCTIONS * Diagnosis code displayed. (Current trouble)* Diagnosis code displayed. (Current trouble)* No diagnosis code. No diagnosis code. Diagnosis code displayed. (Past trouble)* Diagnosis code displayed. (Past trouble)* No diagnosis code or communication with scan tool MB991958 not possible Diagnosis code displayed. OK NG 2 1 3 3 3 3 4 4 5 Coding data check* 6 0000 ｠ * 1 : For how to diagnose CAN bus lines, refer to GROUP 54D P.54D-10. ｠ * 2 : For the CAN bus diagnosis chart, refer to GROUP 54D P.54D-17. GENERAL <BODY AND CHASSIS> 00-7 HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

｠ * 3 : When scan tool MB991958 detects a diagnostic trouble code, its display informs users whether a mechanical problem currently exists or whether it existed before. The message for the former state identifies it as an "Active" and the message for the latter identifies it as a "Stored". ｠ * 4 : For how to treat past trouble, refer to P. 00-17. ｠ * 5 : For how to cope with intermittent malfunctions, refer to P.00-15. ｠ * 6 : For coding data, refer to P.00-34. 2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS If verification of the symptom(s) is difficult, procedures for checking operation and verifying symptoms are shown. 3. DIAGNOSTIC FUNCTION The following trouble code diagnosis are shown. ｠ How to read diagnostic trouble codes ｠ How to erase diagnostic trouble codes ｠ Input inspection service points 4. DIAGNOSTIC TROUBLE CODE CHART If the scan tool displays a diagnostic trouble code, find the applicable inspection procedure according to this chart. 5. SYMPTOM CHART If there are symptoms, even though the scan tools show that no DTCs are set, inspection procedures for each symptom will be found by using this chart. 6. DIAGNOSTIC TROUBLE CODE PROCEDURES Indicates the inspection procedures corresponding to each diagnostic trouble code. (Refer to P.00-9). 7. SYMPTOM PROCEDURES Indicates the inspection procedures corresponding to each symptom listed in the Symptom Chart. (Refer to P.00-9). 8. SERVICE DATA REFERENCE TABLE Inspection items and normal judgment values have been provided in this chart as reference information. 9. CHECK AT ECU TERMINALS Terminal numbers for the ECU connectors, inspection items, and standard values have been provided in this chart as reference information. TERMINAL VOLTAGE CHECKS 1.Connect a needle-nosed wire probe to a voltmeter probe. Short-circuiting the positive (+) probe between a connector terminal and ground could damage the vehicle wiring, the sensor, the ECU, or all three. Use care to prevent this! 2.Insert the needle-nosed wire probe into each of the ECU connector terminals from the wire side, and measure the voltage while referring to the check chart. NOTE: Measure voltage with the ECU connectors connected.You may find it convenient to pull out the ECU to make it easier to reach the connector terminals.Checks don't have to be carried out in the order given in the chart. 3.If voltage readings differ from normal condition values, check related sensors, actuators, and wiring. Replace or repair as needed. 4.After repair or replacement, recheck with the voltmeter to confirm that the repair has corrected the problem. TERMINAL RESISTANCE AND CONTINUITY CHECKS 1.Turn the ignition switch to the "LOCK" (OFF) position. 2.Disconnect the ECU connector. If resistance and continuity checks are performed on the wrong terminals, damage to the vehicle wiring, sensors, ECU, and/or ohmmeter may occur. Use care to prevent this! 3.Measure the resistance and check for continuity between the terminals of the ECU harness-side connector while referring to the check chart. NOTE: Checks don't have to be carried out in the order given in the chart. 4.If the ohmmeter shows any deviation from the Normal Condition value, check the corresponding sensor, actuator and related electrical wiring, then repair or replace. 5.After repair or replacement, recheck with the ohmmeter to confirm that the repair has corrected the problem. 00-8 GENERAL <BODY AND CHASSIS> HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

10. INSPECTION PROCEDURES USING AN OSCILLOSCOPE When there are inspection procedures using an oscilloscope, these are listed. HOW TO USE THE INSPECTION PROCEDURES M10001000135USA0000010001 The causes of many of the problems occurring in electric circuitry are generally the connectors, components, the ECU, and the harnesses between connectors, in that order. These inspection procedures follow this order. They first try to discover a problem with a connector or a defective component. GENERAL <BODY AND CHASSIS> 00-9 HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

(1) Relevant circuit(s) of the component which the DTC indicates are described. (3) Shows the location of the connector(s) from the circuit(s) above. (4) Explains about the operation principle of the component or its relevant parts in that circuit. B-48(B) (2) For connector color, refer to GROUP 80A, How to read configuration diagrams. Connector : B-4 8 Inta ke air tempe rature sensor ZC6012890000 00-10 GENERAL <BODY AND CHASSIS> HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS

2005-2012 Mitsubishi Outlander XL Service and Repair Manual

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