2007-2013 Mitsubishi Outlander Service & Repair Manual
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MITSUBISHI
Outlander
BRAKES 10-10
ANTI-LOCK BRAKE
SYSTEM (ABS) 10-10
General Information 10-10
Wheel Speed Sensor Rings
(Toothed Rings) 10-12
Removal & Installation 10-12
Wheel Speed Sensors 10-10
Removal & Installation 10-10
BLEEDING THE BRAKE
SYSTEM 10-12
Bleeding Procedure 10-12
Bleeding Procedure 10-12
FRONT DISC BRAKES 10-13
Brake Caliper 10-13
Removal & Installation 10-13
Disc Brake Pads 10-13
Removal & Installation 10-13
PARKING BRAKE 10-18
Parking Brake Cables 10-18
Adjustment 10-18
Parking Brake Shoes 10-19
Adjustment 10-20
Removal & Installation 10-19
REAR DISC BRAKES 10-16
Brake Caliper 10-16
Removal & Installation 10-16
Disc Brake Pads 10-16
Removal & Installation 10-16
CHASSIS ELECTRICAL 10-21
AIR BAG (SUPPLEMENTAL
RESTRAINT SYSTEM) 10-21
Airbag Module 10-21
Removal & Installation 10-21
General Information 10-21
Arming the System 10-21
Disarming the System 10-21
Service Precautions 10-21
DRIVETRAIN .10-23
Automatic Transaxle
Assembly 10-23
Removal & Installation 10-23
CVT Transaxle Assembly 10-24
Removal & Installation 10-24
Front Halfshaft 10-26
Removal & Installation 10-26
Rear Driveshaft 10-28
Removal & Installation 10-28
Rear Halfshaft 10-28
Removal & Installation 10-28
Rear Pinion Seal 10-29
Removal & Installation 10-29
Transfer Case Assembly 10-26
Removal & Installation 10-26
ENGINE COOLING 10-29
Engine Fan 10-29
Removal & Installation 10-29
Radiator 10-29
Removal & Installation 10-29
Thermostat 10-32
Removal & Installation 10-32
Water Pump 10-32
Removal & Installation 10-32
ENGINE ELECTRICAL 10-33
CHARGING SYSTEM 10-33
Alternator 10-33
Removal & Installation 10-33
IGNITION SYSTEM 10-34
Firing Orders 10-34
Ignition Coil 10-34
Removal & Installation 10-34
Ignition Timing 10-35
Adjustment 10-36
Inspection 10-35
SparkPlugs 10-36
Removal & Installation 10-36
STARTING SYSTEM 10-37
Starter 10-37
Removal & Installation 10-37
Solenoid or Relay
Replacement 10-37
ENGINE MECHANICAL 10-38
Accessory Drive Belts 10-38
Accessory Belt Routing 10-38
Adjustment 10-38
Inspection 10-38
Removal & Installation 10-38
Balance Shaft 10-38
Removal & Installation 10-38
Camshaft and Valve Lifters 10-40
Inspection 10-49
Removal & Installation 10-40
Crankshaft Damper 10-49
Removal & Installation 10-49
Crankshaft Front Seal 10-50
Removal & Installation 10-50
Cylinder Head 10-51
Removal & Installation 10-51
Engine Assembly 10-55
Removal & Installation 10-55
Exhaust Manifold 10-56
Removal & Installation 10-56
Flywheel 10-61
Removal & Installation 10-61
Intake Manifold 10-61
Removal & Installation 10-61
Main Bearing Torque
Sequence 10-70
Oil Pan 10-65
Removal & Installation 10-65
Oil Pump 10-68
Removal & Installation 10-68
Piston and Ring 10-70
Positioning 10-70
Rear Main Seal 10-70
Removal & Installation 10-70
Rocker Arms/Shafts 10-71
Removal & Installation 10-71
Timing Belt and Sprockets 10-72
Removal & Installation 10-72
Timing Chain and Sprockets...10-76
Removal & Installation 10-76
Timing Chain Cover and
Seal 10-74
Removal & Installation 10-74
Valve Covers 10-77
Removal & Installation 10-77
Valve Lash 10-78
Adjustment 10-78
ENGINE PERFORMANCE
& EMISSION CONTROLS...10-79
Accelerator Pedal Position
(APP) Sensor 10-79
If) O MITSUBISHI
OUTLANDER
Location 10-79
Operation 10-79
Removal & Installation 10-79
Testing 10-79
Barometric Pressure
(BARO)Sensor 10-79
Location 10-79
Operation 10-79
Removals. Installation 10-79
Testing 10-79
Camshaft Position
(CMP) Sensor 10-80
Location 10-80
Operation 10-80
Removal & Installation 10-80
Testing 10-81
Crankshaft Position
(CKP) Sensor 10-81
Location 10-81
Operation 10-81
Removal & Installation 10-82
Testing 10-82
Electric Fan Switch 10-82
Location 10-82
Operation 10-82
Removal & Installation 10-82
Testing 10-83
Electronic Control
Module (ECM) 10-83
Location 10-83
Operation 10-83
Removal & Installation 10-83
Testing 10-84
Engine Coolant Temperature
(ECT) Sensor 10-84
Location 10-84
Operation 10-84
Removal & Installation 10-84
Testing 10-84
Fuel Level Sending Unit 10-84
Location 10-84
Operation 10-84
Removal & Installation 10-84
Testing 10-85
Heated Oxygen (H02S)
Sensor 10-85
Operation 10-85
Removal & Installation 10-85
Testing 10-85
Intake Air Temperature
(IAT) Sensor 10-85
Location 10-85
Operation 10-85
Removal & Installation 10-87
Testing 10-87
Knock Senso
Location..
Operation
Removal 8
Testing....
Malfunction
Light (MIL)
Reset Proc
Manifold Abs
(MAP) Sens
Location..
Operation
Removal I
Testing....
Mass Air Flo
Sensor
Location..
Operation
Removal I
Testing....
Oil Pressure
Location..
Operation
Removal I
Testing....
Throttle Posi
Sensor(TP
Location..
Operation
Removal i
Testing....
Vehicle Spee
(VSS)
Location.,
Operation
Removal I
Testing....
(KS).
Installation.
..10-
..10-
..10-
..10-
..10-
87
87
87
87
Throttle Body 10-93
Removal & Installation 10-93
HEATING & AIR
CONDITIONING SYSTEM... 10-94
idicator
.10-
.10- edures
)lute Pressure
or 10-
10-
10-
Installation 10-
10-
(MAF)
10-
10-
10-
Installation 10-
10-
:!ensor 10-
10-
10-
Installation 10-
10-
on
) 10-
10-
10-
Installation 10-
10-
Sensor
10-
10-
10-
Installation 10-
...10-
Blower Motor 10-94
Removal & Installation 10-94
Heater Core 10-94
Removal & Installation 10-94
PRECAUTIONS 10-10
SPECIFICATIONS AND
MAINTENANCE CHARTS 10-4
-90
-90
90
-90
91
Brake Specifications 10-8
Camshaft Specifications
Chart 10-6
Capacities 10-5
Crankshaft and Connecting
Rod Specifications 10-6
Engine and Vehicle
Identification 10-4
Engine Tune-Up
Specifications 10-4
Fluid Specifications 10-5
General Engine
Specifications 10-4
Piston and Ring Specifications ...10-6
Scheduled Maintenance
Intervals 10-9
Tire, Wheel and Ball Joint
Specifications 10-8
Torque Specifications 10-7
Valve Specifications 10-5
Wheel Alignment 10-7
FUEL 10-91 II STEERING 10-100
GASOLINE FL EL INJECTION
SYSTEM...
Fuel Filter..
Removal
Fuel Pump.
Removal ^ Installation 10-91
Fuel Rail &
Fuel System
10-91
10-91
Installation 10-91
...10-91
njectors 10-92
Removal ^Installation 10-92
Service
Precaution^ 10-91
Fuel Tank...
Removal
Idle Speed
10-94
Installation 10-94
...10-95
Adjustmeit 10-95
Relieving Fu
Pressure
System
.10-91
Power Rack & Pinion
Steering Gear 10-100
Removal & Installation 10-100
Power Steering Pump 10-102
Bleeding 10-103
Removal & Installation 10-102
Steering Linkage 10-103
Removal & Installation 10-103
SUSPENSION.. 10-103
FRONT SUSPENSION 10-103
Lower Control Arm 10-103
Control Arm Bushing
Replacement 10-103
Removal & Installation 10-103
MITSUBISHI
OUTLANDER
MacPherson Strut 10-104
Overhaul 10-104
Removal & Installation 10-104
Stabilizer Bar 10-106
Removal & Installation 10-106
Steering Knuckle 10-105
Removal & Installation 10-105
Wheel Hub and
Bearing 10-107
Adjustment 10-108
Removal & Installation 10-107
REAR SUSPENSION 10-109
Coil Spring 10-109
Removal & Installation 10-109
Control Arms/Links 10-110
Control Arm Bushing
Replacement 10-112
Removal & Installation 10-110
Shock Absorber 10-112
Removal & Installation 10-112
Testing 10-114
Stabilizer Bar 10-114
Removal & Installation 10-114
Wheel Hub and
Bearing 10-115
Adjustment 10-116
Removal & Installation 10-115
in.4 MITSUBISHI
OUTLANDER
SPECIFICATIONS AND MAINTENANCE CHARTS
ENGINE AND VEHICLE IDENTIFICATION
Engine
Code®
4B12/W
4G69/F
6B31/X
Liters (cc)
2.4 (2359)
2.4 (2378)
3.0 (2998)
Cu. In
144
143
183
Cyl. Fuel Sys.
4
4
6
MFI
MFI
MFI
Model Year
•ype
OHC
OHC
OHC
Eng. Mfg.
Mitsubishi
Mitsubishi
Mitsubishi
Code®
7
8
Year
2007
2008
MFI Multiport fuel injection
SOHC: Single overhead camshaft
© Engine ID / 8th digit of the VIN
© 10th digit of the VIN
GENERAL EN 5INE SPECIFICATIONS
Engine Ne
Displacement Engine Horsep
Year Model Liters ID/VIN @r
2007
2008
Outlander
Outlander
Outlander
3.0
2.4
3.0
6B31/X
4B12/W
6B31/X
220@
168@
220@
Net Com- Oil
»wer Torque @ rpm Bore x Stroke pression Pressure
n (ft. Ibs.) (in.) Ratio @ rpm
150
DOO
250
204@4000
167@4100
204@4000
3.45x3.54
3.43x3.78
3.45x3.54
9.5:1
10.5:1
9.5:1
X
®
©
22140_OUTL_C0001
© 4.2 psi or more at curb idle speed
ENGINE TUNE UP SPECIFICATIONS
Engine Spark Plugs
Displacement Engine Gap
Year Liters IDA/IN (in.)
2007
2008
3.0
2.4
3.0
4G69/F
4B12/W
6B31/X
0.028-0.031
0.028-0.031
0.028-0.031
MT
nition
iming
deg.)
AT
2-8B
2-8B
2-8B
Fuel
Pump
(psi)
47
47
47
Idle
Speed Valve
(rpm) Clearance
MT AT In. Ex.
500-700
600-800
500-700
500-700
600-800
500-700
0.004
0.007-
0.009
0.004
HYD
0.011-
0.013
HYD
NOTE: The Vehicle Emission Control Information label often reflects sp>
The label figures must be used if they differ from those in this chart
B: Before top dead center
© Engine cold: 0 004
Engine hot: 0.008
C2) Engine cold: 0 008
Engine hot: 0.012
22140_OUTL_C0003
MITSUBISHI
OUTLANDER 10-5
CAPACITIES
Engine Engine
Displacement Engine Oil with
Year Model Liters ID/VIN Filter
2007
2008
Outlander
Outlander
Outlander
3.0
2.4
3.0
6B31/X
4B12/W
6B31/X
4.5
4.8
4.5
Transmission
(Pts.)
5-Spd Auto.
—
©
©
©
Transfer
Case
(Pts.)
1.12
1.12
1.12
Drive
Axle
Front Rear
(pts.) (pts.)
—
1.06
1.06
1.06
Fuel Cooling
Tank System
(gal.) (qts.)
16.6
16.6
16.6
®
®
®
NOTE: All capacities are approximate Add fluid gradually and ensure a proper fluid level is obtained.
© FWD transaxle: 46 pts
AWD tranaxle: 4.9 pts.
© FWDtransaxle: 16.2 pts.
AWD tranaxle: 17 2 pts.
©Automatictransaxle: 17.4 pts.
CVT tranaxle: 16.4 pts
©Automatic transaxle: 8.7 qts.
CVT tranaxle: 82 qts.
22140_OUTL_C0004
FLUID SPECIFICATIONS
Engine Power Brake
Displacemen Engine Engine Auto. Manual Drive Transfer Steering Master
Year Model Liters IDA/IN Oil Trans. Trans. Axle Case Fluid Cylinder
2007
2008
Outlander
Outlander
Outlander
3.0
2.4
3.0
6B31/X
4B12/W
6B31/X
5W-20
5W-20
5W-20
©
©
©
—
85W-90
85W-90
85W-90
85W-90
85W-90
85W-90
Genuine Mitsubishi
Genuine Mitsubishi
Genuine Mitsubishi
DOT 3 or 4
DOT 3 or 4
DOT 3 or 4
DOT: Department Of Transpotation
©Automatic transaxle: DIA Queen J2
CVT transaxle: DIA Queen CVTF-J1
22140_OUTL_C0014
VALVE SPECIFICATIONS
Spring
Engine Seat Face Spring Test Installed
Displacement Engine Angle Angle Pressure Height
Year Liters ID/VIN (deg.) (deg.) (Ibs. @ in.) (in.)
2007
2008
3.0
2.4
3.0
6B31/X
4B12/W
6B31/X
NA
NA
NA
43.5-44
NA
43.5-44
55.13@1. 940
NA
55.1 3@1. 940
1.9400
NA
1.9400
Stem-to-Guide Stem
Clearance Diameter
(in.) (in.)
Intake Exhaust Intake Exhaust
0.0008-
0.0018
0.0008-
0.0019
0.0008-
0.0018
0.0014-
0.0024
0.0012-
0.0021
0.0014-
0.0024
0.240
NA
0.240
0.240
NA
0.240
NA - Not Available
22140_OUTl_C0007
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$33.99
Column D:
Get your hands on the complete service and repair manual for the 2007-2013 Mitsubishi Outlander. This manual is an invaluable resource for both professional mechanics and DIY enthusiasts, featuring highly detailed diagrams and descriptions that provide comprehensive information on various systems of your Mitsubishi Outlander.
- Clutch
- Engine Lubrication System
- Rear Axle
- Front Suspension
- Rear Suspension
- Electrical System
- General Information
- Engine Mechanical
- Brake System
- Steering System
- Front Axle
- Exhaust System
- Rear Final Drive
- Wheels & Tires
- HVAC
- Fuel System
- Engine Cooling System
- Body
- Automatic Transmission
- Maintenance
- Alphabetical Index
- Accelerator Control System
- Propeller Shaft
- Manual Transmission
This manual is compatible with Windows XP/Vista/Seven, Mac, and Linux operating systems. It is available in English and is instantly accessible online without any shipping costs or delays.
