2003-2006 Mitsubishi Outlander Service & Repair Manual
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2008 ENGINE
Engine Overhaul (2.4L) - Outlander
GENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
Item Specifications
Engine model 4B12
Type In-line OHV, DOHC
Number of cylinders 4
Combustion chamber Pentroof type
Total displacement cm
3
(cu in)
2,359 (144.0)
Cylinder bore mm 88
Piston stroke mm 97
Compression ratio 10.5
Valve timing Intake valve Open 0-40°
Close 64-24°
Exhaust valve Open 44-24°
Close 0-20°
Auto lash adjuster Non-equipped
Item Standard value Limit
Timing chain
Valve clearance mm (in) Intake 0.20 ± 0.03 (0.008 ±
0.001)
-
Exhaust 0.30 ± 0.03 (0.012 ±
0.001)
-
Camshaft
Cam height of camshaft
mm (in)
Intake 44.1 (1.736) 43.6 (1.717)
Exhaust 45.0 (1.772) 44.5 (1.752)
Cylinder head and valves
Distortion of cylinder head bottom mm (in) Within 0.05 (0.002) 0.02 (0.0008)
Grinding limit of cylinder head bottom mm (in) - 0.2 (0.008)
Overall height of cylinder head mm (in) 128.5 (5.06) -
Overall length of valve
mm (in)
Intake 113.18 (4.456) 112.68 (4.436)
Exhaust 105.89 (4.169) 105.39 (4.149)
Valve margin mm (in) Intake 1.022 (0.0402) 0.522 (0.0206)
2008 Mitsubishi Outlander XLS
2008 ENGINE Engine Overhaul (2.4L) - Outlander
2008 Mitsubishi Outlander XLS
2008 ENGINE Engine Overhaul (2.4L) - Outlander
REWORK DIMENSIONS
REWORK DIMENSIONS
Exhaust 1.094 (0.0431) 0.594 (0.0234)
Free height of valve spring mm (in) 47.44 (1.867) -
Squareness of valve spring 2° or less 4°
Clearance between valve
guide and valve stem mm
(in)
Intake 0.020-0.047 (0.0008-
0.0019)
0.10 (0.0039)
Exhaust 0.030-0.054 (0.0012-
0.0021)
0.11 (0.0043)
Valve seat contact width
mm (in)
Intake 1.16-1.46 (0.046-0.058) -
Exhaust 1.35-1.65 (0.053-0.065) -
Press fit the valve guide mm (in) 14.6-15.2 (0.57-0.60) -
Piston and connecting rod
Piston pin press-fit load N (lbf) 7,500-17,500 (1.686-
3.934)
-
Clearance between piston
ring and ring groove mm
(in)
Number 1 0.03-0.07 (0.001-0.003) 0.1 (0.004)
Number 2 0.03-0.07 (0.001-0.003) 0.1 (0.004)
Piston ring end gap mm
(in)
Number 1 0.15-0.25 (0.006-0.011) 0.8 (0.03)
Number 2 0.25-0.40 (0.010-0.016) 0.8 (0.03)
Oil 0.10-0.35 (0.004-0.014) 1.0 (0.04)
Clearance of connecting rod big end thrust mm (in) 0.10-0.25 (0.004-0.010) 0.4 (0.016)
Difference of outside diameter of connecting rod
bolt mm (in)
- 0.1 (0.04)
Connecting rod bearing oil clearance mm (in) 0.018-0.045 (0.0007-
0.0018)
0.1 (0.04)
Crankshaft and cylinder block
Underhead length of crankshaft bearing cap bolt
mm (in)
75.5-76.5 (2.972-3.012) -
Crankshaft end play mm (in) 0.05-0.25 (0.002-0.010) 0.4 (0.016)
Crankshaft journal oil clearance mm (in) 0.012-0.030 (0.0005-
0.0012)
0.08 (0.0031)
Distortion of cylinder block top surface mm (in) - 0.05 (0.0020)
Grinding limit of cylinder block top surface mm (in) - 0.2 (0.008)
Cylinder block cylinder bore mm (in) 88 (3.46) -
Cylindricity of cylinder block mm (in) 0.0076 (0.0003) -
Item Standard value
Cylinder head and valve
Cylinder head oversize valve seat bore diameter mm
Intake
0.30 Over
size
36.22-36.24 (1.426-
1.427)
2008 Mitsubishi Outlander XLS
2008 ENGINE Engine Overhaul (2.4L) - Outlander
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
(in)
Exhaust
0.30 Over
size
30.22-30.24 (1.190-
1.191)
Cylinder head oversize valve guide bore diameter mm (in)
0.25 Over
size
11.23-11.25 (0.442-
0.443)
Item Specification
Generator and ignition system
Idler pulley bolt 48 ± 7 N.m (36 ± 4 ft-lb)
Auto tensioner bolt 22 ± 4 N.m (17 ± 2 ft-lb)
Crankshaft pulley center bolt 210 N.m (155 ft-lb)
Generator nut 44 ± 10 N.m (32 ± 7 ft-lb)
Generator bolt 44 ± 10 N.m (32 ± 7 ft-lb)
Ignition coil bolt 10 ± 2 N.m (89 ± 17 in-lb)
Spark plug 25 ± 5 N.m (19 ± 3 ft-lb)
Power steering pump bracket bolt (M8) 23 ± 2 N.m (17 ± 1 ft-lb)
Power steering pump bracket bolt (M10) 44 ± 8 N.m (33 ± 5 ft-lb)
Throttle body and EGR system
Vacuum pipe and hose bolt (M6) 11 ± 1 N.m (98 ± 8 in-lb)
Vacuum pipe and hose bolt (M8) 24 ± 3 N.m (18 ± 1 ft-lb)
Water pipe bolt 10 ± 2 N.m (89 ± 17 in-lb)
Throttle body bolt 9.5 ± 2.5 N.m (84 ± 22 in-lb)
Throttle body stay bolt 20 ± 2 N.m (15 ± 1 ft-lb)
EGR valve support bolt 20 ± 2 N.m (15 ± 1 ft-lb)
EGR pipe bolt 20 ± 2 N.m (15 ± 1 ft-lb)
EGR support stay A bolt 20 ± 2 N.m (15 ± 1 ft-lb)
EGR support stay B bolt 20 ± 2 N.m (15 ± 1 ft-lb)
EGR valve bolt 24 ± 3 N.m (18 ± 1 ft-lb)
Manifold absolute pressure (MAP) sensor screw 4.0 ± 1.0 N.m (36 ± 8 in-lb)
Solenoid valve screw 4.0 ± 1.0 N.m (36 ± 8 in-lb)
Intake manifold and fuel system
Oil dipstick guide bolt 10 ± 2 N.m (89 ± 17 in-lb)
Injector protector rear bolt 20 ± 2 N.m (15 ± 1 ft-lb)
Fuel rail bolt 20 ± 2 N.m (15 ± 1 ft-lb)
Intake manifold bolt and nut 3.5 ± 1.5 N.m (31 ± 13 in-lb) --> 20 ± 2 N.m (15 ± 1
ft-lb)
Intake manifold stay bolt 20 ± 2 N.m (15 ± 1 ft-lb)
Injector protector front bolt 20 ± 2 N.m (15 ± 1 ft-lb)
Generator bracket bolt 44 ± 8 N.m (33 ± 5 ft-lb)
2008 Mitsubishi Outlander XLS
2008 ENGINE Engine Overhaul (2.4L) - Outlander
Detonation sensor bolt 20 ± 2 N.m (15 ± 1 ft-lb)
Engine oil pressure switch 10 ± 2 N.m (89 ± 17 in-lb)
Exhaust manifold
Exhaust manifold upper cover bolt 14 ± 1 N.m (124 ± 8 in-lb)
Exhaust manifold lower cover bolt 14 ± 1 N.m (124 ± 8 in-lb)
Exhaust manifold nut 49 ± 5 N.m (36 ± 3 ft-lb)
Exhaust manifold bracket C bolt (M8) 20 ± 5 N.m (15 ± 3 ft-lb)
Exhaust manifold bracket A bolt (M10) 41 ± 10 N.m (30 ± 7 ft-lb)
Crankshaft position sensor bolt 11 ± 1 N.m (98 ± 8 in-lb)
Crankshaft position sensor cover bolt (M6) 11 ± 1 N.m (98 ± 8 in-lb)
Crankshaft position sensor cover bolt (M10) 49 ± 6 N.m (36 ± 4 ft-lb)
Water hose and pipe
Water inlet fitting bolt 24 ± 3 N.m (18 ± 1 ft-lb)
Water outlet fitting bolt 24 ± 3 N.m (18 ± 1 ft-lb)
Thermostat housing bolt 24 ± 3 N.m (18 ± 1 ft-lb)
Engine hanger bolt 24 ± 3 N.m (18 ± 1 ft-lb)
Engine coolant temperature sensor 30 ± 9 N.m (22 ± 6 ft-lb)
Water pump bolt 24 ± 3 N.m (18 ± 1 ft-lb)
Water pipe nut 24 ± 3 N.m (18 ± 1 ft-lb)
Camshaft position sensor bolt 11 ± 1 N.m (98 ± 8 in-lb)
Oil pan and timing chain case
Cylinder head cover bolt 3.0 ± 1.0 N.m (27 ± 8 in-lb) --> 5.5 ± 0.5 N.m (49 ±
8 in-lb)
Timing chain case bolt (M6) 10 ± 2 N.m (89 ± 17 in-lb)
Timing chain case bolt (M8 x 10) 13 ± 1 N.m (115 ± 8 in-lb)
Timing chain case bolt (M8 x 28) 24 ± 4 N.m (18 ± 1 ft-lb)
Oil pan bolt (M6) 10 ± 2 N.m (89 ± 17 in-lb)
Oil pan bolt (M8) 29 ± 2 N.m (21 ± 1 ft-lb)
Air compressor bracket bolt 23 ± 6 N.m (17 ± 4 ft-lb)
Oil drain plug 39 ± 5 N.m (29 ± 3 ft-lb)
Oil filter 14 ± 2 N.m (124 ± 17 in-lb)
Positive Crankcase Ventilation Valve 2.5 ± 0.4 N.m (22 ± 3 in-lb)
Engine support bracket bolt 45 ± 5 N.m (33 ± 3 ft-lb)
Timing chain
Chain upper guide bolt 10 ± 2 N.m (89 ± 17 in-lb)
Oil jet bolt 10 ± 2 N.m (89 ± 17 in-lb)
V.V.T. intake sprocket bolt 59 ± 5 N.m (44 ± 3 ft-lb)
V.V.T. exhaust sprocket bolt 59 ± 5 N.m (44 ± 3 ft-lb)
Timing chain tensioner bolt 10 ± 2 N.m (89 ± 17 in-lb)
Tensioner lever bolt 10 ± 2 N.m (89 ± 17 in-lb)
Timing chain guide bolt 10 ± 2 N.m (89 ± 17 in-lb)
2008 Mitsubishi Outlander XLS
2008 ENGINE Engine Overhaul (2.4L) - Outlander
NEW TIGHTENING METHOD BY USING PLASTIC REGION TIGHTENING BOLT
Plastic region tightening bolts are used in some parts of the engine. Install these bolts according to the method
described in the body of the manual because the tightening method of these bolts are different from the
conventional method. The service limit is determined for these bolts. Be sure to strictly follow the service limit
described in the body of the manual.
Parts to be used
1. Cylinder head bolt
2. Bearing cap bolt
3. Connecting rod cap bolt
Tightening method
After tightening to the specified tightening torque, further tighten 90° and 90°, or 180° (90° + 90°).
Follow the tightening method described in the body of the manual because the tightening method differs
from part to part.
SEALANTS
SEALANTS REFERENCE
Camshaft
Engine oil control valve (OCV) bolt 10 ± 2 N.m (89 ± 17 in-lb)
Camshaft bearing cap bolt (M6) 12 ± 1 N.m (107 ± 8 in-lb)
Front camshaft bearing cap bolt (M8) 17 ± 3 N.m (14 ± 2 ft-lb) --> 30 ± 2 N.m (22 ± 1 ft-
lb)
Cylinder head and valves
Cylinder head bolt 35 ± 2 N.m (26 ± 1 ft-lb) --> +180°
Balancer chain
Drive plate bolt 40 N.m (30 ft-lb) --> 130 N.m (95 ft-lb)
Balancer shaft module bolt 20 (15 ft-lb) --> 44 (32 ft-lb) --> 0 --> 20 (15 ft-lb) -
-> +135°
Balancer shaft chain tensioner bolt 10 ± 2 N.m (89 ± 17 in-lb)
Lever tensioner bolt 10 ± 2 N.m (89 ± 17 in-lb)
Balancer shaft chain guide bolt 10 ± 2 N.m (89 ± 17 in-lb)
Ladder frame bolt 26 ± 1 N.m (19 ± 1 ft-lb)
Piston and connecting rod
Connecting rod cap bolt 5.0 N.m (44 in-lb) --> 20 N.m (15 ft-lb) --> +90°
Crankshaft and cylinder block
Crankshaft sensing ring bolt 11 N.m (98 in-lb)
Bearing cap bolt 26.5 ± 2.0 N.m (20 ± 1 ft-lb) --> +45°
Points of application Specified sealant/adhesive
2008 Mitsubishi Outlander XLS
2008 ENGINE Engine Overhaul (2.4L) - Outlander
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What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$31.99
This Mitsubishi Outlander 2003 2004 2005 2006 Service Repair Workshop Manual provides full service and repair instructions for the Mitsubishi Outlander 2003-2006. It covers all major topics including General Information, Engine Mechanical System, Engine Electrical System, Emission Control System, Fuel System, Clutch System, Manual Transaxle System, Automatic Transaxle System, Driveshaft and Axle, Suspension System, Steering System, Restraint, Brake System, Body (Interior and Exterior), Body Electrical System, Heating, Ventilation, and Air Conditioning.
Whether you are a professional mechanic or a DIY enthusiast with basic mechanical skills, this manual offers the same specifications and procedures available to an authorized dealer service department. It contains accurate, clear, and concise text along with illustrations, enabling anyone with basic mechanical knowledge to safely and easily service and repair their vehicle.
Written by the manufacturers, this manual can assist with various repairs, from simple maintenance tasks to more complex procedures. It includes step-by-step instructions, diagrams, illustrations, wiring schematics, and specifications for troubleshooting and repairing the Mitsubishi Outlander 2003-2006.
Available in .PDF format, this manual can be viewed on various devices and printed out as needed. It is compatible with all versions of Windows and Mac, and requires Adobe Reader for viewing. All pages are printable, allowing for easy access in the garage or workshop.
By utilizing this manual, individuals can save a significant amount of money by performing simple repairs themselves. It covers a wide range of systems and components, including steering, suspension, wiring diagrams, troubleshooting, routine maintenance, and more.
For anyone looking to be better informed and more knowledgeable about their vehicle, owning and referring to this Mitsubishi Outlander 2003 2004 2005 2006 Service Repair Workshop Manual is highly beneficial.
