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

2005-2012 Mitsubishi Outlander XL Service and Repair Manual

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