2007-2010 Mitsubishi Outlander North American 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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