Mitsubishi Outlander Service Manual

Free Mitsubishi Service Manual for Mitsubishi Outlander (some call it as Airtrek). This is an original service repair manual written by Mitsubishi to help their qualified mechanics while performing troubleshooting, fault finding, checking, maintaining, replacing, servicing, repairing, adjusting Mitsubishi Outlander.
Over this manual, suffice information on parts catalog + parts diagram, service

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Outlander Workshop Manual:11. Engine 4G63

This probably is the most sought service manual group amongst other groups that was posted before, the Outlander Service Repair Manual for Mitsubishi 4G63 engine (2.0L DOHC I4 engine). This engine features an Auto Lash Adjuster (hydraulic lash adjuster - HLA) with a Roller type rocker arm and electronically controlled multipoint fuel injection (MFI).
The engine service manual group is divided

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Outlander Workshop Manual:12. Engine Lubrication

Group 12 Engine Lubrication is a short and sweet technical information manual covers, engine oil check, engine oil replacement, oil pressure check and oil filter replacement of Mitsubishi Outlander.
Download Mitsubishi Outlander Service Manual: Engine Lubrication (6 pages, 0.5 MB)Back to Mitsubishi Outlander/ Airtrek Service Manual Index PDF

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Outlander Workshop Manual:13. Fuel

An MFI is an advanced fuel injection system which working based on data sent by sensors, ECU and actuators.
The first subgroup covers Multi Port Fuel Injection and the following parts: throttle body, throttle position sensor, basic idle speed, fuel pressure, fuel pump, engine control relay, fuel pump relay, intake air temperature sensor, oxygen sensor, injector, engine ecu, throttle body assy.

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Outlander Workshop Manual:14. Engine Cooling

Engine cooling service manual consists engine coolant leak check, radiator cap valve, engine coolant replacement, fan check and fan relay check and replacement, thermostat check installation and removal, water pump-water hose-water pipa-radiator replacement-troubleshooting.
Download Mitsubishi Outlander Service Manual: Engine Cooling (24 pages, 1.5 MB)Back to Mitsubishi Outlander/ Airtrek Service

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Outlander Workshop Manual:15. Intake & Exhaust

Intake and Exhaust of Outlander Workshop Manual helps Mitsubishi mechanics while maintaining and repairing intake and exhaust parts of Outlander including smaller sub parts such as air cleaner, intake manifold, exhaust manifold, exhaust pipe and main muffler.
Download Mitsubishi Outlander Service Manual: Intake & Exhaust (8 pages, 0.8 MB)Back to Mitsubishi Outlander/ Airtrek Service Manual Index

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Outlander Workshop Manual:16. Engine Electrical

Engine Electrical pdf service manual covers 3 main parts: charging system, starting system, and ignition system.
Charging system deals with alternator that keep the battery charged at constant level. You may find alternator system diagram, troubleshooting alternator, checking alternator charging system, output current test, regulated voltage test, alternator assembly and disassembly.
In the

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Outlander Workshop Manual:17. Engine & Emission Control

Group 17 will deal with Engine control, Emission Control (MPI), Crankcase Emission Control System, Evaporate Emission Control System, EGR System (Exhaust gas recirculation System), Catalytic Converter.
Information of each part are including but not limited to: piping diagram, circuit diagram, hose check, egr valve check, port vacuum check, solenoid valve check, crankcase emission control system,

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Outlander Workshop Manual:21. Clutch

This group is a part of Mitsubishi Outlander Service Manual that deals with clutch, this group is divided into two sub parts: clutch and clutch overhaul.
The first subpart will answer you common questions regarding Outlander's clutch, such as what is clutch fluid Outlander's used, how to adjust clutch pedal, how to bleed clutch master cylinder and clutch release cylinder, how to removal and

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Outlander Workshop Manual:22. Manual Transmission

Mitsubishi Outlander comes with a popular 4G63-DOHC-MPI engine mated with 2 choiches of manual transmissions: F5M42 for 2WD Outlander and W5M42 for 4WD Outlander. Both F5M42 and W5M42 are five speed manual transmission with 1 reverse constant mesh. Specifications, transmission model, engine model, transmission type, gear ratio, final reduction ratio, lubricants will be easily found in the pdf

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Outlander Workshop Manual:25. Propeller Shaft

Outlander's 4WD propeller shaft uses 3 way split 4 joint type propeller shaft with center bearing a Hypoid gear oil SAE 75W-90 or 75W-85W or 80W conforming to API GL-4 is the standard specified lubricant.
When dealing with propeller shaft, mechanics should consider using special tools such as universal joint remover and installer, and bearing remover. Removal and installation steps are depicted

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Outlander Workshop Manual:26. Front Axle

Group 26 of Mitsubishi Outlander Workshop Service manual is to help mechanics on doing regular maintenance of Outlander's Front Axle. Covered herein included but not limited to: Wheel bearing axial play check, front axle hub assembly, front drive shaft assembly removal and installation.
You may also find these information specification of front axle, construction diagram of front axle, front axle

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Outlander Workshop Manual:27. Rear Axle

Group 27 of Outlander service manual covers 2 Wheel Drive Rear Axle (27A) and 4 Wheel Drive Rear Axle (27B). In the pdf manual you may find these topics type of lubricants used, types of sealant and adhesive for rear axle mechanism, rear axle total backlash check, wheel bearing end play check, differential carrier oil seal, rear axle hub assembly-drawing-schematics-removal-installation, drive

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Outlander Workshop Manual:31. Wheel & Tire

Mitsubishi Outlander running on 114.3 PCD (pitch circle diameter) wheel and 215/60R16 95 Tyre. This technical information covers not much information, it only gives information about wheel and tyre troubleshooting, balancing tips, balancer calibration flow chart, tyre wear check, wheel runout check.
Download Mitsubishi Outlander Service Manual: Wheel & Tire (8 pages, 0.6 MB)Back to Mitsubishi

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Outlander Workshop Manual:32. Power Plant Mount

Transmission mounting, engine mounting, engine roll stopper, centermember and crossmember are amongst of parts covered in Power Plant Mount which is group 32 of Mitsubishi Outlander Repair Guide pdf.
Construction diagram of each power plant mount part also available for easier understanding on fault finding, performing maintenance, repair, disassembly and reassembly, inspecting and checking.

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Outlander Workshop Manual:33. Front Suspension

Group 33 of Outlander FSM subjected on Front Suspension and all parts link with it, such as front wheel alignment check, lower arm ball joint, ball dust cover check, strut assy removal and installation, lower arm with ball join and bushing replacement, stabilizer bar.
Outlander's Front suspension is a gas filled hydraulic double acting type McPherson strut with coil spring.
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Outlander Workshop Manual:35. Service Brakes

Service Brakes group of Mitsubishi Outlander service manual consists the following subgroups: Basic Brake System (35A) and Anti-Skid Braking System/ABS (35B).
Outlander avails ventilated disc floating caliper 2 piston on the rear and front brake system, the rear wheel itself is controlled by electronic brake force distribution (EBD) to help reduce vehicle stopping distance as well as to maintain

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Outlander Workshop Manual:36. Parking Brakes

Mitsubishi Outlander parking brake consists three main parts which are parking brake lever, cable and brake lining/drum.
This group concentrates on maintaining, checking & adjustment, removal & installation and installation of each main part written above. (See also: Mitsubishi Outlander PDF for Service Brake).
Download Mitsubishi Outlander Service Manual: Parking Brakes (8 pages, 0.7 MB)Back to

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Outlander Workshop Manual:34. Rear Suspension

Rear Suspension service manual deals with the following parts: control link, upper arm + lower arm, trailing arm assembly, shock absorber assembly, stabilizer bar, rear suspension crossmember along with their specifications, removal + installation, replacement and inspection.
Both Outlander 4WD and 2WD are covered in this manual, supported with construction diagram of each subject and service

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Outlander Workshop Manual:37. Power Steering

Mitsubishi Outlander use a 4-spoke type steering wheel with a shock absorbing and tilt steering mechanism. A vane pump is a prime mover of its hydraulic system.
The Power Steering group will help mechanic on performing diagnostics, fault finding, maintenance, inspection, removal-installation, diassembly-reassembly of steering system including steering wheel, power steering gearbox and linkage,

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