Mitsubishi MOTORS Outlander 2007 Operating instructions

1
2007 Outlander Service Manual,
Technical Information & Body Repair
Manual Data
Volume 1
Volume 2
Volume 3
Technical Information
Manual
Body Repair Manual

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HOW TO USE THIS MANUAL
M20000000290USA0000010000
ABBREVIATIONS
The following abbreviations are used in this manual
for classification of model types.


MFI: Indicates the multiport fuel injection, or
engines equipped with the multiport injection.

A/T: Indicates the automatic transaxle, or models
equipped with automatic transaxle.

FWD: Indicates 2-wheel drive vehicles.

AWD: Indicates 4-wheel drive vehicles.

A/C: Indicates air conditioning.

Keyless Operation System (KOS): Indicates the
Free-hand Security Transmitter (F.A.S.T.-key)
TARGETS OF DEVELOPMENT
M20000000040USA0000010000
The new OUTLANDER has an improved SUV
appearance and cruising performance in any road
conditions. This car has been developed as the new
generation of SUV proposed by Mitsubishi, aiming to
be an all-round car for various applications from daily
use to cruising and leisure use.

EXTERIOR
M20000000170USA0000010000
DESIGN FEATURES

Fine athletic image of powerfulness and driving
performance.

Smart styling with high functionality and stylish
exterior

Representing feelings of refreshment with a highly
refined styling
MAIN FEATURES
ZC501829
1
2, 3
4
5
5
6
6
7
8
5
0007
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 Good stance which combines wide tread with 18-
inch tire <XLS model>
 Progressive diamond-cut nose with neat corners
 Aggressive and handsome face design with sharp
styling
 Headlights with mechanical styling emphasizing
aggressiveness
 Tough lower body with the overfender covering a
large size tire, the undercover, and black
underbody parts
 Dynamic cabin which consists of the roof line with
uplifting feeling and sharp window graphic
 Stylish rear end which comfortably integrates the
unique horizontally split upper/lower tailgates
 Rear combination lights with a sense of integrity
with the glass area, presenting a high-tech image
INTERIOR
M20000000180USA0000010000
DESIGN PURPOSE

Presenting well-trimmed interior space with a sporty
feel

Combining high functionality with stylish design

Neat and carefully established details
MAIN FEATURES
ZC6022030000

Sporty and dynamic styled instrument panel with
uplifting feeling

Unique audio panel integrated in the instrument
panel, representing high quality

Door trim, floor console, and air outlet panel with
powerful silver accent parts in the sculpturesque
styling

Drive mode selector dial in mechanical design

Bucket-type front seats in sporty three dimensional
shape

Functional luggage area equipped with the tonneau
cover, luggage hook, and utility bar
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ENGINE
M20000000200USA0000010000
The 6B31 engine has been developed to achieve high
performance, better fuel economy, smaller size, and
weight reduction.
TRANSAXLE
M20000000210USA0000010001
The F6AJA-type <FWD> or the W6AJA-type <AWD>
6-speed sport mode automatic transaxle has been
developed to achieve excellent fuel economy, further
improved operation, and driving pleasure.
SUSPENSION
M20000000230USA0000010000
ZC601177
<Front suspension>
0000
Stabilizer bar
Coil spring
Shock absorber
Stabilizer link
Lower arm
Front axle crossmember
(Flat crossmember)
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

ZC601183
<Rear suspension>
<FWD>
Trailing arm
Toe control arm
Rear crossmember
Stabilizer bar
Coil spring
Shock absorber
<AWD>
Shock absorber
Stabilizer bar
Rear crossmember
Coil spring
Trailing arm
Toe control arm
Upper arm
0000
The well-proven McPherson strut suspension (front)
and trailing arm type multi-link suspension (rear) have
been adopted.
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ACTIVE SAFETY
M20000000310USA0000010000
ZC600661
CHECK
SE R VIC E
RE Q UIRE D
ASC
OFF
<Except vehicles for CANADA> <Vehicles for CANADA>
ABS warning
light
Brake warning
light ABS warning
light
Brake warning
light
ABS warning light Brake warning light
Stoplight switch
G-sensor <AWD>,
hydraulic unit, ABS-ECU
AWD-ECU <AWD>
Wheel speed sensor
Magnetic encoder for wheel speed detection
Data link connector
Wheel speed sensor
Magnetic
encoder for
wheel speed
detection
0001
The ABS*1has been installed as standard equipment
to prevent the wheels from locking and optimize the
longitudinal brake force distribution depending on the
road surface and loading conditions. In addition, the
ASC*2has also been installed to suppress side slip
and wheel spin during steep steering or on a slippery
road surface, ensuring the ideal brake force and
braking stability through the integrated control of
brake and engine output <standard: LS, optional:
XLS>.

*1: Electronic Brake-force Distribution
*2: Active Stability Control
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PASSIVE SAFETY
M20000000320USA0000010000
SRS AIR BAGS
ZC600850
Driver's air bag
module
Passenger's (front)
air bag module
Side-airbag module
Curtain air bag module
Seat belt with
pre-tensioner
0000
Dual Supplemental Restraint System (SRS) front air
bags deploy only upon detection of frontal impact.
When used in combination with the 3-point ELR seat
belts, they significantly reduce head and upper torso
injury to front-seat occupants.
The seat belts with pre-tensioner work simultaneously
with the SRS. The pre-tensioner takes up seat slack
immediately when a collision takes place by
restraining the front passengers sooner than the SRS.
This prevents the passengers from moving forward.
SIDE-AIRBAGS AND CURTAIN AIR BAGS
During a side collision, the SRS side-airbags
embedded in the front seat side area soften blows to
the front passenger's chest area, and the SRS curtain
air bags integrated into the roof side area soften blows
to the front/rear passenger's head area.
FRONT SEAT BELT
A seat belt with double pre-tensioner for shoulder and
lap has been installed on the driver's seat. A seat belt
with pre-tensioner is on the front passenger's seat.
This retracts the belt to eliminate slack, and increases
the initial restraint for passengers to limit movement
of the passenger, increasing safety. In addition, the
variable force limiter has been installed on the seat
belts (driver's/front passenger's seats) to properly
absorb the load on a passenger by extending the belt
if the belt tension exceeds a certain level, increasing
safety against an accident with a collision.
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BODY CONSTRUCTION
ZC6012910000
The body structure combines a high-energy
absorbing structure (front and rear) and high rigidity
cabin structure to reduce the level of injury to
passengers upon front, rear and side impact, as well
as secure cabin space and to improve passenger
rescue upon impact.
Employment of a top/bottom one-piece door outer
panel and door inner panel pressed door structure
improves door panel rigidity.
SAFETY-ENHANCED FRONT SEATS
The front seats are designed to minimize the risk of
whiplash in a collision from the rear.
The head restraints have been ideally angled forward,
while the seat frame was moved toward the rear.
OTHER SAFETY FEATURES

3-point ELR seat belts

Front fog lamps

Child-protection rear door locks

Brake pedal recede-control device
ENVIRONMENTAL PROTECTION
M20000000270USA0000010000
RECYCLING
Recyclable thermoplastic resin and recycled
materials have been actively used, and multilayer
materials have been integrated into thermoplastic
resin.
Classification Main contents
Components made
of recycled
materials
Chip materials produced during manufacturing process have been reused for the
following components: Bumper, instrument panel, door trims, and radiator grille.
Waste materials produced by other industries have been reused for the following
components: Sound absorbing materials for dash panel or roof, and oil level gauge.
Components made
of materials which
can be easily
recycled
Thermoplastic resin has been used for the purge hose in the engine control system.
Thermoplastic resin has been used for all the materials for the floor carpet.
Thermoplastic resin has been used for the bumper, instrument panel, door trims, and
radiator grille.
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

REDUCTION OF MATERIAL BURDEN ON
ENVIRONMENT
Lead-free materials have been used for the fuel tank,
radiator, heater core, and rubber parts.
Item Main contents
Elimination of
environmental
burden materials
Lead-free materials have been used for the components such as the fuel tank, radiator,
heater core, battery cable terminal, wheel balance weight, power steering high-pressure
hose, glass ceramic print, electrostatic coating, crank bearing metal, connecting rod
bearing metal, crankshaft, connecting rod, harnesses, and intake valve seat.
PVC (polyvinyl chloride)-free materials have been used for the waterproofing film.
Ozone layer
protection
Air conditioning filled with new refrigerant (HFC 134a) has been installed.
Prevention of air
pollution
Organic solvent drainage amount for body painting has been reduced.
SERVICEABILITY AND RELIABILITY
M20000000280USA0000010000
MAINTENANCE-FREE FEATURES

The chain timing belt has been adopted to eliminate
a regular replacement.
ENHANCED DIAGNOSIS SYSTEM
Diagnosis functions have been included for the
following systems, so that it is possible to use the
M.U.T.-III to read the diagnosis codes and service
data and to carry out actuator tests. In addition, it is
also possible to read the diagnosis codes by the
flashing of the warning light in some systems.

Multiport fuel injection system (MFI)

Electronically-controlled AWD

6-speed sport mode automatic transaxle

ABS (with EBD)

Active Stability Control (ASC)

Power windows

Keyless Operation System (KOS)

SRS air bag

Immobilizer

Combination meter

Headlight auto leveling

6-disc CD changer, and AM/FM radio

ETACS

Heater and air conditioning
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BETTER SERVICEABILITY AND
HANDLING

The power steering oil pump has been installed at
the front of the vehicle for better workability.

The engine control module has been installed in the
engine room for better workability.

The instrument panel components can be removed
and installed individually and the frame part is
smaller in size to allow it to be removed and installed
without lowering the steering shaft.

The floor console panel can be removed and
installed individually without tools for parking brake
lever adjustment.

The joint connector has been relocated for better
CAN-related workability.

The service hole for the rear shock absorber
tightening check has been located on the quarter
trim for better workability.

A partial slit has been added on the floor carpet for
easier access to the fuel pump module.
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

VEHICLE IDENTIFICATION
M20000000010USA0000010000
VEHICLE IDENTIFICATION NUMBER LOCATION
ZC6012650000
The vehicle identification number (VIN) is located on a plate
attached to the left top side of the instrument panel.
VEHICLE IDENTIFICATION CODE CHART PLATE
1 2 3 4 5 6 7 8 9 10 11
12
J A 4 M S 3 1 X 1 7 U 0 0 0 0 0 1
ZC6009480000
All vehicle identification numbers contain 17 digits. The vehicle
number is a code which tells country, make, vehicle type, etc.
No. Item Content
1 Country J: Japan
2 Make A: Mitsubishi
3 Vehicle type 4: Multi-purpose vehicle
4 Others GROSS VEHICLE WEIGHT
RATING/BRAKE SYSTEM
M: 5001-6000 lbs/HYDRAULIC
5 Line S: OUTLANDER FWD
T: OUTLANDER AWD
6 Price class 3: Medium
4: High
7 Body 1: 5-door wagon
8 Engine X: 3.0L (6B31) MIVEC
9 Check digits* 0, 1, 2, 3, -----------9, X
10 Model year 7: 2007 year
11 Plant U: Mizushima
12 Serial number 000001 to 999999
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




VEHICLE IDENTIFICATION NUMBER LIST
VEHICLES FOR USA
(FOR FEDERAL EMISSION REGULATION)
VIN (except sequence number) Brand Engine
displacement
Model code
JA4MS31X_7U MITSUBISHI
OUTLANDER
3.0L CW6WXLSYL2M
JA4MS41X_7U CW6WXLHYL2M
CW6WXLXYL2M
JA4MT31X_7U CW6WXLSYZL2M
JA4MT41X_7U CW6WXLHYZL2M
CW6WXLXYZL2M
(FOR CALIFORNIA EMISSION REGULATION)
VIN (except sequence number) Brand Engine
displacement
Model code
JA4MS31X_7U MITSUBISHI
OUTLANDER
3.0L CW6WXLSYL7M
JA4MS41X_7U CW6WXLHYL7M
CW6WXLXYL7M
JA4MT31X_7U CW6WXLSYZL7M
JA4MT41X_7U CW6WXLHYZL7M
CW6WXLXYZL7M
VEHICLES FOR PUERTO RICO
VIN (except sequence number) Brand Engine
displacement
Model code
JA4MS31X_7U MITSUBISHI
OUTLANDER
3.0L CW6WXLSYL2M
CW6WXLMYL2M
JA4MS41X_7U CW6WXLXYL2M
JA4MT31X_7U CW6WXLSYZL2M
VEHICLES FOR CANADA
VIN (except sequence number) Brand Engine
displacement
Model code
JA4MS31X_7U MITSUBISHI
OUTLANDER
3.0L CW6WXLSYL3M
JA4MS41X_7U CW6WXLXYL3M
JA4MT31X_7U CW6WXLSYZL3M
JA4MT41X_7U CW6WXLXYZL3M
 


GENERAL DATA AND SPECIFICATIONS
M20000000300USA0000010000
<Except vehicles for CANADA>
ZC5019470000
5
2
9
7 4
1
8
3
6
Item CW6W
XLSYL2M/7M XLHYL2M/7M XLSYZL2M/7M XLHYZL2M/7M
Vehicle
dimension mm
(in)
Overall length 1 4,640 (182.7) 4,640 (182.7) 4,640 (182.7) 4,640 (182.7)
Overall width 2 1,800 (70.9) 1,800 (70.9) 1,800 (70.9) 1,800 (70.9)
Overall height
(unladen)
3 1,680 (66.1)
<Vehicles
without roof
rail>
1,720 (67.7)
<Vehicles with
roof rail>
1,720 (67.7)
<Vehicles with
roof rail>
1,680 (66.1)
<Vehicles
without roof
rail>
1,720 (67.7)
<Vehicles with
roof rail>
1,720 (67.7)
<Vehicles with
roof rail>
Wheelbase 4 2,670 (105.1) 2,670 (105.1) 2,670 (105.1) 2,670 (105.1)
Tread-front 5 1,540 (60.6) 1,540 (60.6) 1,540 (60.6) 1,540 (60.6)
Tread-rear 6 1,540 (60.6) 1,540 (60.6) 1,540 (60.6) 1,540 (60.6)
Overhang-front 7 965 (38.0) 965 (38.0) 965 (38.0) 965 (38.0)
Overhang-rear 8 1,005 (39.6) 1,005 (39.6) 1,005 (39.6) 1,005 (39.6)
Ground clearance 9 215 (8.5) 215 (8.5) 215 (8.5) 215 (8.5)
Vehicle weight
kg (lb)
Curb weight 1,615 (3,560) 1,635 (3,604) 1,680 (3,703) 1,700 (3,747)
Gross vehicle weight
rating
2,300 (5,071) 2,350 (5,181) 2,350 (5,181)
Gross axle weight
rating-front
1,090 (2,403)
Gross axle weight
rating-rear
1,280 (2,822)
Seating capacity 5
Engine Model No. 6B31
Piston displacement 3.0 L
Transaxle Model No. F6AJA W6AJA
Type 6-speed automatic
Fuel system Fuel supply system Multiport fuel injection
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Item CW6W
XLMYL2M XLXYL2M/7M XLXYZL2M/7M
Vehicle
dimension mm
(in)
Overall length 1 4,640 (182.7) 4,640 (182.7) 4,640 (182.7)
Overall width 2 1,800 (70.9) 1,800 (70.9) 1,800 (70.9)
Overall height
(unladen)
3 1,680 (66.1)
<Vehicles without
roof rail>
1,720 (67.7)
<Vehicles with roof
rail>
1,720 (67.7)
<Vehicles with roof
rail>
1,680 (66.1)
<Vehicles without
roof rail>
1,720 (67.7)
<Vehicles with roof
rail>
Wheelbase 4 2,670 (105.1) 2,670 (105.1) 2,670 (105.1)
Tread-front 5 1,540 (60.6) 1,540 (60.6) 1,540 (60.6)
Tread-rear 6 1,540 (60.6) 1,540 (60.6) 1,540 (60.6)
Overhang-front 7 965 (38.0) 965 (38.0) 965 (38.0)
Overhang-rear 8 1,005 (39.6) 1,005 (39.6) 1,005 (39.6)
Ground clearance 9 215 (8.5) 215 (8.5) 215 (8.5)
Vehicle weight
kg (lb)
Curb weight 1,675 (3,692) 1,670 (3,681) 1,735 (3,825)
Gross vehicle weight
rating
2,300 (5,071) 2,350 (5,181)
Gross axle weight
rating-front
1,090 (2,403)
Gross axle weight
rating-rear
1,280 (2,822)
Seating capacity 7
Engine Model No. 6B31
Piston displacement 3.0 L
Transaxle Model No. F6AJA W6AJA
Type 6-speed automatic
Fuel system Fuel supply system Multiport fuel injection
<Vehicles for CANADA>
ZC5019470000
5
2
9
7 4
1
8
3
6
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Item CW6W
XLSYL3M XLSYZL3M XLXYL3M XLXYZL3M
Vehicle
dimension mm
(in)
Overall length 1 4,640 (182.7) 4,640 (182.7) 4,640 (182.7) 4,640 (182.7)
Overall width 2 1,800 (70.9) 1,800 (70.9) 1,800 (70.9) 1,800 (70.9)
Overall height
(unladen)
3 1,680 (66.1)
<Vehicles
without roof
rail>
1,720 (67.7)
<Vehicles with
roof rail>
1,720 (67.7)
<Vehicles with
roof rail>
1,680 (66.1)
<Vehicles
without roof
rail>
1,720 (67.7)
<Vehicles with
roof rail>
1,720 (67.7)
<Vehicles with
roof rail>
Wheelbase 4 2,670 (105.1) 2,670 (105.1) 2,670 (105.1) 2,670 (105.1)
Tread-front 5 1,540 (60.6) 1,540 (60.6) 1,540 (60.6) 1,540 (60.6)
Tread-rear 6 1,540 (60.6) 1,540 (60.6) 1,540 (60.6) 1,540 (60.6)
Overhang-front 7 965 (38.0) 965 (38.0) 965 (38.0) 965 (38.0)
Overhang-rear 8 1,005 (39.6) 1,005 (39.6) 1,005 (39.6) 1,005 (39.6)
Ground clearance 9 215 (8.5) 215 (8.5) 215 (8.5) 215 (8.5)
Vehicle weight
kg (lb)
Curb weight 1,615 (3,560) 1,680 (3,703) 1,670 (3,681) 1,735 (3,825)
Gross vehicle weight
rating
2,300 (5,071) 2,350 (5,181) 2,300 (5,071) 2,350 (5,181)
Gross axle weight
rating-front
1,090 (2,403)
Gross axle weight
rating-rear
1,100 (2,425)
Seating capacity 5 7
Engine Model No. 6B31
Piston displacement 3.0 L
Transaxle Model No. F6AJA W6AJA F6AJA W6AJA
Type 6-speed automatic
Fuel system Fuel supply system Multiport fuel injection
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




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GENERAL DESCRIPTION
M21102000001USA0000010000
This vehicle is equipped with the newly developed
6B31 engine, a 3.0L V6 Single Over Head Camshaft
(SOHC) 24-valve engine.


The 3.0L engine employs the Mitsubishi Innovative
Valve timing and lift Electronic Control system
(MIVEC).

An aluminum alloy cylinder block is used to be
lightweight and compact.

The cylinders are offset from the center of the
crankshaft.
MAJOR SPECIFICATIONS
ITEMS SPECIFICATIONS
Total displacement cm3(cu in) 2,998 (182.9)
Bore × Stroke mm (in) 87.6 (3.45) × 82.9 (3.26)
Compression ratio 9.5
Combustion chamber Pentroof type
Camshaft arrangement SOHC
Valve timing Intake Open -1° BTDC Low speed cam
18° BTDC High speed cam
Intake Close 37° ABDC Low speed cam
86° ABDC High speed cam
Exhaust Open 55° BBDC
Exhaust Close 17° ATDC
Maximum output kW/r/min (HP/r/min) 164/6,250(220/6,250)
Maximum torque N·m/r/min (lbs-ft/r/min) 276/4,000(204/4,000)
Lash adjuster Exhaust side only
Fuel system Electronic-controlled multiport fuel injection
Ignition system Electronic-controlled 6-coil
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BASE ENGINE
M21102000010USA0000010000
CYLINDER HEAD
ZK602589
Intake side
Exhaust side
Plug guide
Valve guide
Valve seat
AA00
A cylinder head made of an aluminum alloy, which is
lightweight and offers a high level of cooling efficiency,
has been adopted. A pent roof combustion chamber
with a center spark plug has been adopted. It has a
small valve compound angle to create a compact
chamber.
Cross-flow type intake and exhaust ports have been
adopted. Two intake ports and two exhaust ports are
provided independently on the right and left sides.
Four camshaft bearings are provided at the intake and
exhaust sides, respectively. The No. 4 bearing
sustains the thrust load of the camshaft.
VALVE SEAT
The valve stem seals use springs with good seal performance
to prevent oil draining down.
The oversize valve guides are available as spare parts: 0.3.
VALVE GUIDE
A sintered alloy material is used for the valve guides.
The three kinds of the oversize valve guides are available as
spare parts: 0.05, 0.25 and 0.50.
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CYLINDER HEAD GASKET
ZK602583AA00
Oil hole
Water hole
Oil hole
Water hole
Water hole
A 2-layer metal gasket with good sealability and heat
resistance is used for the cylinder head gasket.
ROCKER COVER
ZK602584AA00
Timing belt side
Blow by nipple
P.C.V. valve
Blow by nipple
A lightweight resin material is used for the cylinder gasket cover.
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CYLINDER BLOCK
ZK602585AA00
Cylinder block
Bearing cap
Beam
Right plate
Left plate
An aluminum alloy material is used for the cylinder
block to be lightweight.
The crankshaft journal has 4 bearings. The No.3
bearing carries the thrust load of the crankshaft.
A full Siamese type water jacket is used.
Items Specifications
Bore mm (in.) 87.6(3.45)
Bore pitch mm (in.) 98(3.86)
Stroke mm (in.) 82.9(3.26)
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