2004 Mitsubishi Outlander Service and Repair Manual

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Factory-Grade Data

2004 Mitsubishi Outlander service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you diagnose issues correctly, follow proven repair steps, and use wiring diagrams and system sections to track faults faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical diagnostics with wiring diagrams
  • Coverage across major systems: engine, transmission/driveline, brakes, steering, suspension, HVAC, and more

Trims covered

  • XLS Premium Sport Utility 4-Door
  • LS Sport Utility 4-Door
  • XLS Sport Utility 4-Door

Engines covered

  • 2.4L 2351CC l4 GAS SOHC Naturally Aspirated
  • 2.4L 2378CC l4 GAS SOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2004 Mitsubishi Outlander Recalls & Complaints

NHTSA #04V19700026/04/2004Component: TRAILER HITCHES

CERTAIN SPORT UTILITY VEHICLES MAY HAVE BEEN EQUIPPED WITH DEALER-INSTALLED TRAILER HITCH WIRING HARNESS AND CONTROL MODULE. THE ELECTRONIC CONTROL MODULE CAN OVERHEAT.

Consequence

OVERHEATING OF THE TRAILER HITCH WIRING HARNESS MODULE COULD RESULT IN A FIRE.

Remedy

OWNERS ARE BEING REQUESTED TO STOP USING THE HARNESS UNTIL A NEWLY DESIGNED REPLACEMENT IS PROVIDED

NHTSA #16V45800023/06/2016Component: SUSPENSION:FRONT:CONTROL ARM:LOWER ARM

Mitsubishi Motors North America, Inc. (MMNA) is recalling certain model year 2002-2007 Lancer, 2004 Lancer Wagon, 2003-2006 Lancer Evolution, 2003-2006 Outlander and 2007-2013 Outlander V-6 vehicles o

Consequence

A detached front control arm can result in the loss of control of the vehicle, increasing the risk o

Remedy

MMNA will notify owners, and dealers will inspect the front cross members. Depending on the level o

NHTSA #03V42900003/11/2003Component: VISIBILITY:WINDSHIELD WIPER/WASHER

ON CERTAIN SPORT UTILITY VEHICLES LOCATED IN THE CARIBBEAN, DUE TO A SOFTWARE PROGRAMMING ERROR IN THE ELECTRONIC TIMING AND CONTROL SYSTEM (ETACS), WHILE USING THE INTERMITTENT WIPER MODE, THE INTERM

Consequence

IF THIS OCCURS DURING SEVERE WEATHER AND DURING VEHICLE'S HIGH-SPEED OPERATION, THE DRIVER VISIBILIT

Remedy

DEALERS WILL REPLACE THE ETACS MODULE. OWNER NOTIFICATION BEGAN NOVEMBER 14, 2003. OWNERS SHOULD

NHTSA #04V42800001/09/2004Component: EQUIPMENT:OTHER:LABELS

CERTAIN PASSENGER VEHICLES FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 208, 'OCCUPANT CRASH PROTECTION.' THE BILINGUAL ENGLISH/SPANISH REMOVABLE AIR BAG WARNING L

Consequence

THIS DOES NOT MEET THE REQUIREMENTS OF THE STANDARD.

Remedy

MITSUBISHI CARIBBEAN WILL MAIL A CUSTOMER NOTIFICATION LETTER CONTAINING A WRITTEN DESCRIPTION AND A

TSB #10240443

This is a Dealer Letter sent to dealers informing that Mitsubishi Technical Training has launched the 3rd quarterly technician quiz for 2023.

TSB #10235609

This Technical Service Bulletin provides instructions and material safety data sheets for removal of rap-film adhesive residue.

TSB #10235606

This is a Dealer Letter sent to dealers informing that Mitsubishi Technical Training has launched the 2nd quarterly technician quiz for 2023.

TSB #10235608

This Technical Service Bulletin reviews the regulations that require a label showing the reduction in load carrying capacity be affixed to vehicles when the total net weight of accessories is more than 1.5 percent of the vehicle's gross veh

TSB #10228919

Tech Talk is a service newsletter that was sent out to dealers. It covers various topics and reviews the previous months publications.

TSB #10226082

Tech Talk is a service newsletter that was sent out to dealers. It covers various topics and reviews the previous months publications.

TSB #10211530

This Technical Service Bulletin was sent to dealers to explain the difference between normal dew condensation, which is a natural phenomenon, and water penetration caused by improper sealing or a defective/broken part.

TSB #10208837

This Technical Service Bulletin was sent to dealers informing them to replace the Power Seat Side Shield and apply felt tape when customers complain the Power Seat Side Shield is coming off while entering/exiting the vehicle.

Showing the 8 most recent of 56 technical service bulletins on file with NHTSA.

20160105Component: AIR BAGSCrash reported1 injured

I WAS INVOLCED IN A SERVE ACCIDENT AND HIT ON PASSAGENGER SIDE. MY AIRBAGS DID NOT DEFLAT.

20130208Component: AIR BAGSCrash reported1 injured

SLAMMED MY FRONT DRIVERS SIDE INTO A CEMENT COLUMN IN A PARKING LOT. MY AIRBAG DID NOT DEPLOY. NO MAJOR INJURY JUST A BRUISED JAW AND SORE NECK. INCIDENT 01/17/2013. USAA AUTO INSURANCE SAID CAR W

20130208Component: STRUCTURE:BODYCrash reported1 injured

SLAMMED MY FRONT DRIVERS SIDE INTO A CEMENT COLUMN IN A PARKING LOT. MY AIRBAG DID NOT DEPLOY. NO MAJOR INJURY JUST A BRUISED JAW AND SORE NECK. INCIDENT 01/17/2013. USAA AUTO INSURANCE SAID CAR W

20090902Component: AIR BAGS:FRONTALCrash reported1 injured

1- I WAS DRIVING AT 55MPH(55 POSTED) ON ROUTE 38/LINCOLN HIGHWAY IN WEST CHICAGO, IL AND AS I APPROACHED THE INTERSECTION AN INDIVIDUAL DID NOT YIELD AND TURNED IN FRONT OF MY PATH. I PUT ON BRAKES PR

20080709Component: AIR BAGS:SIDE/WINDOWCrash reported1 injured

IN A DRIVER'S SIDE COLLISION, MY SIDE AIR BAG DID NOT DEPLOY. *TR

Showing the 5 most serious of 73 complaints filed with NHTSA.

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