Mitsubishi Outlander 2003-06

Engine

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NOTE
Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer systems and may require the computer to undergo a relearning process, once the negative battery cable is reconnected.

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Undercover
     
    Hood assembly
     
    Air cleaner assembly and all adjoining air intake duct work
     

  6.  
  7. Drain the engine coolant, engine oil, transaxle and transfer case (if equipped).
  8.  
  9. Remove or disconnect the following:

    Battery and battery tray
     
    Accelerator cable
     
    Radiator
     
    Front exhaust pipe
     
    Drive belt
     

  10.  
  11. Detach the electrical connectors and/or vacuum lines from the following components, as necessary:

    Control wiring harness
     
    Battery wiring harness
     
    Evaporative emission (EVAP) vacuum connection
     
    Brake booster vacuum hose connection
     
    Air Conditioning (A/C) compressor
     
    Power steering oil pressure switch
     
    Crank angle sensor
     
    Manifold differential pressure sensor
     
    Exhaust Gas Recirculation (EGR) solenoid valve
     
    Ignition coil
     
    Fuel injectors
     
    Throttle Position (TP) sensor
     
    Idle Air Control (IAC) motor
     
    Engine Coolant Temperature (ECT) sensor
     
    Camshaft Position (CMP) sensor
     
    Knock Sensor (KS)
     
    ECT gauge unit
     
    Heated Oxygen Sensor (HO2S)
     
    Starter and alternator
     
    Oil pressure switch
     

  12.  
  13. Remove or disconnect the following:

    Power steering pump and brace. Position the assembly aside, but do NOT disconnect the fluid line.
     
    A/C compressor, but do NOT disconnect the lines
     

  14.  


NOTE
Matchmark the installed position of the radiator hoses before disconnecting them.



Upper and lower radiator hoses
 
Heater and purge hoses
 
Fuel lines. Discard the O-rings
 

  1. Pre-tighten the two bolts on the vehicle to assemble the radiator support upper insulator to set Mitsubishi Special tool no. MB991928 or MB991895. See the accompanying figure.

    Transaxle assembly
     


    Click image to see an enlarged view

    Fig. Pre-tighten the two bolts on the vehicle to assemble the radiator support upper insulator for the engine hanger (MB991928 or MB991895)

    Ground cable connection
     
    Self-locking nuts
     

  2.  
  3. Remove the engine front mounting bracket as follows:
    1. Support the engine with a suitable floor jack.
    2.  
    3. Remove the special tools that were installed for transaxle removal.
    4.  
    5. Support the engine with Mitsubishi Special tools MB991454 and MB991527 attached to a chain block or engine hoist.
    6.  


      Click image to see an enlarged view

      Fig. View of the special tools needed to support the engine during mount removal

    7. Place a jack under the oil pan with a block of wood in between to protect the pan. Jack up the engine to take the weight off the engine mount insulator and bracket, then remove the front mounting bracket mounting nuts and bolts, then remove the bracket.
    8.  

  4.  
  5. Make sure that all cables, hoses and harnesses are disconnected from the engine, then use the engine hose to slowly lift the engine up and out of the engine compartment
  6.  


    Click image to see an enlarged view

    Fig. View of the tool MB991928 installed, necessary to support the engine when the transaxle is removed



    Click image to see an enlarged view

    Fig. View of the tool MB991895 installed, necessary to support the engine when the transaxle is removed


To install:

  1. Installation is the reverse of the removal procedure. Torque the engine mounting fasteners to the specifications shown in the accompanying illustration.
  2.  
  3. Fill the coolant system and engine crankcase.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. Start the engine and check for leaks.
  8.  
  9. Install the hood.
  10.  


    Click image to see an enlarged view

    Fig. View of the engine mounts and related components


  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Undercover
     
    Hood assembly
     
    Air cleaner assembly and all adjoining air intake duct work
     

  6.  
  7. Drain the engine coolant, engine oil, transaxle and transfer case (if equipped).
  8.  
  9. Remove or disconnect the following:

    Battery and battery tray
     
    Accelerator cable
     
    Radiator
     
    Front exhaust pipe
     
    Drive belt
     

  10.  
  11. Detach the electrical connectors and/or vacuum lines from the following components, as necessary:

    Control wiring harness
     
    Battery wiring harness
     
    Evaporative emission (EVAP) vacuum connection
     
    Brake booster vacuum hose connection
     
    Air Conditioning (A/C) compressor
     
    Power steering oil pressure switch
     
    Crank angle sensor
     
    Manifold differential pressure sensor
     
    Exhaust Gas Recirculation (EGR) solenoid valve
     
    Ignition coil
     
    Fuel injectors
     
    Throttle Position (TP) sensor
     
    Idle Air Control (IAC) motor
     
    Engine Coolant Temperature (ECT) sensor
     
    Camshaft Position (CMP) sensor
     
    Knock Sensor (KS)
     
    ECT gauge unit
     
    Heated Oxygen Sensor (HO 2 S)
     
    Starter and alternator
     
    Oil pressure switch
     

  12.  
  13. Remove or disconnect the following:
    NOTE
    Matchmark the installed position of the radiator hoses before disconnecting them.



    Power steering pump and brace. Position the assembly aside, but do NOT disconnect the fluid line.
     
    A/C compressor, but do NOT disconnect the lines
     



    Upper and lower radiator hoses
     
    Heater and purge hoses
     
    Fuel lines. Discard the O-rings
     

  14.  
  15. Pre-tighten the two bolts on the vehicle to assemble the radiator support upper insulator to set Mitsubishi Special tool no. MB991928 or MB991895. See the accompanying figure.

    Transaxle assembly

    Click image to see an enlarged view

    Fig. Pre-tighten the two bolts on the vehicle to assemble the radiator support upper insulator for the engine hanger (MB991928 or MB991895)

     
    Ground cable connection
     
    Self-locking nuts

    Click image to see an enlarged view

    Fig. View of the tool MB991928 installed, necessary to support the engine when the transaxle is removed



    Click image to see an enlarged view

    Fig. View of the tool MB991895 installed, necessary to support the engine when the transaxle is removed

     

  16.  
  17. Remove the engine front mounting bracket as follows:
    1. Support the engine with a suitable floor jack.
    2.  
    3. Remove the special tools that were installed for transaxle removal.
    4.  
    5. Support the engine with Mitsubishi Special tools MB991454 and MB991527 attached to a chain block or engine hoist.

      Click image to see an enlarged view

      Fig. View of the special tools needed to support the engine during mount removal

    6.  
    7. Place a jack under the oil pan with a block of wood in between to protect the pan. Jack up the engine to take the weight off the engine mount insulator and bracket, then remove the front mounting bracket mounting nuts and bolts, then remove the bracket.
    8.  

  18.  
  19. Make sure that all cables, hoses and harnesses are disconnected from the engine, then use the engine hose to slowly lift the engine up and out of the engine compartment.
  20.  

To install:

  1. Installation is the reverse of the removal procedure.
    NOTE
    Bolt torques are indicated in the accompanying illustration. The parts indicated with an asterisk (*) should be temporarily tightened, and then fully tightened with the engine weight applied on the body of the vehicle.



    Click image to see an enlarged view

    Fig. Engine mounts and related components

  2.  
  3. Fill the coolant system and engine crankcase.
  4.  
  5. Connect the negative battery cable.
  6.  
  7. On 2006 vehicles, complete the vehicle initialization procedure.
    NOTE
    To complete the initialization procedure the following tools are needed. MB991958 scan tool, MB991824 VCI, MB991827 MUT III USB cable, MB991910 MUT III Main harness -A-

  8.  
  9. Connect the scan tool to the data link connector. To prevent damage to the scan tool be sure that the ignition switch is in the LOCK position before connecting the scan tool.
  10.  
  11. Turn the ignition switch to the ON position.
  12.  
  13. Select -check mode- from the menu screen.
  14.  
  15. Select -erase memory- from the menu screen.
  16.  
  17. Initialize the learning value.
  18.  
  19. On 2006 vehicles, after initialization complete the idle learning procedure.
  20.  
  21. Start the engine. Allow the coolant temperature to reach 176 degrees or more.
  22.  
  23. Stop the engine and place the ignition switch in the LOCK position.
  24.  
  25. After ten seconds, restart the engine.
  26.  
  27. For ten minutes carry out the idling procedure below to confirm that the engine has normal idling.
    NOTE
    If the engine stalls during idling, check the throttle valve of the throttle body for dirt. Correct and perform the procedure again.



    Position the transaxle selector lever in the -P- range, for automatic transaxle and in neutral for manual transaxle
     
    The engine fan is not to be operated
     
    The engine coolant temperature should be 176 degrees or more
     

  28.  
  29. Run the engine and check for leaks.
  30.  
  31. Install the hood.
  32.  

 
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