Mitsubishi Galant 2004-2009 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Galant Applicable Years: 2004, 2005, 2006, 2007, 2008, 2009 👋 Introduction Market Position Segment: Mid-size Sedan Target Audience: Consumers seeking reliable transportation, value-conscious buyers Competitive Analysis Key Competitors: Toyota Camry, Honda Accord, Nissan Altima, Ford Fusion, Chevrolet Malibu Key Features Design Philosophy: Sporty styling, comfortable interior, practical for daily use Value Proposition: Good balance of features, performance, and affordability 📋 Manual Details Coverage Areas Primary Coverage: Workshop Service Repair Page Count Estimated Pages: Hundreds (Specific count not provided, but implies extensive content) Manual Type Type: Factory Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, valve train, timing components, lubrication system, cooling system, fuel injection system, emission control systems Engine Electrical: Ignition system, starting system, charging system, engine control unit (ECU), sensors (crankshaft position, camshaft position, MAP, MAF, O2, TPS, ECT), actuators (injectors, ignition coils), wiring diagrams Transmission Manual: Clutch system, gear shift mechanism, manual transmission assembly, lubrication Transmission Automatic: Automatic transmission assembly, torque converter, valve body, hydraulic control system, transmission control module (TCM), lubrication, cooling Drivetrain: Front-wheel drive (FWD) components, front axle, drive shafts, CV joints, differential Suspension: Front suspension (struts, control arms, ball joints, sway bar), rear suspension (multi-link or beam axle depending on configuration), springs, shock absorbers, bushings Steering: Power steering system (hydraulic pump, rack and pinion, steering column), steering angle sensor Brakes: Front and rear brakes (discs/drums), brake system hydraulics (master cylinder, brake lines, calipers, wheel cylinders), parking brake system, Anti-lock Braking System (ABS) components and diagnostics, Electronic Brake-force Distribution (EBD) Body Exterior: Body panels, doors, hood, trunk, bumpers, fenders, glass, mirrors, seals, trim, paint repair Body Interior: Dashboard, seating, upholstery, door panels, headliner, interior trim, climate control system controls, airbags Electrical Body: Lighting system (headlights, taillights, interior lights), wipers and washers, horn, power windows, power locks, mirrors, instrument cluster, warning lights, infotainment system wiring, security system Climate Control: HVAC system components (compressor, condenser, evaporator, blower motor, heater core), refrigerant system, controls, diagnostics Safety Systems: Airbag system (SRS), seat belt pretensioners, occupant classification system, related sensors and control modules Procedures Included Maintenance: Routine maintenance (oil changes, filter replacements, fluid checks/changes, spark plug replacement, belt inspection/replacement), lubrication points, tire rotation Diagnostics Troubleshooting: Systematic diagnostic procedures, symptom-based troubleshooting guides, fault code interpretation, electrical circuit testing, component testing Repair Rebuild: Detailed step-by-step repair and overhaul procedures for all major components and systems, including engine, transmission, brakes, suspension, steering, and body Replacement: Component removal and installation procedures for all parts, from minor trim pieces to major powertrain components Specifications Settings: Torque specifications for all fasteners, alignment specifications, diagnostic tool usage, special tool requirements Technical Depth Depth: Comprehensive, covering basic maintenance to complete engine and transmission overhauls, including electrical diagnostics and body repair 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable (typical for factory service manuals in PDF format) Print Quality Quality: Professional, high-resolution images and diagrams Binding Type Binding: N/A (Digital PDF download) Paper Type Paper Quality: N/A (Digital PDF download) ⚙️ Engine Specifications Primary Engine Engine Code Options: 4G64 (2.4L I4), 6G72 (3.0L V6) Performance 2.4L I4 Horsepower: Approx. 160 hp @ 5500-6000 rpm (varies by sub-model and market) 2.4L I4 Torque: Approx. 155 lb-ft @ 4000 rpm (varies by sub-model and market) 3.0L V6 Horsepower: Approx. 200 hp @ 5500-6000 rpm (varies by sub-model and market) 3.0L V6 Torque: Approx. 205 lb-ft @ 4000 rpm (varies by sub-model and market) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Engine Management ECU Type: Multi-point Fuel Injection (MPI) engine control unit 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission (MT) - typically on base models and 2.4L variants Optional Transmission Type Optional: 4-speed Automatic Transmission (AT) - typically available on most models, standard on V6 Features Automatic Features: Sportronic (manumatic shifting capability on some models) 📐 Dimensions Exterior Length: Approximately 188.7 inches (4793 mm) Width: Approximately 70.1 inches (1780 mm) Height: Approximately 57.7 inches (1466 mm) Wheelbase: Approximately 106.3 inches (2700 mm) Weights Curb Weight Approx: 3200 - 3500 lbs (1450 - 1590 kg) depending on engine and trim 🛡️ Safety Features Ratings NHTSA Front Impact Driver: Good (for 2004 models, later model ratings may vary) NHTSA Front Impact Passenger: Good (for 2004 models, later model ratings may vary) IIHS Front Offset: Acceptable/Good (depending on year and specific test) Active Features ABS: Standard on most trims Traction Control: Available on some models/trims Passive Features Airbags: Front airbags, available side-impact airbags Seatbelts: 3-point seatbelts with pretensioners, LATCH child seat anchors 💡 Technology Features Infotainment Audio System: AM/FM stereo with CD player, optional premium audio systems (e.g., Rockford Fosgate on higher trims), auxiliary input (later models might have it). Navigation: Optional factory-installed GPS navigation system on higher trim levels. Driver Assistance Cruise...
Front suspension (struts, control arms, ball joints, sway bar), rear suspension (multi-link or beam axle depending on configuration), springs, shock absorbers, bushings
Steering:
Power steering system (hydraulic pump, rack and pinion, steering column), steering angle sensor
Brakes:
Front and rear brakes (discs/drums), brake system hydraulics (master cylinder, brake lines, calipers, wheel cylinders), parking brake system, Anti-lock Braking System (ABS) components and diagnostics, Electronic Brake-force Distribution (EBD)
Dashboard, seating, upholstery, door panels, headliner, interior trim, climate control system controls, airbags
Electrical Body:
Lighting system (headlights, taillights, interior lights), wipers and washers, horn, power windows, power locks, mirrors, instrument cluster, warning lights, infotainment system wiring, security system
Detailed step-by-step repair and overhaul procedures for all major components and systems, including engine, transmission, brakes, suspension, steering, and body
Replacement:
Component removal and installation procedures for all parts, from minor trim pieces to major powertrain components
Specifications Settings:
Torque specifications for all fasteners, alignment specifications, diagnostic tool usage, special tool requirements
Technical Depth
Depth:
Comprehensive, covering basic maintenance to complete engine and transmission overhauls, including electrical diagnostics and body repair
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable (typical for factory service manuals in PDF format)
Print Quality
Quality:
Professional, high-resolution images and diagrams
Binding Type
Binding:
N/A (Digital PDF download)
Paper Type
Paper Quality:
N/A (Digital PDF download)
⚙️ Engine Specifications
Primary Engine
Engine Code Options:
4G64 (2.4L I4), 6G72 (3.0L V6)
Performance
2.4L I4 Horsepower:
Approx. 160 hp @ 5500-6000 rpm (varies by sub-model and market)
2.4L I4 Torque:
Approx. 155 lb-ft @ 4000 rpm (varies by sub-model and market)
3.0L V6 Horsepower:
Approx. 200 hp @ 5500-6000 rpm (varies by sub-model and market)
3.0L V6 Torque:
Approx. 205 lb-ft @ 4000 rpm (varies by sub-model and market)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Engine Management
ECU Type:
Multi-point Fuel Injection (MPI) engine control unit
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission (MT) - typically on base models and 2.4L variants
Optional
Transmission Type Optional:
4-speed Automatic Transmission (AT) - typically available on most models, standard on V6
Features
Automatic Features:
Sportronic (manumatic shifting capability on some models)
📐 Dimensions
Exterior
Length:
Approximately 188.7 inches (4793 mm)
Width:
Approximately 70.1 inches (1780 mm)
Height:
Approximately 57.7 inches (1466 mm)
Wheelbase:
Approximately 106.3 inches (2700 mm)
Weights
Curb Weight Approx:
3200 - 3500 lbs (1450 - 1590 kg) depending on engine and trim
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
Good (for 2004 models, later model ratings may vary)
NHTSA Front Impact Passenger:
Good (for 2004 models, later model ratings may vary)
IIHS Front Offset:
Acceptable/Good (depending on year and specific test)
Active Features
ABS:
Standard on most trims
Traction Control:
Available on some models/trims
Passive Features
Airbags:
Front airbags, available side-impact airbags
Seatbelts:
3-point seatbelts with pretensioners, LATCH child seat anchors
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with CD player, optional premium audio systems (e.g., Rockford Fosgate on higher trims), auxiliary input (later models might have it).
Navigation:
Optional factory-installed GPS navigation system on higher trim levels.
Driver Assistance
Cruise Control:
Standard on most trims
Connectivity
Bluetooth:
Rarely available from factory for this model year range, likely an aftermarket addition.
🔧 Maintenance
Service Intervals
Oil Change Interval Gasoline:
Every 3,750 miles or 3 months (severe service), or 7,500 miles or 6 months (normal service) - consult owner's manual for exact spec
Engine Coolant Flush:
Typically every 30,000 - 60,000 miles or 2-4 years
Transmission Fluid Change At:
Every 30,000 - 60,000 miles, or as per severe service schedule
Fluid Specifications
Engine Oil Type:
API SN or higher, ILSAC GF-5 or higher; SAE 5W-30 recommended for most conditions (check manual for specifics)
Engine Oil Capacity 2.4L:
Approx. 4.5 US quarts (4.25 liters) with filter
Engine Oil Capacity 3.0L V6:
Approx. 4.7 US quarts (4.45 liters) with filter
Transmission Fluid Type At:
DIA QUEEN ATF-SP III or equivalent (Dexron III/Mercon are NOT substitutes)
Transmission Fluid Capacity At:
Approx. 6.6 US quarts (6.2 liters) for fill, higher for overhaul
Power Steering Fluid:
DIA QUEEN ATF-SP III or equivalent
Known Issues
Engine Performance 2.4L:
Occasional oil consumption issues, potential for timing belt issues if not replaced on schedule (if belt-driven, check manual for specifics on engine type).
Transmission Automatic:
Harsh shifting, transmission slipping or failure, particularly on higher mileage vehicles. Often related to fluid degradation or valve body issues.
Suspension:
Premature wear of control arm bushings, ball joints, and strut mounts, leading to knocking noises or poor handling.
Electrical:
Window regulator failures, power door lock actuator issues, intermittent electrical gremlins often related to ground points or aging wiring harnesses.
HVAC:
Blend door actuator failures, blower motor resistor issues, loss of AC effectiveness.
📚 Vehicle History
Brand Heritage
Brand Focus:
Mitsubishi has a history of producing diverse vehicles, from small cars to SUVs and performance vehicles, often emphasizing value and distinctive styling.
Model Evolution
Generation:
This period (2004-2009) represents the eighth generation of the Mitsubishi Galant, which saw a significant redesign.
Design Changes:
The eighth-generation Galant adopted a more aggressive, 'shaved' body style with sharper lines and a distinct front fascia, moving away from its predecessor's more rounded appearance.
Production
Production Location:
North American models were primarily assembled in Normal, Illinois, USA.
Production Years Specific Gen:
2004-2012 (for this generation's North American market run)
🏆 Awards & Recognition
Recognitions
Safety Awards:
Received good crash test ratings from NHTSA for frontal impact in early years, contributing to its appeal as a safe family sedan.
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