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Mitsubushi GALANT Full Service & Repair Manual 1996-2003

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🏷️ Basic Information Identification Make: Mitsubishi Model: Galant Model Generation: E30/E3_A (8th Generation) Model Years: 1996-2003 Codes Chassis Codes: E33A, E35A, E38A, E39A 👋 Introduction Market Position Segment: Mid-size sedan, known for its comfortable ride, sporty handling (especially in V6 and performance variants), and distinctive styling. Competitive Analysis Competitors: Competed against vehicles such as the Toyota Camry, Honda Accord, Nissan Altima, Ford Taurus, Chevrolet Malibu. Key Features Styling: The 8th generation Galant featured a more aerodynamic and rounded design compared to its predecessor, with a prominent grille and distinctive headlight design. Performance Options: Offered a range of efficient 4-cylinder engines and a more potent 3.0L V6 engine, providing a balance of performance and fuel economy. AWD Option: Available with Mitsubishi's advanced all-wheel-drive (AWD) system, enhancing traction and handling in various conditions, particularly on higher trims. Interior Comfort: Generally praised for its comfortable and well-appointed interior, offering a quiet and refined cabin experience. 📋 Manual Details Coverage Areas Scope: Complete factory service, repair, and workshop procedures Page Count Estimated Pages: Over 1500 (typical for comprehensive factory manuals of this era) Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital Download (PDF/similar) 📖 Manual Coverage Systems Covered Engine: All engine variants, including V6 (6G72) and Inline-4 (4G63, 4G93, 4G94), engine mechanical, lubrication, cooling, fuel delivery, ignition, emissions control, turbocharger systems (where applicable). Transmission: Automatic and Manual transmissions, including F4A, F5A, W4A, W5A series automatics and KM132, KM220 series manuals. Repair, overhaul, clutch, torque converter, transmission control. Drivetrain: Front-wheel drive (FWD) and All-wheel drive (AWD) systems, driveshafts, CV joints, differentials, transfer cases, wheel hubs. Suspension: Front and rear suspension systems (MacPherson struts, multi-link), springs, shock absorbers, control arms, sway bars, bushings, alignment specifications. Steering: Power steering system, steering rack, pump, hydraulic lines, steering column, tie rods. Brakes: Front and rear disc brakes, ABS system, brake calipers, rotors, pads, lines, master cylinder, parking brake. Hydraulic system bleeding procedures. Electrical: 12V electrical system, battery, charging system (alternator), starting system (starter motor), lighting (headlights, taillights, interior), power accessories (windows, mirrors, locks), fuses, relays, wiring diagrams for all circuits. HVAC: Heating, Ventilation, and Air Conditioning system, compressor, condenser, evaporator, refrigerant, blower motor, climate controls, dash assembly. Body: Exterior body panels, doors, hoods, trunk, bumpers, glass, interior trim, seating, body repair, corrosion prevention, rust repair techniques, panel replacement. Safety: Airbag system (SRS), seat belts, crumple zones, safety restraint system troubleshooting and repair. Procedures Included Maintenance: Routine maintenance tasks, oil changes, filter replacements, tune-ups, fluid level checks and top-offs, spark plug replacement, belt inspections and replacement. Troubleshooting: Diagnostic procedures for common and uncommon problems, fault code interpretation (OBD-I/OBD-II where applicable), symptom-based diagnostics, circuit testing. Repair: Detailed step-by-step repair instructions for all major components and systems, including engine rebuilds, transmission overhauls, brake caliper replacement, suspension component replacement, electrical component repair, body panel repair. Installation: Instructions for installing aftermarket accessories or replacement parts where applicable. Technical Depth Level: Comprehensive, covering basic to advanced repairs and diagnostics. Suitable for professional technicians and experienced DIYers. 📊 Manual Specifications File Format Digital Format: PDF or similar searchable digital format. Print Quality Resolution: High-resolution, clear text and diagrams for readability. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code V6: 6G72 (SOHC and DOHC variants) Displacement V6: 3.0 Liters (2972 cc) Horsepower V6 Sohc: Approx. 177-185 hp @ 5500-6000 rpm (depending on market and year) Torque V6 Sohc: Approx. 200-210 lb-ft @ 3000-4000 rpm (depending on market and year) Engine Code I4 1: 4G63 (SOHC) Displacement I4 1: 2.4 Liters (2351 cc) Horsepower I4 1: Approx. 130-145 hp @ 5500-6000 rpm Torque I4 1: Approx. 140-155 lb-ft @ 3000-4000 rpm Engine Code I4 2: 4G93 (SOHC) Displacement I4 2: 2.0 Liters (1997 cc) Horsepower I4 2: Approx. 110-130 hp @ 5500-6000 rpm Torque I4 2: Approx. 125-135 lb-ft @ 3000-4000 rpm Engine Features Engine Management: Electronic Fuel Injection (EFI), Distributorless Ignition System (DIS) on many models. Fuel System Fuel Type: Unleaded Gasoline Fuel Delivery: Multi-port Fuel Injection (MPI) Performance 0 60 Mph V6: Approx. 7.5 - 8.5 seconds (depending on drivetrain and conditions) 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission (common on lower trims and some performance variants) Optional Transmission Type Auto: 4-speed Automatic Transmission with Electronically Controlled Sport/Comfort Modes (common on most trims) Features AWD Transmission: Select models featured a viscous coupling All-Wheel Drive (AWD) system paired with the automatic transmission. 📐 Dimensions Exterior Length: Approx. 186.5 inches (4737 mm) Width: Approx. 69.3 inches (1760 mm) Height: Approx. 55.7 inches (1415 mm) Wheelbase: Approx. 104.3 inches (2649 mm) Weights Curb Weight: Approx. 3200 - 3500 lbs (1450 - 1590 kg) depending on engine and trim Gross Vehicle Weight Rating: Varies by model, typically around 4300 lbs (1950 kg) Cargo Trunk Volume: Approx. 14.0 - 15.0 cubic...
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Mitsubushi GALANT Full Service & Repair Manual 1996-2003
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Galant
Model Generation:
E30/E3_A (8th Generation)
Model Years:
1996-2003
Codes
Chassis Codes:
E33A, E35A, E38A, E39A
👋 Introduction
Market Position
Segment:
Mid-size sedan, known for its comfortable ride, sporty handling (especially in V6 and performance variants), and distinctive styling.
Competitive Analysis
Competitors:
Competed against vehicles such as the Toyota Camry, Honda Accord, Nissan Altima, Ford Taurus, Chevrolet Malibu.
Key Features
Styling:
The 8th generation Galant featured a more aerodynamic and rounded design compared to its predecessor, with a prominent grille and distinctive headlight design.
Performance Options:
Offered a range of efficient 4-cylinder engines and a more potent 3.0L V6 engine, providing a balance of performance and fuel economy.
AWD Option:
Available with Mitsubishi's advanced all-wheel-drive (AWD) system, enhancing traction and handling in various conditions, particularly on higher trims.
Interior Comfort:
Generally praised for its comfortable and well-appointed interior, offering a quiet and refined cabin experience.
📋 Manual Details
Coverage Areas
Scope:
Complete factory service, repair, and workshop procedures
Page Count
Estimated Pages:
Over 1500 (typical for comprehensive factory manuals of this era)
Manual Type
Type:
Factory Service Manual / Workshop Manual
Language
Language:
English
Format
Format:
Digital Download (PDF/similar)
📖 Manual Coverage
Systems Covered
Engine:
All engine variants, including V6 (6G72) and Inline-4 (4G63, 4G93, 4G94), engine mechanical, lubrication, cooling, fuel delivery, ignition, emissions control, turbocharger systems (where applicable).
Transmission:
Automatic and Manual transmissions, including F4A, F5A, W4A, W5A series automatics and KM132, KM220 series manuals. Repair, overhaul, clutch, torque converter, transmission control.
Drivetrain:
Front-wheel drive (FWD) and All-wheel drive (AWD) systems, driveshafts, CV joints, differentials, transfer cases, wheel hubs.
Suspension:
Front and rear suspension systems (MacPherson struts, multi-link), springs, shock absorbers, control arms, sway bars, bushings, alignment specifications.
Steering:
Power steering system, steering rack, pump, hydraulic lines, steering column, tie rods.
Brakes:
Front and rear disc brakes, ABS system, brake calipers, rotors, pads, lines, master cylinder, parking brake. Hydraulic system bleeding procedures.
Electrical:
12V electrical system, battery, charging system (alternator), starting system (starter motor), lighting (headlights, taillights, interior), power accessories (windows, mirrors, locks), fuses, relays, wiring diagrams for all circuits.
HVAC:
Heating, Ventilation, and Air Conditioning system, compressor, condenser, evaporator, refrigerant, blower motor, climate controls, dash assembly.
Body:
Exterior body panels, doors, hoods, trunk, bumpers, glass, interior trim, seating, body repair, corrosion prevention, rust repair techniques, panel replacement.
Safety:
Airbag system (SRS), seat belts, crumple zones, safety restraint system troubleshooting and repair.
Procedures Included
Maintenance:
Routine maintenance tasks, oil changes, filter replacements, tune-ups, fluid level checks and top-offs, spark plug replacement, belt inspections and replacement.
Troubleshooting:
Diagnostic procedures for common and uncommon problems, fault code interpretation (OBD-I/OBD-II where applicable), symptom-based diagnostics, circuit testing.
Repair:
Detailed step-by-step repair instructions for all major components and systems, including engine rebuilds, transmission overhauls, brake caliper replacement, suspension component replacement, electrical component repair, body panel repair.
Installation:
Instructions for installing aftermarket accessories or replacement parts where applicable.
Technical Depth
Level:
Comprehensive, covering basic to advanced repairs and diagnostics. Suitable for professional technicians and experienced DIYers.
📊 Manual Specifications
File Format
Digital Format:
PDF or similar searchable digital format.
Print Quality
Resolution:
High-resolution, clear text and diagrams for readability.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code V6:
6G72 (SOHC and DOHC variants)
Displacement V6:
3.0 Liters (2972 cc)
Horsepower V6 Sohc:
Approx. 177-185 hp @ 5500-6000 rpm (depending on market and year)
Torque V6 Sohc:
Approx. 200-210 lb-ft @ 3000-4000 rpm (depending on market and year)
Engine Code I4 1:
4G63 (SOHC)
Displacement I4 1:
2.4 Liters (2351 cc)
Horsepower I4 1:
Approx. 130-145 hp @ 5500-6000 rpm
Torque I4 1:
Approx. 140-155 lb-ft @ 3000-4000 rpm
Engine Code I4 2:
4G93 (SOHC)
Displacement I4 2:
2.0 Liters (1997 cc)
Horsepower I4 2:
Approx. 110-130 hp @ 5500-6000 rpm
Torque I4 2:
Approx. 125-135 lb-ft @ 3000-4000 rpm
Engine Features
Engine Management:
Electronic Fuel Injection (EFI), Distributorless Ignition System (DIS) on many models.
Fuel System
Fuel Type:
Unleaded Gasoline
Fuel Delivery:
Multi-port Fuel Injection (MPI)
Performance
0 60 Mph V6:
Approx. 7.5 - 8.5 seconds (depending on drivetrain and conditions)
🔧 Transmission
Standard
Transmission Type:
5-speed Manual Transmission (common on lower trims and some performance variants)
Optional
Transmission Type Auto:
4-speed Automatic Transmission with Electronically Controlled Sport/Comfort Modes (common on most trims)
Features
AWD Transmission:
Select models featured a viscous coupling All-Wheel Drive (AWD) system paired with the automatic transmission.
📐 Dimensions
Exterior
Length:
Approx. 186.5 inches (4737 mm)
Width:
Approx. 69.3 inches (1760 mm)
Height:
Approx. 55.7 inches (1415 mm)
Wheelbase:
Approx. 104.3 inches (2649 mm)
Weights
Curb Weight:
Approx. 3200 - 3500 lbs (1450 - 1590 kg) depending on engine and trim
Gross Vehicle Weight Rating:
Varies by model, typically around 4300 lbs (1950 kg)
Cargo
Trunk Volume:
Approx. 14.0 - 15.0 cubic feet (0.39 - 0.42 cubic meters)
🛡️ Safety Features
Ratings
NHTSA Frontal Impact:
Good (for models tested with dual airbags and seat belt pretensioners)
IIHS Side Impact:
Acceptable (for models tested)
Active Features
ABS:
Standard on most higher trims, optional on some base models. Four-wheel disc brakes with ABS.
Traction Control:
Available on some AWD models.
Passive Features
Airbags:
Driver and front passenger airbags standard on most models. Side airbags became available on later models or higher trims.
Seatbelts:
Three-point seat belts with pretensioners for front occupants, three-point rear seat belts.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM cassette or CD player, with options for premium audio systems on higher trims. Speaker configurations vary by trim level.
Climate Control:
Manual HVAC controls standard; automatic climate control available on higher trim levels.
Driver Assistance
Cruise Control:
Standard on most models.
Anti Lock Brakes:
ABS was available or standard depending on the trim and model year.
Connectivity
Aux Input:
Not typically equipped with factory auxiliary inputs; aftermarket solutions often required for modern audio connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles (5,000-8,000 km) or 6 months, depending on oil type and driving conditions.
Engine Oil Filter Replacement:
Recommended at every oil change.
Spark Plug Replacement:
Every 30,000-60,000 miles (48,000-96,000 km), depending on spark plug type (copper vs. platinum/iridium).
Timing Belt Replacement:
Critical for 6G72 and 4G63 engines. Typically every 60,000-90,000 miles (96,000-144,000 km) or 5-7 years. Includes tensioner and idler pulley replacement.
Fluid Specifications
Engine Oil Specification:
API SG or higher, SAE 5W-30 or 10W-30 (refer to owner's manual for specific viscosity based on ambient temperature).
Coolant Specification:
Mitsubishi Genuine Long Life Coolant or equivalent ethylene glycol-based antifreeze. Typically a 50/50 mix with distilled water.
Transmission Fluid Type Auto:
Mitsubishi DiaQueen SP III (or equivalent ATF). Do NOT use Dexron/Mercon.
Transmission Fluid Type Manual:
API GL-3 or GL-4, SAE 75W-90 gear oil.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
Mitsubishi Genuine Power Steering Fluid or equivalent ATF (check manual).
Known Issues
Engine Mounts:
Degradation and failure of engine and transmission mounts, leading to vibration and harshness, especially at idle or during acceleration.
Timing Belt Tensioner:
Tensioner failure can lead to premature timing belt wear or catastrophic engine damage if the belt jumps time. Crucial to replace with the belt.
Automatic Transmission Issues:
Some transmissions, particularly the F4A/F5A series, can experience harsh shifting, slipping, or delayed engagement if not properly maintained or if the valve body has issues. Regular fluid changes are vital.
Cv Joints:
Wear on front CV joints and boots, leading to clicking noises during turns, especially on AWD models.
Window Regulators:
Common failure of power window regulators, causing windows to become inoperable or fall into the door panel.
Radiator And Hoses:
Aging radiator and coolant hoses can lead to leaks and overheating. Regular inspection and replacement are recommended.
📚 Vehicle History
Brand Heritage
Manufacturer:
Mitsubishi Motors Corporation, a Japanese multinational automotive manufacturer.
Model Evolution
Generation Designation:
This covers the E30/E3_A generation, which was the eighth generation of the Galant nameplate globally, though in some markets it was positioned differently.
Production
Manufacturing Locations:
Primarily manufactured in Japan, with some assembly or variations in other countries for specific markets.
Production Years Model:
1992-1998 (for the 8th Generation chassis, with the 1996-2003 range focusing on facelifted versions and market-specific variations).
🏆 Awards & Recognition
Recognitions
Customer Satisfaction:
Generally received moderate to good ratings for reliability and value during its production run, though often overshadowed by Japanese competitors in consumer surveys.
Performance Awards:
While not a primary focus for awards, the V6 models and AWD variants were noted for their competent performance and handling characteristics in automotive reviews of the era.
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