Mitsubushi GALANT Service Repair Workshop Manual 1996
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🏷️ Basic Information Identification Make: Mitsubishi Model: Galant Year: 1996 Generation: 8th Generation (E39A/E50A/E60A/E70A/E80A) 👋 Introduction Market Position Segment: Mid-size sedan/coupe Key Selling Points For Era: Comfortable ride, spacious interior, available V6 engine, and distinctive styling. Competitive Analysis Competitors: Honda Accord, Toyota Camry, Nissan Altima, Ford Taurus, Chevrolet Lumina. Key Features Vehicle Highlights: Available AWD, optional V6, focus on ride comfort and practicality. 📋 Manual Details Coverage Areas Market Focus: Global (North American specifications primarily, with common international variations noted) Page Count Estimated Page Count: 1500+ Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Engine: All engine variants (4G63, 4G93, 6G72), including diagnosis, disassembly, assembly, and specifications. Transmission: Manual (F5M21, F5M22) and Automatic (F4A33, V4AW2) transmissions: overhaul, diagnosis, fluid specifications, and control systems. Drivetrain: Front-wheel drive and All-wheel drive (AWD) systems: differentials, drive shafts, CV joints, and AWD coupling. Suspension: Front and rear suspension components, alignment specifications, shock absorbers, springs, bushings, and troubleshooting. Steering: Power steering system, steering rack, linkage, diagnosis, and fluid requirements. Brakes: Front and rear brake systems (disc and drum), ABS system components, hydraulic circuits, pad/rotor specifications, and bleeding procedures. Electrical System: Full wiring diagrams, component locations, fuse/relay data, charging system, starting system, lighting, ignition system, and body electronics. Climate Control: HVAC system operation, refrigerant types, component replacement (compressor, condenser, evaporator), and diagnosis. Body And Interior: Body panel removal/installation, interior trim, seats, glass, door mechanisms, and basic body repair information. Procedures Included Maintenance: Scheduled maintenance (oil changes, filter replacements, spark plugs, belts, fluids), lubrication points, and inspection routines. Diagnostics: Systematic troubleshooting guides for common symptoms, fault codes (if applicable to OBD-I/OBD-II), and diagnostic flowcharts. Repair: Detailed step-by-step repair instructions for component disassembly, reassembly, and replacement for all major systems. Troubleshooting: In-depth guides for identifying and resolving mechanical, electrical, and drivability issues. Technical Depth Depth: Comprehensive from basic maintenance to complete engine and transmission overhaul, including electrical system diagnostics. 📊 Manual Specifications File Format Digital Quality: High-resolution scans, likely searchable PDF with clear text and diagrams. Print Quality Diagram Clarity: Clear, factory-quality diagrams, schematics, and illustrations. Binding Type Binding: N/A (Digital format) Paper Type Paper Quality: N/A (Digital format) ⚙️ Engine Specifications Primary Engine Engine Code Common Usdm: 4G63 (2.4L SOHC) Engine Code V6 Usdm: 6G72 (3.0L SOHC V6) Performance 4G63 Displacement 4G63: 2.4 Liters (2351 cc) Horsepower 4G63 Est: 140-150 hp @ 5500-6000 rpm Torque 4G63 Est: 170-180 lb-ft @ 3000-4000 rpm Performance 6G72 Displacement 6G72: 3.0 Liters (2972 cc) Horsepower 6G72 Est: 185-200 hp @ 5500-6000 rpm Torque 6G72 Est: 205-215 lb-ft @ 4500-5000 rpm Fuel System Injection Type: Multi-port Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 octane minimum) Engine Management Ignition System: Distributorless Ignition System (DIS) or Distributor type depending on market/trim. 🔧 Transmission Standard 4G63 Type 4G63: 5-speed Manual (F5M21) Optional 4G63 Awd Type 4G63 AWD: 4-speed Automatic 4WD (V4AW2) Standard 6G72 Type 6G72: 4-speed Automatic (F4A33) Features AWD System: Active All-Wheel Drive (often referred to as 'full-time 4WD' or 'AWD' depending on market and specific system) with viscous coupling. Fluid Specifications Manual Transmission Fluid: GL-4 Gear Oil (e.g., SAE 75W-90) Automatic Transmission Fluid: Diaqueen SP-III or equivalent ATF (refer to manual for exact specification) 📐 Dimensions Exterior Sedan Length Sedan: Approx. 185.2 inches (4704 mm) Exterior Coupe Length Coupe: Approx. 184.4 inches (4684 mm) Exterior Width: Approx. 70.3 inches (1786 mm) Height: Approx. 55.1 inches (1400 mm) Wheelbase Wheelbase: Approx. 104.7 inches (2659 mm) Weights Curb Weight Est Min: Approx. 3000 lbs (1360 kg) Curb Weight Est Max: Approx. 3400 lbs (1540 kg) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 4/5 Stars (1996 model year, may vary slightly) NHTSA Front Impact Passenger: 4/5 Stars (1996 model year, may vary slightly) Active Features ABS: Available Anti-lock Braking System (ABS) on select trims/models. Passive Features Airbags: Driver and passenger front airbags. Seatbelts: Three-point front and rear seatbelts, pretensioners on front belts. 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with cassette player, optional CD player on higher trims. Speakers: Typically 4 or 6 speaker system. Driver Assistance Cruise Control: Standard on most trims. Connectivity OBD Standard: OBD-I (On-Board Diagnostics) for earlier 1996 models, potentially transitioning to OBD-II on later production or specific markets. 🔧 Maintenance Service Intervals General Oil Change Interval: Every 3,750 - 5,000 miles or 6 months (whichever comes first), depending on driving conditions. Engine Oil Filter Replacement: With every oil change. Air Filter Replacement: Every 15,000 - 30,000 miles or as needed. Spark Plug Replacement: Every 30,000 - 60,000 miles (depending on plug type). Timing Belt Replacement: Critical for 4G63/6G72 engines. Typically 60,000 - 90,000 miles or 5-7 years. Consult manual for exact interval and procedure (interference engine). Fluid Specifications Engine Oil Type 4G63: 10W-30 or 5W-30 API SG/SH (refer to owner's manual for exact...
Systematic troubleshooting guides for common symptoms, fault codes (if applicable to OBD-I/OBD-II), and diagnostic flowcharts.
Repair:
Detailed step-by-step repair instructions for component disassembly, reassembly, and replacement for all major systems.
Troubleshooting:
In-depth guides for identifying and resolving mechanical, electrical, and drivability issues.
Technical Depth
Depth:
Comprehensive from basic maintenance to complete engine and transmission overhaul, including electrical system diagnostics.
📊 Manual Specifications
File Format
Digital Quality:
High-resolution scans, likely searchable PDF with clear text and diagrams.
Print Quality
Diagram Clarity:
Clear, factory-quality diagrams, schematics, and illustrations.
Binding Type
Binding:
N/A (Digital format)
Paper Type
Paper Quality:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Code Common Usdm:
4G63 (2.4L SOHC)
Engine Code V6 Usdm:
6G72 (3.0L SOHC V6)
Performance 4G63
Displacement 4G63:
2.4 Liters (2351 cc)
Horsepower 4G63 Est:
140-150 hp @ 5500-6000 rpm
Torque 4G63 Est:
170-180 lb-ft @ 3000-4000 rpm
Performance 6G72
Displacement 6G72:
3.0 Liters (2972 cc)
Horsepower 6G72 Est:
185-200 hp @ 5500-6000 rpm
Torque 6G72 Est:
205-215 lb-ft @ 4500-5000 rpm
Fuel System
Injection Type:
Multi-port Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 octane minimum)
Engine Management
Ignition System:
Distributorless Ignition System (DIS) or Distributor type depending on market/trim.
🔧 Transmission
Standard 4G63
Type 4G63:
5-speed Manual (F5M21)
Optional 4G63 Awd
Type 4G63 AWD:
4-speed Automatic 4WD (V4AW2)
Standard 6G72
Type 6G72:
4-speed Automatic (F4A33)
Features
AWD System:
Active All-Wheel Drive (often referred to as 'full-time 4WD' or 'AWD' depending on market and specific system) with viscous coupling.
Fluid Specifications
Manual Transmission Fluid:
GL-4 Gear Oil (e.g., SAE 75W-90)
Automatic Transmission Fluid:
Diaqueen SP-III or equivalent ATF (refer to manual for exact specification)
📐 Dimensions
Exterior Sedan
Length Sedan:
Approx. 185.2 inches (4704 mm)
Exterior Coupe
Length Coupe:
Approx. 184.4 inches (4684 mm)
Exterior
Width:
Approx. 70.3 inches (1786 mm)
Height:
Approx. 55.1 inches (1400 mm)
Wheelbase
Wheelbase:
Approx. 104.7 inches (2659 mm)
Weights
Curb Weight Est Min:
Approx. 3000 lbs (1360 kg)
Curb Weight Est Max:
Approx. 3400 lbs (1540 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
4/5 Stars (1996 model year, may vary slightly)
NHTSA Front Impact Passenger:
4/5 Stars (1996 model year, may vary slightly)
Active Features
ABS:
Available Anti-lock Braking System (ABS) on select trims/models.
Passive Features
Airbags:
Driver and passenger front airbags.
Seatbelts:
Three-point front and rear seatbelts, pretensioners on front belts.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, optional CD player on higher trims.
Speakers:
Typically 4 or 6 speaker system.
Driver Assistance
Cruise Control:
Standard on most trims.
Connectivity
OBD Standard:
OBD-I (On-Board Diagnostics) for earlier 1996 models, potentially transitioning to OBD-II on later production or specific markets.
🔧 Maintenance
Service Intervals General
Oil Change Interval:
Every 3,750 - 5,000 miles or 6 months (whichever comes first), depending on driving conditions.
Engine Oil Filter Replacement:
With every oil change.
Air Filter Replacement:
Every 15,000 - 30,000 miles or as needed.
Spark Plug Replacement:
Every 30,000 - 60,000 miles (depending on plug type).
Timing Belt Replacement:
Critical for 4G63/6G72 engines. Typically 60,000 - 90,000 miles or 5-7 years. Consult manual for exact interval and procedure (interference engine).
Fluid Specifications
Engine Oil Type 4G63:
10W-30 or 5W-30 API SG/SH (refer to owner's manual for exact specification and capacity).
Engine Oil Type 6G72:
10W-30 or 5W-30 API SG/SH (refer to owner's manual for exact specification and capacity).
Coolant:
Mitsubishi Long Life Antifreeze/Coolant (or equivalent HOAT coolant) - 50/50 mix.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
Dexron II/III or equivalent ATF.
Known Issues
Common Issues General:
Head gasket leaks (especially on older engines), CV joint wear, power steering pump leaks, ABS sensor issues, HVAC blower motor failure.
Timing Belt Failure Impact:
Interference engine: failure results in catastrophic engine damage.
📚 Vehicle History
Brand Heritage
Mitsubishi History:
Mitsubishi Motors, a Japanese multinational automotive manufacturer with a long history in automotive production and technological innovation.
Model Evolution
Galant Lineage:
The Galant nameplate has been used by Mitsubishi since 1969, evolving through several generations with various body styles and powertrain configurations.
Production
Platform:
E80 platform (for sedan) and E70 platform (for coupe).
Manufacturing Locations:
Primarily Japan, with potential assembly in other global locations.
🏆 Awards & Recognition
Recognitions
Contemporary Awards:
While specific major awards for the '96 Galant are less prominent than for some competitors, it was generally well-regarded for its comfort and value in its class during its production run.
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