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Mitsubishi TJ RALLIART MAGNA 1996-2005 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Magna (TJ Ralliart) Model Code: TJ Series Codes Production Years: 1996-2005 👋 Introduction Market Position Vehicle Segment: Mid-size family sedan and sport sedan (Ralliart variant). Target Audience: Owners seeking to perform their own maintenance and repairs, automotive enthusiasts, and independent repair shops. Competitive Analysis Key Competitors: Holden Commodore, Ford Falcon, Toyota Camry, Nissan Maxima. Key Features Manual Highlight: Most comprehensive service, maintenance, and repair manual available for the TJ Magna Ralliart. Editorial Emphasis: Focus on practical, step-by-step instructions and clear visual aids. 📋 Manual Details Coverage Areas Manual Coverage: Comprehensive service, maintenance, and repair for Mitsubishi TJ Magna and Ralliart models. Page Count Page Count: Extensive (specific number not provided, implies a very detailed manual) Manual Type Manual Type: Service and Repair Manual Language Language: English Format Format: Digital (likely PDF, implied by sales context) 📖 Manual Coverage Systems Covered Engine Service: Detailed repair procedures, diagnostics, and specifications for all engine variants. Transmission Service: Repair and maintenance for both automatic and manual transmissions. Drivetrain Service: Front-wheel drive and all-wheel drive system diagnostics and repair. Suspension Steering: Components, adjustments, and repair procedures for suspension and steering systems. Brake Systems: Diagnosis, repair, and maintenance of braking systems, including ABS. Electrical Systems: Wiring diagrams, component testing, and repair for all electrical systems. Body And Interior: Panel replacement, interior trim, and body hardware repair. Climate Control: HVAC system diagnosis and repair. Fuel System: Fuel injection system diagnostics, fuel pump, and injector service. Cooling System: Radiator, thermostat, and water pump service. Exhaust System: Catalytic converter, muffler, and exhaust pipe repair. Safety Systems: Airbag system diagnosis and repair. Procedures Included Preventive Maintenance: Detailed service intervals and procedures for oil changes, filter replacements, and fluid checks. Troubleshooting Guides: Systematic diagnostic procedures for common and uncommon faults. Engine Rebuilds: Step-by-step instructions for engine disassembly, overhaul, and reassembly. Transmission Overhaul: Detailed procedures for rebuilding automatic and manual transmissions. Brake Pad Rotor Replacement: Clear instructions for servicing braking components. Electrical Component Testing: Guidance on testing sensors, actuators, and control modules. Timing Belt Replacement: Crucial procedures for timing belt service. Suspension Alignment: Specifications and procedures for wheel alignment. Technical Depth Depth Of Information: Encompasses basic maintenance to complex component-level repairs and diagnostics. Diagnostic Capabilities: Includes diagnostic trouble codes (DTCs), symptom-based troubleshooting, and component tests. Special Tools: Identification and usage instructions for specialized tools required for certain repairs. Torque Specifications: Precise torque values for all critical fasteners. Exploded Views: Detailed diagrams showing component assembly and disassembly order. Wiring Diagrams: Comprehensive electrical schematics for all vehicle systems. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Image Resolution: High-resolution, ensuring clarity of diagrams and text. Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Code Magna: 6G72 (3.0L V6 SOHC) and 6G74 (3.5L V6 SOHC/DOHC) Engine Code Ralliart: 6G74 (3.5L V6 DOHC MIVEC) Performance Horsepower 3.0L: Approximately 195-210 hp (varies by year/spec) Horsepower 3.5L: Approximately 200-240 hp (varies by year/spec) Horsepower Ralliart 3.5L Mivec: Approximately 243 hp Torque 3.0L: Approximately 200-215 lb-ft Torque 3.5L: Approximately 215-230 lb-ft Torque Ralliart 3.5L Mivec: Approximately 240 lb-ft Fuel System Fuel Injection Type: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Ignition System: Distributorless Ignition System (DIS) or Coil-on-Plug (COP) 🔧 Transmission Standard Standard Transmission Magna: 4-speed Automatic (e.g., F4A51) Optional Optional Transmission Magna: 5-speed Manual (certain trims/years) Transmission Ralliart: 5-speed Manual or 5-speed 'INVECS-II' Sports Mode Automatic Features Transmission Fluid Magna Auto: DIAQueen ATF-SP II M or equivalent Transmission Fluid Manual: Gear Oil API GL-4 or GL-5, SAE 75W-90 📐 Dimensions Exterior Wheelbase Approx: 2700-2730 mm (depending on model variant) Length Approx: 4750-4850 mm Width Approx: 1750-1780 mm Height Approx: 1400-1450 mm Weights Curb Weight Approx: 1450-1650 kg Gross Vehicle Weight Rating Approx: 2000-2200 kg 🛡️ Safety Features Ratings Australian Ancap Rating: Not rated for early models; later models improved. Active Features ABS: Standard on most models, optional on early base models. Traction Control: Available on higher trims and Ralliart model. Passive Features Airbags: Driver and passenger airbags standard from mid-production onwards; side airbags optional on later models. Seatbelts: Pre-tensioning front seatbelts. 💡 Technology Features Infotainment Audio System: Factory-installed AM/FM radio with cassette player, optional CD player. Upgradable to modern head units. Driver Assistance Cruise Control: Available on most models. Parking Sensors: Optional on later models. Connectivity Auxiliary Input: Not standard; aftermarket solutions required. 🔧 Maintenance Service Intervals Oil Change Interval Engine Oil: Every 10,000 km or 6 months, whichever comes first (check manual for specific engine type). Oil Filter Replacement: At every oil change. Air Filter Replacement: Every 20,000 km or 12 months. Spark Plug Replacement 3.0L: Approximately 60,000 km (depending on spark plug type - platinum recommended). Spark Plug Replacement 3.5L Mivec: Approximately 80,000-100,000 km (Iridium type). Timing Belt Replacement: Every 100,000 km...
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SKU: 495562
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Mitsubishi TJ RALLIART MAGNA 1996-2005 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Magna (TJ Ralliart)
Model Code:
TJ Series
Codes
Production Years:
1996-2005
👋 Introduction
Market Position
Vehicle Segment:
Mid-size family sedan and sport sedan (Ralliart variant).
Target Audience:
Owners seeking to perform their own maintenance and repairs, automotive enthusiasts, and independent repair shops.
Competitive Analysis
Key Competitors:
Holden Commodore, Ford Falcon, Toyota Camry, Nissan Maxima.
Key Features
Manual Highlight:
Most comprehensive service, maintenance, and repair manual available for the TJ Magna Ralliart.
Editorial Emphasis:
Focus on practical, step-by-step instructions and clear visual aids.
📋 Manual Details
Coverage Areas
Manual Coverage:
Comprehensive service, maintenance, and repair for Mitsubishi TJ Magna and Ralliart models.
Page Count
Page Count:
Extensive (specific number not provided, implies a very detailed manual)
Manual Type
Manual Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF, implied by sales context)
📖 Manual Coverage
Systems Covered
Engine Service:
Detailed repair procedures, diagnostics, and specifications for all engine variants.
Transmission Service:
Repair and maintenance for both automatic and manual transmissions.
Drivetrain Service:
Front-wheel drive and all-wheel drive system diagnostics and repair.
Suspension Steering:
Components, adjustments, and repair procedures for suspension and steering systems.
Brake Systems:
Diagnosis, repair, and maintenance of braking systems, including ABS.
Electrical Systems:
Wiring diagrams, component testing, and repair for all electrical systems.
Body And Interior:
Panel replacement, interior trim, and body hardware repair.
Climate Control:
HVAC system diagnosis and repair.
Fuel System:
Fuel injection system diagnostics, fuel pump, and injector service.
Cooling System:
Radiator, thermostat, and water pump service.
Exhaust System:
Catalytic converter, muffler, and exhaust pipe repair.
Safety Systems:
Airbag system diagnosis and repair.
Procedures Included
Preventive Maintenance:
Detailed service intervals and procedures for oil changes, filter replacements, and fluid checks.
Troubleshooting Guides:
Systematic diagnostic procedures for common and uncommon faults.
Engine Rebuilds:
Step-by-step instructions for engine disassembly, overhaul, and reassembly.
Transmission Overhaul:
Detailed procedures for rebuilding automatic and manual transmissions.
Brake Pad Rotor Replacement:
Clear instructions for servicing braking components.
Electrical Component Testing:
Guidance on testing sensors, actuators, and control modules.
Timing Belt Replacement:
Crucial procedures for timing belt service.
Suspension Alignment:
Specifications and procedures for wheel alignment.
Technical Depth
Depth Of Information:
Encompasses basic maintenance to complex component-level repairs and diagnostics.
Diagnostic Capabilities:
Includes diagnostic trouble codes (DTCs), symptom-based troubleshooting, and component tests.
Special Tools:
Identification and usage instructions for specialized tools required for certain repairs.
Torque Specifications:
Precise torque values for all critical fasteners.
Exploded Views:
Detailed diagrams showing component assembly and disassembly order.
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Print Quality
Image Resolution:
High-resolution, ensuring clarity of diagrams and text.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code Magna:
6G72 (3.0L V6 SOHC) and 6G74 (3.5L V6 SOHC/DOHC)
Engine Code Ralliart:
6G74 (3.5L V6 DOHC MIVEC)
Performance
Horsepower 3.0L:
Approximately 195-210 hp (varies by year/spec)
Horsepower 3.5L:
Approximately 200-240 hp (varies by year/spec)
Horsepower Ralliart 3.5L Mivec:
Approximately 243 hp
Torque 3.0L:
Approximately 200-215 lb-ft
Torque 3.5L:
Approximately 215-230 lb-ft
Torque Ralliart 3.5L Mivec:
Approximately 240 lb-ft
Fuel System
Fuel Injection Type:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Ignition System:
Distributorless Ignition System (DIS) or Coil-on-Plug (COP)
🔧 Transmission
Standard
Standard Transmission Magna:
4-speed Automatic (e.g., F4A51)
Optional
Optional Transmission Magna:
5-speed Manual (certain trims/years)
Transmission Ralliart:
5-speed Manual or 5-speed 'INVECS-II' Sports Mode Automatic
Features
Transmission Fluid Magna Auto:
DIAQueen ATF-SP II M or equivalent
Transmission Fluid Manual:
Gear Oil API GL-4 or GL-5, SAE 75W-90
📐 Dimensions
Exterior
Wheelbase Approx:
2700-2730 mm (depending on model variant)
Length Approx:
4750-4850 mm
Width Approx:
1750-1780 mm
Height Approx:
1400-1450 mm
Weights
Curb Weight Approx:
1450-1650 kg
Gross Vehicle Weight Rating Approx:
2000-2200 kg
🛡️ Safety Features
Ratings
Australian Ancap Rating:
Not rated for early models; later models improved.
Active Features
ABS:
Standard on most models, optional on early base models.
Traction Control:
Available on higher trims and Ralliart model.
Passive Features
Airbags:
Driver and passenger airbags standard from mid-production onwards; side airbags optional on later models.
Seatbelts:
Pre-tensioning front seatbelts.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM radio with cassette player, optional CD player. Upgradable to modern head units.
Driver Assistance
Cruise Control:
Available on most models.
Parking Sensors:
Optional on later models.
Connectivity
Auxiliary Input:
Not standard; aftermarket solutions required.
🔧 Maintenance
Service Intervals
Oil Change Interval Engine Oil:
Every 10,000 km or 6 months, whichever comes first (check manual for specific engine type).
Oil Filter Replacement:
At every oil change.
Air Filter Replacement:
Every 20,000 km or 12 months.
Spark Plug Replacement 3.0L:
Approximately 60,000 km (depending on spark plug type - platinum recommended).
Spark Plug Replacement 3.5L Mivec:
Approximately 80,000-100,000 km (Iridium type).
Timing Belt Replacement:
Every 100,000 km or 5 years (critical interval for 6G7 engines).
Fluid Specifications
Engine Oil Spec:
API SG/SH/SJ or ACEA A2/A3, SAE 10W-30 or 10W-40 (check manual for ambient temperature suitability).
Coolant Spec:
Mitsubishi Super Long Life Coolant (LLC) or equivalent ethylene glycol-based coolant, mixed 50/50 with distilled water.
Brake Fluid Spec:
DOT 3 or DOT 4 Brake Fluid.
Known Issues
Common Issue Engine Mounts:
Wear and tear on engine mounts can lead to vibrations.
Common Issue Automatic Transmission:
Some models may experience solenoid issues or torque converter shudder.
Common Issue Suspension Components:
Worn ball joints, control arm bushings, and sway bar links are common with age and mileage.
Common Issue Oil Leaks:
Leaking valve cover gaskets or oil pan seals.
Common Issue Timing Belt Tensioner:
Failure to replace timing belt and tensioner per schedule can lead to catastrophic engine damage.
📚 Vehicle History
Brand Heritage
Parent Company:
Mitsubishi Motors Corporation, Japan.
Model Evolution
Tj Generation:
Third generation Mitsubishi Magna, building on the previous TR/TS series.
Ralliart Introduction:
The Ralliart name was applied to performance-oriented versions of the Magna, often featuring enhanced engines, suspension, and styling.
Design Philosophy:
Focus on comfort, space, and respectable performance for a family sedan, with Ralliart pushing sportier capabilities.
Production
Manufacturing Location:
Mitsubishi Motors Australia (MMA) plant in Tonsley Park, South Australia.
Production End Reason:
Discontinuation of Australian manufacturing operations by Mitsubishi.
🏆 Awards & Recognition
Recognitions
Local Market Success:
The Magna was a significant player in the Australian market, often praised for its value and features for the price.
Ratings
Car Reviews General Sentiment:
Generally positive reviews for comfort, space, and performance, particularly for V6 models. Ralliart models noted for improved dynamics.
Certifications
Manufacturing Standards:
Built to Mitsubishi's global manufacturing standards, adapted for Australian market requirements.
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