Mitsubushi GALANT Digital Workshop Repair Manual 1996-2003

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🏷️ Basic Information Identification Make: Mitsubishi Model: Galant Generation Codes: E50/E60/E70/E80 (1993-1998), EA0 (1998-2003) Covered Years: 1996-2003 👋 Introduction Market Position Vehicle Class: Mid-size Sedan/Coupe Target Audience: DIY mechanics, independent repair shops, Mitsubishi enthusiasts Competitive Analysis Competitors: Toyota Camry, Honda Accord, Nissan Altima, Ford Taurus, Chevrolet Malibu Key Features Distinctive Selling Points: Stylish design (especially early generation), available AWD, robust 4G63 engine option (popular in tuning), comfortable ride, good value proposition. Manual Value Proposition Value For Buyers: Empowers owners to perform a wide range of repairs and maintenance, saving money and extending the vehicle's lifespan. Crucial for diagnosing complex issues and ensuring proper procedures are followed. 📋 Manual Details Coverage Areas Engine Coverage: 4G63 (2.0L SOHC/DOHC), 4G64 (2.4L SOHC), 6A12 (2.0L V6 SOHC/MIVEC), 6G72 (3.0L V6 SOHC) Transmission Coverage: F5M51 (5-speed Manual), W4A51 (4-speed Automatic), V4A51 (4-speed Automatic - INVECS-II) Chassis Coverage: Front Wheel Drive (FWD), All Wheel Drive (AWD) variants Body Styles Covered: Sedan, Coupe (E50/E60 generation) Page Count Estimated Pages: 2000+ Manual Type Type: Digital Workshop Repair Manual Language Language: English Format Format: Digital (likely PDF, HTML) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, valve train, pistons, crankshaft, connecting rods, lubrication system, cooling system, timing belts/chains Engine Performance: Fuel injection (MPI/GDI), ignition system, emissions control, turbocharging (specific variants) Transmission Manual: Clutch, gearbox assembly, shift mechanisms, overhaul procedures Transmission Automatic: Torque converter, valve body, planetary gear sets, hydraulic controls, electronic controls (INVECS-II), overhaul procedures Drivetrain: Front axle, rear axle (AWD), drive shafts, CV joints, differentials Suspension: Front suspension (MacPherson struts), rear suspension (multi-link or trailing arm), shock absorbers, springs, bushings, alignment specifications Steering: Power steering system, steering rack, tie rods, steering column, power steering fluid specifications Brakes: Front and rear brake systems (discs/drums), hydraulic system, ABS (Anti-lock Braking System), brake pad/rotor replacement, brake fluid specifications (DOT 3) Electrical System: Battery, charging system (alternator), starting system, lighting, fuses, relays, wiring diagrams, ECU pinouts Body And Interior: Body panels, doors, windows, seats, dashboard, trim, soundproofing, HVAC system (heating, ventilation, air conditioning) Diagnostics: OBD-II (On-Board Diagnostics II) system, trouble codes (DTCs), diagnostic procedures, sensor testing Procedures Included Maintenance: Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flush, transmission fluid change, brake fluid change, belt inspections/replacement Repair: Engine rebuilding, transmission overhaul, suspension component replacement, brake caliper service, power steering pump replacement, electrical component diagnosis and replacement Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting, common faults and solutions Specifications: Torque specifications for all fasteners, fluid capacities and types, engine timing specifications, diagnostic parameters Wiring Diagrams: Comprehensive electrical schematics for all major systems Technical Depth Depth: Comprehensive; covers everything from basic maintenance to full engine and transmission rebuilds, including electrical diagnostics and body repair. 📊 Manual Specifications File Format File Type: Digital (typically PDF or collection of HTML pages) Searchability: Likely searchable text (if PDF), enabling quick access to specific information. Printability: Printable pages for on-site workshop use. Print Quality Image Resolution: High resolution for clear diagrams, illustrations, and photographs. Binding Type Binding: Not applicable for digital format; physical equivalent would be perfect bound or spiral bound. Paper Type Paper: Not applicable for digital format; physical equivalent would be durable paper stock suitable for workshop environments. ⚙️ Engine Specifications Primary Engine Engine Codes And Displacements: 4G63 (2.0L SOHC/DOHC I4), 4G64 (2.4L SOHC I4), 6A12 (2.0L SOHC/MIVEC V6), 6G72 (3.0L SOHC V6) Performance Horsepower And Torque: Varies by engine and year, e.g., 4G63 (approx. 140-150 hp for N/A, 240+ hp for Turbo variants), 4G64 (approx. 140-150 hp), 6A12 (approx. 150-170 hp), 6G72 (approx. 170-200 hp). Fuel System Fuel Delivery: Multi-Point Fuel Injection (MPI) for most, Gasoline Direct Injection (GDI) on some later models. Fuel pump, fuel filter, injectors. Ignition System Ignition Type: Electronic ignition with distributor or Distributorless Ignition System (DIS) depending on engine and year. Cooling System Coolant Type: Ethylene Glycol based coolant (typically pink or red for Mitsubishi vehicles of this era). Capacity: ~7-8 liters. Lubrication System Oil Type And Capacity: API SG/SH or higher. Viscosity: 5W-30 or 10W-30 depending on climate. Capacity: ~4.5-5.5 liters (varies by engine). 🔧 Transmission Standard Transmission Type Standard: 5-speed Manual Transmission (F5M51) on many models, 4-speed Automatic (W4A51/V4A51) common on others. Optional Transmission Type Optional: All-Wheel Drive (AWD) system often paired with automatic transmissions, featuring INVECS-II electronic control. Features Automatic Transmission Features: INVECS-II (Intelligent and Innovative Vehicle Electronic Control system) allowing adaptive shift patterns. Fluid Specifications Automatic Transmission Fluid: DIA QUEEN ATF SP-II or equivalent (e.g., Dexron III compatible, but specific Mitsubishi fluid is recommended). Capacity: ~7-8 liters for a full flush/fill. Manual Transmission Fluid: API GL-4, SAE 75W-90 gear oil. Capacity: ~2-2.5 liters. 📐 Dimensions Exterior Length: Approx. 4700-4800 mm (Sedan), 4500-4600 mm (Coupe) Width: Approx. 1700-1730 mm Height: Approx. 1390-1420 mm (Coupe), 1430-1450 mm (Sedan) Wheelbase: Approx. 2700 mm Interior Seating Capacity: 5 passengers Cargo Trunk Capacity: Approx. 15-17 cubic...

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Tags: 1996 1997 1998 1999 2000 2001 2002 2003 Car GALANT Mitsubishi Mitsubushi

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Galant

Generation Codes:

E50/E60/E70/E80 (1993-1998), EA0 (1998-2003)

Covered Years:

1996-2003

👋 Introduction

Market Position

Vehicle Class:

Mid-size Sedan/Coupe

Target Audience:

DIY mechanics, independent repair shops, Mitsubishi enthusiasts

Competitive Analysis

Competitors:

Toyota Camry, Honda Accord, Nissan Altima, Ford Taurus, Chevrolet Malibu

Key Features

Distinctive Selling Points:

Stylish design (especially early generation), available AWD, robust 4G63 engine option (popular in tuning), comfortable ride, good value proposition.

Manual Value Proposition

Value For Buyers:

Empowers owners to perform a wide range of repairs and maintenance, saving money and extending the vehicle's lifespan. Crucial for diagnosing complex issues and ensuring proper procedures are followed.

📋 Manual Details

Coverage Areas

Engine Coverage:

4G63 (2.0L SOHC/DOHC), 4G64 (2.4L SOHC), 6A12 (2.0L V6 SOHC/MIVEC), 6G72 (3.0L V6 SOHC)

Transmission Coverage:

F5M51 (5-speed Manual), W4A51 (4-speed Automatic), V4A51 (4-speed Automatic - INVECS-II)

Chassis Coverage:

Front Wheel Drive (FWD), All Wheel Drive (AWD) variants

Body Styles Covered:

Sedan, Coupe (E50/E60 generation)

Page Count

Estimated Pages:

2000+

Manual Type

Type:

Digital Workshop Repair Manual

Language

Language:

English

Format

Format:

Digital (likely PDF, HTML)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, valve train, pistons, crankshaft, connecting rods, lubrication system, cooling system, timing belts/chains

Engine Performance:

Fuel injection (MPI/GDI), ignition system, emissions control, turbocharging (specific variants)

Transmission Manual:

Clutch, gearbox assembly, shift mechanisms, overhaul procedures

Transmission Automatic:

Torque converter, valve body, planetary gear sets, hydraulic controls, electronic controls (INVECS-II), overhaul procedures

Drivetrain:

Front axle, rear axle (AWD), drive shafts, CV joints, differentials

Suspension:

Front suspension (MacPherson struts), rear suspension (multi-link or trailing arm), shock absorbers, springs, bushings, alignment specifications

Steering:

Power steering system, steering rack, tie rods, steering column, power steering fluid specifications

Brakes:

Front and rear brake systems (discs/drums), hydraulic system, ABS (Anti-lock Braking System), brake pad/rotor replacement, brake fluid specifications (DOT 3)

Electrical System:

Battery, charging system (alternator), starting system, lighting, fuses, relays, wiring diagrams, ECU pinouts

Body And Interior:

Body panels, doors, windows, seats, dashboard, trim, soundproofing, HVAC system (heating, ventilation, air conditioning)

Diagnostics:

OBD-II (On-Board Diagnostics II) system, trouble codes (DTCs), diagnostic procedures, sensor testing

Procedures Included

Maintenance:

Oil changes, filter replacements (oil, air, fuel, cabin), spark plug replacement, coolant flush, transmission fluid change, brake fluid change, belt inspections/replacement

Repair:

Engine rebuilding, transmission overhaul, suspension component replacement, brake caliper service, power steering pump replacement, electrical component diagnosis and replacement

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting, common faults and solutions

Specifications:

Torque specifications for all fasteners, fluid capacities and types, engine timing specifications, diagnostic parameters

Wiring Diagrams:

Comprehensive electrical schematics for all major systems

Technical Depth

Depth:

Comprehensive; covers everything from basic maintenance to full engine and transmission rebuilds, including electrical diagnostics and body repair.

📊 Manual Specifications

File Format

File Type:

Digital (typically PDF or collection of HTML pages)

Searchability:

Likely searchable text (if PDF), enabling quick access to specific information.

Printability:

Printable pages for on-site workshop use.

Print Quality

Image Resolution:

High resolution for clear diagrams, illustrations, and photographs.

Binding Type

Binding:

Not applicable for digital format; physical equivalent would be perfect bound or spiral bound.

Paper Type

Paper:

Not applicable for digital format; physical equivalent would be durable paper stock suitable for workshop environments.

⚙️ Engine Specifications

Primary Engine

Engine Codes And Displacements:

4G63 (2.0L SOHC/DOHC I4), 4G64 (2.4L SOHC I4), 6A12 (2.0L SOHC/MIVEC V6), 6G72 (3.0L SOHC V6)

Performance

Horsepower And Torque:

Varies by engine and year, e.g., 4G63 (approx. 140-150 hp for N/A, 240+ hp for Turbo variants), 4G64 (approx. 140-150 hp), 6A12 (approx. 150-170 hp), 6G72 (approx. 170-200 hp).

Fuel System

Fuel Delivery:

Multi-Point Fuel Injection (MPI) for most, Gasoline Direct Injection (GDI) on some later models. Fuel pump, fuel filter, injectors.

Ignition System

Ignition Type:

Electronic ignition with distributor or Distributorless Ignition System (DIS) depending on engine and year.

Cooling System

Coolant Type:

Ethylene Glycol based coolant (typically pink or red for Mitsubishi vehicles of this era). Capacity: ~7-8 liters.

Lubrication System

Oil Type And Capacity:

API SG/SH or higher. Viscosity: 5W-30 or 10W-30 depending on climate. Capacity: ~4.5-5.5 liters (varies by engine).

🔧 Transmission

Standard

Transmission Type Standard:

5-speed Manual Transmission (F5M51) on many models, 4-speed Automatic (W4A51/V4A51) common on others.

Optional

Transmission Type Optional:

All-Wheel Drive (AWD) system often paired with automatic transmissions, featuring INVECS-II electronic control.

Features

Automatic Transmission Features:

INVECS-II (Intelligent and Innovative Vehicle Electronic Control system) allowing adaptive shift patterns.

Fluid Specifications

Automatic Transmission Fluid:

DIA QUEEN ATF SP-II or equivalent (e.g., Dexron III compatible, but specific Mitsubishi fluid is recommended). Capacity: ~7-8 liters for a full flush/fill.

Manual Transmission Fluid:

API GL-4, SAE 75W-90 gear oil. Capacity: ~2-2.5 liters.

📐 Dimensions

Exterior

Length:

Approx. 4700-4800 mm (Sedan), 4500-4600 mm (Coupe)

Width:

Approx. 1700-1730 mm

Height:

Approx. 1390-1420 mm (Coupe), 1430-1450 mm (Sedan)

Wheelbase:

Approx. 2700 mm

Interior

Seating Capacity:

5 passengers

Cargo

Trunk Capacity:

Approx. 15-17 cubic feet (varies by body style and rear seat configuration)

Weights

Curb Weight:

Approx. 1400-1600 kg (varies significantly by engine and drivetrain)

Gross Vehicle Weight Rating:

Approx. 1900-2100 kg

🛡️ Safety Features

Ratings

NHTSA Ratings:

Variable by year and testing regime. Early models may have limited data. Later models generally performed adequately for their time.

Active Features

Anti-lock Braking System (ABS) available on many models, especially higher trims and AWD variants.

Traction Control:

Traction Control System (TCS) available on select AWD and higher trim models.

Passive Features

Airbags:

Driver and front passenger airbags standard on most models; side airbags became available on later models.

Seat Belts:

Three-point seat belts with pretensioners for front occupants, three-point belts for rear occupants.

Body Structure:

Reinforced safety cage construction with front and rear crumple zones.

💡 Technology Features

Infotainment

Audio System:

Factory-installed AM/FM stereo with CD player or cassette tape, potentially with premium sound systems (e.g., Infinity) on higher trims. Manual covers speaker replacement and head unit troubleshooting.

Climate Control:

Manual or automatic climate control systems. Manual covers HVAC system diagnosis, fan motor replacement, refrigerant recharge procedures (with proper equipment).

Driver Assistance

Cruise Control:

Available on many models, featuring vacuum or electronic actuation. Manual provides diagnosis and repair for cruise control system faults.

Security System:

Factory alarm system and immobilizer on some models. Manual covers key fob programming and alarm system troubleshooting.

Connectivity

Phone Integration:

Not prevalent in this era; factory options for Bluetooth or hands-free calling were rare or non-existent. Aftermarket solutions may have been installed.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, whichever comes first. Consult manual for specific engine recommendations.

Air Filter Replacement:

Every 15,000-30,000 miles (24,000-48,000 km) or annually.

Spark Plug Replacement:

Platinum-tipped plugs: 60,000-100,000 miles. Standard plugs: 30,000 miles. Consult manual for exact type and interval.

Timing Belt Replacement:

Crucial for 4G63 and 6A12 engines. Recommended every 60,000-100,000 miles (96,000-160,000 km). Failure can cause catastrophic engine damage. The manual will detail the procedure and required torque settings.

Coolant Flush:

Every 30,000 miles (48,000 km) or 2-3 years.

Fluid Specifications

Brake Fluid:

DOT 3 (or DOT 4 for some later models, check manual). Flush every 2-3 years or 30,000 miles.

Power Steering Fluid:

Use genuine Mitsubishi power steering fluid or Dexron II/III compatible fluid. Capacity: Approx. 1 liter.

Known Issues

Common Faults:

Transmission control module (TCU) failures in automatic transmissions, O2 sensor failures, catalytic converter issues, minor oil leaks from valve cover or oil pan gaskets, worn CV joints (especially on AWD models), HVAC blower motor resistor failure.

Diagnosis Of Common Issues:

The manual provides diagnostic flowcharts for these issues, including how to test sensors, modules, and mechanical components.

📚 Vehicle History

Brand Heritage

Mitsubishi Motors:

Mitsubishi Motors Corporation is a Japanese multinational automotive manufacturer. Known for its engineering prowess and diverse product range, including rally-winning vehicles.

Model Evolution

Galant Generations Overview:

The Galant has a long history, dating back to the 1960s. The 1996-2003 models represent the E50/E60 (introduced 1993) and EA0 (introduced 1998) generations, respectively. The E50/E60 generation was known for its sleek styling and available VR-4 performance variant (though the VR-4 version is not explicitly covered by the product name for these specific years, its underpinning technology might be referenced).

Generation Differences:

The E50/E60 generation featured a more aerodynamic, coupe-like sedan design and offered advanced technologies like Active ECS (Electronically Controlled Suspension) on certain trims. The EA0 generation adopted a more conventional sedan profile, but continued to offer robust engine options and AWD.

Production

Manufacturing Locations:

Primarily Japan (Mizushima Plant), with some production in other global facilities.

Production Years:

The E50/E60 generation ran from 1993 to 1998. The EA0 generation ran from 1998 to 2003.

🏆 Awards & Recognition

Recognitions

Model Specific Awards:

While not as decorated as some direct competitors, the Galant was generally well-regarded for its styling and value. Specific awards for this generation might be less prominent than for models like the Lancer Evolution.

Ratings

Consumer Reports Ratings:

Variable ratings depending on the year and specific powertrain. Generally received average to above-average marks for reliability during its initial run, but can be prone to certain common issues as they age.

Certifications

Emissions Compliance:

Designed to meet US EPA and CARB emissions standards for the respective model years. Manual covers emissions control system components and diagnostics.