Mitsubishi TJ RALLIART MAGNA 1996-2005 Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Magna (TJ Series) Model Variant: Ralliart Production Years Covered: 1996-2005 Codes Platform Code: TJ 👋 Introduction Market Position Target Audience: Professional technicians and advanced DIY enthusiasts Competitive Analysis Value Proposition: Provides comprehensive factory-level repair information, enabling owners to perform complex maintenance and repairs, saving on dealership labor costs. Key Features Content Richness: Hundreds of pages with step-by-step instructions, top-quality diagrams, and exploded views. Accessibility: Instant digital download for immediate access to repair information. Customization: Ability to print entire manual or specific pages as needed. Knowledge Transfer: Empowers users with factory-trained technician knowledge for informed maintenance and repair decisions. 📋 Manual Details Coverage Areas Market Focus: Australia and potentially other right-hand drive markets where the Magna was sold Trim Levels Covered: All Ralliart variants and likely comparable Magna trims Page Count Estimated Pages: Hundreds (exact count not specified but implied to be comprehensive) Manual Type Type: Complete Official Full Factory Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, overhaul, performance tuning Transmission: Automatic and Manual transmission service, repair, overhaul, diagnostics Drivetrain: Front-wheel drive system, axles, CV joints, differential service Suspension: Front and rear suspension components, shock absorbers, springs, bushings, alignment procedures Steering: Power steering system, steering rack, column, linkage repair and adjustment Brakes: Hydraulic system, ABS, disc and drum brake service, caliper and rotor replacement, brake fluid specifications Electrical System: Wiring diagrams, component testing, starter, alternator, battery service, lighting, ignition system Fuel System: Fuel pump, injectors, fuel filter replacement, fuel pressure testing, evaporative emissions control Cooling System: Radiator, water pump, thermostat, coolant specifications, fan operation Exhaust System: Muffler, catalytic converter, exhaust pipe replacement Body And Interior: Body panel repair, door mechanisms, trim removal, seat adjustment, interior component replacement HVAC: Air conditioning system, heater core, blower motor, refrigerant charging Body Control Module: Functions, diagnostics, and repair of body electronic modules Safety Systems: Airbag system operation and diagnostics, seatbelt service Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs Troubleshooting: Systematic diagnostic procedures for common and uncommon faults Repair: Step-by-step repair instructions for all major vehicle systems Disassembly Assembly: Detailed procedures for component removal and reinstallation Rebuilding: Engine and transmission rebuilding procedures Cleaning: Component cleaning and preparation for assembly Adjustment: Calibration and adjustment of various systems (e.g., parking brake, throttle linkage) Installation: Procedures for installing new or replacement parts Torque Specifications: Precise torque values for all fasteners Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine/transmission rebuilds, intended for professional technicians but accessible to skilled DIYers. 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Full Printable Zoom Capability: YES Binding Type Binding: Digital Download (printable) Paper Type Paper Type: N/A (Digital) Software Requirements Reader: Adobe PDF Reader Decompression: WinZip (implied for download, not for manual use) Compatibility Operating Systems: All Versions of Windows & Mac Delivery Method: Instant Download ⚙️ Engine Specifications Primary Engine Engine Family: 6G7 Series V6 (likely 6G72, 6G74 or a variant) Displacement Options: Commonly 3.0L (6G72) and 3.5L (6G74) SOHC or DOHC variants for this era Magna. Performance Horsepower Range: Estimated 140-170 kW (188-228 hp) depending on engine variant. Torque Range: Estimated 270-330 Nm (199-243 lb-ft) depending on engine variant. Fuel System Injection Type: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Petrol (Premium Unleaded recommended for performance variants) Ignition System Type: Distributorless Ignition System (DIS) or Coil-on-Plug (COP) depending on model year and engine. Engine Management ECU Type: Factory Electronic Control Unit (ECU) with diagnostic capabilities. 🔧 Transmission Standard Type: Likely 4-speed Automatic (e.g., F4A51, W4A51) as standard on many Magna variants. Optional Type: 5-speed Manual Transmission (e.g., KM132, KM232 variants) may have been available, especially on sportier trims. Features Automatic Control: Electronic control for optimal shift points and fuel economy. Fluid Specifications Automatic Transmission Fluid: Refer to manual for specific ATF type (e.g., Diamond SP-III or equivalent). Manual Transmission Fluid: Refer to manual for specific gear oil specification (e.g., API GL-4 or GL-5, SAE 75W-90). 📐 Dimensions Exterior Body Styles: Sedan and Wagon (Estates/Safari) Weights Curb Weight Range: Approximately 1450 - 1650 kg (3197 - 3638 lbs) depending on body style and equipment. 🛡️ Safety Features Ratings Crash Test Standards: Australian NCAP or equivalent standards applicable during production years. Active Features ABS: Anti-lock Braking System (ABS) typically standard on higher trims and Ralliart. Passive Features Airbags: Driver and front passenger airbags standard. Side airbags may be optional or standard on later models/trims. Seatbelts: Three-point inertia reel seatbelts with pre-tensioners for front occupants. 💡 Technology Features Infotainment Audio System: Factory fitted radio/cassette or CD player with speaker systems. Potential for dealer-fitted upgrades. Driver Assistance Cruise Control: Typically available on higher trim levels and Ralliart variants. Connectivity OBD Ii: On-Board Diagnostics II (OBD-II) port present for fault code retrieval, facilitating diagnosis. 🔧 Maintenance Service...
Body panel repair, door mechanisms, trim removal, seat adjustment, interior component replacement
HVAC:
Air conditioning system, heater core, blower motor, refrigerant charging
Body Control Module:
Functions, diagnostics, and repair of body electronic modules
Safety Systems:
Airbag system operation and diagnostics, seatbelt service
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs
Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults
Repair:
Step-by-step repair instructions for all major vehicle systems
Disassembly Assembly:
Detailed procedures for component removal and reinstallation
Rebuilding:
Engine and transmission rebuilding procedures
Cleaning:
Component cleaning and preparation for assembly
Adjustment:
Calibration and adjustment of various systems (e.g., parking brake, throttle linkage)
Installation:
Procedures for installing new or replacement parts
Torque Specifications:
Precise torque values for all fasteners
Technical Depth
Depth:
Comprehensive, covering everything from basic maintenance to complete engine/transmission rebuilds, intended for professional technicians but accessible to skilled DIYers.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Full Printable
Zoom Capability:
YES
Binding Type
Binding:
Digital Download (printable)
Paper Type
Paper Type:
N/A (Digital)
Software Requirements
Reader:
Adobe PDF Reader
Decompression:
WinZip (implied for download, not for manual use)
Compatibility
Operating Systems:
All Versions of Windows & Mac
Delivery
Method:
Instant Download
⚙️ Engine Specifications
Primary Engine
Engine Family:
6G7 Series V6 (likely 6G72, 6G74 or a variant)
Displacement Options:
Commonly 3.0L (6G72) and 3.5L (6G74) SOHC or DOHC variants for this era Magna.
Performance
Horsepower Range:
Estimated 140-170 kW (188-228 hp) depending on engine variant.
Torque Range:
Estimated 270-330 Nm (199-243 lb-ft) depending on engine variant.
Fuel System
Injection Type:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Petrol (Premium Unleaded recommended for performance variants)
Ignition System
Type:
Distributorless Ignition System (DIS) or Coil-on-Plug (COP) depending on model year and engine.
Engine Management
ECU Type:
Factory Electronic Control Unit (ECU) with diagnostic capabilities.
🔧 Transmission
Standard
Type:
Likely 4-speed Automatic (e.g., F4A51, W4A51) as standard on many Magna variants.
Optional
Type:
5-speed Manual Transmission (e.g., KM132, KM232 variants) may have been available, especially on sportier trims.
Features
Automatic Control:
Electronic control for optimal shift points and fuel economy.
Fluid Specifications
Automatic Transmission Fluid:
Refer to manual for specific ATF type (e.g., Diamond SP-III or equivalent).
Manual Transmission Fluid:
Refer to manual for specific gear oil specification (e.g., API GL-4 or GL-5, SAE 75W-90).
📐 Dimensions
Exterior
Body Styles:
Sedan and Wagon (Estates/Safari)
Weights
Curb Weight Range:
Approximately 1450 - 1650 kg (3197 - 3638 lbs) depending on body style and equipment.
🛡️ Safety Features
Ratings
Crash Test Standards:
Australian NCAP or equivalent standards applicable during production years.
Active Features
ABS:
Anti-lock Braking System (ABS) typically standard on higher trims and Ralliart.
Passive Features
Airbags:
Driver and front passenger airbags standard. Side airbags may be optional or standard on later models/trims.
Seatbelts:
Three-point inertia reel seatbelts with pre-tensioners for front occupants.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette or CD player with speaker systems. Potential for dealer-fitted upgrades.
Driver Assistance
Cruise Control:
Typically available on higher trim levels and Ralliart variants.
Connectivity
OBD Ii:
On-Board Diagnostics II (OBD-II) port present for fault code retrieval, facilitating diagnosis.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 10,000 km or 6 months, whichever comes first (refer to manual for exact spec).
Transmission Fluid Change:
Automatic transmission fluid service recommended at 40,000 - 80,000 km intervals, manual at 60,000 - 100,000 km.
Timing Belt:
Critical service item for V6 engines. Interval typically 90,000-100,000 km or 5-7 years. Failure can cause catastrophic engine damage.
Fluid Specifications
Engine Oil Grade:
Likely 10W-30 or 10W-40 API SG or higher (refer to manual for precise grade and specification).
Coolant Type:
Ethylene glycol based coolant, typically a 50/50 mix with distilled water.
Known Issues
Engine Mounts:
Wear and tear leading to vibration or clunking noises.
Transmission Solenoids:
Failure in automatic transmissions can lead to erratic shifting or no gear engagement.
Power Steering Pump:
Leaking or noisy pumps can be an issue with age.
Cooling System Hoses:
Degradation and cracking of rubber hoses can lead to leaks.
📚 Vehicle History
Brand Heritage
Manufacturer:
Mitsubishi Motors Corporation
Model Evolution
Generation:
Third generation Magna (TJ series), following the TR/TS Magna.
Ralliart Positioning:
Ralliart variants typically offered enhanced performance, sportier styling, and upgraded suspension/braking components over standard Magna models.
Production
Manufacturing Location:
Australia (Adelaide, South Australia)
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