Mitsubushi TJ RALLIART MAGNA 1996-2005 Full Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Magna (TJ Series) Trim Level: Ralliart Year: 1996-2005 Codes Chassis Code: TJ 👋 Introduction Market Position Target Audience: Enthusiast owners, DIY mechanics, professional repair shops seeking detailed service information. Competitive Analysis Value Proposition: Provides factory-level repair and maintenance information, crucial for preserving the performance and longevity of a performance-oriented model like the Ralliart Magna. Key Features Diagrams: High-quality diagrams and exploded views for clarity in repair procedures. Text Clarity: Easy-to-read text sections with clear, concise instructions. Accessibility: Downloadable PDF format allows for instant access and use on various devices, even in remote locations. 📋 Manual Details Coverage Areas Region Covered: Primarily Australia (as Ralliart trim was prevalent) Page Count Estimated Pages: Varies by specific content; professional manuals typically 1000+ pages Manual Type Type: Full Service and Repair Manual Language Language: English Format Format: PDF (Downloadable) 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, overhaul for 3.5L V6 (6G74) engine variants including Ralliart specifics. Transmission: Service and repair for automatic and manual transmissions, including fluid changes, component overhaul, and troubleshooting. Drivetrain: Front-wheel drive (FWD) and All-wheel drive (AWD) systems, including differentials, driveshafts, and CV joints. Suspension: Front and rear suspension components, alignment specifications, shock absorbers, springs, bushings, and steering linkage. Brakes: Front and rear brake systems (disc and drum), ABS components, hydraulic circuits, parking brake, and bleeding procedures. Steering: Power steering system, steering rack, column, and associated components. Electrical: Full electrical schematics, starter, alternator, battery, lighting systems, ignition system, fuel injection control, and accessory circuits. Body And Chassis: Body panel removal and installation, structural components, interior trim, exterior trim, and corrosion protection. Climate Control: Air conditioning system (refrigerant, compressor, condenser, evaporator), heater, and ventilation. Fuel System: Fuel tank, fuel pump, fuel injectors, fuel filter, and evaporative emission control (EVAP) system. Exhaust System: Exhaust manifold, catalytic converter, mufflers, and pipes. Procedures Included Maintenance: Scheduled maintenance, fluid changes (oil, coolant, transmission fluid, brake fluid), filter replacements, spark plug replacement, and inspections. Troubleshooting: Diagnostic procedures for common drivability issues, electrical faults, and mechanical problems, often with flowcharts. Repair: Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation. Rebuilds: Comprehensive instructions for engine and transmission overhauls, including clearances and tolerances. Installation: Instructions for installing aftermarket parts or replacing major components. Technical Depth Depth: Extremely high. Covers everything from basic fluid changes to complete engine and transmission rebuilds, including detailed electrical diagnostics. Diagnostic Tools: References to required diagnostic tools and procedures, including OBD-II scanning and specific test equipment. Torque Specifications: Precise torque values for all critical fasteners across all systems. Clearances Tolerances: Detailed specifications for engine, transmission, and bearing clearances. 📊 Manual Specifications File Format Format: PDF Print Quality Printability: Full printable Zoom Capability: Yes (Zoom IN/OUT) Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) Delivery Delivery Method: Instant Download Requirements Software Requirements: Adobe PDF Reader & WinZip Compatibility Operating Systems: All Versions of Windows & Mac ⚙️ Engine Specifications Primary Engine Engine Code: 6G74 (SOHC and DOHC variants likely exist, Ralliart typically DOHC MIVEC) Configuration: 3.5L V6 SOHC/DOHC MPI (Multi-Point Injection) Performance Horsepower Range: Approx. 147-185 kW (197-248 hp) depending on DOHC MIVEC and specific tuning for Ralliart. Torque Range: Approx. 316-333 Nm (233-246 lb-ft) depending on DOHC MIVEC and specific tuning for Ralliart. Fuel System Injection Type: Electronic Multi-Point Fuel Injection (MPI) Fuel Type: Unleaded Petrol (Octane rating typically 95 RON recommended for performance variants) Technical Features Valvetrain: SOHC or DOHC with MIVEC (Mitsubishi Innovative Valve timing Electronic Control) on performance variants. 🔧 Transmission Standard Type: 4-speed Automatic (INVECS-II Sport Mode likely standard on Ralliart) Optional Type: 5-speed Manual Transmission (less common on Ralliart, but possible) Features Automatic Features: Sport mode, adaptive shift logic (INVECS-II) 📐 Dimensions Exterior Body Styles: Sedan, Wagon Weights Curb Weight Range: Approx. 1500-1650 kg (depending on body style and drivetrain) 🛡️ Safety Features Ratings Ancap Rating: Varies by specific model year and test; older models may not have ANCAP ratings or may have lower ratings than contemporary vehicles. Active Features ABS: Standard (Anti-lock Braking System) Traction Control: Likely available on Ralliart models Passive Features Airbags: Driver and front passenger airbags standard, side airbags may be optional on later models. 💡 Technology Features Infotainment Audio System: Factory fitted CD player or cassette with radio. Upgrade options common. Driver Assistance Cruise Control: Standard on most Ralliart variants. Connectivity Standard Features: Basic power windows, power mirrors, central locking. Bluetooth/USB connectivity would be aftermarket. 🔧 Maintenance Service Intervals Engine Oil Change: Typically every 10,000-15,000 km or 6-12 months, whichever comes first. Consult manual for exact mileage. Transmission Fluid Change: Automatic transmission fluid: 40,000-80,000 km. Manual transmission fluid: 60,000-100,000 km. Consult manual for specifics. Coolant Change: Typically every 40,000-80,000 km or 2-4 years. Use genuine Mitsubishi coolant. Fluid Specifications Engine Oil: Refer to manual for specific viscosity grade (e.g., 5W-30,...
Enthusiast owners, DIY mechanics, professional repair shops seeking detailed service information.
Competitive Analysis
Value Proposition:
Provides factory-level repair and maintenance information, crucial for preserving the performance and longevity of a performance-oriented model like the Ralliart Magna.
Key Features
Diagrams:
High-quality diagrams and exploded views for clarity in repair procedures.
Text Clarity:
Easy-to-read text sections with clear, concise instructions.
Accessibility:
Downloadable PDF format allows for instant access and use on various devices, even in remote locations.
📋 Manual Details
Coverage Areas
Region Covered:
Primarily Australia (as Ralliart trim was prevalent)
Page Count
Estimated Pages:
Varies by specific content; professional manuals typically 1000+ pages
Manual Type
Type:
Full Service and Repair Manual
Language
Language:
English
Format
Format:
PDF (Downloadable)
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, repair, overhaul for 3.5L V6 (6G74) engine variants including Ralliart specifics.
Transmission:
Service and repair for automatic and manual transmissions, including fluid changes, component overhaul, and troubleshooting.
Drivetrain:
Front-wheel drive (FWD) and All-wheel drive (AWD) systems, including differentials, driveshafts, and CV joints.
Suspension:
Front and rear suspension components, alignment specifications, shock absorbers, springs, bushings, and steering linkage.
Brakes:
Front and rear brake systems (disc and drum), ABS components, hydraulic circuits, parking brake, and bleeding procedures.
Steering:
Power steering system, steering rack, column, and associated components.
Electrical:
Full electrical schematics, starter, alternator, battery, lighting systems, ignition system, fuel injection control, and accessory circuits.
Body And Chassis:
Body panel removal and installation, structural components, interior trim, exterior trim, and corrosion protection.
Climate Control:
Air conditioning system (refrigerant, compressor, condenser, evaporator), heater, and ventilation.
Fuel System:
Fuel tank, fuel pump, fuel injectors, fuel filter, and evaporative emission control (EVAP) system.
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, and pipes.
Diagnostic procedures for common drivability issues, electrical faults, and mechanical problems, often with flowcharts.
Repair:
Step-by-step instructions for component removal, disassembly, repair, reassembly, and installation.
Rebuilds:
Comprehensive instructions for engine and transmission overhauls, including clearances and tolerances.
Installation:
Instructions for installing aftermarket parts or replacing major components.
Technical Depth
Depth:
Extremely high. Covers everything from basic fluid changes to complete engine and transmission rebuilds, including detailed electrical diagnostics.
Diagnostic Tools:
References to required diagnostic tools and procedures, including OBD-II scanning and specific test equipment.
Torque Specifications:
Precise torque values for all critical fasteners across all systems.
Clearances Tolerances:
Detailed specifications for engine, transmission, and bearing clearances.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Printability:
Full printable
Zoom Capability:
Yes (Zoom IN/OUT)
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
Delivery
Delivery Method:
Instant Download
Requirements
Software Requirements:
Adobe PDF Reader & WinZip
Compatibility
Operating Systems:
All Versions of Windows & Mac
⚙️ Engine Specifications
Primary Engine
Engine Code:
6G74 (SOHC and DOHC variants likely exist, Ralliart typically DOHC MIVEC)
Configuration:
3.5L V6 SOHC/DOHC MPI (Multi-Point Injection)
Performance
Horsepower Range:
Approx. 147-185 kW (197-248 hp) depending on DOHC MIVEC and specific tuning for Ralliart.
Torque Range:
Approx. 316-333 Nm (233-246 lb-ft) depending on DOHC MIVEC and specific tuning for Ralliart.
Fuel System
Injection Type:
Electronic Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded Petrol (Octane rating typically 95 RON recommended for performance variants)
Technical Features
Valvetrain:
SOHC or DOHC with MIVEC (Mitsubishi Innovative Valve timing Electronic Control) on performance variants.
🔧 Transmission
Standard
Type:
4-speed Automatic (INVECS-II Sport Mode likely standard on Ralliart)
Optional
Type:
5-speed Manual Transmission (less common on Ralliart, but possible)
Features
Automatic Features:
Sport mode, adaptive shift logic (INVECS-II)
📐 Dimensions
Exterior
Body Styles:
Sedan, Wagon
Weights
Curb Weight Range:
Approx. 1500-1650 kg (depending on body style and drivetrain)
🛡️ Safety Features
Ratings
Ancap Rating:
Varies by specific model year and test; older models may not have ANCAP ratings or may have lower ratings than contemporary vehicles.
Active Features
ABS:
Standard (Anti-lock Braking System)
Traction Control:
Likely available on Ralliart models
Passive Features
Airbags:
Driver and front passenger airbags standard, side airbags may be optional on later models.
💡 Technology Features
Infotainment
Audio System:
Factory fitted CD player or cassette with radio. Upgrade options common.
Driver Assistance
Cruise Control:
Standard on most Ralliart variants.
Connectivity
Standard Features:
Basic power windows, power mirrors, central locking. Bluetooth/USB connectivity would be aftermarket.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Typically every 10,000-15,000 km or 6-12 months, whichever comes first. Consult manual for exact mileage.
Transmission Fluid Change:
Automatic transmission fluid: 40,000-80,000 km. Manual transmission fluid: 60,000-100,000 km. Consult manual for specifics.
Coolant Change:
Typically every 40,000-80,000 km or 2-4 years. Use genuine Mitsubishi coolant.
Fluid Specifications
Engine Oil:
Refer to manual for specific viscosity grade (e.g., 5W-30, 10W-40) and API service classification. Likely synthetic or semi-synthetic.
Transmission Fluid Auto:
Genuine Mitsubishi Diamond ATF SP-III or equivalent is critical for INVECS-II transmissions.
Transmission Fluid Manual:
GL-4 or GL-5 gear oil, specific viscosity grade as per manual.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine Mounts:
Can degrade over time, leading to increased vibration and noise.
Automatic Transmission:
INVECS-II can sometimes exhibit hesitant shifting or torque converter issues if not maintained. Fluid changes are crucial.
Suspension Bushings:
Wear in control arm and sway bar bushings can lead to clunking noises and poor handling.
Radiator:
Plastic end tanks can become brittle and leak over time.
Air Conditioning:
Common issues include refrigerant leaks, compressor clutch failure, or blend door actuator problems.
📚 Vehicle History
Brand Heritage
Motorsport:
Mitsubishi has a strong rally heritage, and the Ralliart branding signifies a performance-oriented variant, often with enhancements inspired by motorsport.
Model Evolution
Tj Series:
The TJ Magna was a significant evolution, introducing a more modern chassis and styling, with the Ralliart package further enhancing its sporting credentials.
Production
Manufacturing Location:
Australia (Adelaide, South Australia)
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