Mitsubishi Galant Workshop Service Repair Manual 1996-2003
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๐ท๏ธ Basic Information Identification Make: Mitsubishi Model: Galant Generations Covered: Eighth Generation (1994-2003) Product Name: Mitsubishi Galant Workshop Service Repair Manual 1996-2003 ๐ Introduction Market Position Vehicle Segment: Mid-size Sedan (European/Japanese markets primarily) Competitive Analysis Competitors 1996-2003: Honda Accord, Toyota Camry, Nissan Altima, Ford Mondeo, Mazda MX-6. Key Features Vehicle Selling Points: Often praised for its distinctive styling (especially the coupe-like sedan profile), comfortable ride, and available V6 engines. Offered good value for money. Manual Value Proposition Manual Benefit: Provides comprehensive, specific repair and maintenance guidance for owners and technicians, enabling confident DIY repairs and efficient professional servicing. ๐ Manual Details Coverage Areas Years Covered: 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 Page Count Estimated Page Count: Extensive (specific number not provided, but indicated as comprehensive) Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format File Format: PDF Delivery Delivery Method: Instant Download ๐ Manual Coverage Systems Covered Engine Repair: Engine removal/installation, cylinder head/valve service, cylinder/piston overhaul, crankshaft/primary shaft inspection and repair, crankcase service. Fuel System: Comprehensive fuel system diagnostics and repair. Transmission Service: Clutch service, gearshift linkage adjustment, sub-transmission service, transmission overhaul and repair, crankshaft/primary shaft specifics. Suspension Steering: Front wheel and suspension service, rear wheel and suspension service. Brake System: Hydraulic brake system inspection, repair, and maintenance. Electrical System: Battery and charging system, ignition system, electric starter, switches, electrical diagrams included. Body And Chassis: Body repair, frame straightening, door mechanisms, glass, interior trim, and exterior trim procedures. Steering System: Power steering system inspection, repair, and component replacement. Exhaust System: Exhaust system components, catalytic converter, mufflers, and hangers. Cooling System: Radiator, hoses, water pump, thermostat, and cooling fan service. Procedures Included Maintenance: Routine maintenance, fluid changes, inspections, and adjustments. Diagnostics: Troubleshooting guides and diagnostic procedures for various systems. Rebuilding: Detailed instructions for rebuilding major components like the engine and transmission. Wiring: Re-wiring procedures and electrical schematic interpretation. Troubleshooting: Extensive troubleshooting section covering common symptoms and their likely causes across all major vehicle systems. Technical Depth Depth Of Coverage: Comprehensive, covering everything from basic maintenance to in-depth engine and transmission rebuilds, including electrical systems. Electrical Diagrams: Includes detailed wiring diagrams for all electrical systems, crucial for diagnosing and repairing electrical faults. ๐ Manual Specifications File Format Compatibility: PC and MAC compatible Viewing Options: Printable pages, printable entire manual, viewable on screen. Interactivity: Zoom in/out functionality Searchable Text: PDF format typically allows for text searching, greatly enhancing usability for finding specific information. Print Quality Diagram Quality: Step-by-step diagrams included for clarity Binding Type Binding Type: Digital (PDF) - No physical binding Paper Type Paper Type: N/A (Digital Format) โ๏ธ Engine Specifications Primary Engine Engine Options 1996-2003: 4G63 2.0L I4 (Naturally Aspirated & Turbocharged for specific markets/trims), 6G72 3.0L V6 (SOHC & DOHC). Performance 2.0L I4 (4G63 Na) Estimated Hp: Approx. 130-140 hp 3.0L V6 (6G72 Sohc) Estimated Hp: Approx. 180-200 hp 3.0L V6 (6G72 DOHc) Estimated Hp: Approx. 200-210 hp Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Engine Codes Covered Common Engine Codes: 4G63, 6G72 ๐ง Transmission Standard Transmission Options: 5-speed Manual Transmission (5MT), 4-speed Automatic Transmission (4AT) Optional Optional Transmission: Refer to specific market/trim for optional availability (e.g., INVECS-II automatic for some markets). Features Transmission Features: Front-wheel drive (FWD) standard. Some performance variants or specific markets may have offered All-Wheel Drive (AWD) - check manual for specifics. ๐ Dimensions Exterior Body Styles: 4-door Sedan Weights Curb Weight Range: Approx. 1300-1500 kg (depending on engine and trim) Gross Vehicle Weight Rating: Refer to vehicle's compliance plate or manual for specific GVWR. ๐ก๏ธ Safety Features Ratings Crash Test Performance: Varies by region and testing agency. Check specific regional safety reports for NHTSA or Euro NCAP data for the period. Active Features Available Active Safety: Anti-lock Braking System (ABS), Traction Control System (TCS - typically on higher trims or V6 models). Passive Features Available Passive Safety: Driver and passenger airbags, seatbelt pre-tensioners. ๐ก Technology Features Infotainment Infotainment Systems: Basic AM/FM/Cassette or CD players, optional premium audio systems. Navigation was rare and typically aftermarket or very high-end dealer options for this era. Driver Assistance Available Driver Assistance: Cruise control was standard on most models. ABS and TCS were the primary electronic driver aids. Connectivity Connectivity Features: Limited to basic accessory power outlets. No integrated Bluetooth or USB connectivity in stock form. ๐ง Maintenance Service Intervals Oil Change Interval: Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions. Consult manual for exact recommendations. Timing Belt Replacement: Critical for 4G63 and 6G72 engines. Recommended replacement every 60,000-90,000 miles (96,000-144,000 km). Failure can cause catastrophic engine damage. Manual will specify exact interval and procedure. Spark Plug Replacement: Intervals vary by plug type (copper, platinum, iridium). Consult manual for specific recommendations. Fluid Specifications Engine Oil Specification: SAE 5W-30 or 10W-30 API SG or higher. Consult manual for precise viscosity...
Mitsubishi Galant Workshop Service Repair Manual 1996-2003
๐ Introduction
Market Position
Vehicle Segment:
Mid-size Sedan (European/Japanese markets primarily)
Competitive Analysis
Competitors 1996-2003:
Honda Accord, Toyota Camry, Nissan Altima, Ford Mondeo, Mazda MX-6.
Key Features
Vehicle Selling Points:
Often praised for its distinctive styling (especially the coupe-like sedan profile), comfortable ride, and available V6 engines. Offered good value for money.
Manual Value Proposition
Manual Benefit:
Provides comprehensive, specific repair and maintenance guidance for owners and technicians, enabling confident DIY repairs and efficient professional servicing.
๐ Manual Details
Coverage Areas
Years Covered:
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Page Count
Estimated Page Count:
Extensive (specific number not provided, but indicated as comprehensive)
Refer to specific market/trim for optional availability (e.g., INVECS-II automatic for some markets).
Features
Transmission Features:
Front-wheel drive (FWD) standard. Some performance variants or specific markets may have offered All-Wheel Drive (AWD) - check manual for specifics.
๐ Dimensions
Exterior
Body Styles:
4-door Sedan
Weights
Curb Weight Range:
Approx. 1300-1500 kg (depending on engine and trim)
Gross Vehicle Weight Rating:
Refer to vehicle's compliance plate or manual for specific GVWR.
๐ก๏ธ Safety Features
Ratings
Crash Test Performance:
Varies by region and testing agency. Check specific regional safety reports for NHTSA or Euro NCAP data for the period.
Active Features
Available Active Safety:
Anti-lock Braking System (ABS), Traction Control System (TCS - typically on higher trims or V6 models).
Passive Features
Available Passive Safety:
Driver and passenger airbags, seatbelt pre-tensioners.
๐ก Technology Features
Infotainment
Infotainment Systems:
Basic AM/FM/Cassette or CD players, optional premium audio systems. Navigation was rare and typically aftermarket or very high-end dealer options for this era.
Driver Assistance
Available Driver Assistance:
Cruise control was standard on most models. ABS and TCS were the primary electronic driver aids.
Connectivity
Connectivity Features:
Limited to basic accessory power outlets. No integrated Bluetooth or USB connectivity in stock form.
๐ง Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions. Consult manual for exact recommendations.
Timing Belt Replacement:
Critical for 4G63 and 6G72 engines. Recommended replacement every 60,000-90,000 miles (96,000-144,000 km). Failure can cause catastrophic engine damage. Manual will specify exact interval and procedure.
Spark Plug Replacement:
Intervals vary by plug type (copper, platinum, iridium). Consult manual for specific recommendations.
Fluid Specifications
Engine Oil Specification:
SAE 5W-30 or 10W-30 API SG or higher. Consult manual for precise viscosity and API classification based on ambient temperature and engine type.
Coolant Specification:
Mitsubishi Diaqueen Super Long Life Coolant (or equivalent) with a 50/50 mix of antifreeze and distilled water. Check manual for color and type.
Transmission Fluid Automatic:
DIA QUEEN ATF-SP III (or equivalent). Critical to use the correct type to avoid transmission damage.
Transmission Fluid Manual:
Refer to manual for specific GL-4 or GL-5 gear oil specifications.
Known Issues
Common Wear Items:
CV joints, suspension components (bushings, ball joints), engine mounts, and exhaust systems can wear over time. Automatic transmission issues can arise if fluid maintenance is neglected.
Engine Specific Notes:
The 4G63 engine is generally robust, but early turbo variants may experience issues related to oil starvation or turbocharger wear if not maintained properly. Head gasket issues can occur on high-mileage examples of any engine.
๐ Vehicle History
Brand Heritage
Mitsubishi Reputation:
Mitsubishi has a long history of producing reliable and often innovative vehicles, with a strong presence in rally racing (Lancer Evolution) and robust four-wheel-drive technology.
Model Evolution
Galant Eighth Gen Key Changes:
The eighth generation marked a significant departure with more aerodynamic styling, improved interior comfort, and a focus on refinement. It offered a more upscale feel compared to some predecessors.
Production
Production Locations:
Primarily manufactured in Japan. Some assembly may have occurred in other regions depending on market.
Production Years Specific
Eighth Generation Production Years:
1994-2003 (model years often start a year earlier)
๐ Awards & Recognition
Recognitions
Consumer Ratings Period:
The eighth-generation Galant received mixed reviews upon release, with praise for styling and V6 power but criticism for ride quality and interior materials compared to some rivals. Specific awards are not widely documented for this model year range.