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Mitsubishi Galant 1996 Full Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Galant Year: 1996 Codes Chassis Code: E30, E33, E34, E35, E38, E39, E3A (varies by market and specific chassis designation) Engine Code Primary: 4G63 (2.0L SOHC/DOHC) Engine Code Secondary: 6G72 (3.0L V6 SOHC) 👋 Introduction Market Position Positioning: The 1996 Mitsubishi Galant was a mid-size sedan positioned as a practical, reliable, and stylish family car with a focus on value and accessible performance, particularly in its sporty GS trims. Competitive Analysis Competitors: Competed against vehicles such as the Honda Accord, Toyota Camry, Nissan Altima, Ford Taurus, and Chevrolet Lumina. Key Features Design: Aerodynamic styling, comfortable interior, available with front-wheel drive or optional all-wheel drive (AWD) on select models (e.g., AWD GS). Engine Options: Offered with a robust 2.4L 4-cylinder engine and a smooth 3.0L V6, providing a range of performance choices. 📋 Manual Details Coverage Areas Primary Coverage: North American and Global Markets Secondary Coverage: Specific regional variants might have minor differences noted Page Count Estimated Page Count: 1500-2500 (typical for a comprehensive service manual) Manual Type Type: Full Service & Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine (4G63, 6G72), Transmission (Manual & Automatic), Drivetrain, Fuel System, Exhaust System Chassis: Suspension (Front & Rear), Steering System, Brake System, Wheel & Tire Service Electrical: Ignition System, Lighting, Instrumentation, Power Accessories, HVAC Controls, Engine Control Unit (ECU) Diagnostics Body: Exterior Body Panels, Interior Trim, Glass, Doors, Seats, Restraints (SRS) Procedures Included Maintenance: Routine maintenance checks, fluid changes, filter replacements, lubrication, timing belt replacement Repair: Component disassembly, assembly, replacement, and adjustment for all major systems Troubleshooting: Diagnostic procedures, symptom-based troubleshooting charts, electrical circuit diagrams Diagnostics: On-board diagnostics (OBD-I) interpretation, sensor testing, actuator testing Technical Depth Depth: Comprehensive: From basic fluid checks and filter changes to full engine and transmission rebuilds, including detailed electrical diagnostics and bodywork repair. 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchability: Typically text-searchable within the PDF for quick information retrieval Print Quality Quality: High-resolution scans suitable for printing key sections or the entire manual Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Code: 4G63 Displacement: 2351 cc (2.4 Liters) Configuration: Inline 4-cylinder, DOHC (Dual Overhead Camshaft), 16 valves Horsepower Est: 140 hp @ 5500 rpm Torque Est: 144 lb-ft @ 4500 rpm Fuel Induction: Multi-port Fuel Injection (MPI) Secondary Engine Engine Code: 6G72 Displacement: 2972 cc (3.0 Liters) Configuration: V6, SOHC (Single Overhead Camshaft), 24 valves Horsepower Est: 175 hp @ 5500 rpm Torque Est: 180 lb-ft @ 4500 rpm Fuel Induction: Multi-port Fuel Injection (MPI) Fuel System Type: Electronic Fuel Injection (EFI) Octane Rating: 87 Octane (minimum recommended, 91 for optimal performance in V6) 🔧 Transmission Standard Type 4Cyl: 5-speed Manual Type V6: 4-speed Automatic (INVECS-II) Optional Type 4Cyl: 4-speed Automatic (INVECS-II) Type V6 AWD: 4-speed Automatic (INVECS-II) with All-Wheel Drive (AWD) Features AWD System: Optional Active All-Wheel Drive (AWD) system with viscous coupling on certain trims, particularly the AWD GS. Fluid Specifications Automatic Fluid Type: Mitsubishi DiaQueen SP-III or equivalent Dexron-III ATF Manual Fluid Type: API GL-4 Gear Oil (SAE 75W-90 or 80W-90 recommended) 📐 Dimensions Exterior Length Est: 4700-4750 mm (185-187 inches) Width Est: 1750-1770 mm (68.9-69.7 inches) Height Est: 1390-1420 mm (54.7-55.9 inches) Wheelbase Est: 2640-2670 mm (103.9-105.1 inches) Weights Curb Weight Est Min: 1300 kg (2866 lbs) Curb Weight Est Max: 1550 kg (3417 lbs) 🛡️ Safety Features Ratings NHTSA Front Impact: Likely 3-star or 4-star (typical for the era, documentation may vary) Active Features ABS: Available Anti-lock Braking System (ABS) on most models, standard on higher trims. Passive Features Airbags: Driver and passenger front airbags standard on most trims. Seatbelts: Front and rear three-point seatbelts, pre-tensioners for front seatbelts. Structure: Reinforced body structure with crumple zones. 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with cassette player, optional CD player available on higher trims. Basic speaker configurations. Driver Assistance Cruise Control: Electronic cruise control standard on most trims. Climate Control: Manual air conditioning and heating, with optional automatic climate control on some V6 models. Connectivity Connectivity Features: Limited to basic audio connectivity (cassette/CD). No modern Bluetooth or USB integration. 🔧 Maintenance Service Intervals Oil Change Interval: Every 3,750-7,500 miles (6,000-12,000 km) or 6-12 months, depending on driving conditions (refer to manual for specific recommendations). Air Filter Replacement: Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection. Timing Belt Replacement: Critical: Typically every 60,000 miles (96,000 km) or 4 years for the 4G63 engine (non-interference potential varies, but recommended replacement is vital). Spark Plug Replacement: Every 30,000-60,000 miles (48,000-96,000 km) depending on plug type. Fluid Specifications Engine Oil Type: API SJ or higher, SAE 5W-30 or 5W-40 recommended (check owner's manual for climate-specific viscosity). Coolant Type: Ethylene glycol-based coolant,...
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Mitsubishi Galant 1996 Full Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Galant
Year:
1996
Codes
Chassis Code:
E30, E33, E34, E35, E38, E39, E3A (varies by market and specific chassis designation)
Engine Code Primary:
4G63 (2.0L SOHC/DOHC)
Engine Code Secondary:
6G72 (3.0L V6 SOHC)
👋 Introduction
Market Position
Positioning:
The 1996 Mitsubishi Galant was a mid-size sedan positioned as a practical, reliable, and stylish family car with a focus on value and accessible performance, particularly in its sporty GS trims.
Competitive Analysis
Competitors:
Competed against vehicles such as the Honda Accord, Toyota Camry, Nissan Altima, Ford Taurus, and Chevrolet Lumina.
Key Features
Design:
Aerodynamic styling, comfortable interior, available with front-wheel drive or optional all-wheel drive (AWD) on select models (e.g., AWD GS).
Engine Options:
Offered with a robust 2.4L 4-cylinder engine and a smooth 3.0L V6, providing a range of performance choices.
📋 Manual Details
Coverage Areas
Primary Coverage:
North American and Global Markets
Secondary Coverage:
Specific regional variants might have minor differences noted
Page Count
Estimated Page Count:
1500-2500 (typical for a comprehensive service manual)
Manual Type
Type:
Full Service & Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (4G63, 6G72), Transmission (Manual & Automatic), Drivetrain, Fuel System, Exhaust System
Chassis:
Suspension (Front & Rear), Steering System, Brake System, Wheel & Tire Service
Electrical:
Ignition System, Lighting, Instrumentation, Power Accessories, HVAC Controls, Engine Control Unit (ECU) Diagnostics
Body:
Exterior Body Panels, Interior Trim, Glass, Doors, Seats, Restraints (SRS)
Procedures Included
Maintenance:
Routine maintenance checks, fluid changes, filter replacements, lubrication, timing belt replacement
Repair:
Component disassembly, assembly, replacement, and adjustment for all major systems
Troubleshooting:
Diagnostic procedures, symptom-based troubleshooting charts, electrical circuit diagrams
Diagnostics:
On-board diagnostics (OBD-I) interpretation, sensor testing, actuator testing
Technical Depth
Depth:
Comprehensive: From basic fluid checks and filter changes to full engine and transmission rebuilds, including detailed electrical diagnostics and bodywork repair.
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Searchability:
Typically text-searchable within the PDF for quick information retrieval
Print Quality
Quality:
High-resolution scans suitable for printing key sections or the entire manual
Binding Type
Binding:
N/A (Digital PDF format)
Paper Type
Paper Type:
N/A (Digital PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
4G63
Displacement:
2351 cc (2.4 Liters)
Configuration:
Inline 4-cylinder, DOHC (Dual Overhead Camshaft), 16 valves
Horsepower Est:
140 hp @ 5500 rpm
Torque Est:
144 lb-ft @ 4500 rpm
Fuel Induction:
Multi-port Fuel Injection (MPI)
Secondary Engine
Engine Code:
6G72
Displacement:
2972 cc (3.0 Liters)
Configuration:
V6, SOHC (Single Overhead Camshaft), 24 valves
Horsepower Est:
175 hp @ 5500 rpm
Torque Est:
180 lb-ft @ 4500 rpm
Fuel Induction:
Multi-port Fuel Injection (MPI)
Fuel System
Type:
Electronic Fuel Injection (EFI)
Octane Rating:
87 Octane (minimum recommended, 91 for optimal performance in V6)
🔧 Transmission
Standard
Type 4Cyl:
5-speed Manual
Type V6:
4-speed Automatic (INVECS-II)
Optional
Type 4Cyl:
4-speed Automatic (INVECS-II)
Type V6 AWD:
4-speed Automatic (INVECS-II) with All-Wheel Drive (AWD)
Features
AWD System:
Optional Active All-Wheel Drive (AWD) system with viscous coupling on certain trims, particularly the AWD GS.
Fluid Specifications
Automatic Fluid Type:
Mitsubishi DiaQueen SP-III or equivalent Dexron-III ATF
Manual Fluid Type:
API GL-4 Gear Oil (SAE 75W-90 or 80W-90 recommended)
📐 Dimensions
Exterior
Length Est:
4700-4750 mm (185-187 inches)
Width Est:
1750-1770 mm (68.9-69.7 inches)
Height Est:
1390-1420 mm (54.7-55.9 inches)
Wheelbase Est:
2640-2670 mm (103.9-105.1 inches)
Weights
Curb Weight Est Min:
1300 kg (2866 lbs)
Curb Weight Est Max:
1550 kg (3417 lbs)
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Likely 3-star or 4-star (typical for the era, documentation may vary)
Active Features
ABS:
Available Anti-lock Braking System (ABS) on most models, standard on higher trims.
Passive Features
Airbags:
Driver and passenger front airbags standard on most trims.
Seatbelts:
Front and rear three-point seatbelts, pre-tensioners for front seatbelts.
Structure:
Reinforced body structure with crumple zones.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, optional CD player available on higher trims. Basic speaker configurations.
Driver Assistance
Cruise Control:
Electronic cruise control standard on most trims.
Climate Control:
Manual air conditioning and heating, with optional automatic climate control on some V6 models.
Connectivity
Connectivity Features:
Limited to basic audio connectivity (cassette/CD). No modern Bluetooth or USB integration.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750-7,500 miles (6,000-12,000 km) or 6-12 months, depending on driving conditions (refer to manual for specific recommendations).
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on inspection.
Timing Belt Replacement:
Critical: Typically every 60,000 miles (96,000 km) or 4 years for the 4G63 engine (non-interference potential varies, but recommended replacement is vital).
Spark Plug Replacement:
Every 30,000-60,000 miles (48,000-96,000 km) depending on plug type.
Fluid Specifications
Engine Oil Type:
API SJ or higher, SAE 5W-30 or 5W-40 recommended (check owner's manual for climate-specific viscosity).
Coolant Type:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Use long-life coolant if specified.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine 4G63:
Timing belt failure if not replaced on schedule (can cause interference damage), potential for oil leaks from valve cover gasket or oil pan.
Transmission Auto:
Hesitation or rough shifting can indicate low fluid, worn clutches, or solenoid issues. Regular fluid changes are crucial.
Suspension:
Worn front control arm bushings and ball joints, rear trailing arm bushings leading to alignment issues and noise.
Electrical:
Power window regulators, intermittent wiper switch issues, HVAC blower motor resistor failure.
Corrosion:
Rust can be an issue on rocker panels, wheel wells, and strut towers, especially in areas with road salt.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors:
Mitsubishi Motors Corporation, a Japanese multinational automotive manufacturer with a long history of engineering innovation and diverse product lines.
Model Evolution
Galant Generation:
This manual covers the sixth generation (E30 chassis) of the Mitsubishi Galant, produced from 1987-1993, with facelifts and updates extending into 1996 for certain markets. The 1996 model year represents the later part of this generation's lifecycle.
Production
Production Years:
1987-1993 (E30 generation primary production), with 1996 being a model year within this platform's extended availability or a specific market's continuation.
Manufacturing Locations:
Primarily Japan, with assembly also occurring in other international locations.
🏆 Awards & Recognition
Recognitions
Performance Awards:
While not a frequent award winner in its class, the Galant, especially the AWD GS variant with the 4G63 engine, was praised for its sporty handling and performance characteristics.
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