Mitsubishi Galant 2001 All Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Galant Year: 2001 Codes Chassis Code: CJ/CK/CM Series Engine Code Primary: 4G63 (2.0L SOHC) Engine Code Optional Usdm: 6G72 (3.0L SOHC V6) Transmission Code Primary: F4A41/42 (4-speed automatic) Transmission Code Manual Primary: KM223/224 (5-speed manual) 👋 Introduction Market Position Segment: Mid-size sedan Target Audience: DIY enthusiasts, independent repair shops, and owners seeking in-depth knowledge of their vehicle. Competitive Analysis Competitors 2001: Honda Accord, Toyota Camry, Nissan Altima, Ford Mondeo (Europe), Mazda 626. Key Features Vehicle Strengths 2001: Styling, comfortable ride, availability of V6 engine, reasonable reliability, good value for money. Manual Value Proposition: Empowers owners to perform complex maintenance and repairs, diagnose issues accurately, and maintain their vehicle to factory standards, saving money and ensuring longevity. 📋 Manual Details Coverage Areas Manual Type: Factory Service Manual / Repair Manual Language: English Format: Downloadable Digital File (PDF) Page Count: Approx. 1500-2000 Pages (estimated for comprehensive factory coverage) File Format File Type: PDF (Portable Document Format) Searchability: Searchable text for quick information retrieval. Printability: Printable for offline use and convenient reference in a workshop environment. Quality: High-resolution scans, ensuring clarity of text and diagrams. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing belt/chain, lubrication system, cooling system, fuel injection, exhaust system (excluding catalytic converter specifics). Engine Electrical: Ignition system, starter system, charging system, engine control module (ECM) diagnosis, sensors (crankshaft position, camshaft position, O2, MAP, TPS), actuators (idle control, fuel injectors). Transmission Automatic: Hydraulic control system, valve body, torque converter, planetary gear sets, solenoids, transmission control module (TCM) diagnosis, fluid and filter service. Transmission Manual: Clutch system, gear linkages, transmission gear sets, bearings, seals, fluid service. Brakes: Hydraulic system, ABS (Anti-lock Braking System) diagnosis and components, brake lines, master cylinder, calipers, pads, rotors, parking brake system. Suspension: Front and rear suspension components (struts, shocks, springs, control arms, ball joints, bushings), wheel alignment specifications. Steering: Power steering system (pump, rack and pinion, hoses), steering column, intermediate shaft, alignment specifications. Electrical System Chassis: 12V battery, alternator, starter, lighting systems (headlights, taillights, interior lights), wipers, horn, power windows, power locks, mirrors, fuses and relays. Body Interior Exterior: Door mechanisms, latches, handles, glass, body panels, trim, seats, dashboard, carpeting, headliner, HVAC (Heating, Ventilation, and Air Conditioning) system (evaporator, condenser, compressor, blower motor, refrigerant charging). Safety Systems: Airbag system (SRS) diagnosis and component replacement, seatbelt mechanisms. Procedures Included Routine Maintenance: Oil and filter changes, air filter replacement, spark plug replacement, coolant flush and fill, transmission fluid service, brake fluid service, power steering fluid service. Diagnostic Troubleshooting: Step-by-step diagnostic procedures for common and complex issues using diagnostic trouble codes (DTCs), visual inspections, and electrical testing. Component Removal Installation: Detailed instructions for removing and installing virtually every component covered by the manual, from engine parts to interior trim. Engine Rebuild: Comprehensive instructions for engine disassembly, inspection, measurement, and reassembly, including torque specifications. Transmission Overhaul: Detailed procedures for the disassembly, inspection, and reassembly of both automatic and manual transmissions. Brake System Repair: Brake bleeding procedures, caliper and master cylinder replacement, ABS component replacement. Suspension Steering Adjustment: Ball joint replacement, tie rod end replacement, power steering pump and rack replacement. Electrical Component Testing: Testing of sensors, actuators, relays, and wiring harnesses using multimeters and oscilloscopes. HVAC System Service: Refrigerant evacuation and charging, component replacement (compressor, condenser, evaporator), leak detection. Body Panel Replacement: Procedures for removing and installing fenders, doors, bumpers, and related trim. Technical Depth Depth Level: Comprehensive: Covers all aspects from basic fluid changes and checks to complete engine and transmission overhauls, including advanced diagnostics and electrical troubleshooting. Wiring Diagrams: Detailed electrical wiring diagrams for all major systems, including power distribution, engine control, lighting, and accessories. Special Tools: Identification and usage instructions for specialized tools required for specific repair procedures. Torque Specifications: Precise torque values for all critical fasteners in engine, transmission, chassis, and bodywork. Tolerances Measurements: Specifications for component wear limits and critical measurements for engine and transmission parts. Diagnostic Charts: Troubleshooting flowcharts and symptom-based diagnostic trees. ⚙️ Engine Specifications Primary Engine Engine Type Primary: Inline 4-cylinder, DOHC (Double Overhead Camshafts) Displacement Primary: 1997 cc (2.0 Liters) Bore X Stroke Primary: 86.0 mm x 86.0 mm Compression Ratio Primary: 9.5:1 (estimated) Horsepower Primary: 140 hp @ 6000 rpm (approx.) Torque Primary: 137 lb-ft @ 4500 rpm (approx.) Optional Engine Usdm Engine Type Optional Usdm: V-type 6-cylinder, SOHC (Single Overhead Camshaft) Displacement Optional Usdm: 2972 cc (3.0 Liters) Bore X Stroke Optional Usdm: 86.0 mm x 86.0 mm Compression Ratio Optional Usdm: 8.8:1 (estimated) Horsepower Optional Usdm: 195 hp @ 5500 rpm (approx.) Torque Optional Usdm: 207 lb-ft @ 4500 rpm (approx.) Fuel System Fuel Delivery System: Electronic Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Recommended Octane: 87 Octane (minimum) for 4-cylinder,...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Galant

Year:

Codes

Chassis Code:

CJ/CK/CM Series

Engine Code Primary:

4G63 (2.0L SOHC)

Engine Code Optional Usdm:

6G72 (3.0L SOHC V6)

Transmission Code Primary:

F4A41/42 (4-speed automatic)

Transmission Code Manual Primary:

KM223/224 (5-speed manual)

👋 Introduction

Market Position

Segment:

Mid-size sedan

Target Audience:

DIY enthusiasts, independent repair shops, and owners seeking in-depth knowledge of their vehicle.

Competitive Analysis

Competitors 2001:

Honda Accord, Toyota Camry, Nissan Altima, Ford Mondeo (Europe), Mazda 626.

Key Features

Vehicle Strengths 2001:

Styling, comfortable ride, availability of V6 engine, reasonable reliability, good value for money.

Manual Value Proposition:

Empowers owners to perform complex maintenance and repairs, diagnose issues accurately, and maintain their vehicle to factory standards, saving money and ensuring longevity.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Manual / Repair Manual

Language:

English

Format:

Downloadable Digital File (PDF)

Page Count:

Approx. 1500-2000 Pages (estimated for comprehensive factory coverage)

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Searchable text for quick information retrieval.

Printability:

Printable for offline use and convenient reference in a workshop environment.

Quality:

High-resolution scans, ensuring clarity of text and diagrams.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing belt/chain, lubrication system, cooling system, fuel injection, exhaust system (excluding catalytic converter specifics).

Engine Electrical:

Ignition system, starter system, charging system, engine control module (ECM) diagnosis, sensors (crankshaft position, camshaft position, O2, MAP, TPS), actuators (idle control, fuel injectors).

Transmission Automatic:

Hydraulic control system, valve body, torque converter, planetary gear sets, solenoids, transmission control module (TCM) diagnosis, fluid and filter service.

Transmission Manual:

Clutch system, gear linkages, transmission gear sets, bearings, seals, fluid service.

Brakes:

Hydraulic system, ABS (Anti-lock Braking System) diagnosis and components, brake lines, master cylinder, calipers, pads, rotors, parking brake system.

Suspension:

Front and rear suspension components (struts, shocks, springs, control arms, ball joints, bushings), wheel alignment specifications.

Steering:

Power steering system (pump, rack and pinion, hoses), steering column, intermediate shaft, alignment specifications.

Electrical System Chassis:

12V battery, alternator, starter, lighting systems (headlights, taillights, interior lights), wipers, horn, power windows, power locks, mirrors, fuses and relays.

Body Interior Exterior:

Door mechanisms, latches, handles, glass, body panels, trim, seats, dashboard, carpeting, headliner, HVAC (Heating, Ventilation, and Air Conditioning) system (evaporator, condenser, compressor, blower motor, refrigerant charging).

Safety Systems:

Airbag system (SRS) diagnosis and component replacement, seatbelt mechanisms.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter replacement, spark plug replacement, coolant flush and fill, transmission fluid service, brake fluid service, power steering fluid service.

Diagnostic Troubleshooting:

Step-by-step diagnostic procedures for common and complex issues using diagnostic trouble codes (DTCs), visual inspections, and electrical testing.

Component Removal Installation:

Detailed instructions for removing and installing virtually every component covered by the manual, from engine parts to interior trim.

Engine Rebuild:

Comprehensive instructions for engine disassembly, inspection, measurement, and reassembly, including torque specifications.

Transmission Overhaul:

Detailed procedures for the disassembly, inspection, and reassembly of both automatic and manual transmissions.

Brake System Repair:

Brake bleeding procedures, caliper and master cylinder replacement, ABS component replacement.

Suspension Steering Adjustment:

Ball joint replacement, tie rod end replacement, power steering pump and rack replacement.

Electrical Component Testing:

Testing of sensors, actuators, relays, and wiring harnesses using multimeters and oscilloscopes.

HVAC System Service:

Refrigerant evacuation and charging, component replacement (compressor, condenser, evaporator), leak detection.

Body Panel Replacement:

Procedures for removing and installing fenders, doors, bumpers, and related trim.

Technical Depth

Depth Level:

Comprehensive: Covers all aspects from basic fluid changes and checks to complete engine and transmission overhauls, including advanced diagnostics and electrical troubleshooting.

Wiring Diagrams:

Detailed electrical wiring diagrams for all major systems, including power distribution, engine control, lighting, and accessories.

Special Tools:

Identification and usage instructions for specialized tools required for specific repair procedures.

Torque Specifications:

Precise torque values for all critical fasteners in engine, transmission, chassis, and bodywork.

Tolerances Measurements:

Specifications for component wear limits and critical measurements for engine and transmission parts.

Diagnostic Charts:

Troubleshooting flowcharts and symptom-based diagnostic trees.

⚙️ Engine Specifications

Primary Engine

Engine Type Primary:

Inline 4-cylinder, DOHC (Double Overhead Camshafts)

Displacement Primary:

1997 cc (2.0 Liters)

Bore X Stroke Primary:

86.0 mm x 86.0 mm

Compression Ratio Primary:

9.5:1 (estimated)

Horsepower Primary:

140 hp @ 6000 rpm (approx.)

Torque Primary:

137 lb-ft @ 4500 rpm (approx.)

Optional Engine Usdm

Engine Type Optional Usdm:

V-type 6-cylinder, SOHC (Single Overhead Camshaft)

Displacement Optional Usdm:

2972 cc (3.0 Liters)

Bore X Stroke Optional Usdm:

86.0 mm x 86.0 mm

Compression Ratio Optional Usdm:

8.8:1 (estimated)

Horsepower Optional Usdm:

195 hp @ 5500 rpm (approx.)

Torque Optional Usdm:

207 lb-ft @ 4500 rpm (approx.)

Fuel System

Fuel Delivery System:

Electronic Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded Gasoline

Recommended Octane:

87 Octane (minimum) for 4-cylinder, 89 Octane (recommended) for V6

🔧 Transmission

Standard

Transmission Type Standard:

5-speed Manual

Optional

Transmission Type Optional:

4-speed Automatic with Overdrive

Features

Clutch Type:

Dry single plate (manual transmission)

Transmission Fluid Type Auto:

DIAQueen ATF SP-III or equivalent (check manual for exact specs)

Transmission Fluid Capacity Auto:

Approx. 7.5-8.0 liters (total fill, subject to variation)

Transmission Fluid Type Manual:

API GL-4, SAE 75W-90 (check manual for exact specs)

Transmission Fluid Capacity Manual:

Approx. 2.2 liters (subject to variation)

📐 Dimensions

Exterior

Length:

4750 mm (187.0 in)

Width:

1775 mm (69.9 in)

Height:

1425 mm (56.1 in) (4-cyl) / 1435 mm (56.5 in) (V6)

Wheelbase:

2700 mm (106.3 in)

Front Track:

1515 mm (59.6 in)

Rear Track:

1505 mm (59.3 in)

Cargo

Trunk Volume:

Approx. 480 liters (17.0 cu ft) (estimated)

Weights

Curb Weight 4Cyl Manual:

Approx. 1410 kg (3108 lbs)

Curb Weight V6 Auto:

Approx. 1540 kg (3395 lbs)

Gross Vehicle Weight Rating:

Varies by trim and configuration (refer to vehicle placard).

🛡️ Safety Features

Ratings

NHTSA Front Driver Impact:

Good (refer to specific model year and testing data for definitive ratings).

NHTSA Front Passenger Impact:

Good (refer to specific model year and testing data for definitive ratings).

IIHS Side Impact:

Acceptable (refer to specific model year and testing data for definitive ratings).

Active Features

Standard on most trims, optional on base models.

Traction Control:

Optional on V6 models.

Passive Features

Airbags Front:

Driver and front passenger airbags (SRS).

Seatbelts:

Three-point seatbelts with pretensioners for front occupants.

Child Seat Anchors:

LATCH system (Lower Anchors and Tethers for CHildren) typically present.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with CD player and cassette player (optional premium sound system available on higher trims).

Display:

Basic digital clock and radio display. No integrated navigation or color screens on base models.

Driver Assistance

Cruise Control:

Standard on most trims.

Connectivity

Auxiliary Input:

Not standard. Aftermarket solutions typically required for modern device connectivity.

Bluetooth:

Not available from factory.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 7,500 miles or 6 months (using synthetic oil), or 3,750 miles / 3 months with conventional oil and severe driving conditions.

Air Filter Replacement:

Every 30,000 miles or as needed based on driving environment.

Spark Plug Replacement 4Cyl:

Every 60,000 miles (Iridium-tipped spark plugs recommended).

Spark Plug Replacement V6:

Every 60,000 miles (Iridium-tipped spark plugs recommended).

Timing Belt Replacement:

Every 90,000 - 105,000 miles or 7 years (critical for 4G63 engine to prevent catastrophic damage).

Coolant Flush Replace:

Every 30,000 miles or 2 years.

Fluid Specifications

Engine Oil Viscosity:

SAE 5W-30 (preferred), SAE 10W-30 acceptable.

Engine Oil Capacity:

4.2 US quarts (4.0 liters) with filter for 4-cylinder; 4.5 US quarts (4.3 liters) with filter for V6.

Coolant Type:

Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based antifreeze).

Known Issues

Common Issues 4Cyl Engine:

Timing belt failure (if not replaced on schedule), occasional oil leaks from valve cover gasket or oil pan, intake manifold gasket leaks.

Common Issues V6 Engine:

Timing belt failure (critical maintenance), rear main seal oil leaks, occasional rough idle due to vacuum leaks or spark plug issues.

Common Issues Transmission:

Automatic transmission clutch pack wear (especially in high-mileage vehicles), occasional transmission fluid leaks.

Common Issues Suspension:

Worn control arm bushings, strut mount failure, tie rod end wear leading to steering looseness.

Common Issues Electrical:

Power window motor failure, intermittent gauge cluster issues, alternator failure.

Common Issues HVAC:

Blend door actuator failure (affecting temperature control), refrigerant leaks.

📚 Vehicle History

Brand Heritage

Mitsubishi Motors History:

Founded in 1970 as a spin-off from Mitsubishi Heavy Industries, known for engineering prowess and diverse product lines.

Model Evolution

Galant Generations:

This 2001 model belongs to the 8th generation (1996-2003), which introduced a more distinctive styling and platform improvements.

8Th Gen Facelifts:

The 8th generation received a facelift for the 2001 model year, featuring updated front and rear styling, improved interior amenities, and revised powertrain options.

Production

Manufacturing Locations:

Primary production in Japan (Mizushima Plant) and North America (Normal, Illinois, USA).

Production Years 8Th Gen:

1996-2003

🏆 Awards & Recognition

Recognitions

Jdpowers Initial Quality:

Variable, but typically ranked in the mid-to-upper tier for its class in the early 2000s.

Ratings

Consumer Reports Reliability:

Generally considered average to good, with specific model years and powertrains showing better reliability than others. The 4G63 engine is known for its robustness.

Certifications

Emission Standards:

Meets EPA emission standards for its model year.