Mitsubishi Galant Legnum Aspire Service Repair Manual 1996-2003
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🏷️ Basic Information Identification Make: Mitsubishi Model: Galant Legnum Aspire Model Variant: Legnum Aspire Year Range Covered: 1996-2003 👋 Introduction Market Position Target Audience: Owners of Mitsubishi Galant Legnum Aspire models (1996-2003) seeking to perform maintenance, diagnostics, and repairs. Competitive Analysis Advantage Over Factory Cd: Digital accessibility, no physical media requirement, potentially lower cost compared to official CD-ROMs. Key Features Digital Delivery: Instant email delivery, eliminating shipping wait times and costs. Visual Aids: Includes numerous pictures and diagrams to aid in understanding procedures. 📋 Manual Details Coverage Areas Primary Coverage: Complete workshop service and repair information Regional Applicability: Likely global, assuming common specifications for the model range Page Count Estimated Page Count: Extensive (Likely 1000+ pages based on typical workshop manuals for this era) Manual Type Type: Workshop Service and Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Full engine overhaul, rebuild procedures, component testing, timing belt/chain replacement, lubrication, cooling system, fuel system (injection, pumps, injectors, filters), exhaust system. Transmission Drivetrain: Automatic and manual transmission service, rebuild, fluid changes, clutch service, drive shafts, differentials. Suspension Steering: Front and rear suspension components, shock absorbers, struts, springs, control arms, ball joints, wheel bearings, steering rack, power steering system, alignment specifications. Brakes: Brake system diagnostics, repair, pad and rotor replacement, caliper service, hydraulic system, ABS system troubleshooting and repair. Electrical Electronics: Complete electrical system schematics, wiring diagrams, starter, alternator, battery, lighting systems, power windows, mirrors, central locking, instrument cluster, audio system. Heating Air Conditioning: HVAC system diagnosis, repair, refrigerant handling, blower motor, evaporator, condenser, climate control unit. Emission Control: Emission control systems, catalytic converter, oxygen sensors, EGR system, EVAP system, diagnostic trouble codes (DTCs). Body Chassis: Body panel repair, interior trim, doors, glass, bumpers, structural components, rust repair considerations. Procedures Included Maintenance: Scheduled maintenance, fluid changes, filter replacements, lubrication, spark plug replacement, belt inspections. Troubleshooting: Diagnostic procedures for various systems, symptom-based troubleshooting guides, common fault finding. Repair Rebuild: Step-by-step repair instructions for all major components, engine and transmission rebuilds, suspension and brake component replacement. Technical Specifications: Torque specifications, clearances, fluid capacities, wiring diagrams, diagnostic data. Technical Depth Depth: Comprehensive workshop level, suitable for both DIY enthusiasts and professional mechanics. 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Searchability: Likely searchable text (OCR'd content), enabling quick information retrieval. Print Quality Printable: Fully printable by section or in its entirety. Binding Type Binding: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Codes Typical: 4G93 (1.8L I4), 4G94 (2.0L I4), 6A12 (2.0L V6), 6A13 (2.5L V6). Specific engine depends on Legnum variant and market. Aspire trim often featured V6 engines. Performance Horsepower Range Typical: Approximately 120-150 hp for 4-cylinder engines, 140-170 hp for naturally aspirated V6 engines, and potentially higher for turbocharged variants (e.g., VR-4 models, though Aspire usually focused on non-turbo). Torque Range Typical: Varies significantly with engine displacement and configuration, but generally in the 130-200 lb-ft range for naturally aspirated engines. Fuel System Injection Type: Electronic Fuel Injection (EFI) with multi-point injection (MPI) or direct injection (GDI) on later models. Maintenance Timing Belt Replacement Interval: Typically 60,000 to 100,000 miles or 5-7 years, depending on engine and specific model. Crucial for interference engines. Oil Capacity Typical: 4.5 - 5.5 liters (approx. 4.7 - 5.8 US quarts) for 4-cylinder, 5.0 - 6.0 liters (approx. 5.3 - 6.3 US quarts) for V6 engines, depending on filter. Always verify with manual. Recommended Oil Viscosity: Often 5W-30 or 10W-30 API SN or higher. Varies by climate and engine. Manual will specify exact grade. 🔧 Transmission Standard Transmission Options: Available with both 5-speed manual and 4-speed automatic transmissions. Automatic often featured INVECS-II Sport Mode. Optional All Wheel Drive: Certain Legnum variants, particularly those based on the Galant VR-4 platform (though Aspire typically front-wheel drive), offered All-Wheel Drive (AWD) systems. Manual should cover AWD specifics if applicable to the model variant. Features Automatic Transmission Control: INVECS-II (Intelligent & Innovative Vehicle Electronic Control system) for adaptive shifting and sport mode. Maintenance Automatic Transmission Fluid Type: Typically DiaQueen SP-II or equivalent ATF. Manual will provide exact specification and change interval. 📐 Dimensions Exterior Body Style: Station Wagon (Estate) Wheelbase Approx: 2635 mm (103.7 inches) Length Approx: 4640 mm (182.7 inches) Width Approx: 1730 mm (68.1 inches) Height Approx: 1470 mm (57.9 inches) Weights Curb Weight Approx: 1400-1600 kg (3086-3527 lbs), depending on engine and transmission. 🛡️ Safety Features Ratings Crash Test Ratings: Varies by market and year. Older models may not have comparable modern ratings. Consult specific market safety reports. Active Features ABS: Standard on Aspire trims. Traction Control: Available on some higher-spec models, particularly AWD variants. Passive Features Airbags: Driver and passenger front airbags standard. Side airbags optional or standard on later models. Seatbelts: Front seatbelt pretensioners. 💡 Technology Features Infotainment Audio System:...
Front and rear suspension components, shock absorbers, struts, springs, control arms, ball joints, wheel bearings, steering rack, power steering system, alignment specifications.
Brakes:
Brake system diagnostics, repair, pad and rotor replacement, caliper service, hydraulic system, ABS system troubleshooting and repair.
Electrical Electronics:
Complete electrical system schematics, wiring diagrams, starter, alternator, battery, lighting systems, power windows, mirrors, central locking, instrument cluster, audio system.
Heating Air Conditioning:
HVAC system diagnosis, repair, refrigerant handling, blower motor, evaporator, condenser, climate control unit.
Comprehensive workshop level, suitable for both DIY enthusiasts and professional mechanics.
📊 Manual Specifications
File Format
File Type:
Portable Document Format (PDF)
Searchability:
Likely searchable text (OCR'd content), enabling quick information retrieval.
Print Quality
Printable:
Fully printable by section or in its entirety.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Codes Typical:
4G93 (1.8L I4), 4G94 (2.0L I4), 6A12 (2.0L V6), 6A13 (2.5L V6). Specific engine depends on Legnum variant and market. Aspire trim often featured V6 engines.
Performance
Horsepower Range Typical:
Approximately 120-150 hp for 4-cylinder engines, 140-170 hp for naturally aspirated V6 engines, and potentially higher for turbocharged variants (e.g., VR-4 models, though Aspire usually focused on non-turbo).
Torque Range Typical:
Varies significantly with engine displacement and configuration, but generally in the 130-200 lb-ft range for naturally aspirated engines.
Fuel System
Injection Type:
Electronic Fuel Injection (EFI) with multi-point injection (MPI) or direct injection (GDI) on later models.
Maintenance
Timing Belt Replacement Interval:
Typically 60,000 to 100,000 miles or 5-7 years, depending on engine and specific model. Crucial for interference engines.
Oil Capacity Typical:
4.5 - 5.5 liters (approx. 4.7 - 5.8 US quarts) for 4-cylinder, 5.0 - 6.0 liters (approx. 5.3 - 6.3 US quarts) for V6 engines, depending on filter. Always verify with manual.
Recommended Oil Viscosity:
Often 5W-30 or 10W-30 API SN or higher. Varies by climate and engine. Manual will specify exact grade.
🔧 Transmission
Standard
Transmission Options:
Available with both 5-speed manual and 4-speed automatic transmissions. Automatic often featured INVECS-II Sport Mode.
Optional
All Wheel Drive:
Certain Legnum variants, particularly those based on the Galant VR-4 platform (though Aspire typically front-wheel drive), offered All-Wheel Drive (AWD) systems. Manual should cover AWD specifics if applicable to the model variant.
Features
Automatic Transmission Control:
INVECS-II (Intelligent & Innovative Vehicle Electronic Control system) for adaptive shifting and sport mode.
Maintenance
Automatic Transmission Fluid Type:
Typically DiaQueen SP-II or equivalent ATF. Manual will provide exact specification and change interval.
📐 Dimensions
Exterior
Body Style:
Station Wagon (Estate)
Wheelbase Approx:
2635 mm (103.7 inches)
Length Approx:
4640 mm (182.7 inches)
Width Approx:
1730 mm (68.1 inches)
Height Approx:
1470 mm (57.9 inches)
Weights
Curb Weight Approx:
1400-1600 kg (3086-3527 lbs), depending on engine and transmission.
🛡️ Safety Features
Ratings
Crash Test Ratings:
Varies by market and year. Older models may not have comparable modern ratings. Consult specific market safety reports.
Active Features
ABS:
Standard on Aspire trims.
Traction Control:
Available on some higher-spec models, particularly AWD variants.
Passive Features
Airbags:
Driver and passenger front airbags standard. Side airbags optional or standard on later models.
Seatbelts:
Front seatbelt pretensioners.
💡 Technology Features
Infotainment
Audio System:
Factory-equipped AM/FM/CD/Cassette players. Options for premium sound systems (e.g., Rockford Fosgate) on higher trims.
Climate Control:
Manual or automatic climate control systems depending on trim level. Digital climate control on premium variants.
Driver Assistance
Cruise Control:
Standard on most Aspire trims.
Keyless Entry:
Available as an option or standard on higher trims.
Connectivity
Internet Connectivity:
N/A (Vehicle era predates widespread internet connectivity in automotive systems).
🔧 Maintenance
Service Intervals
Oil And Filter Change:
Typically every 7,500 to 10,000 miles (12,000 to 16,000 km) or 6-12 months, whichever comes first. Consult manual for specific recommendations based on driving conditions.
Air Filter Replacement:
Recommended every 15,000 to 30,000 miles (24,000 to 48,000 km) or as needed based on inspection.
Cabin Air Filter:
If equipped, typically every 12,000 to 20,000 miles (19,000 to 32,000 km).
Fluid Specifications
Coolant Type:
Mitsubishi Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based antifreeze. Manual will specify color and type.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid, depending on ABS system. Manual will confirm.
Known Issues
Engine Component:
Timing belt wear (critical on V6 engines), potential for oil leaks from valve cover gaskets and oil pan.
Transmission Component:
Automatic transmission solenoid issues or wear in higher mileage vehicles. Manual transmission clutch wear.
Suspension Component:
Wear in control arm bushings and ball joints leading to knocking sounds or poor handling. Strut mounts can also fail.
Electrical Component:
Corrosion on electrical connectors, particularly ground points. Window regulator motors can fail.
Body Component:
Rust formation in common areas like wheel arches, rocker panels, and rear hatch, especially in corrosive climates.
📚 Vehicle History
Brand Heritage
Mitsubishi Legacy:
Mitsubishi Motors, a Japanese automotive manufacturer with a history dating back to 1917, known for durable and reliable vehicles across various segments.
Model Evolution
Galant Lineage:
The Galant is a long-standing model line for Mitsubishi, evolving through numerous generations. The Legnum was a station wagon variant of the eighth-generation Galant (E50/E60/E70/E80 chassis), introduced in 1996 as a successor to the Lancer Station Wagon.
Production
Manufacturing Locations:
Primarily Japan. Some markets may have received locally assembled units.
Model Production Period:
Eighth-generation Galant and Legnum production ran from 1996 to 2003. The Legnum was a unique model to the Japanese market and specific export regions, not always sold concurrently with all Galant sedan variants globally.
🏆 Awards & Recognition
Recognitions
Model Accolades:
While specific awards for the Legnum Aspire trim are not widely publicized, the eighth-generation Galant platform was generally well-regarded for its comfortable ride, refined styling, and competent V6 engines. Mitsubishi vehicles of this era were often noted for reliability and value.
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