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Mitsubushi GALANT LEGNUM 1996-2002 Workshop Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Galant / Legnum Model Years Covered: 1996-2002 Codes Chassis Codes: E3_A (Galant Sedan/Coupe), EA_A (Galant Sedan/Hatchback), EC_A (Legnum Wagon) 👋 Introduction Market Position Vehicle Segment: Mid-size sedan (Galant) and station wagon (Legnum) known for their sporty styling and capable chassis, particularly the V6 models. Competitive Analysis Key Competitors: Toyota Camry, Honda Accord, Mazda 626/Mazda Atenza, Nissan Maxima/Altima, Subaru Legacy during its production run. Key Features Distinctive Attributes: Sporty 'Dynamic-Shape' design, available all-wheel drive (AWD) on some models, powerful V6 engines, and the unique Legnum wagon variant. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Language: English Format: Digital (likely PDF, based on common industry practice for this era of manual) Page Count Estimated Page Count: High volume, typically 1000+ pages for comprehensive workshop manuals of this era. 📖 Manual Coverage Systems Covered Engine Systems: Engine mechanicals (cylinder head, block, pistons, crankshaft, camshafts), fuel injection, ignition, cooling, lubrication, emission control systems, turbocharger systems (where applicable). Transmission Systems: Manual transmission (F5M42), Automatic transmission (F4Axx series, e.g., F4A51, F4A42), driveline components (axles, driveshafts, differentials). Brake Systems: Front and rear disc brakes, ABS (Anti-lock Braking System), brake hydraulics, parking brake. Suspension And Steering: Front suspension (MacPherson strut, multi-link), rear suspension (independent multi-link), power steering system, steering gear/rack. Electrical Systems: Battery, starting system, charging system, lighting systems (headlamps, taillamps, interior), instrument cluster, wiring diagrams, fuses, relays, power windows, mirrors, central locking, wipers, horn. Body And Chassis: Body panel repair, interior trim, exterior trim, chassis components, exhaust system, fuel tank, cooling system components, HVAC (Heating, Ventilation, and Air Conditioning) system. Procedures Included Maintenance Procedures: Oil changes, filter replacements, fluid checks and changes (coolant, brake fluid, transmission fluid, power steering fluid), spark plug replacement, air filter replacement, belt inspection and replacement. Repair Procedures: Engine overhaul (cylinder head gasket, piston rings, bearing replacement), transmission overhaul and replacement, brake caliper/rotor/pad replacement, suspension component replacement (struts, control arms, bushings), starter motor/alternator replacement, fuel pump replacement, radiator replacement, HVAC component repair. Troubleshooting Guides: Diagnostic procedures for common drivability issues, electrical faults, cooling system problems, transmission performance issues, and more, often including fault codes and symptom-based diagnosis. Diagnostics: On-board diagnostics (OBD-I/OBD-II), sensor testing, actuator testing, wiring harness continuity checks. Technical Depth Depth Of Coverage: Comprehensive, covering everything from routine maintenance and basic repairs to complex engine and transmission overhauls and in-depth electrical system diagnostics. 📊 Manual Specifications File Format File Type: PDF (typically) Searchability: Likely text-searchable for efficient information retrieval. Print Quality Image Resolution: High enough for clear diagrams and illustrations. Binding Type Binding: Not applicable for digital format; if physical, typically spiral-bound or comb-bound for lay-flat use. Paper Type Paper Quality: Not applicable for digital format; if physical, would be durable paper suitable for workshop environments. ⚙️ Engine Specifications Primary Engine Engine Family 4G63: 2.0L Inline-4 DOHC (potentially turbocharged in performance variants like the VR-4, though not explicitly stated in product info, it's common for this engine). Engine Family 6A13: 2.5L V6 SOHC/DOHC (known for smooth power delivery and a more sporting feel). Engine Family 4D68: 2.0L Inline-4 SOHC Turbocharged Diesel (less common in some markets, but offered for fuel efficiency). Engine Family 4G64: 2.4L Inline-4 SOHC (a reliable and common option for mainstream models). Performance Hp Range: Estimated 130-150 hp for naturally aspirated 4-cylinders, 170-200 hp for V6, and potentially 240-280 hp for turbo variants (if applicable). Torque Range: Torque figures vary significantly by engine, with V6 and turbo variants offering substantially more torque for better acceleration. Fuel System Injection Type: Multi-point Fuel Injection (MPI) or Direct Fuel Injection (DFI) depending on engine and specific model year/variant. 🔧 Transmission Standard Manual Transmission: F5M42 - 5-speed manual transmission, known for its durability and positive shift feel. Optional Automatic Transmission: F4Axx Series (e.g., F4A51, F4A42) - 4-speed automatic transmission, often with an overdrive gear for improved fuel economy. Features All Wheel Drive: Available on some performance-oriented models (e.g., Galant VR-4, Legnum VR-4), typically paired with a sophisticated AWD system, often an electronically controlled multi-plate clutch system. 📐 Dimensions Exterior Length Galant: Approx. 4600-4750 mm (depending on body style and market). Length Legnum: Approx. 4690-4750 mm (wagon variant). Width: Approx. 1740-1780 mm. Height: Approx. 1380-1420 mm (sedan), 1500-1550 mm (wagon). Weights Curb Weight: Approx. 1350-1600 kg (depending on engine, transmission, and features). 🛡️ Safety Features Ratings Crash Test Data: Information may vary by market and testing authority (e.g., NHTSA, Euro NCAP). Look for specific reports for the relevant year and region. Active Features ABS: Anti-lock Braking System (ABS) was often available or standard on higher trims and performance models. Traction Control: Traction Control System (TCS) was available on certain models, especially those with AWD. Passive Features Airbags: Driver and front passenger airbags were standard on most models by the later part of this production run. Seatbelts: Three-point front and rear seatbelts, with pre-tensioners...
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Mitsubushi GALANT LEGNUM 1996-2002 Workshop Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Galant / Legnum
Model Years Covered:
1996-2002
Codes
Chassis Codes:
E3_A (Galant Sedan/Coupe), EA_A (Galant Sedan/Hatchback), EC_A (Legnum Wagon)
👋 Introduction
Market Position
Vehicle Segment:
Mid-size sedan (Galant) and station wagon (Legnum) known for their sporty styling and capable chassis, particularly the V6 models.
Competitive Analysis
Key Competitors:
Toyota Camry, Honda Accord, Mazda 626/Mazda Atenza, Nissan Maxima/Altima, Subaru Legacy during its production run.
Key Features
Distinctive Attributes:
Sporty 'Dynamic-Shape' design, available all-wheel drive (AWD) on some models, powerful V6 engines, and the unique Legnum wagon variant.
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Repair Manual
Language:
English
Format:
Digital (likely PDF, based on common industry practice for this era of manual)
Page Count
Estimated Page Count:
High volume, typically 1000+ pages for comprehensive workshop manuals of this era.
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanicals (cylinder head, block, pistons, crankshaft, camshafts), fuel injection, ignition, cooling, lubrication, emission control systems, turbocharger systems (where applicable).
Transmission Systems:
Manual transmission (F5M42), Automatic transmission (F4Axx series, e.g., F4A51, F4A42), driveline components (axles, driveshafts, differentials).
Brake Systems:
Front and rear disc brakes, ABS (Anti-lock Braking System), brake hydraulics, parking brake.
Suspension And Steering:
Front suspension (MacPherson strut, multi-link), rear suspension (independent multi-link), power steering system, steering gear/rack.
Electrical Systems:
Battery, starting system, charging system, lighting systems (headlamps, taillamps, interior), instrument cluster, wiring diagrams, fuses, relays, power windows, mirrors, central locking, wipers, horn.
Body And Chassis:
Body panel repair, interior trim, exterior trim, chassis components, exhaust system, fuel tank, cooling system components, HVAC (Heating, Ventilation, and Air Conditioning) system.
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements, fluid checks and changes (coolant, brake fluid, transmission fluid, power steering fluid), spark plug replacement, air filter replacement, belt inspection and replacement.
Repair Procedures:
Engine overhaul (cylinder head gasket, piston rings, bearing replacement), transmission overhaul and replacement, brake caliper/rotor/pad replacement, suspension component replacement (struts, control arms, bushings), starter motor/alternator replacement, fuel pump replacement, radiator replacement, HVAC component repair.
Troubleshooting Guides:
Diagnostic procedures for common drivability issues, electrical faults, cooling system problems, transmission performance issues, and more, often including fault codes and symptom-based diagnosis.
Diagnostics:
On-board diagnostics (OBD-I/OBD-II), sensor testing, actuator testing, wiring harness continuity checks.
Technical Depth
Depth Of Coverage:
Comprehensive, covering everything from routine maintenance and basic repairs to complex engine and transmission overhauls and in-depth electrical system diagnostics.
📊 Manual Specifications
File Format
File Type:
PDF (typically)
Searchability:
Likely text-searchable for efficient information retrieval.
Print Quality
Image Resolution:
High enough for clear diagrams and illustrations.
Binding Type
Binding:
Not applicable for digital format; if physical, typically spiral-bound or comb-bound for lay-flat use.
Paper Type
Paper Quality:
Not applicable for digital format; if physical, would be durable paper suitable for workshop environments.
⚙️ Engine Specifications
Primary Engine
Engine Family 4G63:
2.0L Inline-4 DOHC (potentially turbocharged in performance variants like the VR-4, though not explicitly stated in product info, it's common for this engine).
Engine Family 6A13:
2.5L V6 SOHC/DOHC (known for smooth power delivery and a more sporting feel).
Engine Family 4D68:
2.0L Inline-4 SOHC Turbocharged Diesel (less common in some markets, but offered for fuel efficiency).
Engine Family 4G64:
2.4L Inline-4 SOHC (a reliable and common option for mainstream models).
Performance
Hp Range:
Estimated 130-150 hp for naturally aspirated 4-cylinders, 170-200 hp for V6, and potentially 240-280 hp for turbo variants (if applicable).
Torque Range:
Torque figures vary significantly by engine, with V6 and turbo variants offering substantially more torque for better acceleration.
Fuel System
Injection Type:
Multi-point Fuel Injection (MPI) or Direct Fuel Injection (DFI) depending on engine and specific model year/variant.
🔧 Transmission
Standard
Manual Transmission:
F5M42 - 5-speed manual transmission, known for its durability and positive shift feel.
Optional
Automatic Transmission:
F4Axx Series (e.g., F4A51, F4A42) - 4-speed automatic transmission, often with an overdrive gear for improved fuel economy.
Features
All Wheel Drive:
Available on some performance-oriented models (e.g., Galant VR-4, Legnum VR-4), typically paired with a sophisticated AWD system, often an electronically controlled multi-plate clutch system.
📐 Dimensions
Exterior
Length Galant:
Approx. 4600-4750 mm (depending on body style and market).
Length Legnum:
Approx. 4690-4750 mm (wagon variant).
Width:
Approx. 1740-1780 mm.
Height:
Approx. 1380-1420 mm (sedan), 1500-1550 mm (wagon).
Weights
Curb Weight:
Approx. 1350-1600 kg (depending on engine, transmission, and features).
🛡️ Safety Features
Ratings
Crash Test Data:
Information may vary by market and testing authority (e.g., NHTSA, Euro NCAP). Look for specific reports for the relevant year and region.
Active Features
ABS:
Anti-lock Braking System (ABS) was often available or standard on higher trims and performance models.
Traction Control:
Traction Control System (TCS) was available on certain models, especially those with AWD.
Passive Features
Airbags:
Driver and front passenger airbags were standard on most models by the later part of this production run.
Seatbelts:
Three-point front and rear seatbelts, with pre-tensioners for front occupants often included.
💡 Technology Features
Infotainment
Audio System:
Factory-installed radio/cassette player, often with CD changer capability. Speaker configurations vary by trim level.
Driver Assistance
Cruise Control:
Available on many models, typically operated via steering wheel or stalk controls.
Connectivity
OBD Standard:
OBD-II compliance began to be phased in around this period. Early models may use OBD-I.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 7,500 to 10,000 miles (12,000 to 16,000 km) or 6 to 12 months, whichever comes first, depending on driving conditions and oil type used. Refer to manual for exact specifications.
Timing Belt Replacement:
Critical for interference engines (e.g., 4G63, 6A13). Typically every 60,000 to 100,000 miles (96,000 to 160,000 km). Failure can cause severe engine damage.
Fluid Specifications
Engine Oil Type:
API SG/SH or higher. Viscosity grades commonly 5W-30, 10W-30, or 10W-40 depending on climate. Check manual for specific recommendations.
Coolant Type:
Ethylene glycol-based coolant. Typically a 50/50 mix of coolant and distilled water. Refer to manual for specific Mitsubishi coolant type or equivalent.
Transmission Fluid Manual:
API GL-4 or GL-5 gear oil, viscosity typically 75W-90 or 80W-90. Check manual for exact specification.
Transmission Fluid Automatic:
Dexron II/III or equivalent ATF (Automatic Transmission Fluid). Check manual for exact Mitsubishi specification (e.g., Diaqueen SPIII).
Power Steering Fluid:
Typically ATF Dexron II/III or a specific power steering fluid. Refer to manual.
Known Issues
Common Wear Items:
Suspension bushings, ball joints, tie rod ends, wheel bearings due to age and mileage. Clutch wear on manual transmissions.
Engine Specific Issues:
Oil leaks from valve cover or oil pan gaskets, radiator hose degradation, potential for timing belt failure if not replaced on schedule (especially on interference engines).
Automatic Transmission Issues:
Slipping gears, harsh shifting, or failure to engage can occur with age and fluid degradation. Torque converter issues are also possible.
Electrical Issues:
Corrosion on electrical connectors, power window motor failures, intermittent issues with sensors or modules due to age.
📚 Vehicle History
Brand Heritage
Mitsubishi Automotive History:
Mitsubishi Motors Corporation has a long history in automotive manufacturing, known for its diverse range of vehicles, from small economy cars to robust SUVs and performance vehicles. The Galant nameplate has been a significant model for the brand for many years.
Model Evolution
Galant Legnum Generation:
This generation (E3_A, EA_A, EC_A) represented Mitsubishi's move towards more aerodynamic and distinctive styling compared to previous generations. The introduction of the Legnum wagon variant broadened its appeal.
Production
Manufacturing Locations:
Primarily manufactured in Japan, with potential assembly in other global locations depending on market demand.
🏆 Awards & Recognition
Recognitions
Industry Accolades:
While specific awards might be difficult to pinpoint without dedicated research, Mitsubishi vehicles from this era were generally praised for their value, performance (especially V6 and turbo models), and distinctive styling, contributing to their market presence.
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