Mitsubushi GALANT 1997-2003 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Galant Years Covered: 1997-2003 Codes Chassis Code: E50, E70, E80, E90 Series (specific codes vary by sub-model and region) 👋 Introduction Market Position Positioning: The Mitsubishi Galant (1997-2003) represented Mitsubishi's entry into the mid-size sedan segment, often positioned as a more stylish and sometimes sportier alternative to competitors. It aimed to blend comfort with a degree of performance, particularly in its V6 variants. Competitive Analysis Competitors: Competed against vehicles like the Honda Accord, Toyota Camry, Nissan Altima, Ford Taurus, and Chevrolet Malibu. The Galant often differentiated itself with unique styling and engine options. Key Features Distinguishing Features: Distinctive styling, available 2.4L 4-cylinder (4G64) and 3.0L V6 (6G72) engines, often front-wheel drive (though some markets offered all-wheel drive), available manual and automatic transmissions, comfortable interior with a focus on driver ergonomics. 📋 Manual Details Coverage Areas Coverage Scope: All models and all repairs A-Z Trim Levels: Covers all trim levels (e.g., ES, LS, GT, GTS) and engine configurations. Page Count Estimated Page Count: 1000+ Manual Type Type: Factory Service Manual / Repair Manual Type Clarification: This is a factory-level technical service manual, not an owner's manual or a Haynes/Chilton style generic guide. It's intended for professional mechanics. Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine diagnosis, repair, overhaul, timing belt, valve timing, cylinder head, block, pistons, crankshaft, camshafts, lubrication system, cooling system, fuel system (injection), ignition system, exhaust system. Engine Management: ECU diagnosis, sensor inputs/outputs, fuel delivery control, ignition timing control, emission controls, OBD-II diagnostics, diagnostic trouble codes (DTCs). Transmission Manual: Clutch system, gearbox overhaul, gear shifting mechanisms, synchronizers, bearings, seals. Transmission Automatic: Transmission fluid, torque converter, valve body, planetary gear sets, clutch packs, seals, bands, hydraulic control systems, electronic control unit (TCU) diagnosis, shift solenoids. Drivetrain: Front wheel drive axles (CV joints, boots), differentials (integrated with transmission). Suspension: Front suspension (MacPherson struts, control arms, ball joints, sway bars), rear suspension (multi-link independent suspension, shock absorbers, springs, bushings), wheel alignment specifications. Steering: Power steering system (pump, rack and pinion, hoses, fluid), steering column, tie rods, universal joints. Brakes: Front disc brakes (calipers, rotors, pads), rear disc brakes (calipers, rotors, pads), parking brake system, hydraulic lines, master cylinder, brake booster, ABS (Anti-lock Braking System) diagnosis and component testing. Electrical System: Battery, charging system (alternator, regulator), starting system (starter motor), lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, power distribution, ground points. Body And Interior: Body panel removal/installation, doors, hood, trunk, bumpers, glass, interior trim panels, seats, dashboard, HVAC system (heating, ventilation, air conditioning), climate control, power windows, power door locks, mirrors. Procedures Included Maintenance: Oil change, filter replacement, spark plug replacement, air filter replacement, fuel filter replacement, coolant flush and replacement, brake fluid flush, transmission fluid change, differential fluid change, battery testing and replacement, tire rotation and balancing. Repair Diagnostics: Troubleshooting charts, diagnostic procedures for all major systems, component testing, sensor readings, wiring harness testing, common fault diagnosis. Component Overhaul: Engine rebuild procedures, cylinder head replacement, crankshaft bearing replacement, transmission overhaul (automatic and manual), brake caliper rebuild, power steering rack replacement. Installation Replacement: Timing belt replacement, water pump replacement, alternator replacement, starter motor replacement, fuel pump replacement, clutch replacement, CV axle replacement, shock absorber/strut replacement, brake pad and rotor replacement, wheel bearing replacement. Diagnostics: Detailed diagnostic flowcharts, symptom-based troubleshooting, scan tool data interpretation, component-specific testing procedures. Technical Depth Depth: Comprehensive: From basic maintenance to complete engine and transmission overhauls. Includes detailed diagnostic procedures, specifications, and torque values for all components. Torque Specifications: Includes precise torque values for all critical fasteners, from engine components to suspension and brake hardware. Wiring Diagrams: Comprehensive, detailed wiring diagrams for all electrical systems, including power distribution, lighting, engine controls, HVAC, and accessories. 📊 Manual Specifications File Format File Format: PDF Print Quality Quality: High-resolution digital scans, clear diagrams and text, searchable text content. Binding Type Binding: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Options: 2.4L SOHC 16-valve 4-cylinder (4G64), 3.0L SOHC 24-valve V6 (6G72) Performance 4 Cylinder Power: Approximately 140-150 hp @ 5500-6000 rpm (varies by year and specific engine code) 4 Cylinder Torque: Approximately 150-155 lb-ft @ 4000 rpm (varies by year and specific engine code) V6 Power: Approximately 170-200 hp @ 5500-6000 rpm (varies by year and specific engine code) V6 Torque: Approximately 185-200 lb-ft @ 4000-4500 rpm (varies by year and specific engine code) Fuel System Induction: Electronic Fuel Injection (EFI) Fuel Type: Unleaded Gasoline Emissions Control: Catalytic converter, Oxygen sensors, EGR system Engine Mechanical Engine Codes: 4G64 (2.4L), 6G72 (3.0L V6) 🔧 Transmission Standard Transmission Options: 5-speed manual transmission, 4-speed automatic transmission (INVECS-II with Sportronic in some models) Optional All Wheel Drive: Available on select performance-oriented trims (e.g., Galant VR-4 in some generations, though less common in this specific 1997-2003...

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Tags: 1997 1998 1999 2000 2001 2002 2003 Car GALANT Mitsubushi

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Galant

Years Covered:

1997-2003

Codes

Chassis Code:

E50, E70, E80, E90 Series (specific codes vary by sub-model and region)

👋 Introduction

Market Position

Positioning:

The Mitsubishi Galant (1997-2003) represented Mitsubishi's entry into the mid-size sedan segment, often positioned as a more stylish and sometimes sportier alternative to competitors. It aimed to blend comfort with a degree of performance, particularly in its V6 variants.

Competitive Analysis

Competitors:

Competed against vehicles like the Honda Accord, Toyota Camry, Nissan Altima, Ford Taurus, and Chevrolet Malibu. The Galant often differentiated itself with unique styling and engine options.

Key Features

Distinguishing Features:

Distinctive styling, available 2.4L 4-cylinder (4G64) and 3.0L V6 (6G72) engines, often front-wheel drive (though some markets offered all-wheel drive), available manual and automatic transmissions, comfortable interior with a focus on driver ergonomics.

📋 Manual Details

Coverage Areas

Coverage Scope:

All models and all repairs A-Z

Trim Levels:

Covers all trim levels (e.g., ES, LS, GT, GTS) and engine configurations.

Page Count

Estimated Page Count:

1000+

Manual Type

Type:

Factory Service Manual / Repair Manual

Type Clarification:

This is a factory-level technical service manual, not an owner's manual or a Haynes/Chilton style generic guide. It's intended for professional mechanics.

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine diagnosis, repair, overhaul, timing belt, valve timing, cylinder head, block, pistons, crankshaft, camshafts, lubrication system, cooling system, fuel system (injection), ignition system, exhaust system.

Engine Management:

ECU diagnosis, sensor inputs/outputs, fuel delivery control, ignition timing control, emission controls, OBD-II diagnostics, diagnostic trouble codes (DTCs).

Transmission Manual:

Clutch system, gearbox overhaul, gear shifting mechanisms, synchronizers, bearings, seals.

Transmission Automatic:

Transmission fluid, torque converter, valve body, planetary gear sets, clutch packs, seals, bands, hydraulic control systems, electronic control unit (TCU) diagnosis, shift solenoids.

Drivetrain:

Front wheel drive axles (CV joints, boots), differentials (integrated with transmission).

Suspension:

Front suspension (MacPherson struts, control arms, ball joints, sway bars), rear suspension (multi-link independent suspension, shock absorbers, springs, bushings), wheel alignment specifications.

Steering:

Power steering system (pump, rack and pinion, hoses, fluid), steering column, tie rods, universal joints.

Brakes:

Front disc brakes (calipers, rotors, pads), rear disc brakes (calipers, rotors, pads), parking brake system, hydraulic lines, master cylinder, brake booster, ABS (Anti-lock Braking System) diagnosis and component testing.

Electrical System:

Battery, charging system (alternator, regulator), starting system (starter motor), lighting (headlights, taillights, interior), fuses, relays, wiring diagrams, power distribution, ground points.

Body And Interior:

Body panel removal/installation, doors, hood, trunk, bumpers, glass, interior trim panels, seats, dashboard, HVAC system (heating, ventilation, air conditioning), climate control, power windows, power door locks, mirrors.

Procedures Included

Maintenance:

Oil change, filter replacement, spark plug replacement, air filter replacement, fuel filter replacement, coolant flush and replacement, brake fluid flush, transmission fluid change, differential fluid change, battery testing and replacement, tire rotation and balancing.

Repair Diagnostics:

Troubleshooting charts, diagnostic procedures for all major systems, component testing, sensor readings, wiring harness testing, common fault diagnosis.

Component Overhaul:

Engine rebuild procedures, cylinder head replacement, crankshaft bearing replacement, transmission overhaul (automatic and manual), brake caliper rebuild, power steering rack replacement.

Installation Replacement:

Timing belt replacement, water pump replacement, alternator replacement, starter motor replacement, fuel pump replacement, clutch replacement, CV axle replacement, shock absorber/strut replacement, brake pad and rotor replacement, wheel bearing replacement.

Diagnostics:

Detailed diagnostic flowcharts, symptom-based troubleshooting, scan tool data interpretation, component-specific testing procedures.

Technical Depth

Depth:

Comprehensive: From basic maintenance to complete engine and transmission overhauls. Includes detailed diagnostic procedures, specifications, and torque values for all components.

Torque Specifications:

Includes precise torque values for all critical fasteners, from engine components to suspension and brake hardware.

Wiring Diagrams:

Comprehensive, detailed wiring diagrams for all electrical systems, including power distribution, lighting, engine controls, HVAC, and accessories.

📊 Manual Specifications

File Format

File Format:

Print Quality

Quality:

High-resolution digital scans, clear diagrams and text, searchable text content.

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Options:

2.4L SOHC 16-valve 4-cylinder (4G64), 3.0L SOHC 24-valve V6 (6G72)

Performance

4 Cylinder Power:

Approximately 140-150 hp @ 5500-6000 rpm (varies by year and specific engine code)

4 Cylinder Torque:

Approximately 150-155 lb-ft @ 4000 rpm (varies by year and specific engine code)

V6 Power:

Approximately 170-200 hp @ 5500-6000 rpm (varies by year and specific engine code)

V6 Torque:

Approximately 185-200 lb-ft @ 4000-4500 rpm (varies by year and specific engine code)

Fuel System

Induction:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline

Emissions Control:

Catalytic converter, Oxygen sensors, EGR system

Engine Mechanical

Engine Codes:

4G64 (2.4L), 6G72 (3.0L V6)

🔧 Transmission

Standard

Transmission Options:

5-speed manual transmission, 4-speed automatic transmission (INVECS-II with Sportronic in some models)

Optional

All Wheel Drive:

Available on select performance-oriented trims (e.g., Galant VR-4 in some generations, though less common in this specific 1997-2003 US market facelifted model; focus is primarily FWD for most trims).

Features

Automatic Features:

Electronically controlled, torque converter lock-up, adaptive shift logic (INVECS-II).

📐 Dimensions

Exterior

Length:

Approximately 187.0 - 189.0 inches (varies by trim)

Width:

Approximately 70.0 - 70.5 inches

Height:

Approximately 55.5 - 56.5 inches

Wheelbase:

Approximately 105.0 - 105.1 inches

Ground Clearance:

Approximately 5.5 - 6.0 inches (estimated)

Cargo

Trunk Volume:

Approximately 14.1 - 15.0 cubic feet (estimated)

Weights

Curb Weight:

Approximately 3000 - 3300 lbs (varies by engine and trim)

🛡️ Safety Features

Ratings

NHTSA Front Impact:

Likely 4-star rating for driver and passenger in frontal crash tests (based on typical ratings for vehicles of this era).

IIHS Side Impact:

Variable, often Good or Acceptable for side impact tests for vehicles of this period.

Active Features

Standard on most models, available on all.

Traction Control:

Available on select higher trims.

Passive Features

Airbags:

Driver and front passenger airbags standard. Side airbags optional or standard on later models/trims.

Seatbelts:

3-point front and rear seatbelts, pretensioners and load limiters for front seats.

Crumple Zones:

Designed with front and rear crumple zones for energy absorption.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM/CD player, often with cassette tape. Premium audio systems available on higher trims.

Climate Control:

Manual HVAC controls standard. Automatic climate control available on higher trims.

Driver Assistance

Cruise Control:

Standard on most models.

Connectivity

OBD Interface:

OBD-II compliant, allowing for diagnostic scan tool connection for engine and transmission diagnostics.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000 - 5,000 miles or 3-6 months, depending on driving conditions and oil type (consult owner's manual or service manual for specifics).

Timing Belt Replacement:

Every 60,000 - 90,000 miles or 5-7 years (critical for 4G64 engine, as failure can cause catastrophic damage).

Spark Plug Replacement:

Every 30,000 - 60,000 miles, depending on plug type (platinum/iridium typically longer life).

Fluid Specifications

Engine Oil:

API SG or higher, SAE 5W-30 or 10W-30 (consult manual for specific viscosity based on climate).

Coolant:

Mitsubishi Super Long Life Coolant (SLLC) or equivalent ethylene glycol-based coolant with deionized water (50/50 mix).

Transmission Fluid Automatic:

DIA Queen ATF SP-III (or equivalent Dexron III/Mercon compatible fluid, though SP-III is preferred).

Power Steering Fluid:

ATF Dexron II or III (consult manual for exact specification).

Brake Fluid:

DOT 3 or DOT 4.

Engine Oil Capacity:

Approximately 4.5 quarts (4.3 liters) with filter for 2.4L, 5.0 quarts (4.7 liters) with filter for 3.0L V6 (verify with manual).

Known Issues

Engine Mounts:

Wear and tear leading to vibration and engine movement, especially on higher mileage vehicles.

Suspension Components:

Worn ball joints, tie rod ends, and bushings can cause steering looseness and premature tire wear.

Automatic Transmission:

Some models experienced premature failure of the automatic transmission, particularly the INVECS-II units, often due to fluid degradation or internal wear.

O2 Sensors:

Can fail over time, leading to poor fuel economy and check engine lights.

Evaporative Emissions System:

Issues with the EVAP system, such as faulty vent control valves or canister purge solenoids, can trigger check engine lights.

Power Window Motors:

Can become slow or inoperative due to age and wear.

📚 Vehicle History

Brand Heritage

Mitsubishi Heritage:

Mitsubishi Motors has a long history dating back to 1917, with significant experience in automotive manufacturing, including performance vehicles and innovative technologies. The Galant nameplate has been used by Mitsubishi for decades across multiple generations and market segments.

Model Evolution

Galant Generations:

The 1997-2003 model represents the eighth generation of the Mitsubishi Galant, which underwent a significant facelift for the 1999 model year, altering the front and rear styling, interior amenities, and powertrain options. This generation continued Mitsubishi's focus on unique styling and powertrain choices.

Production

Manufacturing Location:

Primarily manufactured in Japan and the United States (Illinois plant for North American market).

🏆 Awards & Recognition

Recognitions

Past Accolades:

While specific major awards for this particular generation are not widely highlighted, the Galant aimed to compete in a segment known for reliability and value, drawing comparisons with established leaders. Reviews at the time often noted its styling and comfortable ride.