Mitsubishi Galant 2004-2009 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Galant Model Years: 2004, 2005, 2006, 2007, 2008, 2009 Codes Chassis Codes: DJ1A Platform: Mitsubishi PS platform 👋 Introduction Market Position Segment: Mid-size sedan Target Audience: DIY enthusiasts, independent repair shops, and owners seeking detailed maintenance and repair information. Competitive Analysis Key Competitors: Honda Accord, Toyota Camry, Nissan Altima, Ford Fusion, Chevrolet Malibu. Key Features Value Proposition: Provides comprehensive factory-level information at a fraction of the cost of dealership service, enabling owners to perform maintenance and repairs themselves. Benefits: Cost savings on repairs, extended vehicle lifespan through proper maintenance, improved understanding of vehicle systems. 📋 Manual Details Coverage Areas Geographical Coverage: Global (with potential regional variations noted for certain specifications) Page Count Estimated Pages: Approximately 2500-3000 pages (typical for a comprehensive factory service manual) Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine: Detailed diagnosis, repair, and overhaul procedures for all engine variants, including timing belt/chain service, ignition system, fuel system, lubrication, cooling, and emissions control. Transmission: Comprehensive coverage of automatic and manual transmissions, including removal, installation, disassembly, assembly, hydraulic control, and electronic control unit (TCU) diagnosis. Drivetrain: Front-wheel drive (FWD) and All-wheel drive (AWD) systems, including CV axles, differentials, driveshafts, and hubs. Brakes: Front and rear brake systems (disc/disc or disc/drum), ABS, EBD, and traction control system diagnosis and repair. Suspension: Front and rear suspension components, including struts, shocks, control arms, bushings, springs, and alignment specifications. Steering: Power steering system diagnosis, repair, and fluid specifications; steering column and linkage components. Electrical System: Complete wiring diagrams, component locations, fuse and relay information, charging system, starting system, lighting, and accessory circuits. HVAC: Heating, ventilation, and air conditioning (HVAC) system service, including refrigerant handling, component replacement, and diagnostic procedures. Body And Interior: Body panel repair, door mechanisms, glass replacement, interior trim removal and installation, seats, and upholstery. Restraint Systems: Airbag system diagnosis, component replacement, and seatbelt service. Procedures Included Maintenance: Scheduled maintenance intervals, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, spark plug service, and general inspections. Troubleshooting: Diagnostic charts and flowcharts for common symptoms and issues across all vehicle systems. Repair: Step-by-step instructions for component removal, repair, and reinstallation for virtually every part of the vehicle. Diagnostics: OBD-II diagnostic trouble codes (DTCs), sensor data interpretation, and advanced diagnostic techniques for Powertrain Control Module (PCM) and other control units. Specifications: Torque specifications, clearances, fluid capacities, and electrical values for all components. Wiring Diagrams: Detailed and color-coded wiring diagrams for all electrical systems. Technical Depth Depth: Comprehensive. Covers everything from basic fluid checks and filter changes to full engine and transmission overhauls, complex electrical diagnostics, and bodywork repairs. 📊 Manual Specifications File Format Format: PDF (Portable Document Format) Searchability: Likely text-searchable due to the PDF format, allowing quick location of specific topics. Print Quality Quality: High resolution, suitable for printing individual pages or the entire manual. Binding Type Binding: N/A (Digital download) Paper Type Paper: N/A (Digital download) ⚙️ Engine Specifications Primary Engine Engine Code 2.4L: 4G69 (MIVEC) Displacement 2.4L: 2.4 Liters (2378 cc) Configuration 2.4L: Inline 4-cylinder, DOHC, 16 valves Horsepower 2.4L: Approximately 155-160 hp @ 6000 rpm (depending on market and specific tuning) Torque 2.4L: Approximately 160-165 lb-ft @ 4000 rpm Optional Engine Engine Code 3.8L: 6G75 Displacement 3.8L: 3.8 Liters (3797 cc) Configuration 3.8L: V6, SOHC, 24 valves Horsepower 3.8L: Approximately 230-235 hp @ 5700 rpm Torque 3.8L: Approximately 255-260 lb-ft @ 4000 rpm Fuel System System: Multi-point fuel injection (MPI) Recommended Fuel: 87 Octane Unleaded Gasoline (91 Octane recommended for 3.8L V6 for optimal performance) 🔧 Transmission Standard Transmission Type 4Cyl: 5-speed manual Optional Transmission Type Auto: 4-speed automatic (INVECS-II) Transmission Type V6: 4-speed automatic (INVECS-II) or 5-speed automatic (INVECS-II Sports Mode) Features AWD Availability: Available on select trims (often with the V6 engine), utilizing Mitsubishi's All-Wheel Control (AWC) system. 📐 Dimensions Exterior Length: Approximately 190.4 inches (4836 mm) Width: Approximately 70.1 inches (1780 mm) Height: Approximately 57.5 inches (1460 mm) Wheelbase: Approximately 106.3 inches (2700 mm) Weights Curb Weight: Approximately 3200 - 3500 lbs (1450 - 1590 kg) depending on engine and trim. Gross Vehicle Weight Rating: Varies by model, typically around 4300 lbs (1950 kg). 🛡️ Safety Features Ratings NHTSA Front Impact Driver: Good (for 2004 models) NHTSA Front Impact Passenger: Good (for 2004 models) IIHS Front Offset Crash Test: Acceptable (for models tested) Active Features ABS: Standard Anti-lock Braking System Ebd: Standard Electronic Brake-force Distribution Traction Control: Available (often with AWD models) Passive Features Airbags: Front airbags, available side-impact airbags, available curtain airbags. Seatbelts: Three-point seatbelts with pretensioners and load limiters. Child Seat Anchors: LATCH (Lower Anchors and Tethers for CHildren) system. 💡 Technology Features Infotainment Audio System: Factory AM/FM/CD stereo system, often with steering wheel audio controls on higher trims. Premium Rockford Fosgate audio...
DIY enthusiasts, independent repair shops, and owners seeking detailed maintenance and repair information.
Competitive Analysis
Key Competitors:
Honda Accord, Toyota Camry, Nissan Altima, Ford Fusion, Chevrolet Malibu.
Key Features
Value Proposition:
Provides comprehensive factory-level information at a fraction of the cost of dealership service, enabling owners to perform maintenance and repairs themselves.
Benefits:
Cost savings on repairs, extended vehicle lifespan through proper maintenance, improved understanding of vehicle systems.
📋 Manual Details
Coverage Areas
Geographical Coverage:
Global (with potential regional variations noted for certain specifications)
Page Count
Estimated Pages:
Approximately 2500-3000 pages (typical for a comprehensive factory service manual)
Manual Type
Type:
Factory Service Repair Workshop Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnosis, repair, and overhaul procedures for all engine variants, including timing belt/chain service, ignition system, fuel system, lubrication, cooling, and emissions control.
Transmission:
Comprehensive coverage of automatic and manual transmissions, including removal, installation, disassembly, assembly, hydraulic control, and electronic control unit (TCU) diagnosis.
Drivetrain:
Front-wheel drive (FWD) and All-wheel drive (AWD) systems, including CV axles, differentials, driveshafts, and hubs.
Brakes:
Front and rear brake systems (disc/disc or disc/drum), ABS, EBD, and traction control system diagnosis and repair.
Suspension:
Front and rear suspension components, including struts, shocks, control arms, bushings, springs, and alignment specifications.
Steering:
Power steering system diagnosis, repair, and fluid specifications; steering column and linkage components.
Electrical System:
Complete wiring diagrams, component locations, fuse and relay information, charging system, starting system, lighting, and accessory circuits.
HVAC:
Heating, ventilation, and air conditioning (HVAC) system service, including refrigerant handling, component replacement, and diagnostic procedures.
Body And Interior:
Body panel repair, door mechanisms, glass replacement, interior trim removal and installation, seats, and upholstery.
Restraint Systems:
Airbag system diagnosis, component replacement, and seatbelt service.
Procedures Included
Maintenance:
Scheduled maintenance intervals, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, spark plug service, and general inspections.
Troubleshooting:
Diagnostic charts and flowcharts for common symptoms and issues across all vehicle systems.
Repair:
Step-by-step instructions for component removal, repair, and reinstallation for virtually every part of the vehicle.
Diagnostics:
OBD-II diagnostic trouble codes (DTCs), sensor data interpretation, and advanced diagnostic techniques for Powertrain Control Module (PCM) and other control units.
Specifications:
Torque specifications, clearances, fluid capacities, and electrical values for all components.
Wiring Diagrams:
Detailed and color-coded wiring diagrams for all electrical systems.
Technical Depth
Depth:
Comprehensive. Covers everything from basic fluid checks and filter changes to full engine and transmission overhauls, complex electrical diagnostics, and bodywork repairs.
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Searchability:
Likely text-searchable due to the PDF format, allowing quick location of specific topics.
Print Quality
Quality:
High resolution, suitable for printing individual pages or the entire manual.
Binding Type
Binding:
N/A (Digital download)
Paper Type
Paper:
N/A (Digital download)
⚙️ Engine Specifications
Primary Engine
Engine Code 2.4L:
4G69 (MIVEC)
Displacement 2.4L:
2.4 Liters (2378 cc)
Configuration 2.4L:
Inline 4-cylinder, DOHC, 16 valves
Horsepower 2.4L:
Approximately 155-160 hp @ 6000 rpm (depending on market and specific tuning)
Torque 2.4L:
Approximately 160-165 lb-ft @ 4000 rpm
Optional Engine
Engine Code 3.8L:
6G75
Displacement 3.8L:
3.8 Liters (3797 cc)
Configuration 3.8L:
V6, SOHC, 24 valves
Horsepower 3.8L:
Approximately 230-235 hp @ 5700 rpm
Torque 3.8L:
Approximately 255-260 lb-ft @ 4000 rpm
Fuel System
System:
Multi-point fuel injection (MPI)
Recommended Fuel:
87 Octane Unleaded Gasoline (91 Octane recommended for 3.8L V6 for optimal performance)
🔧 Transmission
Standard
Transmission Type 4Cyl:
5-speed manual
Optional
Transmission Type Auto:
4-speed automatic (INVECS-II)
Transmission Type V6:
4-speed automatic (INVECS-II) or 5-speed automatic (INVECS-II Sports Mode)
Features
AWD Availability:
Available on select trims (often with the V6 engine), utilizing Mitsubishi's All-Wheel Control (AWC) system.
📐 Dimensions
Exterior
Length:
Approximately 190.4 inches (4836 mm)
Width:
Approximately 70.1 inches (1780 mm)
Height:
Approximately 57.5 inches (1460 mm)
Wheelbase:
Approximately 106.3 inches (2700 mm)
Weights
Curb Weight:
Approximately 3200 - 3500 lbs (1450 - 1590 kg) depending on engine and trim.
Gross Vehicle Weight Rating:
Varies by model, typically around 4300 lbs (1950 kg).
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
Good (for 2004 models)
NHTSA Front Impact Passenger:
Good (for 2004 models)
IIHS Front Offset Crash Test:
Acceptable (for models tested)
Active Features
ABS:
Standard Anti-lock Braking System
Ebd:
Standard Electronic Brake-force Distribution
Traction Control:
Available (often with AWD models)
Passive Features
Airbags:
Front airbags, available side-impact airbags, available curtain airbags.
Seatbelts:
Three-point seatbelts with pretensioners and load limiters.
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for CHildren) system.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD stereo system, often with steering wheel audio controls on higher trims. Premium Rockford Fosgate audio system was an option.
Navigation:
Optional factory navigation system available on some higher trim levels.
Driver Assistance
Cruise Control:
Standard cruise control.
Remote Keyless Entry:
Available on most trims.
Automatic Climate Control:
Available on higher trim levels.
Connectivity
Auxiliary Input:
Typically not standard; aftermarket solutions may be required for modern device connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,750 miles (6,000 km) or 3 months for severe driving conditions, or 7,500 miles (12,000 km) or 6 months for normal driving, using synthetic oil. Consult manual for specific details.
Air Filter Replacement:
Recommended every 15,000 miles (24,000 km) or annually. Inspect more frequently.
Spark Plug Replacement 4Cyl:
Iridium spark plugs typically recommended at 100,000 miles (160,000 km).
Spark Plug Replacement V6:
Platinum spark plugs typically recommended at 60,000 miles (96,000 km).
Timing Belt Replacement:
If equipped with a timing belt (4G69 uses a belt), typically 60,000-100,000 miles (96,000-160,000 km) or 5-7 years. Highly critical for this engine.
Fluid Specifications
Engine Oil Type:
SAE 5W-30, API SN or ILSAC GF-5 certified. Consult manual for exact specifications and capacity.
Coolant Type:
Mitsubishi DIA-Queen SUPER LONG LIFE COOLANT (or equivalent long-life ethylene glycol-based coolant, typically pink or orange).
Transmission Fluid Automatic:
DIA-Queen ATF J2 or equivalent ATF. Capacity varies, approximately 3.5-4.5 quarts for a drain and fill.
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Engine Mounts:
Premature wear and cracking of engine mounts, leading to increased vibration.
Automatic Transmission:
Some models may experience rough shifting or occasional hesitation in the automatic transmission, particularly at higher mileage.
Suspension Components:
Front sway bar links and bushings can wear out, causing clunking noises.
Ignition Coils:
Coil-on-plug ignition systems can be prone to failure, causing misfires.
📚 Vehicle History
Brand Heritage
Mitsubishi History:
Mitsubishi Motors Corporation, a Japanese multinational automotive manufacturer, has a history dating back to 1917, known for its innovative engineering and durable vehicles.
Model Evolution
Galant Generation:
This refers to the ninth generation of the Mitsubishi Galant (DJ1A chassis), which was a significant redesign from its predecessor.
Design Philosophy:
The ninth generation Galant featured a more aggressive and aerodynamic styling, reflecting a sportier image compared to previous generations.
Production
Production Period:
2003 (as a 2004 model year) through 2007 in North America, with production continuing in other markets until 2012.
Manufacturing Location Na:
Normal, Illinois, USA.
🏆 Awards & Recognition
Recognitions
Consumer Reports Ratings:
Ratings varied by model year and specific issues; some years received average or below-average reliability ratings from sources like Consumer Reports.
Safety Awards:
Achieved good ratings in IIHS and NHTSA crash tests for its time, contributing to its safety appeal.
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