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Mitsubushi GALANT 4G63 6A13 4D68 Full Service & Repair Manual

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The Mitsubishi Galant, primarily covering the 8th Generation produced from 1994 to 2003, represents a mid-size sedan known for its blend of comfort, performance, and value. This model offered a...
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Mitsubushi GALANT 4G63 6A13 4D68 Full Service & Repair Manual
The Mitsubishi Galant, primarily covering the 8th Generation produced from 1994 to 2003, represents a mid-size sedan known for its blend of comfort, performance, and value. This model offered a range of versatile engines, including the robust 4G63, the smooth 6A13 V6, and the efficient 4D68 diesel, catering to diverse global markets. Variants included sedan and potentially coupe or hatchback body styles, with some performance-oriented models featuring advanced All-Wheel Control (AWC) system. The Galant's engineering quality and reliability were hallmarks, making it a competitive choice against contemporaries like the Honda Accord and Toyota Camry. This comprehensive factory service and repair workshop manual provides essential information for maintaining and repairing the Mitsubishi Galant. Its scope covers all major vehicle systems, including powertrain (engines 4G63, 6A13, 4D68, and their management systems), transmissions (manual and automatic), drivetrain (FWD and AWD), chassis (suspension, steering, brakes), and electrical systems. Detailed procedures for routine maintenance, diagnostic troubleshooting, component repair, and electrical diagnostics are included, targeting professional technicians and experienced DIY mechanics. The manual's extensive coverage ensures owners and service personnel have the necessary factory-level data to preserve the longevity and performance of their Galant.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Galant
Generations Covered:
Primarily 8th Generation (1994-2003), with specific engine coverage applicable to some earlier/later models.
Codes
Engine Codes Covered:
4G63, 6A13, 4D68
👋 Introduction
Market Position
Model Segment:
Mid-size sedan, known for its balance of comfort, performance, and value.
Competitive Analysis
Key Competitors:
Honda Accord, Toyota Camry, Nissan Altima, Mazda 626/Mazda 6.
Key Features
Engine Options:
The manual covers versatile Mitsubishi engines, including the performance-oriented 4G63 (often turbocharged in performance variants), the smooth V6 6A13, and the efficient diesel 4D68.
Manual Value Proposition:
Provides factory-level diagnostic and repair information, essential for maintaining the longevity and performance of these vehicles.
Manual Value Proposition
No Expiry Fees:
Highlights perpetual access and no subscription fees, a significant benefit for users.
📋 Manual Details
Coverage Areas
Primary Markets:
Global, with emphasis on markets where these engines and the Galant model were prevalent (North America, Japan, Europe, Australia).
Vehicle Variants:
Sedan and potentially Coupe/Hatchback variants depending on engine applicability.
Page Count
Estimated Pages:
Comprehensive (typically 1500+ pages for full factory manuals).
Manual Type
Type:
Factory Service & Repair Workshop Manual
Language
Language:
English
Format
Format:
Digital Download (PDF)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine mechanicals (4G63, 6A13, 4D68 variants), engine management systems (ECU, sensors, actuators), fuel delivery, ignition, exhaust, cooling, lubrication.
Transmission:
Manual and Automatic transmission servicing, repair, diagnostics, and overhaul (specific types to be detailed).
Drivetrain:
Front-wheel drive (FWD) and All-wheel drive (AWD) systems, including differentials, drive shafts, and CV joints.
Chassis:
Suspension (front and rear), steering system, brakes (hydraulic, ABS), wheel alignment.
Electrical:
Wiring diagrams, lighting, instrumentation, power accessories, starting and charging system, body electrical, fuse and relay locations.
Body And Trim:
Exterior body panels, interior trim, HVAC system, safety systems (airbags, seatbelts).
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug service, belt inspections.
Diagnostic Troubleshooting:
Step-by-step diagnostic procedures for common faults, DTC (Diagnostic Trouble Code) interpretation.
Component Repair Overhaul:
Detailed instructions for engine component replacement (e.g., head gasket, pistons, valves), transmission rebuilds, brake caliper overhauls, suspension arm replacement.
Electrical Diagnostics:
Circuit tracing, testing of sensors and actuators, wiring harness repair.
Body Repair:
Panel replacement, door mechanism repair, glass replacement procedures.
Technical Depth
Depth:
Comprehensive, covering everything from basic fluid checks to complete engine and transmission rebuilds.
Target Audience:
Professional technicians and experienced DIY mechanics.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Typically text-searchable PDF for efficient information retrieval.
Print Quality
Printability:
Designed for digital viewing, but printable for workshop use.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
4G63 Variant Details:
Inline 4-cylinder, DOHC, 16-valve. Displacement typically 2.0L. Known for its robust design and potential for turbocharging (e.g., in performance trims like the Galant VR-4). Power output varied widely based on aspiration and specific model year (e.g., 140-200+ hp naturally aspirated, 240-280+ hp turbocharged).
6A13 Variant Details:
V6, SOHC or DOHC, 24-valve. Displacement typically 2.5L. Offered in naturally aspirated configurations, providing smoother power delivery and a refined driving experience. Power output generally in the 160-190 hp range.
4D68 Variant Details:
Inline 4-cylinder, SOHC, turbocharged diesel. Displacement typically 2.0L. Focus on fuel efficiency and torque. Power output typically in the 80-100 hp range.
Performance
4G63 Typical Hp:
140-280+ hp (depending on turbocharging and specific model)
6A13 Typical Hp:
160-190 hp
4D68 Typical Hp:
80-100 hp
Fuel System
Fuel Delivery Type:
Multi-point fuel injection (MPI) for gasoline engines; Direct injection or indirect injection for diesel.
Fuel Type:
Unleaded gasoline (Octane rating as per manufacturer recommendation), Diesel fuel.
🔧 Transmission
Standard
Manual Transmission Type:
5-speed manual (common across variants).
Optional
Automatic Transmission Type:
4-speed and 5-speed automatic transmissions (e.g., INVECS-II).
Features
AWD Availability:
Available on certain performance variants (e.g., Galant VR-4), featuring Mitsubishi's advanced All-Wheel Control (AWC) system.
Transmission Fluid Spec:
Specific ATF (e.g., DiaQueen ATF SP-III for automatics) or gear oil for manuals, detailed in the manual.
📐 Dimensions
Exterior
Body Styles:
4-door Sedan, 2-door Coupe (GTO/3000GT sibling models shared platform elements).
Wheelbase Approx:
2635 mm (8th Gen Sedan).
Length Approx:
4680 mm (8th Gen Sedan).
Weights
Curb Weight Range:
1350 kg - 1550 kg (depending on engine and drivetrain).
🛡️ Safety Features
Ratings
Crash Test Data:
Refer to NHTSA/Euro NCAP for specific model year ratings. The 8th Gen Galant generally performed adequately for its era.
Active Features
ABS:
Standard or optional Anti-lock Braking System (ABS).
Traction Control:
Optional Traction Control System (TCS) or Active Stability Control (ASC) on some variants.
Passive Features
Airbags:
Front airbags standard; side airbags optional on higher trims.
Seatbelts:
Pre-tensioning front seatbelts with force limiters.
💡 Technology Features
Infotainment
Audio System:
Factory fitted AM/FM/CD players, often with premium sound system options (e.g., Rockford Fosgate) on higher trims.
Navigation:
Optional factory navigation systems available on some models, primarily in later production years.
Driver Assistance
Cruise Control:
Standard or optional cruise control system.
Keyless Entry:
Available keyless entry and remote start systems on certain trims.
Connectivity
Power Accessories:
Power windows, power door locks, power mirrors, power seats (driver and/or passenger) were common options.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 5,000-10,000 km or 6-12 months, depending on driving conditions and oil type used (refer to manual for specific recommendations).
Timing Belt Replacement:
Crucial for 4G63 and 6A13 engines. Typically 90,000-150,000 km or 5-7 years. Failure can cause severe engine damage. Manual will specify interval and procedure.
Fluid Specifications
Engine Oil Spec:
API SJ/SL or ACEA A3/B3, viscosity grade SAE 5W-30 or 10W-40 (depending on climate and engine variant, e.g., 5W-30 for 4G63/6A13).
Coolant Spec:
Ethylene glycol based coolant, typically Mitsubishi Super Long Life Coolant (or equivalent) with a 50/50 mix. Capacity varies by engine.
Brake Fluid Spec:
DOT 3 or DOT 4.
Known Issues
4G63 Common Problems:
Turbocharger failure (on turbo models), oil leaks (valve cover gasket, oil pan gasket), rear main seal leaks, timing belt tensioner issues.
6A13 Common Problems:
Intake manifold gasket leaks, valve cover gasket leaks, potential for carbon buildup in V6 engines, spark plug tube seal leaks.
4D68 Common Problems:
Glow plug issues, injector seal leaks, turbocharger wear, potential for head gasket failure under heavy load.
Transmission Common Problems:
Automatic transmission shudder or delayed engagement, manual clutch wear.
📚 Vehicle History
Brand Heritage
Mitsubishi Reputation:
Mitsubishi has a history of producing reliable and sometimes performance-oriented vehicles, with the Galant being a cornerstone sedan model.
Model Evolution
Galant Legacy:
The Galant nameplate has been used by Mitsubishi for decades, evolving through multiple generations and design philosophies, with the 8th generation representing a more aerodynamic and modern design.
Production
Production Years 8Th Gen:
1994-2003 (depending on market).
Manufacturing Locations:
Primarily Japan, with assembly in other global locations depending on the target market.
🏆 Awards & Recognition
Recognitions
Model Awards:
Specific awards vary by year and market. Mitsubishi vehicles of this era were often recognized for value and reliability in their segments.
Ratings
Consumer Reports Mentions:
Check historical Consumer Reports data for specific year ratings on reliability and owner satisfaction.
Certifications
Iso Certification Manufacturing:
Mitsubishi adhered to ISO quality standards in manufacturing, ensuring a baseline for vehicle construction.
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