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Mitsubushi GALANT Service Repair Manual 96-03

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The Mitsubishi Galant, produced from 1996 to 2003, was a mid-size sedan known for its distinctive styling, sporty appeal, and available All-Wheel Drive (AWD) system. Competing against segment stalwarts like...
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Mitsubushi GALANT Service Repair Manual 96-03
The Mitsubishi Galant, produced from 1996 to 2003, was a mid-size sedan known for its distinctive styling, sporty appeal, and available All-Wheel Drive (AWD) system. Competing against segment stalwarts like the Honda Accord and Toyota Camry, the Galant offered a choice between efficient 4-cylinder and powerful V6 engines, including the well-regarded 4G63 and 6A13 variants. Its engineering quality and reliability were key selling points, with many models featuring advanced technologies for their time, such as optional traction control and robust suspension systems that contributed to its engaging driving dynamics. This comprehensive Service and Repair Manual in English is designed to guide owners, mechanics, and technicians through the maintenance and repair of the Mitsubishi Galant. It covers all essential systems, including engine variants, manual and automatic transmissions, drivetrain, brakes, suspension, steering, and the complete electrical system. Detailed procedures for routine maintenance, troubleshooting, component repair, and even rebuilding are provided, along with technical specifications and diagnostic guidance. The manual aims to ensure the longevity and optimal performance of your vehicle.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Galant
Years Covered:
1996-2003
👋 Introduction
Market Position
Positioning:
The Mitsubishi Galant during this era competed in the mid-size sedan segment, often positioned as a sporty and technologically advanced option with distinctive styling, particularly the Japanese-market 'Evo' variants which influenced global perception.
Competitive Analysis
Competitors:
Key competitors included the Honda Accord, Toyota Camry, Nissan Altima, and Mazda 626.
Key Features
Features Vehicle:
Available with potent 4-cylinder and V6 engines, optional AWD (AWD versions were particularly popular for their performance and handling characteristics), distinctive styling, and a comfortable interior.
Features Manual:
This manual offers a complete guide for DIY enthusiasts and professional mechanics, covering all aspects of repair and maintenance with detailed diagrams and step-by-step instructions.
📋 Manual Details
Coverage Areas
Manual Type:
Service and Repair Manual
Language:
English
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine:
All engine variants (4G63 2.0L DOHC, 6A13 2.5L V6)
Transmission:
Manual and Automatic Transmissions
Drivetrain:
Front-Wheel Drive (FWD) and All-Wheel Drive (AWD) systems
Brakes:
Hydraulic Brake System, ABS (Anti-lock Braking System)
Suspension:
Front and Rear Suspension Systems, Steering
Electrical:
Complete Electrical System, Wiring Diagrams, ECUs, Lighting, Ignition
Body:
Body Panels, Doors, Glass, Interior Trim, HVAC (Heating, Ventilation, and Air Conditioning)
Fuel System:
Fuel Delivery, Injection, Emissions Control
Cooling System:
Radiator, Coolant, Thermostat, Fans
Exhaust System:
Exhaust Manifold, Catalytic Converter, Muffler
Safety Systems:
Airbags, Seatbelts
Procedures Included
Maintenance:
Routine Service, Oil Changes, Filter Replacements, Spark Plugs
Troubleshooting:
Diagnostic Procedures for all Systems, Fault Code Interpretation
Repair:
Component Removal, Installation, and Overhaul (Engine, Transmission, Suspension, Brakes, etc.)
Rebuilding:
Detailed Engine and Transmission Rebuild Procedures
Refurbishment:
Bodywork Repair, Interior Refurbishment
Restoration:
Guidance applicable to restoration projects
Technical Depth
Depth:
Comprehensive: From basic maintenance to advanced diagnostics and complete mechanical/electrical overhauls.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable Text (OCR processed)
Printability:
Printable Pages
Resolution:
High-Resolution Graphics and Diagrams
Organization:
Hyperlinked Chapters and Sections
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
4G63
Description 1:
2.0L DOHC 16-valve Inline-4
Displacement 1:
1997 cc
Horsepower 1:
Approx. 140-150 hp (varies by market and trim)
Torque 1:
Approx. 135-140 lb-ft (varies by market and trim)
Optional Engine
Engine Code 2:
6A13
Description 2:
2.5L SOHC 24-valve V6
Displacement 2:
2498 cc
Horsepower 2:
Approx. 160-170 hp (varies by market and trim)
Torque 2:
Approx. 160-170 lb-ft (varies by market and trim)
Fuel System
Induction:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline (87 Octane or higher recommended)
Performance
Timing Belt:
Timing belt driven (4G63) / Timing belt driven (6A13)
🔧 Transmission
Standard
Transmission Type Standard:
5-Speed Manual Transmission
Optional
Transmission Type Optional:
4-Speed Automatic Transmission (INVECS-II)
Features
AWD System:
Optional All-Wheel Drive (AWD) with Active Transfer Clutch (ATC) on certain models.
Transmission Fluid Spec Auto:
DiaQueen ATF-SP II M (or equivalent Dexron III/Mercon)
Transmission Fluid Spec Manual:
API GL-4 SAE 75W-90 gear oil
📐 Dimensions
Exterior
Length:
Approx. 185.8 inches (4719 mm)
Width:
Approx. 69.1 inches (1755 mm)
Height:
Approx. 55.3 inches (1405 mm)
Wheelbase:
Approx. 104.7 inches (2660 mm)
Weights
Curb Weight:
Approx. 3000-3300 lbs (1360-1500 kg), varies by configuration.
🛡️ Safety Features
Ratings
NHTSA Front Driver Impact:
4-star (1997 model year, varies by specific test and year)
NHTSA Front Passenger Impact:
4-star (1997 model year, varies by specific test and year)
Active Features
ABS:
Available Anti-lock Braking System (ABS) on most models.
Traction Control:
Optional Traction Control System (TCS) on some higher trims.
Passive Features
Airbags:
Driver and Passenger Frontal Airbags.
Seatbelts:
Three-point front and rear seatbelts.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/Cassette or CD player with optional premium sound systems.
Climate Control:
Manual or automatic climate control systems.
Driver Assistance
Cruise Control:
Standard cruise control on most trims.
Connectivity
Power Features:
Power windows, power door locks, power mirrors.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles (5,000-8,000 km) or 3-6 months, depending on driving conditions. Consult manual for specific recommendations.
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km).
Spark Plug Replacement:
Every 30,000-60,000 miles (48,000-96,000 km), depending on plug type (e.g., platinum).
Timing Belt Replacement:
Every 60,000-90,000 miles (96,000-144,000 km). Critical maintenance item for 4G63 and 6A13 engines to prevent catastrophic failure.
Fluid Specifications
Engine Oil Spec:
SAE 5W-30 or 10W-30 API SJ or higher (check manual for exact viscosity and API classification).
Coolant Spec:
Mitsubishi Super Long Life Coolant (MS-9100) or equivalent ethylene glycol-based coolant with corrosion inhibitors.
Brake Fluid Spec:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Problem 1:
Ignition coil failure (especially on V6 models), leading to misfires.
Common Problem 2:
Automatic transmission issues, including harsh shifting or slipping, particularly with higher mileage units.
Common Problem 3:
Catalytic converter failure, often indicated by poor engine performance or check engine light.
Common Problem 4:
Wheel bearing wear, especially on AWD models.
Common Problem 5:
Power window motor failure.
📚 Vehicle History
Brand Heritage
Manufacturer:
Mitsubishi Motors Corporation, a Japanese automotive manufacturer with a history dating back to the early 20th century.
Model Evolution
Generation:
This period (1996-2003) represents the sixth generation of the Mitsubishi Galant, which saw significant styling and engineering updates from its predecessor.
Production
Assembly Locations:
Primarily assembled in Japan, with some models potentially assembled in other global locations.
🏆 Awards & Recognition
Recognitions
Awards History:
While specific awards for the 1996-2003 Galant are not as prominent as some other generations or Mitsubishi models, it was generally well-regarded for its value and distinctive styling at the time of its release.
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