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Mitsubushi GALANT 2004-2010 Service Repair Manual

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The Galant, produced from 2004 to 2010 for the USA and Canada markets, is a mid-size sedan known for its comfortable ride and stylish design, particularly after its 2007 facelift....
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Mitsubushi GALANT 2004-2010 Service Repair Manual
The Galant, produced from 2004 to 2010 for the USA and Canada markets, is a mid-size sedan known for its comfortable ride and stylish design, particularly after its 2007 facelift. This generation, designated E15A/E16A, offered a choice between a 2.4L 4-cylinder engine and a potent 3.8L V6, providing a balance of efficiency and performance. Notable features include available premium audio systems and, on later models, electronic stability control, reflecting a commitment to driver comfort and safety. Manufactured in Normal, Illinois, the Galant aimed to compete in a crowded segment with models like the Toyota Camry and Honda Accord, distinguishing itself with its distinctive attributes and robust engine options. This comprehensive factory service manual provides in-depth coverage for the Galant (2004-2010), serving as an essential resource for owners and technicians. The manual details maintenance procedures, including scheduled intervals for oil changes and coolant replacement, as well as diagnostic and repair processes for all major vehicle systems. It covers powertrain, chassis, electrical, and body components, offering extensive wiring diagrams, torque specifications, and troubleshooting charts for accurate fault identification and resolution. Furthermore, the manual includes information on HVAC, fuel, and exhaust systems, along with specific procedures for calibration and reset functions, ensuring thorough understanding and effective upkeep of the vehicle.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Galant
Year:
2004-2010
Market:
USA/Canada
Codes
Vehicle Generation Codes:
E15A/E16A (North American designation for the ninth generation Galant)
👋 Introduction
Market Position
Segment:
Mid-size Sedan
Competitive Analysis
Key Competitors:
Toyota Camry, Honda Accord, Ford Fusion, Nissan Altima, Chevrolet Malibu
Key Features
Distinctive Attributes:
Known for its comfortable ride, stylish (for its time) design, and often available V6 engines offering good performance. The latter half of this generation (post-facelift) saw notable improvements in interior quality and features.
Engine Options:
Available with a fuel-efficient 2.4L 4-cylinder and a powerful 3.8L V6, offering a choice between economy and performance.
📋 Manual Details
Coverage Areas
Regions Covered:
USA, Canada
Page Count
Estimated Page Count:
Approximately 2000-3000 pages (typical for comprehensive factory service manuals)
Manual Type
Type:
Factory Service Manual (FSM) / Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF, searchable)
📖 Manual Coverage
Systems Covered
Powertrain:
Engine, Transmission, Drivetrain (FWD/AWD), Exhaust System
Chassis:
Suspension (Front & Rear), Steering, Brakes (ABS, Power Assist), Wheels & Tires
Electrical:
Engine Control Module (ECM), Powertrain Control Module (PCM), Body Control Module (BCM), Lighting, Instrumentation, Audio System, Power Accessories, HVAC Controls, Safety Systems (Airbags, Seatbelts)
Body:
Exterior Body Panels, Doors, Hood, Trunk, Interior Trim, Seats, Glass
Infotainment And Audio:
Diagnosis and repair of audio systems, navigation (if equipped), speakers, and antenna.
Security And Alarms:
Immobilizer system, keyless entry system, alarm system troubleshooting.
Driver Controls:
Steering wheel controls, pedal assembly, ignition switch, gear selector.
Procedures Included
Maintenance:
Scheduled maintenance intervals, fluid checks and changes, filter replacements, spark plug replacement, belt replacement
Diagnostics:
Troubleshooting charts, DTC (Diagnostic Trouble Code) interpretation, circuit diagrams, component testing procedures
Repair:
Engine rebuild, transmission overhaul, brake caliper replacement, suspension component replacement, electrical component repair, body panel repair
Calibration Reset:
Throttle body relearn, idle air control relearn, steering angle sensor calibration, adaptive transmission relearn
HVAC System:
Diagnosis and repair of air conditioning, heating, and ventilation systems, including refrigerant handling and component replacement.
Fuel System:
Fuel pump replacement, fuel filter service, fuel injector cleaning and replacement, evaporative emissions control (EVAP) system troubleshooting.
Exhaust System:
Catalytic converter replacement, muffler and pipe repair/replacement, oxygen sensor diagnosis and replacement.
Body And Paint:
Information on door panel removal, interior trim, seat removal, and basic body repair techniques.
Lighting System:
Headlight, taillight, interior light bulb replacement and troubleshooting, wiring.
Technical Depth
Depth:
Comprehensive (covers everything from basic fluid changes to complete engine and transmission overhauls, including electrical diagnostics and bodywork)
Wiring Diagrams:
Extensive electrical wiring diagrams for all vehicle systems, crucial for diagnosing electrical faults.
Torque Specifications:
Detailed torque specifications for all critical fasteners, essential for proper assembly and preventing component damage.
Special Tools:
Identification of specialized tools required for specific repair procedures.
Troubleshooting Charts:
Step-by-step troubleshooting flowcharts for common symptoms and DTCs.
Component Testing:
Detailed procedures for testing the functionality of individual components using multimeters and scan tools.
Manual Completeness
Coverage Scope:
Covers all models and all repairs A-Z, indicating a truly comprehensive guide.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Text-searchable
Print Quality
Image Resolution:
High-resolution scans for clear diagrams and images
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code And Type:
4G69 (2.4L SOHC MIVEC I4), 6G75 (3.8L SOHC MIVEC V6)
Performance
2.4L I4 Horsepower:
Approximately 156 hp @ 5800 rpm
2.4L I4 Torque:
Approximately 162 lb-ft @ 4000 rpm
3.8L V6 Horsepower:
Approximately 230 hp @ 5800 rpm (early models), 258 hp @ 6000 rpm (later models)
3.8L V6 Torque:
Approximately 250 lb-ft @ 4700 rpm (early models), 258 lb-ft @ 4500 rpm (later models)
Fuel System
Fuel Delivery:
Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Engine Management
Ignition System:
Electronic Ignition (Distributorless Ignition System - DIS on some models)
Emissions Control:
On-board diagnostics (OBD-II) system, catalytic converters, EGR system (if equipped), EVAP system.
🔧 Transmission
Standard
Transmission Type I4:
5-speed Manual Transmission (MT)
Optional
Transmission Type I4 V6:
4-speed Automatic Transmission (AT), 5-speed Automatic Transmission (INVECS-II with Sportronic)
Features
Sportronic Mode:
Driver-selectable manual shifting capability on automatic transmissions
Transmission Fluid Capacity
Atf Capacity Approximate:
Approximately 7-9 quarts (check manual for precise capacity)
📐 Dimensions
Exterior
Length:
Approximately 188.2 - 189.8 inches
Width:
Approximately 70.1 - 70.3 inches
Height:
Approximately 57.7 inches
Wheelbase:
Approximately 106.3 inches
Ground Clearance:
Approximately 5.7 inches
Weights
Curb Weight I4:
Approximately 3250 - 3400 lbs
Curb Weight V6:
Approximately 3500 - 3700 lbs
🛡️ Safety Features
Ratings
NHTSA Front Crash Test:
Generally rated 4 stars for driver and passenger (varies by model year and specific testing)
IIHS Front Offset Crash Test:
Acceptable to Good (depending on year and specific tests, some models may have had structural improvements over the generation)
Active Features
Braking System:
Front Ventilated Disc, Rear Solid Disc (ABS standard on most models)
Electronic Stability Control:
Electronic Stability Control (ESC) or Active Stability Control (ASC) became more widely available on later models.
Passive Features
Airbags:
Front driver and passenger airbags, side-impact airbags (optional on some trims)
Seatbelts:
Three-point seatbelts with pretensioners and load limiters
💡 Technology Features
Infotainment
Audio System Features:
AM/FM stereo, CD player, optional Rockford Fosgate premium audio system, steering wheel audio controls (on higher trims).
Driver Assistance
Traction Control:
Traction Control System (TCS) available on V6 models, and optional on some I4 trims.
Connectivity
Auxiliary Input:
Likely an optional auxiliary audio input jack (3.5mm) on later models or aftermarket integration.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 miles or 6 months (severe service), or 7,500 miles or 12 months (normal service) with synthetic blend or full synthetic oil.
Engine Coolant Replacement:
Initial replacement at 60,000 miles or 5 years, then every 30,000 miles or 3 years thereafter.
Timing Belt Replacement:
Not applicable; these models utilize a timing chain.
Fluid Specifications
Engine Oil Specification:
SAE 5W-30 API SN or newer (check owner's manual for precise specification based on climate)
Transmission Fluid Type At:
Diamond SP-III (or equivalent ATF)
Power Steering Fluid Type:
Power Steering Fluid (specific Mitsubishi fluid recommended, or DEXRON-III/VI compatible)
Engine Coolant Type:
Mitsubishi Super Long Life Coolant (or equivalent HOAT coolant, typically pink or red)
Known Issues
Engine Idling Problems:
Can be related to dirty throttle body, faulty Idle Air Control (IAC) valve, or vacuum leaks.
Transmission Hesitation:
Pre-facelift models with 4-speed automatic can exhibit delayed shifts or rough engagement. Software updates or internal transmission issues can occur.
Suspension Noise:
Worn sway bar links, ball joints, or control arm bushings can lead to clunking or rattling noises, particularly over bumps.
Power Window Motors:
Failure of power window regulators or motors is a common wear item.
📚 Vehicle History
Brand Heritage
Mitsubishi Legacy:
Mitsubishi Motors, a Japanese automaker with a long history in automotive manufacturing, known for performance-oriented vehicles like the Lancer Evolution and sporty coupes.
Model Evolution
Galant Ninth Generation:
The 2004-2010 Galant represents the ninth generation, a significant redesign from previous generations. It moved to a more muscular, American-market focused design. Initially launched with a 2.4L I4 and a 3.0L V6, the V6 was later upgraded to a 3.8L unit. A significant facelift occurred around the 2007 model year, improving styling and interior appointments.
Production
Manufacturing Location:
Normal, Illinois, USA (for North American market)
🏆 Awards & Recognition
Recognitions
Safety Awards:
Received varying safety ratings from NHTSA and IIHS; specific awards may not be prominent, but met federal safety standards.
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