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2002 Mitsubishi Galant Service Repair Manual

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The Mitsubishi Galant, produced for the 2002 model year, is a mid-size sedan celebrated for its distinctive styling, comfortable ride, and a balanced offering of performance and value. This generation,...
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2002 Mitsubishi Galant Service Repair Manual
The Mitsubishi Galant, produced for the 2002 model year, is a mid-size sedan celebrated for its distinctive styling, comfortable ride, and a balanced offering of performance and value. This generation, part of the eighth generation of the Galant lineage, was designed to compete with other popular sedans of its era, providing families and commuters with a reliable and refined transportation option. Available with either an efficient inline-4 or a more potent V6 engine, the Galant offered a responsive driving experience, further enhanced by its spacious interior and a suite of available technologies. Its commitment to safety was underscored by top safety ratings from the NHTSA, making it a well-rounded choice in the competitive automotive market. This comprehensive service and repair manual is designed for dealership and professional technicians, covering all essential aspects of the 2002 Mitsubishi Galant. It provides detailed, step-by-step instructions for routine maintenance, major repairs, and troubleshooting across all major vehicle systems, including engine mechanicals, powertrain, suspension, brakes, steering, and electrical components. Users will find in-depth information on diagnostic procedures, special tool usage, and technical specifications, ensuring accurate and efficient maintenance and repair. The manual's scope encompasses everything from basic fluid changes and filter replacements to complete engine overhauls and transmission rebuilds, serving as an authoritative resource for preserving the vehicle's performance and longevity.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Galant
Year:
2002
Codes
Platform Code:
M
Chassis Code:
E50/E70/E80 Series (specific to 2002 generation)
👋 Introduction
Market Position
Segment:
Mid-size sedan
Target Audience:
Families, commuters seeking a reliable and comfortable sedan.
Competitive Analysis
Competitors:
Honda Accord, Toyota Camry, Nissan Altima, Ford Taurus.
Key Features
Design:
Distinctive styling, spacious interior, comfortable ride.
Powertrain Options:
Responsive V6 engine, efficient inline-4 option.
Value Proposition:
Offering a balance of performance, comfort, and reliability at a competitive price point.
📋 Manual Details
Coverage Areas
Primary Coverage:
North America
Secondary Coverage:
Global markets with similar configurations
Page Count
Estimated Pages:
1500-2000 (typical for comprehensive service manuals)
Manual Type
Type:
Service and Repair Manual
Distinction:
Dealership/Professional Technician Level
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing system, lubrication, cooling.
Engine Performance:
Fuel injection, ignition system, emissions control, turbocharging (if applicable).
Transmission Manual:
Manual transmission: disassembly, assembly, gear ratios, clutch operation, synchronizers.
Transmission Automatic:
Automatic transmission: valve body, torque converter, planetary gear sets, hydraulic controls, electronic control unit.
Drivetrain:
Front-wheel drive, axles, CV joints, differential.
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, bushings, alignment specifications.
Brakes:
Front and rear brake systems, calipers, rotors, pads, master cylinder, ABS system, parking brake.
Steering:
Power steering system, steering rack, tie rods, steering column, wheel alignment.
Electrical System:
Battery, alternator, starter, ignition switch, lighting, power windows, locks, mirrors, wipers.
Body And Interior:
Body panels, doors, hood, trunk, bumpers, seats, dashboard, trim components, weatherstripping.
HVAC:
Heating, Ventilation, and Air Conditioning system: compressor, condenser, evaporator, blower motor, controls.
Diagnostics:
On-board diagnostics (OBD-II) systems, trouble codes, scan tool usage, diagnostic procedures.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement.
Major Repairs:
Engine overhaul, transmission rebuild, suspension component replacement, brake system repair, electrical component troubleshooting.
Troubleshooting:
System-specific diagnostic flowcharts, symptom-based troubleshooting guides, common problem identification.
Special Tools:
Identification and usage of specialized tools required for specific repair procedures.
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete component overhaul and diagnostics.
Detail Level:
Detailed step-by-step instructions, torque specifications, wiring diagrams, exploded views, component locations.
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, searchable text with clear vector-based diagrams.
Printability:
Printable pages for in-shop use.
Binding Type
Binding:
N/A (PDF format)
Paper Type
Paper:
N/A (PDF format)
⚙️ Engine Specifications
Primary Engine
Engine Code:
6G72 (3.0L V6)
Engine Type:
SOHC V6
Displacement:
2972 cc (3.0 Liters)
Bore X Stroke:
86.0 mm x 86.0 mm
Compression Ratio:
9.0:1
Horsepower Net:
200 hp @ 5500 rpm
Torque Net:
205 lb-ft @ 4500 rpm
Secondary Engine
Engine Code:
4G63 (2.4L Inline-4)
Engine Type:
DOHC Inline-4
Displacement:
2351 cc (2.4 Liters)
Horsepower Net:
140 hp @ 5500 rpm
Torque Net:
150 lb-ft @ 3500 rpm
Performance
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline (87 octane recommended)
Ignition System:
Electronic Ignition (Distributorless Ignition System - DIS on some models)
Emissions Control:
Catalytic converter, EGR system, evaporative emission control (EVAP).
🔧 Transmission
Standard
Transmission Type:
4-speed Automatic (F4A42)
Optional
Transmission Type:
5-speed Manual (F5M33)
Features
Automatic Features:
Electronically controlled, Lock-up torque converter.
Fluid Specifications
Automatic Transmission Fluid:
Diamond SP-III (or equivalent)
Manual Transmission Fluid:
GL-4 SAE 75W-90
📐 Dimensions
Exterior
Length:
186.0 inches
Width:
70.7 inches
Height:
56.7 inches
Wheelbase:
107.7 inches
Weights
Curb Weight:
3300 - 3500 lbs (approx.)
🛡️ Safety Features
Ratings
NHTSA Frontal Driver:
5 Stars (2002 Model Year)
NHTSA Frontal Passenger:
5 Stars (2002 Model Year)
IIHS Moderate Overlap Front:
Good (for similar vehicles of the era)
Active Features
ABS:
Standard (4-wheel Anti-lock Braking System)
Traction Control:
Optional on some V6 models
Passive Features
Airbags Front:
Driver and front passenger airbags (SRS)
Airbags Side:
Optional front side-impact airbags on higher trims
Seatbelts:
3-point front and rear seatbelts, pretensioners and load limiters for front seats.
💡 Technology Features
Infotainment
Audio System:
Optional Rockford Fosgate premium audio system, standard AM/FM/CD player.
Climate Control:
Manual or automatic climate control options.
Driver Assistance
Cruise Control:
Standard on most trims.
Keyless Entry:
Optional on some models.
Connectivity
OBD Ii Port:
Standard for diagnostics and emissions monitoring.
🔧 Maintenance
Service Intervals
Oil Change:
Every 3,750 miles or 3 months (severe conditions) / 7,500 miles or 6 months (normal conditions) using synthetic oil.
Engine Air Filter:
Inspect every 15,000 miles, replace as needed or every 30,000 miles.
Spark Plugs:
Replace every 60,000 miles (platinum or iridium type recommended).
Timing Belt:
Replace every 90,000 miles or 7 years (V6 engine).
Fluid Specifications
Engine Oil:
SAE 5W-30 (API Service SG or higher, or ILSAC GF-2 or higher)
Engine Coolant:
Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based coolant with distilled water)
Brake Fluid:
DOT 3
Known Issues
Engine Mounts:
Degradation of engine and transmission mounts leading to vibration.
Oxygen Sensors:
Premature failure of oxygen sensors, affecting fuel economy and emissions.
Automatic Transmission:
Occasional hard shifts or slippage, often related to fluid condition or valve body issues.
Power Steering:
Leaks from power steering hoses or pump failure.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors:
Founded in 1970, Mitsubishi Motors Corporation is a Japanese multinational automotive manufacturer.
Model Evolution
Galant Lineage:
The Galant nameplate has been used by Mitsubishi since 1969, with numerous generations and body styles.
Eighth Generation:
The 2002 model is part of the eighth generation (1996-2004), known for its distinctive styling and improved refinement.
Production
Manufacturing Location:
Primary assembly in North America (Normal, Illinois, USA) and Japan.
🏆 Awards & Recognition
Recognitions
Safety Awards:
The 2002 Galant received top safety ratings from NHTSA, contributing to its appeal.
Ratings
Consumer Reports:
Mixed reviews depending on the year and specific components, common for vehicles of this era to have some reliability concerns in certain areas.
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