Mitsubushi GALANT Workshop Repair Manual All 1996-2003 ModelS COVERED

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The Mitsubishi Galant, produced from 1996 through 2003, represents a notable entry in the mid-size sedan market. This generation, built on the 8th Generation platform (often referred to by chassis...

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Taper: Car

Distributeur:

UGS: 125775

Mots clés: 1996 1997 1998 1999 2000 2001 2002 2003 Car Cars GALANT Mitsubishi Mitsubushi

Variantes de produits

Description

The Mitsubishi Galant, produced from 1996 through 2003, represents a notable entry in the mid-size sedan market. This generation, built on the 8th Generation platform (often referred to by chassis codes like E50, E70, E80, E90, or the 'DJ-1' platform), was designed to offer a compelling blend of distinctive styling, comfortable ride quality, and competitive performance. Available with efficient 2.4L four-cylinder engines or more potent 3.0L V6 options, and in some markets with all-wheel drive capabilities, the Galant appealed to a broad range of drivers. Its engineering quality and reliability were key selling points, positioning it as a strong contender against established rivals in its segment. This comprehensive workshop repair manual is designed to serve as the definitive guide for maintaining and repairing your Mitsubishi Galant. It covers an extensive array of systems, including detailed procedures for engine mechanical and management, manual and automatic transmissions, drivetrain, suspension, steering, brakes, and the complete electrical system. Furthermore, the manual provides in-depth coverage of routine maintenance, troubleshooting common issues, component repair and replacement, overhauls, and necessary adjustments, all supported by detailed diagrams, illustrations, and torque specifications. Its scope ensures that both novice owners and professional technicians have the information needed to keep their Galant in optimal condition.

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Galant

Model Years Covered:

1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003

Codes

Platform Code:

8th Generation (E50/E70/E80/E90 chassis for early production, chassis codes vary by market and specific model, but generally refer to the 'DJ-1' platform for this generation).

👋 Introduction

Market Position

Positioning:

The Mitsubishi Galant of this generation was positioned as a mid-size sedan, often competing with models like the Toyota Camry, Honda Accord, and Ford Mondeo, offering a balance of comfort, performance, and value.

Competitive Analysis

Comparison:

This generation Galant featured distinct styling and offered various engine options, including efficient four-cylinders and more powerful V6 engines. Some models included advanced features for their time, such as all-wheel drive.

Key Features

Manual Value Proposition:

Provides comprehensive, accurate, and detailed repair information, enabling DIY enthusiasts and professional technicians to perform all necessary maintenance and repairs efficiently.

Vehicle Appeal:

Known for its distinctive styling, comfortable ride, and available V6 engines, the Galant offered a compelling option in the competitive mid-size sedan segment.

📋 Manual Details

Coverage Areas

Market Coverage:

Global (North America, Europe, Asia, etc. - specific market variations may exist, but manual aims for broad applicability)

Page Count

Estimated Page Count:

Extensive (Specific page count not provided, but typical workshop manuals for this era and complexity are often 1000+ pages)

Manual Type

Type:

Workshop Repair Manual / Service Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, cylinder head, pistons, connecting rods, crankshaft, timing system (belts/chains), lubrication system, cooling system, fuel injection system, exhaust system

Engine Management:

ECU (Engine Control Unit), sensors (MAP, TPS, O2, crank, cam), ignition system (coils, plugs), fuel delivery, emissions control systems (EVAP, EGR)

Transmission Manual:

Clutch system, gearbox assembly, internal components, shift mechanism, lubrication

Transmission Automatic:

Torque converter, valve body, planetary gear sets, hydraulic controls, transmission fluid, electronic controls, shift solenoids

Drivetrain:

Front-wheel drive (FWD) / All-wheel drive (AWD) systems, drive shafts, CV joints, differentials, wheel bearings

Suspension:

Front suspension (MacPherson struts, control arms, sway bar), rear suspension (multi-link, trailing arms, coil springs), shock absorbers, springs, bushings

Steering:

Power steering system (pump, rack, hoses), steering column, tie rods, steering linkage

Brakes:

Front and rear disc brakes (calipers, rotors, pads), anti-lock braking system (ABS) components (sensors, hydraulic unit), brake lines, master cylinder, parking brake

Electrical System:

Battery, charging system (alternator), starting system (starter motor), lighting system (headlights, taillights, interior), fuses, relays, wiring harnesses

Body And Chassis:

Body panel removal/installation, door mechanisms, glass, interior trim, frame straightening (basic), chassis components

Climate Control:

Air conditioning (compressor, condenser, evaporator, refrigerant), heating system (heater core, blower motor), HVAC controls

Safety Systems:

Airbag system (SRS components, sensors, control module), seat belt mechanisms

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspections

Troubleshooting:

Diagnostic procedures, symptom-based troubleshooting, error code interpretation

Repair And Replacement:

Component removal, disassembly, repair, reassembly, and installation for all major systems

Overhauls:

Engine and transmission overhaul procedures

Adjustments:

Valve adjustments, brake adjustments, clutch adjustments, alignment specifications

Torque Specifications:

Detailed torque values for critical fasteners across all systems

Technical Depth

Depth:

Comprehensive (Covers everything from basic maintenance to complete engine rebuilds and complex diagnostics)

Diagrams Illustrations:

Extensive (Includes exploded views, wiring diagrams, schematics, and step-by-step illustrations)

Diagnostic Codes:

Inclusion of OBD-II diagnostic trouble codes (DTCs) and troubleshooting pathways

📊 Manual Specifications

File Format

Compatibility:

PC & Mac Compatible (Windows 95, 98, 2000, NT, XP, Vista, 7, 8, and later versions supported)

Print Quality

Quality:

High Quality PDF (Designed for clarity and readability, supports printing)

Binding Type

Type:

N/A (Digital Download)

Paper Type

Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Options:

Common engines include the 2.4L 4-cylinder (4G64) and the 3.0L V6 (6G72). Specific engine variants depend on market and trim level.

Performance

2.4L 4G64 Power:

Approx. 140-150 hp (depending on specific model year and tuning)

3.0L V6 6G72 Power:

Approx. 190-205 hp (depending on specific model year and tuning)

Torque 2.4L:

Approx. 150-160 lb-ft

Torque 3.0L V6:

Approx. 200-215 lb-ft

Fuel System

Type:

Electronic Fuel Injection (EFI)

Fuel Type:

Unleaded Gasoline

Engine Mechanical

Timing Drive:

Timing Belt (for 4G64) or Timing Chain (for 6G72, typically). Manual covers replacement and adjustment procedures.

🔧 Transmission

Standard

Transmission Options:

5-speed manual transmission or 4-speed automatic transmission were common options, varying by market and trim level.

Optional

Drivetrain Options:

Front-Wheel Drive (FWD) standard on most models. All-Wheel Drive (AWD) available on specific performance-oriented trims (e.g., Galant VR-4 in some markets).

Features

Automatic Transmission Features:

Some models featured Sportronic (manual shifting mode) for the automatic transmission.

📐 Dimensions

Exterior

Body Styles:

Primarily 4-door sedan.

Wheelbase:

Approximately 104.5 inches (2654 mm) – may vary slightly by specific model.

Weights

Curb Weight:

Typically ranging from 3,100 to 3,500 lbs (1400-1600 kg), depending on engine and equipment.

🛡️ Safety Features

Ratings

Crash Test Performance:

While specific ratings can vary by testing agency and year, this generation generally performed acceptably for its time. The manual will detail SRS system components and safety features.

Active Features

Active Safety:

Anti-lock Braking System (ABS) available on many models. Traction Control System (TCS) may be present on higher trims.

Passive Features

Passive Safety:

Driver and front passenger airbags standard. Side airbags and seat belt pre-tensioners may be available on certain trims.

💡 Technology Features

Infotainment

Audio System:

Factory-installed AM/FM stereo with CD player or cassette, and speaker configurations varied by trim. Manual covers basic electrical troubleshooting for these systems.

Driver Assistance

Cruise Control:

Cruise control was a common feature, covered in the electrical systems section.

Connectivity

Remote Keyless Entry:

Available on many models, with troubleshooting for the receiver and transmitter covered in the electrical section.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 5,000 to 7,500 miles (8,000 to 12,000 km) or 6 months, depending on driving conditions. Manual will specify based on engine type and oil used.

Timing Belt Replacement:

For 4G64 engines, typically recommended every 60,000 to 90,000 miles (96,000 to 145,000 km). Crucial procedure covered in detail.

Fluid Specifications

Engine Oil:

Typically 5W-30 or 10W-30 synthetic or conventional oil meeting API or ILSAC specifications. Manual will provide precise recommendations and capacities.

Automatic Transmission Fluid:

Specific ATF type (e.g., ATF SP-II, SP-III or equivalent). Manual will specify the correct fluid and capacity.

Coolant:

Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Manual will specify type and capacity.

Brake Fluid:

DOT 3 or DOT 4 brake fluid. Manual will specify correct type and bleeding procedures.

Known Issues

Common Wear Items:

Exhaust system components, suspension bushings, CV joint boots, and potential for oil leaks from valve cover gaskets or oil pan gaskets.

Engine Performance Issues:

Possible issues with intake manifold gaskets, crank position sensors, and ignition components. Manual provides diagnostic steps.

Transmission Issues:

Over time, automatic transmission solenoids or valve bodies can develop issues. Manual includes diagnostic and repair procedures.

📚 Vehicle History

Brand Heritage

Mitsubishi Legacy:

Mitsubishi has a long history in automotive manufacturing, known for reliable vehicles and innovative technologies, including performance-oriented models and AWD systems.

Model Evolution

Eighth Generation:

The 8th generation Galant (1994-2003 globally, with North American introduction in 1999) featured a significant styling shift and chassis updates, offering a more aerodynamic and contemporary design compared to its predecessors.

Production

Manufacturing Locations:

Produced in various Mitsubishi plants globally, including Japan and the United States (Illinois for North American market).

🏆 Awards & Recognition

Recognitions

Industry Acknowledgments:

While specific major awards for this generation may not be as prominent as some competitors, the Galant was generally well-received for its styling and value proposition. The manual's comprehensive nature is its key 'award' for the owner.