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Mitsubishi Galant 2004 Workshop Service Repair Manual

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The Mitsubishi Galant, produced for the 2004 model year, is a mid-size sedan built on the Mitsubishi PS platform. Known for its distinctive wedge styling and comfortable interior, the Galant...
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Mitsubishi Galant 2004 Workshop Service Repair ManualMitsubishi Galant 2004 Workshop Service Repair ManualMitsubishi Galant 2004 Workshop Service Repair Manual
The Mitsubishi Galant, produced for the 2004 model year, is a mid-size sedan built on the Mitsubishi PS platform. Known for its distinctive wedge styling and comfortable interior, the Galant offered a choice between a 2.4L SOHC inline-4 engine producing approximately 140 horsepower, or an optional 3.0L SOHC V6 engine delivering around 195 horsepower. These front-wheel-drive vehicles were designed to provide a balance of features, comfort, and affordability, targeting families and commuters. Standard features often included anti-lock braking systems and front airbags, with optional side airbags and traction control available on select trims. This service repair manual in English provides comprehensive guidance for the 2004 Mitsubishi Galant. It covers all essential aspects of vehicle maintenance, diagnostics, and repair, including detailed procedures for the engine, transmission, brakes, electrical system, suspension, steering, HVAC, and body chassis. The manual offers step-by-step instructions for routine maintenance, troubleshooting common and complex issues, and complete overhauls of major components. It serves as an indispensable resource for owners, mechanics, and technicians to ensure the proper upkeep and repair of the vehicle.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Galant
Year:
2004
Codes
Platform:
Mitsubishi PS platform
👋 Introduction
Market Position
Segment:
Mid-size sedan
Target Audience:
Families, commuters, and those seeking a reliable and comfortable sedan with a focus on value.
Competitive Analysis
Key Competitors:
Toyota Camry, Honda Accord, Nissan Altima, Ford Fusion, Chevrolet Malibu.
Key Features
Design:
The 2004 Galant featured a distinctive 'wedge' styling and was known for its comfortable interior and generally reliable powertrain options.
Value Proposition:
Offered a balance of features, comfort, and affordability compared to some rivals, often with aggressive pricing.
📋 Manual Details
Coverage Areas
Manual Type:
Complete Official Factory Service Repair Manual
Language:
English
Format:
PDF Download
Page Count
Estimated Page Count:
Hundreds of pages (specific count not provided, but implied to be extensive)
📖 Manual Coverage
Systems Covered
Engine:
Covers all aspects of engine operation, including maintenance, diagnostics, repair, and overhaul for all available engine variants.
Transmission:
Detailed coverage of automatic and manual transmission systems, including removal, installation, overhaul, and diagnostics.
Brakes:
Comprehensive information on ABS, brake hydraulics, caliper and rotor service, parking brake, and troubleshooting brake system faults.
Electrical System:
Extensive coverage of the vehicle's electrical system, including wiring diagrams, component testing, diagnostics for lighting, ignition, charging, starting, and power accessories.
Suspension Steering:
Detailed procedures for front and rear suspension components, steering system maintenance, alignment specifications, and troubleshooting.
HVAC:
Information on air conditioning system service, refrigerant handling, climate control unit diagnostics, and heater core replacement.
Body Chassis:
Covers exterior and interior body panels, doors, windows, locks, and chassis component repairs.
Exhaust System:
Details on exhaust manifold, catalytic converter, mufflers, and pipe replacement.
Fuel System:
Coverage of fuel pump, injectors, fuel filter replacement, fuel pressure testing, and evaporative emission control (EVAP).
Procedures Included
Maintenance:
Includes routine maintenance procedures such as oil changes, filter replacements, fluid checks and top-offs, and tune-ups.
Diagnostics:
Detailed diagnostic flowcharts and troubleshooting steps for identifying and resolving common and complex vehicle issues.
Repair:
Step-by-step repair procedures for virtually all mechanical and electrical components of the vehicle.
Overhaul:
In-depth instructions for complete engine and transmission overhauls.
Troubleshooting:
Systematic approach to diagnosing and fixing various problems, often with detailed symptom-to-cause correlation.
Technical Depth
Depth:
Comprehensive, covering everything from basic scheduled maintenance to complex electrical diagnostics and complete engine rebuilds. Suitable for professional technicians and advanced DIY enthusiasts.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable due to being an official factory manual.
Print Quality
Printability:
Designed for printing, allowing users to print specific sections or the entire manual.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code 1:
4G64 (2.4L SOHC Inline-4)
Displacement 1:
2351 cc (2.4 Liters)
Horsepower 1:
140 hp @ 5500 rpm (approx.)
Torque 1:
147 lb-ft @ 3500 rpm (approx.)
Optional Engine
Engine Code 2:
6G72 (3.0L SOHC V6)
Displacement 2:
2972 cc (3.0 Liters)
Horsepower 2:
195 hp @ 5500 rpm (approx.)
Torque 2:
203 lb-ft @ 3750 rpm (approx.)
Fuel System
Fuel Delivery:
Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded gasoline
Engine Management
ECU Type:
Manufacturer-specific Engine Control Unit (ECU)
Emission Controls:
Catalytic converter, O2 sensors, EVAP system.
🔧 Transmission
Standard Transmission
Type 1:
4-speed Automatic (FWD)
Optional Transmission
Type 2:
5-speed Manual (available on some 4-cylinder models)
Features
FWD Layout:
All models are front-wheel drive.
Fluid Specification
Automatic Transmission Fluid:
Mitsubishi Diaqueen SPIII (or equivalent ATF SP III)
Fluid Capacity
Automatic Transmission Capacity:
Approximately 7.2 liters (7.6 US quarts) for a dry fill, less for a drain and refill.
📐 Dimensions
Exterior
Length:
4800 mm (189.0 inches)
Width:
1775 mm (69.9 inches)
Height:
1430 mm (56.3 inches)
Wheelbase:
2710 mm (106.7 inches)
Weights
Curb Weight Min:
Approximately 1460 kg (3219 lbs) for 4-cylinder manual.
Curb Weight Max:
Approximately 1550 kg (3417 lbs) for V6 automatic.
Cargo
Trunk Volume:
Approximately 0.42 cubic meters (15 cubic feet)
🛡️ Safety Features
Ratings
NHTSA Driver Front Impact:
Good (refer to specific NHTSA reports for exact year/testing conditions)
NHTSA Passenger Front Impact:
Good (refer to specific NHTSA reports for exact year/testing conditions)
Active Features
ABS:
Standard on most trims, Anti-lock Braking System.
Traction Control:
Optional on some models, Traction Control System (TCS).
Passive Features
Airbags Front:
Driver and front passenger airbags.
Airbags Side:
Optional front side-impact airbags.
Seatbelts:
Three-point seatbelts with pretensioners for front occupants.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD stereo system, some models may have premium audio with cassette tape player.
Navigation:
Optional factory navigation system was available on higher trim levels.
Driver Assistance
Cruise Control:
Standard on most trims.
Connectivity
Power Accessories:
Power windows, power door locks, power mirrors.
🔧 Maintenance
Service Intervals Oil
Oil Change Interval:
Every 7,500 miles or 6 months, whichever comes first (under normal driving conditions).
Fluid Specifications
Engine Oil Type:
API Certified SAE 5W-30 (Synthetic blend recommended).
Engine Oil Capacity:
4.5 liters (4.8 US quarts) with filter change for 2.4L, 4.2 liters (4.4 US quarts) with filter change for 3.0L V6.
Coolant Type:
Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based coolant with long-life additives).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid Type:
Mitsubishi Genuine Power Steering Fluid or equivalent DEXRON®-III (or compatible ATF).
Known Issues
Engine Mounts:
Wear and tear on engine mounts can lead to increased vibration and noise.
Timing Belt:
The 4G64 engine uses a timing belt that requires replacement at recommended intervals (e.g., 60,000-100,000 miles) to prevent catastrophic engine damage.
Catalytic Converter:
Can fail over time, leading to performance issues and check engine lights.
Automatic Transmission:
Some units may experience shifting issues or premature wear if not maintained properly.
Maintenance Schedule Summary
15K 30K Miles:
Oil change, filter replacement, tire rotation, inspect brakes, fluids, belts, hoses.
60K Miles:
Replace spark plugs, timing belt (if applicable), serpentine belt, inspect transmission fluid, coolant.
📚 Vehicle History
Brand Heritage
Manufacturer:
Mitsubishi Motors Corporation, a Japanese multinational automotive manufacturer.
Model Evolution
Generation 8:
The 2004 model year represents the final iteration of the eighth generation Galant (produced from 1998-2003 in Japan, with North American production continuing until 2004).
North American Market:
The Galant was a popular sedan in North America, known for its distinctive styling and value proposition.
Production
Manufacturing Location:
North American models were primarily assembled in Normal, Illinois, USA.
🏆 Awards & Recognition
Recognitions
Safety Award Example:
While specific awards for the 2004 model are less common, the Galant platform often received 'Good' ratings in IIHS crash tests for its generation.
Ratings
Consumer Reports General:
Consumer Reports typically rated the Galant as average to below-average in predicted reliability compared to segment leaders during this period, often citing issues with the transmission and electrical systems.
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