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Mitsubishi Galant 1996 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Galant Year: 1996 Codes Chassis Code: E3_A, E3_9 Engine Codes: 4G93 (1.8L SOHC), 4G63 (2.0L DOHC MPI), 6A12 (2.0L V6 SOHC MPI), 6A12TT...
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Type: Car
Vendor:
Sku: 149009
Mitsubishi Galant 1996 Service Repair ManualMitsubishi Galant 1996 Service Repair ManualMitsubishi Galant 1996 Service Repair ManualMitsubishi Galant 1996 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Galant
Year:
1996
Codes
Chassis Code:
E3_A, E3_9
Engine Codes:
4G93 (1.8L SOHC), 4G63 (2.0L DOHC MPI), 6A12 (2.0L V6 SOHC MPI), 6A12TT (2.0L V6 Twin Turbo MPI)
👋 Introduction
Market Position
Segment:
Mid-size sedan.
Target Audience:
Families and individuals seeking reliable and comfortable transportation with a sporty driving experience.
Competitive Analysis
Competitors:
Honda Accord, Toyota Camry, Nissan Altima, Mazda 626, Ford Taurus.
Key Features
Design:
Aerodynamic styling, spacious interior, available all-wheel drive (AWD) on some variants.
Performance:
Responsive engines, including a potent V6 and an available twin-turbo V6 (VR-4 model), balanced handling.
Value Proposition:
Good balance of performance, comfort, and reliability for its class.
📋 Manual Details
Coverage Areas
Coverage:
Comprehensive service and repair for all major vehicle systems.
Page Count
Pages:
Estimated 1000+ pages (typical for a full factory service manual)
Manual Type
Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, block, crankshaft, connecting rods, pistons, timing belt/chain, valve train.
Engine Electrical:
Ignition system, starter motor, alternator, battery, charging system, engine control unit (ECU), sensors (crankshaft position, camshaft position, MAP, TPS, O2), fuel injection system.
Fuel System:
Fuel tank, fuel pump, fuel lines, fuel filter, fuel injectors, fuel pressure regulator.
Transmission Manual:
Clutch, gearbox assembly, gear shifting mechanisms, removal and installation.
Transmission Automatic:
Torque converter, transmission control unit (TCU), valve body, planetary gear sets, hydraulic circuits, removal and installation.
Drivetrain:
Driveshafts, CV joints, differential, front and rear axles.
Suspension:
Front suspension (MacPherson struts), rear suspension (multi-link), control arms, springs, shock absorbers, stabilizers.
Steering:
Steering column, steering rack, power steering pump, hydraulic lines, steering wheel.
Brakes:
Front and rear brakes (disc/drum configurations), ABS system, brake calipers, rotors, pads, master cylinder, brake lines, parking brake.
Electrical System:
Wiring diagrams, fuses, relays, lighting (headlights, taillights, interior), power windows, power locks, mirrors, wipers, horn, climate control blower motor.
HVAC:
Air conditioning system, heater core, blower motor, climate control panel, refrigerant recharge.
Body And Frame:
Body panel removal/installation, door mechanisms, hood, trunk, bumpers, glass replacement, interior trim.
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, exhaust pipes.
Cooling System:
Radiator, water pump, thermostat, coolant hoses, cooling fan.
Procedures Included
Scheduled Maintenance:
Oil changes, filter replacements, fluid checks and changes, spark plug replacement, timing belt replacement intervals.
Diagnostic Troubleshooting:
Step-by-step diagnostic procedures for common and uncommon issues, including DTC (Diagnostic Trouble Code) interpretation.
Component Repair:
Detailed instructions for removing, inspecting, repairing, and reinstalling major components and sub-assemblies.
Overhaul:
Complete engine and transmission overhaul procedures with specifications.
Wiring Diagrams:
Comprehensive electrical wiring schematics for all vehicle systems.
Specifications Data:
Torque specifications, clearances, fluid capacities, timing specifications, etc.
Special Tools:
Identification and usage instructions for specialized tools required for specific repairs.
Technical Depth
Depth:
Factory-level diagnostic and repair procedures, suitable for professional technicians but accessible to experienced DIY enthusiasts.
📊 Manual Specifications
File Format
Quality:
High-resolution scans, searchable text (OCR'd), printable pages.
Print Quality
Resolution:
Clear and legible text and diagrams.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine 1 Variant:
1.8L SOHC 16-valve Inline-4 (4G93)
Engine 1 Displacement:
1830 cc
Engine 1 Power:
Approximately 110-120 hp
Engine 1 Torque:
Approximately 120-130 lb-ft
Engine 2 Variant:
2.0L DOHC 16-valve MPI Inline-4 (4G63)
Engine 2 Displacement:
1997 cc
Engine 2 Power:
Approximately 140-150 hp
Engine 2 Torque:
Approximately 130-140 lb-ft
Engine 3 Variant:
2.0L SOHC 24-valve MPI V6 (6A12)
Engine 3 Displacement:
1998 cc
Engine 3 Power:
Approximately 140-150 hp
Engine 3 Torque:
Approximately 130-140 lb-ft
Engine 4 Variant:
2.0L V6 Twin Turbo MPI (6A12TT - VR-4)
Engine 4 Displacement:
1998 cc
Engine 4 Power:
Approximately 240 hp
Engine 4 Torque:
Approximately 250-260 lb-ft
Performance
Fuel Type:
Unleaded Gasoline
Fuel System
Injection Type:
Multi-Point Fuel Injection (MPI)
Fuel Octane Rating:
87 octane minimum (91 recommended for V6 Twin Turbo)
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transmission
Optional
Transmission Type Optional:
4-speed Automatic Transmission (INVECS-II)
Features
Transmission Features:
Available All-Wheel Drive (AWD) with viscous coupling center differential, especially on VR-4 models. Sportronic (manual shift mode) on some automatic transmissions.
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90
Automatic Transmission Fluid:
DIAQueen ATF SP-III or equivalent
📐 Dimensions
Exterior
Length:
Approximately 4660 mm (183.5 in)
Width:
Approximately 1750 mm (68.9 in)
Height:
Approximately 1390 mm (54.7 in) for coupe, 1420 mm (55.9 in) for sedan
Wheelbase:
Approximately 2700 mm (106.3 in)
Weights
Curb Weight:
Approximately 1300-1550 kg (2866-3417 lbs) depending on trim and drivetrain
Gross Vehicle Weight Rating:
Varies by model, typically around 1800-2000 kg
Cargo
Trunk Volume:
Approximate: Sedan - 14.5 cu ft, Coupe - 10.3 cu ft
🛡️ Safety Features
Ratings
NHTSA Driver Side Impact:
Not explicitly rated by NHTSA for 1996 model year publicly available data, but generally considered safe for its era.
IIHS Crash Test Performance:
Information not readily available for specific 1996 IIHS ratings.
Active Features
ABS:
Anti-lock Braking System (ABS) available on most models, standard on some higher trims.
Traction Control:
Traction Control System (TCS) available on higher performance models (e.g., VR-4).
Passive Features
Airbags:
Driver and passenger front airbags.
Seatbelts:
3-point front and rear seatbelts, pretensioners for front seatbelts.
Rollover Protection:
Reinforced body structure for side impact protection.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo cassette player with optional CD changer. Speaker configurations vary by trim.
Climate Control:
Manual or automatic climate control systems available, depending on trim level.
Driver Assistance
Cruise Control:
Standard on most trims.
Connectivity
Connectivity Features:
Limited by era; primarily focused on basic audio and vehicle controls. No integrated Bluetooth or smartphone connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first.
Engine Oil Filter Replacement:
At every oil change.
Air Filter Replacement:
Every 15,000 miles (24,000 km) or annually.
Spark Plug Replacement:
Every 60,000 miles (96,000 km) for standard plugs, or 100,000 miles (160,000 km) for platinum-tipped plugs.
Timing Belt Replacement:
Every 60,000 miles (96,000 km) or 5 years, whichever comes first (critical for interference engines).
Fluid Specifications
Engine Oil Type:
API SG, SJ, or ILSAC GF-2, SAE 5W-30 or 10W-30 (check owner's manual for specific climate recommendations).
Coolant Type:
Ethylene glycol based antifreeze, 50/50 mixture with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Power Steering Fluid:
Automatic Transmission Fluid (ATF) Dexron II or equivalent.
Known Issues
Engine Issues:
Timing belt failure (if not replaced on schedule), head gasket leaks on some V6 engines, oil leaks from valve cover gaskets and front crankshaft seal.
Transmission Issues:
Automatic transmission failure or harsh shifting (often due to fluid degradation or solenoid issues), clutch wear on manual transmissions.
Suspension Issues:
Worn ball joints, control arm bushings, and tie rod ends; premature wear of struts/shocks.
Electrical Issues:
Corroded ground points, failing power window motors, HVAC blower resistor failure, intermittent dashboard warning lights.
Rust:
Susceptible to rust in areas with road salt, particularly around wheel arches, rocker panels, and subframes.
📚 Vehicle History
Brand Heritage
Heritage:
Mitsubishi Motors Corporation, a Japanese multinational automotive manufacturer with a history dating back to 1917.
Model Evolution
Generation:
Fifth Generation (1991-1995 for some markets, updated for 1996 onwards in North America as a facelifted model)
Major Updates 1996:
Facelift including revised front and rear styling, updated interior features, and engine improvements. Introduction of the powerful 6A12TT V6 Twin Turbo engine for the VR-4 model.
Production
Manufacturing Location:
Japan
Production Years:
Globally: 1991-1999 (specific generation details may vary by market).
🏆 Awards & Recognition
Recognitions
Awards And Accolades:
While no specific prominent awards are widely cited for the 1996 model, the Galant generation generally received positive reviews for its styling, performance (especially VR-4), and handling in its class during the mid-1990s.
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