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Mitsubishi Galant 2004-2009 Service Repair Workshop Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Galant Model Years: 2004, 2005, 2006, 2007, 2008, 2009 Codes Chassis Codes: DJ1A Platform: Mitsubishi PS platform 👋 Introduction Market Position Segment: Mid-size...
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Sku: 167001
Mitsubishi Galant 2004-2009 Service Repair Workshop ManualMitsubishi Galant 2004-2009 Service Repair Workshop ManualMitsubishi Galant 2004-2009 Service Repair Workshop ManualMitsubishi Galant 2004-2009 Service Repair Workshop Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Galant
Model Years:
2004, 2005, 2006, 2007, 2008, 2009
Codes
Chassis Codes:
DJ1A
Platform:
Mitsubishi PS platform
👋 Introduction
Market Position
Segment:
Mid-size sedan
Target Audience:
DIY enthusiasts, independent repair shops, and owners seeking detailed maintenance and repair information.
Competitive Analysis
Key Competitors:
Honda Accord, Toyota Camry, Nissan Altima, Ford Fusion, Chevrolet Malibu.
Key Features
Value Proposition:
Provides comprehensive factory-level information at a fraction of the cost of dealership service, enabling owners to perform maintenance and repairs themselves.
Benefits:
Cost savings on repairs, extended vehicle lifespan through proper maintenance, improved understanding of vehicle systems.
📋 Manual Details
Coverage Areas
Geographical Coverage:
Global (with potential regional variations noted for certain specifications)
Page Count
Estimated Pages:
Approximately 2500-3000 pages (typical for a comprehensive factory service manual)
Manual Type
Type:
Factory Service Repair Workshop Manual
Language
Language:
English
Format
Format:
Downloadable PDF
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnosis, repair, and overhaul procedures for all engine variants, including timing belt/chain service, ignition system, fuel system, lubrication, cooling, and emissions control.
Transmission:
Comprehensive coverage of automatic and manual transmissions, including removal, installation, disassembly, assembly, hydraulic control, and electronic control unit (TCU) diagnosis.
Drivetrain:
Front-wheel drive (FWD) and All-wheel drive (AWD) systems, including CV axles, differentials, driveshafts, and hubs.
Brakes:
Front and rear brake systems (disc/disc or disc/drum), ABS, EBD, and traction control system diagnosis and repair.
Suspension:
Front and rear suspension components, including struts, shocks, control arms, bushings, springs, and alignment specifications.
Steering:
Power steering system diagnosis, repair, and fluid specifications; steering column and linkage components.
Electrical System:
Complete wiring diagrams, component locations, fuse and relay information, charging system, starting system, lighting, and accessory circuits.
HVAC:
Heating, ventilation, and air conditioning (HVAC) system service, including refrigerant handling, component replacement, and diagnostic procedures.
Body And Interior:
Body panel repair, door mechanisms, glass replacement, interior trim removal and installation, seats, and upholstery.
Restraint Systems:
Airbag system diagnosis, component replacement, and seatbelt service.
Procedures Included
Maintenance:
Scheduled maintenance intervals, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, spark plug service, and general inspections.
Troubleshooting:
Diagnostic charts and flowcharts for common symptoms and issues across all vehicle systems.
Repair:
Step-by-step instructions for component removal, repair, and reinstallation for virtually every part of the vehicle.
Diagnostics:
OBD-II diagnostic trouble codes (DTCs), sensor data interpretation, and advanced diagnostic techniques for Powertrain Control Module (PCM) and other control units.
Specifications:
Torque specifications, clearances, fluid capacities, and electrical values for all components.
Wiring Diagrams:
Detailed and color-coded wiring diagrams for all electrical systems.
Technical Depth
Depth:
Comprehensive. Covers everything from basic fluid checks and filter changes to full engine and transmission overhauls, complex electrical diagnostics, and bodywork repairs.
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Searchability:
Likely text-searchable due to the PDF format, allowing quick location of specific topics.
Print Quality
Quality:
High resolution, suitable for printing individual pages or the entire manual.
Binding Type
Binding:
N/A (Digital download)
Paper Type
Paper:
N/A (Digital download)
⚙️ Engine Specifications
Primary Engine
Engine Code 2.4L:
4G69 (MIVEC)
Displacement 2.4L:
2.4 Liters (2378 cc)
Configuration 2.4L:
Inline 4-cylinder, DOHC, 16 valves
Horsepower 2.4L:
Approximately 155-160 hp @ 6000 rpm (depending on market and specific tuning)
Torque 2.4L:
Approximately 160-165 lb-ft @ 4000 rpm
Optional Engine
Engine Code 3.8L:
6G75
Displacement 3.8L:
3.8 Liters (3797 cc)
Configuration 3.8L:
V6, SOHC, 24 valves
Horsepower 3.8L:
Approximately 230-235 hp @ 5700 rpm
Torque 3.8L:
Approximately 255-260 lb-ft @ 4000 rpm
Fuel System
System:
Multi-point fuel injection (MPI)
Recommended Fuel:
87 Octane Unleaded Gasoline (91 Octane recommended for 3.8L V6 for optimal performance)
🔧 Transmission
Standard
Transmission Type 4Cyl:
5-speed manual
Optional
Transmission Type Auto:
4-speed automatic (INVECS-II)
Transmission Type V6:
4-speed automatic (INVECS-II) or 5-speed automatic (INVECS-II Sports Mode)
Features
AWD Availability:
Available on select trims (often with the V6 engine), utilizing Mitsubishi's All-Wheel Control (AWC) system.
📐 Dimensions
Exterior
Length:
Approximately 190.4 inches (4836 mm)
Width:
Approximately 70.1 inches (1780 mm)
Height:
Approximately 57.5 inches (1460 mm)
Wheelbase:
Approximately 106.3 inches (2700 mm)
Weights
Curb Weight:
Approximately 3200 - 3500 lbs (1450 - 1590 kg) depending on engine and trim.
Gross Vehicle Weight Rating:
Varies by model, typically around 4300 lbs (1950 kg).
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
Good (for 2004 models)
NHTSA Front Impact Passenger:
Good (for 2004 models)
IIHS Front Offset Crash Test:
Acceptable (for models tested)
Active Features
ABS:
Standard Anti-lock Braking System
Ebd:
Standard Electronic Brake-force Distribution
Traction Control:
Available (often with AWD models)
Passive Features
Airbags:
Front airbags, available side-impact airbags, available curtain airbags.
Seatbelts:
Three-point seatbelts with pretensioners and load limiters.
Child Seat Anchors:
LATCH (Lower Anchors and Tethers for CHildren) system.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/CD stereo system, often with steering wheel audio controls on higher trims. Premium Rockford Fosgate audio system was an option.
Navigation:
Optional factory navigation system available on some higher trim levels.
Driver Assistance
Cruise Control:
Standard cruise control.
Remote Keyless Entry:
Available on most trims.
Automatic Climate Control:
Available on higher trim levels.
Connectivity
Auxiliary Input:
Typically not standard; aftermarket solutions may be required for modern device connectivity.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,750 miles (6,000 km) or 3 months for severe driving conditions, or 7,500 miles (12,000 km) or 6 months for normal driving, using synthetic oil. Consult manual for specific details.
Air Filter Replacement:
Recommended every 15,000 miles (24,000 km) or annually. Inspect more frequently.
Spark Plug Replacement 4Cyl:
Iridium spark plugs typically recommended at 100,000 miles (160,000 km).
Spark Plug Replacement V6:
Platinum spark plugs typically recommended at 60,000 miles (96,000 km).
Timing Belt Replacement:
If equipped with a timing belt (4G69 uses a belt), typically 60,000-100,000 miles (96,000-160,000 km) or 5-7 years. Highly critical for this engine.
Fluid Specifications
Engine Oil Type:
SAE 5W-30, API SN or ILSAC GF-5 certified. Consult manual for exact specifications and capacity.
Coolant Type:
Mitsubishi DIA-Queen SUPER LONG LIFE COOLANT (or equivalent long-life ethylene glycol-based coolant, typically pink or orange).
Transmission Fluid Automatic:
DIA-Queen ATF J2 or equivalent ATF. Capacity varies, approximately 3.5-4.5 quarts for a drain and fill.
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Engine Mounts:
Premature wear and cracking of engine mounts, leading to increased vibration.
Automatic Transmission:
Some models may experience rough shifting or occasional hesitation in the automatic transmission, particularly at higher mileage.
Suspension Components:
Front sway bar links and bushings can wear out, causing clunking noises.
Ignition Coils:
Coil-on-plug ignition systems can be prone to failure, causing misfires.
📚 Vehicle History
Brand Heritage
Mitsubishi History:
Mitsubishi Motors Corporation, a Japanese multinational automotive manufacturer, has a history dating back to 1917, known for its innovative engineering and durable vehicles.
Model Evolution
Galant Generation:
This refers to the ninth generation of the Mitsubishi Galant (DJ1A chassis), which was a significant redesign from its predecessor.
Design Philosophy:
The ninth generation Galant featured a more aggressive and aerodynamic styling, reflecting a sportier image compared to previous generations.
Production
Production Period:
2003 (as a 2004 model year) through 2007 in North America, with production continuing in other markets until 2012.
Manufacturing Location Na:
Normal, Illinois, USA.
🏆 Awards & Recognition
Recognitions
Consumer Reports Ratings:
Ratings varied by model year and specific issues; some years received average or below-average reliability ratings from sources like Consumer Reports.
Safety Awards:
Achieved good ratings in IIHS and NHTSA crash tests for its time, contributing to its safety appeal.
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