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Mitsubushi GALANT Complete Workshop Repair Manual 1996-2003

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This manual covers the Galant, produced for the North American market between 1996 and 2003. Known for its distinctive styling and often offering a sporty driving experience, particularly in its...
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Mitsubushi GALANT Complete Workshop Repair Manual 1996-2003
This manual covers the Galant, produced for the North American market between 1996 and 2003. Known for its distinctive styling and often offering a sporty driving experience, particularly in its VR-4 variant, the Galant was a competitive mid-size sedan. This generation featured a range of engine options, including efficient four-cylinder engines and powerful V6 and turbocharged variants, paired with either manual or automatic transmissions, with all-wheel drive available on performance models. The Galant was engineered to provide a balance of comfort, performance, and value, often standing out with its unique design cues and available advanced features for its time. This comprehensive workshop repair manual is designed to be an indispensable resource for maintaining and repairing your Galant. It provides in-depth coverage of all major vehicle systems, including detailed procedures for engine mechanical and electrical components, fuel and exhaust systems, transmissions (manual and automatic), drivetrain, suspension, steering, brakes, and body and chassis systems. You will find step-by-step instructions for routine maintenance, advanced diagnostics, troubleshooting common issues, and complete repair procedures, all supported by essential technical specifications, torque values, and wiring diagrams. This manual empowers owners and technicians with the knowledge to keep the Galant in optimal condition.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Galant
Generation Code:
E3_A, E5_A, E7_A, E8_A, EA
Model Years Covered:
1996-2003
👋 Introduction
Market Position
Vehicle Segment:
Mid-size Sedan (often positioned as a sporty or upscale alternative)
Competitive Set:
Honda Accord, Toyota Camry, Nissan Altima, Ford Taurus, Chevrolet Lumina
Competitive Analysis
Galant Strengths:
Unique styling (especially during this generation), often good value, available V6 engines, sporty handling in some trims
Galant Weaknesses:
Interior materials perceived as less premium than some rivals, reliability perception varied by engine/transmission
Key Features
Manual Value Proposition:
Empowers owners to perform repairs, saving significant costs compared to dealership or independent shop labor.
Manual Ease Of Use:
Designed to make repair jobs easy to do with clear instructions and detailed diagrams.
📋 Manual Details
Coverage Areas
Primary Coverage:
North American Market (primarily, but covers global variants where applicable)
Specific Markets:
USA, Canada, Mexico
Page Count
Estimated Pages:
2000+
Manual Type
Type:
Complete Workshop Repair Manual
Language
Language:
English
Format
Digital Format:
Downloadable (PDF likely)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, block, pistons, crankshaft, camshafts, timing, lubrication, cooling
Engine Electrical:
Ignition system, starting system, charging system, engine control (ECU), sensors, actuators
Fuel System:
Fuel tank, pump, lines, injectors, fuel pressure regulator, emissions control (EVAP)
Transmission Manual:
Clutch, gearshift mechanism, gearbox overhaul, removal/installation
Transmission Automatic:
Transmission removal/installation, overhaul, torque converter, valve body, hydraulic control
Drivetrain:
Axles, CV joints, differential, drive shafts
Suspension:
Front and rear suspension components, struts, shocks, control arms, bushings, springs
Steering:
Steering column, rack and pinion, power steering system (pump, lines, fluid)
Brakes:
Front and rear brakes (discs/drums), ABS system, hydraulic lines, master cylinder, calipers, parking brake
Body Chassis:
Frame, body panels, doors, hood, trunk, bumpers, glass, seals
Electrical Body:
Lighting (headlights, taillights, interior), wipers, horn, power windows, power locks, mirrors, antenna
HVAC:
Air conditioning, heating, ventilation system, blower motor, climate control unit, refrigerant, cabin filter
Interior:
Seats, dashboard, trim panels, airbags, seatbelts
Procedures Included
Maintenance Tasks:
Oil changes, filter replacements, tune-ups, fluid checks and replacements, brake pad/shoe replacement
Diagnostic Procedures:
Troubleshooting guides, fault code interpretation (OBD-II), symptom-based diagnostics
Repair Procedures:
Component removal, disassembly, reassembly, adjustment, replacement
Special Tools:
Identification and usage of specialized tools for specific repair tasks
Wiring Diagrams:
Comprehensive electrical circuit diagrams for all systems
Torque Specifications:
Precise torque values for all critical fasteners
Technical Depth
Depth:
Full rebuild procedures for major components (engine, transmission)
Diagnostics Level:
Advanced diagnostics, including circuit testing and component troubleshooting
Completeness:
Professional quality, in-depth service and repair information
📊 Manual Specifications
File Format
Digital Format:
Likely PDF, optimized for PC, MAC, Tablets & Smartphones
Searchability:
Searchable text content for quick information retrieval
Print Quality
Printability:
Printable pages for physical reference
Binding Type
Digital Binding:
N/A (downloadable file)
Paper Type
Digital Paper Type:
N/A (digital format)
⚙️ Engine Specifications
Primary Engine
Engine Code Common 1:
4G63 (2.0L DOHC Turbo - VR-4 model)
Engine Code Common 2:
6G72 (3.0L SOHC V6)
Engine Code Common 3:
4G93 (1.8L SOHC)
Engine Code Common 4:
4G94 (2.4L DOHC)
Performance
Hp 2.4L:
Approximately 140-150 hp (depending on year and specific variant)
Hp 3.0L V6:
Approximately 195-200 hp
Hp 4G63 Turbo (Vr-4):
Approximately 240-280 hp (factory figures, often higher with modifications)
Torque 2.4L:
Approximately 150-160 lb-ft
Torque 3.0L V6:
Approximately 200-210 lb-ft
Torque 4G63 Turbo (Vr-4):
Approximately 250-280 lb-ft
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Recommended Fuel:
Unleaded gasoline (Octane rating varies by engine, premium recommended for V6 and Turbo)
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual (availability varies by trim and engine)
Optional
Transmission Type Optional:
4-speed Automatic (Invvecs-II Sportronic on some models)
Features
AWD Availability:
Available on VR-4 model, featuring viscous coupling center differential and limited-slip rear differential.
Sportronic Transmission:
Manual shifting mode for automatic transmission on select models, allowing driver control over gear selection.
📐 Dimensions
Exterior
Length:
Approx. 187-189 inches (varies slightly by year/trim)
Width:
Approx. 70 inches
Height:
Approx. 55-57 inches
Wheelbase:
Approx. 104.4 inches
Weights
Curb Weight:
Approx. 3000-3400 lbs (varies by engine and trim)
🛡️ Safety Features
Ratings
NHTSA Ratings:
Varies by year; typically 4-star frontal driver, 3-star frontal passenger in some years. Side impact ratings may vary.
Active Features
ABS:
Standard on most models by mid-production, optional or standard on others.
Traction Control:
Available on higher trims, particularly with V6 and AWD.
Passive Features
Airbags:
Driver and passenger front airbags standard on most models. Side airbags optional or available on later models.
Seatbelts:
Front pretensioners and load limiters.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/Cassette/CD players, optional premium audio systems (e.g., Infinity).
Climate Control:
Manual or automatic climate control systems available depending on trim level.
Driver Assistance
Cruise Control:
Standard or available on most models.
Keyless Entry:
Available on higher trim levels.
Connectivity
OBD Ii Port:
Standard for diagnostic trouble codes (DTCs) on 1996 and newer vehicles.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 3,750 to 5,000 miles or 6 months (refer to manual for specific engine/oil type).
Air Filter Replacement:
Every 30,000 miles or as needed based on driving conditions.
Spark Plug Replacement:
Platinum tipped plugs typically 60,000-100,000 miles; standard plugs 30,000 miles (verify type).
Timing Belt Replacement:
Crucial for 4G63/4G93 engines (non-interference recommended at 60,000 miles, interference at 70,000-90,000 miles). Consult manual for specific engine type.
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 5W-30 or 10W-30 recommended (verify with manual for specific engine/climate).
Coolant Type:
Ethylene glycol based antifreeze, typically a green or orange coolant. Refer to manual for specific type and mix ratio.
Transmission Fluid Atf:
Mitsubishi DIA Queen ATF-J2 or equivalent for automatics. Manual transmission fluid API GL-4 or GL-5.
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Common Issues Engine:
Oil leaks (valve cover gasket, oil pan gasket), piston ring wear (high mileage 4G63/4G93), radiator issues, potential for head gasket failure on high-mileage V6s.
Common Issues Transmission:
Automatic transmission harsh shifting or failure (especially earlier models), clutch wear in manuals.
Common Issues Suspension:
Worn suspension bushings, premature strut/shock absorber wear, front end noises.
Common Issues Electrical:
Window regulator failures, power lock actuator issues, alternator problems, sensor failures (e.g., crankshaft position sensor).
📚 Vehicle History
Brand Heritage
Mitsubishi Reputation:
Known for rally heritage (Lancer Evolution), innovative technologies, and robust engineering, though sometimes overlooked in mainstream segments.
Model Evolution
Previous Generations:
The Galant has a long history dating back to the 1960s, with various design and platform changes.
8Th Generation Debut:
This generation (1994-2004 globally, 1996-2003 in North America) marked a significant styling shift with a more aerodynamic and rounded design compared to its predecessor.
Platform Sharing:
Shared platform elements with other Mitsubishi models of the era, including the Eclipse and Endeavor in some aspects.
Production
Manufacturing Locations:
Primarily Japan, with some assembly in other global locations.
🏆 Awards & Recognition
Recognitions
Past Awards:
While specific major awards for this generation are not prominent, the Galant was generally well-regarded for its styling and performance, especially in VR-4 trim, often competing well within its segment.
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