Mitsubushi GALANT Service Repair Workshop Manual 1996-2003

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类型: Car

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标签: 1996 1997 1998 1999 2000 2001 2002 2003 Car GALANT Mitsubishi Mitsubushi

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Description

Welcome to the comprehensive service and repair manual for the Mitsubishi Galant, Eighth Generation, produced from 1996 to 2003. This model, known for its distinctive styling and engaging driving dynamics, offered a competitive package in the mid-size sedan market, with notable features including available all-wheel drive and turbocharged performance on its acclaimed VR-4 variants. Engineered with a focus on reliability and driver enjoyment, the Galant provided a comfortable ride and a good value proposition, making it a popular choice against contemporaries like the Honda Accord and Toyota Camry. This manual covers all trim levels, from the ES to the performance-oriented VR-4, across global markets. This workshop manual is your definitive guide to understanding, maintaining, and repairing your Mitsubishi Galant. It provides in-depth coverage of all major systems, including detailed procedures for engine mechanicals, fuel and ignition systems, manual and automatic transmissions, drivetrain components, suspension, steering, brakes, and the complete electrical system. You will find step-by-step instructions for routine maintenance, complex diagnostics, component rebuilds, and troubleshooting common issues. With over 1500 pages of information, this manual is designed to empower owners, mechanics, and technicians with the knowledge required to perform professional-level service and ensure the longevity and optimal performance of your vehicle.

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Galant

Model Generation:

Eighth Generation (1996-2003)

Product Name:

Mitsubishi Galant Service Repair Workshop Manual 1996-2003

Codes

Chassis Codes:

E50, E60, E70, E80

👋 Introduction

Market Position

Market Segment:

Mid-size sedan, known for its sporty handling and available performance variants (especially the VR-4).

Competitive Analysis

Key Competitors:

Honda Accord, Toyota Camry, Nissan Altima, Ford Taurus, Chevrolet Lumina.

Key Features

Vehicle Highlights:

Distinctive styling, comfortable ride, available all-wheel drive and turbocharged engine on VR-4 models, good value proposition.

Manual Value Proposition

Technician Grade Info:

Provides the same level of detail and accuracy as manuals used by dealership technicians, enabling DIYers and independent shops to perform professional-level service.

📋 Manual Details

Coverage Areas

Geographic Coverage:

Global (specific regional variations may exist for certain components/specifications, but the core mechanical and electrical information is comprehensive)

Trim Level Coverage:

All trim levels (e.g., ES, LS, GS, GT, VR-4)

Page Count

Estimated Page Count:

1500+ (typical for comprehensive workshop manuals of this era)

Manual Type

Manual Type:

Factory-Authorized Service and Repair Workshop Manual

Language

Language:

English

Format

Format:

Likely Printed Manual or Digital PDF (as commonly sold for older vehicles)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, diagnosis, repair, timing belt/chain, lubrication, cooling system, emissions control systems

Engine Management:

Fuel injection system (MPI), ignition system, electronic control unit (ECU) diagnosis and programming, sensor testing

Transmission Manual:

Clutch system, gearbox assembly, disassembly, repair, shift linkage, torque specifications

Transmission Automatic:

Automatic transmission assembly, disassembly, diagnosis, repair, valve body, torque converter, hydraulic control, ATF specifications

Drivetrain:

Front-wheel drive (FWD), all-wheel drive (AWD) system (especially for VR-4 models), differential, driveshafts, CV joints, wheel bearings

Suspension:

Front and rear suspension components, shock absorbers, struts, control arms, bushings, springs, anti-roll bars, alignment specifications

Steering:

Power steering system, steering gear, steering column, tie rods, power steering fluid specifications

Brakes:

Brake system components (calipers, rotors, pads, master cylinder, brake lines), anti-lock braking system (ABS) diagnosis and repair, parking brake, brake fluid specifications

Electrical System:

Battery, charging system (alternator), starting system (starter motor), wiring diagrams, fuses, relays, lighting system, horn

Body And Interior:

Body panel removal/installation, door mechanisms, interior trim, seats, airbags, climate control system (HVAC), body sealing

Comfort And Convenience:

Power windows, power locks, mirrors, sunroof, cruise control, remote keyless entry (if equipped)

Safety Systems

Airbags:

Airbag system components, SRS control unit, diagnostic procedures, safety precautions during servicing

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, spark plug replacement, fluid checks and top-offs, tire rotation

Diagnostics:

Troubleshooting flowcharts, symptom-based diagnostics, OBD-II diagnostic trouble codes (DTCs) and their interpretations

Repair Procedures:

Step-by-step instructions for component removal, overhaul, and reinstallation

Component Rebuild:

Detailed instructions for rebuilding engines, transmissions, and other major components

Electrical Troubleshooting:

Locating faults in electrical circuits using wiring diagrams, testing components

Technical Depth

Depth Of Information:

Comprehensive: Covers everything from basic fluid changes and filter replacements to complete engine and transmission overhauls, including complex electrical diagnostics and bodywork repairs.

📊 Manual Specifications

File Format

File Format:

If PDF: Searchable text, high-resolution diagrams, printable pages. If Printed: Clear typography, durable paper, organized layout.

Print Quality

Print Quality:

High-quality printing with clear, legible text and sharp, detailed diagrams and illustrations.

Binding Type

Binding Type:

If Printed: Likely spiral-bound or perfect-bound for durability and lay-flat usability in a workshop environment.

Paper Type

Paper Type:

If Printed: Heavy-duty paper stock suitable for workshop conditions, resistant to grease and dirt.

⚙️ Engine Specifications

Primary Engine

Engine Options:

2.4L (4G64) Inline-4, 3.0L (6G72) V6, 2.0L (4G63T) Turbocharged Inline-4 (VR-4)

Performance

Horsepower Range:

Approximately 145 hp (2.4L) to 280 hp (VR-4) depending on engine and market.

Torque Range:

Approximately 150 lb-ft (2.4L) to 280 lb-ft (VR-4) depending on engine and market.

Fuel System

Fuel Delivery:

Electronic Multi-Point Fuel Injection (MPI).

Engine Codes

Engine Codes:

4G64, 6G72, 4G63T

🔧 Transmission

Standard

Standard Transmission:

5-speed manual transmission.

Optional

Optional Transmission:

4-speed automatic transmission.

Features

AWD System:

Active All-Wheel Drive (AWD) with viscous coupling and planetary center differential (standard on VR-4 models).

📐 Dimensions

Exterior

Wheelbase:

Approximately 105.1 inches (2670 mm).

Length:

Approximately 186.8 inches (4745 mm).

Width:

Approximately 69.5 inches (1765 mm).

Height:

Approximately 55.1 inches (1400 mm).

Weights

Curb Weight:

Varies by model and equipment, typically ranging from 3100 lbs to 3600 lbs.

🛡️ Safety Features

Ratings

NHTSA Ratings:

Information not readily available for specific model year ratings in a standardized format; refer to NHTSA archives for detailed crash test data.

Active Features

Anti-lock Braking System (ABS) available on most models.

Traction Control:

Traction Control System (TCS) available on some higher trims, particularly the VR-4.

Passive Features

Airbags:

Driver and front passenger airbags standard across most trims.

Seatbelts:

Three-point front and rear seatbelts, pretensioners for front seats.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with cassette player and optional CD player, with various speaker configurations.

Climate Control:

Manual or automatic climate control (HVAC) systems.

Driver Assistance

Cruise Control:

Standard on most higher trims.

Connectivity

Keyless Entry:

Optional remote keyless entry system.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 7,500 miles (12,000 km) or 6 months, whichever comes first, using synthetic or synthetic blend oil.

Timing Belt Replacement:

Recommended every 60,000 to 90,000 miles (96,000 to 145,000 km), critical for 6G72 V6 and 4G64 engines to prevent catastrophic damage.

Spark Plug Replacement:

Typically 30,000 to 60,000 miles, depending on plug type (copper, platinum, iridium).

Fluid Specifications

Engine Oil Type:

API Service SG or SH, viscosity SAE 5W-30 or 5W-40 (check owner's manual for specific conditions).

Coolant Type:

Ethylene glycol-based coolant (pink or green, typically a 50/50 mix with distilled water).

Automatic Transmission Fluid Type:

Mitsubishi ATF SP-II or equivalent.

Power Steering Fluid Type:

Dexron II or equivalent.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Known Issues

Common Problems:

Timing belt failure (if not replaced on schedule), transmission control issues (automatic), power window regulator failure, A/C compressor clutch failure, fuel pump failure, exhaust manifold cracks (V6).

Filter Part Numbers

Oil Filter Example:

Mitsubishi MD069802 or equivalent (e.g., Fram PH2, Wix 51515 - specific part numbers may vary).

Air Filter Example:

Mitsubishi MR188710 or equivalent (e.g., Fram CA3980, Wix 42351 - specific part numbers may vary).

📚 Vehicle History

Brand Heritage

Mitsubishi Motors History:

Founded in 1970, Mitsubishi Motors has a history of producing a diverse range of vehicles, including performance cars and reliable sedans. The Galant is a long-standing model in their lineup.

Model Evolution

Galant Generations:

The eighth generation (1996-2003) represented a significant styling update and incorporated advanced technologies for its time, aiming to compete with established Japanese and American sedans.

Production

Manufacturing Locations:

Primarily manufactured in Japan (Okazaki Plant) and North America (Normal, Illinois, USA).

🏆 Awards & Recognition

Recognitions

Model Accolades:

While specific major awards for the 1996-2003 Galant are not widely publicized, it was generally regarded as a competent and stylish sedan in its class, often praised for its value and handling, especially the VR-4 variant.