2002 Mitsubishi Galant Service & Repair Manual

This 2002 Mitsubishi Galant Service & Repair Manual Covers

• Complete factory workshop procedures
• Scheduled servicing and maintenance
• Engine repairs and overhaul
• Transmission servicing
• Mechanical repairs
• Electrical diagnostics
• Factory wiring diagrams
• Body repairs
• Diagnostic troubleshooting
• Technical specifications
• Component testing
• Preventative maintenance

Engine Options

Petrol

• 2.0L 4G63 DOHC Inline-4
• 2.4L 4G64 SOHC Inline-4
• 2.5L 6A13 V6
• 3.0L 6G72 V6

Transmission Options

• 5-speed manual transmission
• 4-speed INVECS-II automatic transmission

Engine and Drivetrain Repair Coverage

• Complete engine overhaul procedures
• Engine removal and installation
• Cylinder head servicing
• Valve train inspection and repair
• Timing belt replacement procedures
• Balance shaft timing procedures
• Camshaft servicing
• Crankshaft servicing
• Fuel injection system diagnostics
• Ignition system servicing
• Cooling system repairs
• Engine lubrication system servicing
• Intake and exhaust manifold repairs
• EVAP system diagnostics
• Emissions control servicing
• Manual transmission overhaul
• Automatic transmission diagnostics
• Clutch servicing
• Differential repairs
• Driveshaft servicing
• CV joint inspection and replacement

Chassis, Steering and Suspension

• Front MacPherson strut suspension servicing
• Rear multi-link suspension repairs
• Hydraulic power steering diagnostics
• Steering rack overhaul
• Wheel bearing replacement
• Ball joint servicing
• Suspension bush replacement
• Shock absorber servicing
• Coil spring inspection
• Stabiliser bar repairs
• Wheel alignment specifications

Braking Systems

• Hydraulic brake system servicing
• Front disc brake overhaul
• Rear disc brake servicing
• Rear drum brake servicing (where equipped)
• ABS diagnostics
• Brake booster inspection
• Brake master cylinder overhaul
• Brake line inspection
• Parking brake adjustment
• Wheel speed sensor diagnostics

Electrical Systems and Wiring

• Complete factory wiring diagrams
• Engine control module diagnostics
• Charging system testing
• Starting system diagnostics
• Alternator servicing
• Starter motor overhaul
• Battery testing
• Lighting system wiring
• Instrument cluster diagnostics
• Power window diagnostics
• Central locking repairs
• Power mirror wiring
• Cruise control diagnostics
• Audio system wiring
• Wiper and washer servicing
• Immobiliser diagnostics (where fitted)
• Relay testing
• Connector pin-outs
• Ground point locations
• Electrical circuit testing

Air Conditioning and HVAC

• Air conditioning diagnostics
• Heater unit servicing
• Compressor replacement
• Condenser servicing
• Evaporator repairs
• Refrigerant circuit testing
• HVAC control inspection
• Blower motor servicing
• Heater core replacement

Body, Interior and Restraint Systems

• SRS airbag diagnostics
• Seat belt pretensioner servicing
• Dashboard removal
• Door trim removal
• Window regulator servicing
• Power seat repairs (where fitted)
• Exterior lighting repairs
• Interior trim servicing
• Door lock servicing
• Boot lid adjustments
• Exterior mirror repairs
• Sunroof servicing (where fitted)

Diagnostics and Troubleshooting

• MUT-II factory diagnostic procedures
• Engine performance diagnostics
• Fuel system troubleshooting
• Misfire diagnostics
• Idle speed diagnostics
• Charging system testing
• Starting system diagnosis
• Automatic transmission diagnostics
• ABS troubleshooting
• SRS fault diagnosis
• Electrical circuit testing
• Sensor testing procedures
• Actuator testing
• Factory diagnostic flowcharts

Common Error Codes Covered

Engine Codes

• P0100 — Mass or Volume Air Flow Circuit Malfunction
• P0105 — Manifold Absolute Pressure/Barometric Pressure Circuit Malfunction
• P0115 — Engine Coolant Temperature Circuit Malfunction
• P0120 — Throttle Position Sensor Circuit Malfunction
• P0135 — Oxygen Sensor Heater Circuit Malfunction (Bank 1 Sensor 1)
• P0171 — System Too Lean (Bank 1)
• P0300 — Random/Multiple Cylinder Misfire Detected
• P0301 — Cylinder 1 Misfire Detected
• P0302 — Cylinder 2 Misfire Detected
• P0303 — Cylinder 3 Misfire Detected
• P0304 — Cylinder 4 Misfire Detected
• P0325 — Knock Sensor Circuit Malfunction
• P0335 — Crankshaft Position Sensor Circuit Malfunction
• P0340 — Camshaft Position Sensor Circuit Malfunction
• P0401 — Exhaust Gas Recirculation Flow Insufficient
• P0420 — Catalyst System Efficiency Below Threshold (Bank 1)
• P0442 — EVAP System Small Leak Detected
• P0455 — EVAP System Large Leak Detected
• P0505 — Idle Air Control System Malfunction

Transmission Codes

• P0700 — Transmission Control System Malfunction
• P0715 — Input/Turbine Speed Sensor Circuit Malfunction
• P0720 — Output Speed Sensor Circuit Malfunction
• P0730 — Incorrect Gear Ratio
• P0733 — Gear 3 Incorrect Ratio
• P0743 — Torque Converter Clutch Solenoid Electrical
• P0750 — Shift Solenoid A Malfunction
• P0755 — Shift Solenoid B Malfunction

ABS and Chassis Codes

• C1015 — Front Right Wheel Speed Sensor Circuit
• C1020 — Front Left Wheel Speed Sensor Circuit
• C1210 — Brake Pressure Sensor Fault
• C2116 — ABS Pump Motor Circuit Fault

Network Communication Codes

• U1100 — CAN Communication Line Error
• U1101 — Engine and Transmission Communication Error

Body Control Codes

• B1206 — Driver Door Lock Circuit Malfunction
• B1213 — Passenger Door Lock Circuit Malfunction
• B2404 — Blower Motor Circuit Malfunction

Plus many other codes included in the manual.

Fuse Box Diagram

• Engine compartment fuse box layout
• Passenger compartment fuse box layout
• Fuse identification chart
• Relay locations
• Fuse amperage ratings
• Protected circuit identification
• Power distribution diagrams

Wiring Diagrams

• Engine management wiring
• Fuel injection wiring
• Ignition system wiring
• Charging system wiring
• Starting system wiring
• Automatic transmission wiring
• Manual transmission wiring
• ABS wiring
• SRS wiring
• Air conditioning wiring
• Lighting circuits
• Instrument cluster wiring
• Power windows
• Central locking
• Cruise control
• Audio system wiring
• Connector views
• Ground point diagrams

Serpentine Belt and Timing System Information

• Timing belt replacement procedures
• Balance shaft timing procedures
• Camshaft timing specifications
• Timing mark illustrations
• Crankshaft timing procedures
• Timing belt inspection limits
• Timing belt tension adjustment
• Accessory drive belt routing
• Drive belt tension specifications

Torque Specifications

• Cylinder head bolt torque
• Main bearing cap torque
• Connecting rod bolt torque
• Crankshaft pulley torque
• Camshaft sprocket torque
• Flywheel and flexplate torque
• Wheel nut torque
• Brake caliper torque
• Suspension fastener torque
• Steering component torque
• Engine mount torque
• Spark plug torque

Maintenance and Service Information

• Factory maintenance schedules
• Engine oil specifications
• Automatic transmission fluid specifications
• Manual transmission oil specifications
• Coolant specifications
• Brake fluid specifications
• Power steering fluid specifications
• Timing belt replacement intervals
• Spark plug replacement
• Air filter servicing
• Fuel filter replacement
• Drive belt inspection
• Brake inspection procedures
• Tyre rotation procedures
• Battery maintenance

Who Is This Manual For?

• New Zealand automotive workshops
• Independent repair garages
• Automotive technicians
• Auto electricians
• Diagnostic specialists
• Fleet maintenance teams
• DIY owners
• Automotive training institutions