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Mitsubishi

Mitsubishi TJ RALLIART MAGNA 1996-2005 Service Repair Manual

Mitsubishi TJ RALLIART MAGNA 1996-2005 Service Repair Manual

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Vehicle data plateRef 495562
Brand
Mitsubishi
Vehicle
Cars
Models covered
MAGNA, Misc, RALLIART, TJ
Years
1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
Format
PDF, searchable, print-ready
Delivery
Instant download after checkout
Language
English

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🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Magna (TJ Ralliart)
Model Code:
TJ Series
Codes
Production Years:
1996-2005
👋 Introduction
Market Position
Vehicle Segment:
Mid-size family sedan and sport sedan (Ralliart variant).
Target Audience:
Owners seeking to perform their own maintenance and repairs, automotive enthusiasts, and independent repair shops.
Competitive Analysis
Key Competitors:
Holden Commodore, Ford Falcon, Toyota Camry, Nissan Maxima.
Key Features
Manual Highlight:
Most comprehensive service, maintenance, and repair manual available for the TJ Magna Ralliart.
Editorial Emphasis:
Focus on practical, step-by-step instructions and clear visual aids.
📋 Manual Details
Coverage Areas
Manual Coverage:
Comprehensive service, maintenance, and repair for Mitsubishi TJ Magna and Ralliart models.
Page Count
Page Count:
Extensive (specific number not provided, implies a very detailed manual)
Manual Type
Manual Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF, implied by sales context)
📖 Manual Coverage
Systems Covered
Engine Service:
Detailed repair procedures, diagnostics, and specifications for all engine variants.
Transmission Service:
Repair and maintenance for both automatic and manual transmissions.
Drivetrain Service:
Front-wheel drive and all-wheel drive system diagnostics and repair.
Suspension Steering:
Components, adjustments, and repair procedures for suspension and steering systems.
Brake Systems:
Diagnosis, repair, and maintenance of braking systems, including ABS.
Electrical Systems:
Wiring diagrams, component testing, and repair for all electrical systems.
Body And Interior:
Panel replacement, interior trim, and body hardware repair.
Climate Control:
HVAC system diagnosis and repair.
Fuel System:
Fuel injection system diagnostics, fuel pump, and injector service.
Cooling System:
Radiator, thermostat, and water pump service.
Exhaust System:
Catalytic converter, muffler, and exhaust pipe repair.
Safety Systems:
Airbag system diagnosis and repair.
Procedures Included
Preventive Maintenance:
Detailed service intervals and procedures for oil changes, filter replacements, and fluid checks.
Troubleshooting Guides:
Systematic diagnostic procedures for common and uncommon faults.
Engine Rebuilds:
Step-by-step instructions for engine disassembly, overhaul, and reassembly.
Transmission Overhaul:
Detailed procedures for rebuilding automatic and manual transmissions.
Brake Pad Rotor Replacement:
Clear instructions for servicing braking components.
Electrical Component Testing:
Guidance on testing sensors, actuators, and control modules.
Timing Belt Replacement:
Crucial procedures for timing belt service.
Suspension Alignment:
Specifications and procedures for wheel alignment.
Technical Depth
Depth Of Information:
Encompasses basic maintenance to complex component-level repairs and diagnostics.
Diagnostic Capabilities:
Includes diagnostic trouble codes (DTCs), symptom-based troubleshooting, and component tests.
Special Tools:
Identification and usage instructions for specialized tools required for certain repairs.
Torque Specifications:
Precise torque values for all critical fasteners.
Exploded Views:
Detailed diagrams showing component assembly and disassembly order.
Wiring Diagrams:
Comprehensive electrical schematics for all vehicle systems.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Print Quality
Image Resolution:
High-resolution, ensuring clarity of diagrams and text.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Quality:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Code Magna:
6G72 (3.0L V6 SOHC) and 6G74 (3.5L V6 SOHC/DOHC)
Engine Code Ralliart:
6G74 (3.5L V6 DOHC MIVEC)
Performance
Horsepower 3.0L:
Approximately 195-210 hp (varies by year/spec)
Horsepower 3.5L:
Approximately 200-240 hp (varies by year/spec)
Horsepower Ralliart 3.5L Mivec:
Approximately 243 hp
Torque 3.0L:
Approximately 200-215 lb-ft
Torque 3.5L:
Approximately 215-230 lb-ft
Torque Ralliart 3.5L Mivec:
Approximately 240 lb-ft
Fuel System
Fuel Injection Type:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Ignition System:
Distributorless Ignition System (DIS) or Coil-on-Plug (COP)
🔧 Transmission
Standard
Standard Transmission Magna:
4-speed Automatic (e.g., F4A51)
Optional
Optional Transmission Magna:
5-speed Manual (certain trims/years)
Transmission Ralliart:
5-speed Manual or 5-speed 'INVECS-II' Sports Mode Automatic
Features
Transmission Fluid Magna Auto:
DIAQueen ATF-SP II M or equivalent
Transmission Fluid Manual:
Gear Oil API GL-4 or GL-5, SAE 75W-90
📐 Dimensions
Exterior
Wheelbase Approx:
2700-2730 mm (depending on model variant)
Length Approx:
4750-4850 mm
Width Approx:
1750-1780 mm
Height Approx:
1400-1450 mm
Weights
Curb Weight Approx:
1450-1650 kg
Gross Vehicle Weight Rating Approx:
2000-2200 kg
🛡️ Safety Features
Ratings
Australian Ancap Rating:
Not rated for early models; later models improved.
Active Features
ABS:
Standard on most models, optional on early base models.
Traction Control:
Available on higher trims and Ralliart model.
Passive Features
Airbags:
Driver and passenger airbags standard from mid-production onwards; side airbags optional on later models.
Seatbelts:
Pre-tensioning front seatbelts.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM radio with cassette player, optional CD player. Upgradable to modern head units.
Driver Assistance
Cruise Control:
Available on most models.
Parking Sensors:
Optional on later models.
Connectivity
Auxiliary Input:
Not standard; aftermarket solutions required.
🔧 Maintenance
Service Intervals
Oil Change Interval Engine Oil:
Every 10,000 km or 6 months, whichever comes first (check manual for specific engine type).
Oil Filter Replacement:
At every oil change.
Air Filter Replacement:
Every 20,000 km or 12 months.
Spark Plug Replacement 3.0L:
Approximately 60,000 km (depending on spark plug type - platinum recommended).
Spark Plug Replacement 3.5L Mivec:
Approximately 80,000-100,000 km (Iridium type).
Timing Belt Replacement:
Every 100,000 km or 5 years (critical interval for 6G7 engines).
Fluid Specifications
Engine Oil Spec:
API SG/SH/SJ or ACEA A2/A3, SAE 10W-30 or 10W-40 (check manual for ambient temperature suitability).
Coolant Spec:
Mitsubishi Super Long Life Coolant (LLC) or equivalent ethylene glycol-based coolant, mixed 50/50 with distilled water.
Brake Fluid Spec:
DOT 3 or DOT 4 Brake Fluid.
Known Issues
Common Issue Engine Mounts:
Wear and tear on engine mounts can lead to vibrations.
Common Issue Automatic Transmission:
Some models may experience solenoid issues or torque converter shudder.
Common Issue Suspension Components:
Worn ball joints, control arm bushings, and sway bar links are common with age and mileage.
Common Issue Oil Leaks:
Leaking valve cover gaskets or oil pan seals.
Common Issue Timing Belt Tensioner:
Failure to replace timing belt and tensioner per schedule can lead to catastrophic engine damage.
📚 Vehicle History
Brand Heritage
Parent Company:
Mitsubishi Motors Corporation, Japan.
Model Evolution
Tj Generation:
Third generation Mitsubishi Magna, building on the previous TR/TS series.
Ralliart Introduction:
The Ralliart name was applied to performance-oriented versions of the Magna, often featuring enhanced engines, suspension, and styling.
Design Philosophy:
Focus on comfort, space, and respectable performance for a family sedan, with Ralliart pushing sportier capabilities.
Production
Manufacturing Location:
Mitsubishi Motors Australia (MMA) plant in Tonsley Park, South Australia.
Production End Reason:
Discontinuation of Australian manufacturing operations by Mitsubishi.
🏆 Awards & Recognition
Recognitions
Local Market Success:
The Magna was a significant player in the Australian market, often praised for its value and features for the price.
Ratings
Car Reviews General Sentiment:
Generally positive reviews for comfort, space, and performance, particularly for V6 models. Ralliart models noted for improved dynamics.
Certifications
Manufacturing Standards:
Built to Mitsubishi's global manufacturing standards, adapted for Australian market requirements.

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Check the model year and engine before you buy

Manufacturers change procedures, wiring and part numbers between model years and engine options. If your VIN plate shows a year or engine code that is not listed on the data plate above, contact us with the model, year and VIN and we will confirm coverage before you order.

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