Mitsubishi Galant 1992 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Galant Year: 1992 Codes Chassis Code: E3_A (for Sedan), E3_W (for Wagon) Engine Codes: 4G63 (2.0L SOHC/DOHC), 4G64 (2.4L SOHC) 👋 Introduction Market Position Segment: Mid-size sedan and wagon, competing in a crowded segment against models like the Toyota Camry, Honda Accord, and Ford Taurus. Competitive Analysis Strengths: Known for its sporty handling (especially with the 4-wheel steering option on some trims), DOHC engine performance, and distinctive styling of the E3_A generation. Weaknesses: Perceived reliability concerns compared to some Japanese competitors, potential for rust in certain climates, interior material quality. Key Features Performance Trims: GT, GSR trims often featured the potent 4G63 DOHC engine and sport-tuned suspension. Optional Technologies: All-wheel steering (AWS), Anti-lock Braking System (ABS), optional leather upholstery, premium audio systems. 📋 Manual Details Coverage Areas Primary Coverage: North American Market Models (USDM, CDN, MSpec) Secondary Coverage: May include some specifications relevant to JDM/EDM variants where applicable. Page Count Estimated Pages: 1500-2000 (estimated, as exact count not provided in product info, typical for comprehensive service manuals of this era) Manual Type Type: Factory Service Manual / Repair Manual Language Language: English Format Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, engine performance, fuel system, ignition system, exhaust system, engine cooling system, lubrication system. Transmission Drivetrain: Manual transmission (W5MG1, KM132), Automatic transmission (F4A41, F4A42), driveline components (axles, CV joints, driveshafts), clutch system. Chassis Suspension Steering: Front suspension (MacPherson strut), rear suspension (multi-link), steering system (power steering), wheel alignment specifications. Brakes: Front disc brakes, rear drum brakes (standard), optional rear disc brakes, ABS system (where equipped), hydraulic system, parking brake. Electrical Electronic: Battery, charging system, starting system, lighting system, instrument cluster, engine control unit (ECU) and sensors, body control modules, audio system, power windows, power mirrors, climate control. Body Interior: Body construction, exterior trim, interior trim, seats, door mechanisms, glass, HVAC system (heater, air conditioning). Procedures Included Maintenance: Scheduled maintenance (oil changes, filter replacements, fluid checks), tune-up procedures, inspection points. Repair: Detailed step-by-step repair instructions for all major systems, including engine disassembly/reassembly, transmission overhaul, suspension component replacement, brake caliper servicing. Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting guides, electrical diagnostic charts, common fault codes (OBD-I). Specifications Data: Torque specifications, clearances, fluid capacities, electrical resistance values, diagnostic parameters. Technical Depth Depth: Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, including electrical system diagnostics and body repairs. Geared towards professional technicians but accessible for experienced DIYers. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable if original document was digitized with OCR. Print Quality Quality: Dependent on source digitization; generally good for clarity of diagrams and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Code 1: 4G63 Displacement 1: 2.0 Liters (1997 cc) Configuration 1: Inline 4-cylinder, DOHC 16-valve (for performance variants), SOHC 8-valve (for base models) Horsepower 1: Approx. 135-145 hp (SOHC), 195-200 hp (DOHC Turbocharged - rare in North America for '92, more common in '90-'91 models or JDM) Torque 1: Approx. 125-130 lb-ft (SOHC), 200-210 lb-ft (DOHC Turbocharged) Secondary Engine Engine Code 2: 4G64 Displacement 2: 2.4 Liters (2351 cc) Configuration 2: Inline 4-cylinder, SOHC 8-valve Horsepower 2: Approx. 130-140 hp Torque 2: Approx. 138-145 lb-ft Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded gasoline (Octane rating recommended in manual, typically 87 or 89). 🔧 Transmission Standard Transmission Type 1: 5-speed Manual Transmission (e.g., KM132, W5MG1 for performance models) Optional Transmission Type 2: 4-speed Automatic Transmission (e.g., F4A41, F4A42) with lock-up torque converter Features Manual Gear Ratios: Specific gear ratios available in manual for each transmission model (e.g., KM132 1st: 3.58, 2nd: 2.04, 3rd: 1.37, 4th: 1.00, 5th: 0.83, Reverse: 3.54) Automatic Modes: Sport/Economy mode selection on some automatic transmissions. Fluid Specifications Manual Transmission Fluid: API GL-4, SAE 75W-90 (or as specified in manual). Automatic Transmission Fluid: DIAQueen ATF-SP II M (or equivalent Dexron II/III compatible fluid, check manual for precise spec). 📐 Dimensions Exterior Wheelbase: Approx. 104.3 inches (2650 mm) Length: Approx. 180.5 inches (4585 mm) for sedan Width: Approx. 69.1 inches (1755 mm) Height: Approx. 54.1 inches (1375 mm) for sedan Weights Curb Weight: Varies by trim and options, typically 2900-3300 lbs (1315-1500 kg). Gross Vehicle Weight Rating: Specified by trim level, generally around 4000-4200 lbs (1814-1905 kg). 🛡️ Safety Features Ratings NHTSA Crash Test Results: NHTSA data from this era is less comprehensive than modern standards. Refer to individual vehicle reports if available. Active Features ABS: Optional Anti-lock Braking System (ABS) available on select models, typically front wheels only or front and rear. Aws: Optional All-Wheel Steering (AWS) available on some higher trims (e.g., LS, ES), enhancing maneuverability. Passive Features Airbags: Driver-side airbag was standard on most trims for 1992 in the US. Passenger airbag was not common. Seatbelts: 3-point...

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Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Galant

Year:

Codes

Chassis Code:

E3_A (for Sedan), E3_W (for Wagon)

Engine Codes:

4G63 (2.0L SOHC/DOHC), 4G64 (2.4L SOHC)

👋 Introduction

Market Position

Segment:

Mid-size sedan and wagon, competing in a crowded segment against models like the Toyota Camry, Honda Accord, and Ford Taurus.

Competitive Analysis

Strengths:

Known for its sporty handling (especially with the 4-wheel steering option on some trims), DOHC engine performance, and distinctive styling of the E3_A generation.

Weaknesses:

Perceived reliability concerns compared to some Japanese competitors, potential for rust in certain climates, interior material quality.

Key Features

Performance Trims:

GT, GSR trims often featured the potent 4G63 DOHC engine and sport-tuned suspension.

Optional Technologies:

All-wheel steering (AWS), Anti-lock Braking System (ABS), optional leather upholstery, premium audio systems.

📋 Manual Details

Coverage Areas

Primary Coverage:

North American Market Models (USDM, CDN, MSpec)

Secondary Coverage:

May include some specifications relevant to JDM/EDM variants where applicable.

Page Count

Estimated Pages:

1500-2000 (estimated, as exact count not provided in product info, typical for comprehensive service manuals of this era)

Manual Type

Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

PDF (Digital Download)

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, engine performance, fuel system, ignition system, exhaust system, engine cooling system, lubrication system.

Transmission Drivetrain:

Manual transmission (W5MG1, KM132), Automatic transmission (F4A41, F4A42), driveline components (axles, CV joints, driveshafts), clutch system.

Chassis Suspension Steering:

Front suspension (MacPherson strut), rear suspension (multi-link), steering system (power steering), wheel alignment specifications.

Brakes:

Front disc brakes, rear drum brakes (standard), optional rear disc brakes, ABS system (where equipped), hydraulic system, parking brake.

Electrical Electronic:

Battery, charging system, starting system, lighting system, instrument cluster, engine control unit (ECU) and sensors, body control modules, audio system, power windows, power mirrors, climate control.

Body Interior:

Body construction, exterior trim, interior trim, seats, door mechanisms, glass, HVAC system (heater, air conditioning).

Procedures Included

Maintenance:

Scheduled maintenance (oil changes, filter replacements, fluid checks), tune-up procedures, inspection points.

Repair:

Detailed step-by-step repair instructions for all major systems, including engine disassembly/reassembly, transmission overhaul, suspension component replacement, brake caliper servicing.

Troubleshooting:

Diagnostic flowcharts, symptom-based troubleshooting guides, electrical diagnostic charts, common fault codes (OBD-I).

Specifications Data:

Torque specifications, clearances, fluid capacities, electrical resistance values, diagnostic parameters.

Technical Depth

Depth:

Comprehensive, covering basic maintenance to complete engine and transmission rebuilds, including electrical system diagnostics and body repairs. Geared towards professional technicians but accessible for experienced DIYers.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable if original document was digitized with OCR.

Print Quality

Quality:

Dependent on source digitization; generally good for clarity of diagrams and text.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

Displacement 1:

2.0 Liters (1997 cc)

Configuration 1:

Inline 4-cylinder, DOHC 16-valve (for performance variants), SOHC 8-valve (for base models)

Horsepower 1:

Approx. 135-145 hp (SOHC), 195-200 hp (DOHC Turbocharged - rare in North America for '92, more common in '90-'91 models or JDM)

Torque 1:

Approx. 125-130 lb-ft (SOHC), 200-210 lb-ft (DOHC Turbocharged)

Secondary Engine

Engine Code 2:

Displacement 2:

2.4 Liters (2351 cc)

Configuration 2:

Inline 4-cylinder, SOHC 8-valve

Horsepower 2:

Approx. 130-140 hp

Torque 2:

Approx. 138-145 lb-ft

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI)

Fuel Type:

Unleaded gasoline (Octane rating recommended in manual, typically 87 or 89).

🔧 Transmission

Standard Transmission

Type 1:

5-speed Manual Transmission (e.g., KM132, W5MG1 for performance models)

Optional Transmission

Type 2:

4-speed Automatic Transmission (e.g., F4A41, F4A42) with lock-up torque converter

Features

Manual Gear Ratios:

Specific gear ratios available in manual for each transmission model (e.g., KM132 1st: 3.58, 2nd: 2.04, 3rd: 1.37, 4th: 1.00, 5th: 0.83, Reverse: 3.54)

Automatic Modes:

Sport/Economy mode selection on some automatic transmissions.

Fluid Specifications

Manual Transmission Fluid:

API GL-4, SAE 75W-90 (or as specified in manual).

Automatic Transmission Fluid:

DIAQueen ATF-SP II M (or equivalent Dexron II/III compatible fluid, check manual for precise spec).

📐 Dimensions

Exterior

Wheelbase:

Approx. 104.3 inches (2650 mm)

Length:

Approx. 180.5 inches (4585 mm) for sedan

Width:

Approx. 69.1 inches (1755 mm)

Height:

Approx. 54.1 inches (1375 mm) for sedan

Weights

Curb Weight:

Varies by trim and options, typically 2900-3300 lbs (1315-1500 kg).

Gross Vehicle Weight Rating:

Specified by trim level, generally around 4000-4200 lbs (1814-1905 kg).

🛡️ Safety Features

Ratings

NHTSA Crash Test Results:

NHTSA data from this era is less comprehensive than modern standards. Refer to individual vehicle reports if available.

Active Features

Optional Anti-lock Braking System (ABS) available on select models, typically front wheels only or front and rear.

Optional All-Wheel Steering (AWS) available on some higher trims (e.g., LS, ES), enhancing maneuverability.

Passive Features

Airbags:

Driver-side airbag was standard on most trims for 1992 in the US. Passenger airbag was not common.

Seatbelts:

3-point front seatbelts with pretensioners, 3-point rear seatbelts. Lap belt for center rear occupant.

Child Safety:

Rear door child safety locks, LATCH anchor points were not standard in this era.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with cassette player. Optional CD player and premium sound systems (e.g., Mitsubishi/Infinity).

Climate Control:

Manual climate control (heater and A/C). Automatic climate control may have been an option on top trims.

Driver Assistance

Cruise Control:

Standard on most higher trims, optional on base models.

Power Features:

Power windows, power door locks, power mirrors were common options/standard on higher trims.

Connectivity

Early Electronic Features:

While not 'connectivity' as we know it today, this era saw the introduction of more sophisticated ECU control and diagnostics (OBD-I).

🔧 Maintenance

Service Intervals

Engine Oil Filter Change:

Every 3,750 - 7,500 miles (6,000 - 12,000 km) or 6-12 months, depending on driving conditions and oil type used (consult manual for specifics).

Air Filter Replacement:

Every 15,000 - 30,000 miles (24,000 - 48,000 km) or as needed based on inspection.

Spark Plug Replacement:

Every 30,000 - 60,000 miles (48,000 - 96,000 km) for standard plugs, potentially longer for platinum-tipped plugs.

Timing Belt Replacement:

Crucial for 4G63/4G64 engines. Typically every 60,000 - 90,000 miles (96,000 - 144,000 km) or 5-7 years. **Non-interference engines will still have damage if belt breaks, but catastrophic failure is less common than interference engines.** Verify specific engine type in manual.

Fluid Specifications

Engine Coolant:

Mitsubishi Super Long Life Coolant (or equivalent ethylene glycol-based coolant with corrosion inhibitors), typically 50/50 mix with distilled water. Capacity approx. 6.3 quarts (6.0 L).

Brake Fluid:

DOT 3 or DOT 4 Brake Fluid (check manual for precise specification). Flush and replace every 2-3 years.

Power Steering Fluid:

ATF (Automatic Transmission Fluid) type A or Dexron II (check manual).

Known Issues

Engine Oil Leaks:

Common for valve cover gaskets, oil pan gaskets, and crankshaft/camshaft seals to degrade over time.

Suspension Wear:

Worn ball joints, tie rod ends, and strut mounts can lead to noise and poor handling.

Electrical Gremlins:

Corroded grounds, failing relays, and degraded wiring harnesses can cause intermittent electrical issues.

Rust Corrosion:

Prone to rust on wheel arches, rocker panels, and subframes, especially in regions with road salt.

Automatic Transmission Issues:

Some automatic transmissions can develop issues with solenoids or torque converters at higher mileage.

📚 Vehicle History

Brand Heritage

Mitsubishi Motors:

Founded in 1970, Mitsubishi Motors Corporation is a Japanese multinational automotive manufacturer with a history of producing innovative and durable vehicles, including sporty performance cars and reliable sedans.

Model Evolution

Galant E3 A Generation:

The 1992 model year marks the facelift and continuation of the fifth generation (E3_A) Galant, introduced in late 1987. This generation featured a more aerodynamic design and offered front-wheel drive and optional all-wheel drive, along with advanced features like AWS.

Performance Variants:

The Galant VR-4, a rally-homologation model featuring a turbocharged 4G63 engine and AWD, was a significant halo model for this generation, though the '92 US market didn't receive the full VR-4 spec directly. Performance variants like the GT or GSR carried elements of this sporty DNA.

Production

Manufacturing Locations:

Primarily produced in Japan (Mizushima Plant, Okayama Prefecture) and also assembled in various global locations under license or CKD kits.

Production Years

E3 A Generation Production:

1987-1993

🏆 Awards & Recognition

Recognitions

Car And Driver 10Best:

The E3_A Galant generation (specifically the GSR and AWD versions) was often praised by automotive journalists for its handling and performance, and was a frequent contender or recipient of '10Best' lists from publications like Car and Driver.

Automotive Journalism Praise:

The Galant, particularly the performance-oriented variants, was recognized for its engaging driving dynamics and sophisticated chassis design for its time.