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Mitsubishi Galant 1989-1993 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Galant Generation: E30/E40 Production Years Covered: 1989-1993 Codes Chassis Codes: E31, E32, E33, E34, E35, E38, E39, E43, E44, E45, E46, E47, E48 👋 Introduction Market Position Segment: Compact to mid-size sedan, known for its advanced styling and European-influenced design. Competitive Analysis Competitors: Honda Accord, Toyota Camry, Nissan Altima, Mazda 626, Ford Tempo, Chevrolet Corsica. Key Features Design Philosophy: Stylish, aerodynamic, and comfortable interior, often featuring advanced (for its time) technology and handling. Performance Variants: The availability of the turbocharged GSR model provided a performance-oriented option. 📋 Manual Details Coverage Areas Primary Coverage: All models and configurations of Mitsubishi Galant from 1989 to 1993 Engine Coverage: 4G37 1.8L, 4G63 2.0L (SOHC & DOHC), 4G63T 2.0L Turbocharged, 6A10 1.6L V6 (JDM), 6A11 1.8L V6 (JDM), 6A12 2.0L V6 (JDM) Transmission Coverage: 5-speed manual transaxle, 4-speed automatic transaxle Page Count Estimated Page Count: Extensive (Factory Service Manuals are typically 1000+ pages) Manual Type Type: Factory Service Repair Manual (FSM) Language Language: English Format Digital Format: PDF Archival Format: WinRAR 📖 Manual Coverage Systems Covered Engine: Detailed diagnostics, repair, overhaul procedures, component testing for all engine variants, including timing belt replacement, valve adjustments, and turbocharger systems. Fuel: Fuel injection system (MPI, GDI where applicable), fuel pump, injectors, pressure regulator, fuel filter replacement, and fuel tank service. Cooling: Radiator, water pump, thermostat, cooling fan operation, hoses, and coolant flush procedures. Intake And Exhaust: Intake manifold, throttle body, exhaust manifold, catalytic converter, muffler, and emissions control components. Emission Control: EGR system, PCV system, evaporative emission control (EVAP), and oxygen sensor diagnostics. Clutch: Clutch disc, pressure plate, release bearing, hydraulic clutch system, adjustment, and replacement. Manual Transaxle: Internal component inspection, gear engagement, synchronizers, seals, fluid changes, and clutch-related transaxle removal/installation. Automatic Transaxle: Transmission fluid type and capacity, valve body diagnostics, torque converter, shift solenoid operation, and complete overhaul procedures. Propeller Shaft: Driveshaft, universal joints, constant velocity (CV) joints (if applicable), and balancing. Front Axle: CV shafts, wheel bearings, steering knuckle, and hub assembly. Rear Axle: Suspension components, trailing arms, control arms, wheel bearings, and differential (if applicable). Wheel And Tire: Tire pressure recommendations, rotation, wheel balancing, alignment specifications, and wheel bolt torque. Power Plant Mount: Engine and transmission mount inspection and replacement. Front Suspension: MacPherson struts, control arms, ball joints, tie rod ends, sway bar, and alignment procedures. Active Electronic Control Suspension: Diagnostic and repair procedures for electronically controlled suspension systems (if equipped on specific trims/markets). Control Suspension: Standard suspension component diagnosis and repair. Rear Suspension: Multi-link independent suspension (common on this generation), shock absorbers, springs, bushings, and alignment. Service Brakes: Front disc brakes, rear drum or disc brakes, brake pad/shoe replacement, rotor/drum resurfacing/replacement, brake fluid type and bleeding procedures, ABS system diagnostics (if equipped). Parking Brakes: Parking brake system operation, adjustment, and cable replacement. Alphabetical Index: Complete index for quick reference to specific topics and components. Procedures Included General Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement. Troubleshooting: Systematic diagnostic flowcharts and symptom-based troubleshooting for various mechanical and electrical issues. Repair Procedures: Step-by-step instructions for component removal, installation, and adjustment for all covered systems. Diagnostic Codes: Explanation and interpretation of diagnostic trouble codes (DTCs) for electronically managed systems (OBD-I). Technical Depth Depth: Comprehensive factory-level detail suitable for professional mechanics and advanced DIY enthusiasts. Electrical Diagrams: Inclusion of wiring diagrams for all major electrical systems, including engine management, lighting, HVAC, and accessories. Specifications And Tolerances: Precise technical data, torque values, clearances, and wear limits for all serviceable components. 📊 Manual Specifications File Format Digital Format: PDF (searchable and bookmarked) Print Quality Page Printability: All pages printable Binding Type Digital Binding: None (Digital Download) Paper Type Digital Paper Type: N/A (Digital Document) File Organization Bookmarking: Completely bookmarked for easy navigation Searchability: Complete searchable text File Origin Authenticity: Real files, not scans ⚙️ Engine Specifications Primary Engine Common Engine Options: 2.0L 4G63 (SOHC and DOHC), 2.0L 4G63T (Turbocharged DOHC) Performance 4G63 DOHc Hp: Approximately 135-150 hp (naturally aspirated) 4G63T Gsr Hp: Approximately 195 hp (turbocharged) 4G63 Torque: Varies by variant, e.g., ~125 lb-ft for NA DOHC, ~203 lb-ft for turbo Fuel System Injection Type: Multi-Point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline (87 octane minimum, 91+ recommended for turbo models) Engine Management ECU Type: OBD-I (On-Board Diagnostics, First Generation) 🔧 Transmission Standard Manual Transmission: 5-speed manual transaxle (e.g., KM210, KM211 variants) Optional Automatic Transmission: 4-speed automatic transaxle (e.g., F4A21, F4A22 variants) Features Manual Transaxle Fluid: API GL-4, SAE 75W-90 or 80W-90 gear oil (specific type may vary, consult manual) Automatic Transaxle Fluid: Mitsubishi Genuine ATF SP or equivalent 📐 Dimensions Exterior Wheelbase: Approx. 100.4 inches (2550 mm) Length: Approx. 176.8 inches (4490 mm) Width: Approx. 68.1 inches (1730 mm) Height: Approx. 54.7 inches (1390 mm) Weights Curb Weight: Approx. 2800-3200 lbs (1270-1450 kg),...
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Mitsubishi Galant 1989-1993 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Galant
Generation:
E30/E40
Production Years Covered:
1989-1993
Codes
Chassis Codes:
E31, E32, E33, E34, E35, E38, E39, E43, E44, E45, E46, E47, E48
👋 Introduction
Market Position
Segment:
Compact to mid-size sedan, known for its advanced styling and European-influenced design.
Competitive Analysis
Competitors:
Honda Accord, Toyota Camry, Nissan Altima, Mazda 626, Ford Tempo, Chevrolet Corsica.
Key Features
Design Philosophy:
Stylish, aerodynamic, and comfortable interior, often featuring advanced (for its time) technology and handling.
Performance Variants:
The availability of the turbocharged GSR model provided a performance-oriented option.
📋 Manual Details
Coverage Areas
Primary Coverage:
All models and configurations of Mitsubishi Galant from 1989 to 1993
Engine Coverage:
4G37 1.8L, 4G63 2.0L (SOHC & DOHC), 4G63T 2.0L Turbocharged, 6A10 1.6L V6 (JDM), 6A11 1.8L V6 (JDM), 6A12 2.0L V6 (JDM)
Transmission Coverage:
5-speed manual transaxle, 4-speed automatic transaxle
Page Count
Estimated Page Count:
Extensive (Factory Service Manuals are typically 1000+ pages)
Manual Type
Type:
Factory Service Repair Manual (FSM)
Language
Language:
English
Format
Digital Format:
PDF
Archival Format:
WinRAR
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, repair, overhaul procedures, component testing for all engine variants, including timing belt replacement, valve adjustments, and turbocharger systems.
Fuel:
Fuel injection system (MPI, GDI where applicable), fuel pump, injectors, pressure regulator, fuel filter replacement, and fuel tank service.
Cooling:
Radiator, water pump, thermostat, cooling fan operation, hoses, and coolant flush procedures.
Intake And Exhaust:
Intake manifold, throttle body, exhaust manifold, catalytic converter, muffler, and emissions control components.
Emission Control:
EGR system, PCV system, evaporative emission control (EVAP), and oxygen sensor diagnostics.
Clutch:
Clutch disc, pressure plate, release bearing, hydraulic clutch system, adjustment, and replacement.
Manual Transaxle:
Internal component inspection, gear engagement, synchronizers, seals, fluid changes, and clutch-related transaxle removal/installation.
Automatic Transaxle:
Transmission fluid type and capacity, valve body diagnostics, torque converter, shift solenoid operation, and complete overhaul procedures.
Propeller Shaft:
Driveshaft, universal joints, constant velocity (CV) joints (if applicable), and balancing.
Front Axle:
CV shafts, wheel bearings, steering knuckle, and hub assembly.
Rear Axle:
Suspension components, trailing arms, control arms, wheel bearings, and differential (if applicable).
Wheel And Tire:
Tire pressure recommendations, rotation, wheel balancing, alignment specifications, and wheel bolt torque.
Power Plant Mount:
Engine and transmission mount inspection and replacement.
Front Suspension:
MacPherson struts, control arms, ball joints, tie rod ends, sway bar, and alignment procedures.
Active Electronic Control Suspension:
Diagnostic and repair procedures for electronically controlled suspension systems (if equipped on specific trims/markets).
Control Suspension:
Standard suspension component diagnosis and repair.
Rear Suspension:
Multi-link independent suspension (common on this generation), shock absorbers, springs, bushings, and alignment.
Service Brakes:
Front disc brakes, rear drum or disc brakes, brake pad/shoe replacement, rotor/drum resurfacing/replacement, brake fluid type and bleeding procedures, ABS system diagnostics (if equipped).
Parking Brakes:
Parking brake system operation, adjustment, and cable replacement.
Alphabetical Index:
Complete index for quick reference to specific topics and components.
Procedures Included
General Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement.
Troubleshooting:
Systematic diagnostic flowcharts and symptom-based troubleshooting for various mechanical and electrical issues.
Repair Procedures:
Step-by-step instructions for component removal, installation, and adjustment for all covered systems.
Diagnostic Codes:
Explanation and interpretation of diagnostic trouble codes (DTCs) for electronically managed systems (OBD-I).
Technical Depth
Depth:
Comprehensive factory-level detail suitable for professional mechanics and advanced DIY enthusiasts.
Electrical Diagrams:
Inclusion of wiring diagrams for all major electrical systems, including engine management, lighting, HVAC, and accessories.
Specifications And Tolerances:
Precise technical data, torque values, clearances, and wear limits for all serviceable components.
📊 Manual Specifications
File Format
Digital Format:
PDF (searchable and bookmarked)
Print Quality
Page Printability:
All pages printable
Binding Type
Digital Binding:
None (Digital Download)
Paper Type
Digital Paper Type:
N/A (Digital Document)
File Organization
Bookmarking:
Completely bookmarked for easy navigation
Searchability:
Complete searchable text
File Origin
Authenticity:
Real files, not scans
⚙️ Engine Specifications
Primary Engine
Common Engine Options:
2.0L 4G63 (SOHC and DOHC), 2.0L 4G63T (Turbocharged DOHC)
Performance
4G63 DOHc Hp:
Approximately 135-150 hp (naturally aspirated)
4G63T Gsr Hp:
Approximately 195 hp (turbocharged)
4G63 Torque:
Varies by variant, e.g., ~125 lb-ft for NA DOHC, ~203 lb-ft for turbo
Fuel System
Injection Type:
Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (87 octane minimum, 91+ recommended for turbo models)
Engine Management
ECU Type:
OBD-I (On-Board Diagnostics, First Generation)
🔧 Transmission
Standard
Manual Transmission:
5-speed manual transaxle (e.g., KM210, KM211 variants)
Optional
Automatic Transmission:
4-speed automatic transaxle (e.g., F4A21, F4A22 variants)
Features
Manual Transaxle Fluid:
API GL-4, SAE 75W-90 or 80W-90 gear oil (specific type may vary, consult manual)
Automatic Transaxle Fluid:
Mitsubishi Genuine ATF SP or equivalent
📐 Dimensions
Exterior
Wheelbase:
Approx. 100.4 inches (2550 mm)
Length:
Approx. 176.8 inches (4490 mm)
Width:
Approx. 68.1 inches (1730 mm)
Height:
Approx. 54.7 inches (1390 mm)
Weights
Curb Weight:
Approx. 2800-3200 lbs (1270-1450 kg), depending on engine and trim
Gross Vehicle Weight Rating:
Refer to vehicle specific label or manual
🛡️ Safety Features
Ratings
NHTSA Rating:
Varies by model year and specific crash test configurations; generally considered safe for its era.
Active Features
ABS:
Anti-lock Braking System (optional on some models, standard on higher trims/later years)
Passive Features
Airbags:
Driver-side airbag (optional/standard depending on year and trim), Passenger airbag not typically available on early models.
Seatbelts:
Three-point front seatbelts with pretensioners, three-point rear seatbelts.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/Cassette player, with options for CD players on higher trims or later models. Speaker configurations vary.
Driver Assistance
Cruise Control:
Available on most models as standard or optional.
Climate Control:
Manual or automatic climate control systems, depending on trim level.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,000-5,000 miles (4,800-8,000 km) or 6 months, using recommended oil type.
Timing Belt Replacement:
Every 60,000 miles (96,000 km) or 4 years for 4G63 engines (critical interval to prevent catastrophic engine damage).
Coolant Flush:
Every 30,000 miles (48,000 km) or 2 years.
Fluid Specifications
Engine Oil Viscosity:
SAE 5W-30 or 10W-30 (check manual for specific temperature ranges)
Engine Oil Capacity:
Approx. 4.2-4.5 quarts (4.0-4.2 liters) with filter change, depending on engine.
Brake Fluid Type:
DOT 3 or DOT 4
Known Issues
Common Wear Items:
CV boots, motor mounts, strut mounts, exhaust system components, O2 sensors, and water pumps can be common wear items.
Turbo Specific Issues:
Turbocharger health, oil feed/return lines, and intercooler integrity are critical for GSR models.
Electrical Aging:
As with any vehicle of this age, wiring harness degradation, corroded connectors, and failing sensors can occur.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors:
Mitsubishi Motors has a history dating back to 1917, with automotive production beginning in the 1960s. Known for innovation and diverse product lines.
Model Evolution
Galant Generations:
The 1989-1993 models represent the fifth generation (E30/E40 series), a significant redesign from its predecessor, emphasizing styling and performance.
Production
Manufacturing Locations:
Primarily Japan (Mizushima Plant), with some assembly in other international locations depending on market.
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
While not explicitly listed for the 1989-1993 models, the Galant line has historically been recognized for its value and engineering.
Ratings
Consumer Reports:
Consumer Reports evaluations for this era generally pointed to good reliability for the powertrain but some average or below-average ratings for certain interior components and body integrity, typical for the time.
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