Mitsubishi Starion 1982-1989 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Starion Generation: A180/A187 Production Years Covered: 1982-1989 👋 Introduction Market Position Historical Context: The Mitsubishi Starion (and its North American counterpart, the Dodge/Chrysler Conquest) was a rear-wheel-drive sports coupe that competed in the performance car segment of the 1980s, known for its aggressive styling and turbocharged engine options. Competitive Analysis Key Competitors: Competed against vehicles like the Nissan 300ZX, Toyota Supra, Mazda RX-7, Porsche 944, and Chevrolet Camaro/Pontiac Firebird during its production run. Key Features Design Philosophy: Characterized by a sharp, angular design, wide stance, pop-up headlights, and a driver-focused cockpit. Performance Focus: Emphasized turbocharged performance, rear-wheel drive handling, and a sporty driving experience. 📋 Manual Details Coverage Areas Model Years: 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989 Global Markets: Covers models sold worldwide including JDM (e.g., Mitsubishi Starion), Dodge/Chrysler Conquest (North America) Page Count Page Count: 700+ Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format File Format: PDF Download Type: Instant Download 📖 Manual Coverage Systems Covered Engine: Detailed coverage of 4G63 2.0L SOHC & DOHC Turbocharged engines, including turbocharger system, fuel injection, ignition system, cooling system, lubrication system, engine mechanical (disassembly, assembly, specifications). Transmission: Coverage of manual (KM132, KM211) and automatic (F4A33) transmissions, including removal, installation, disassembly, assembly, adjustments, and fluid specifications. Drivetrain: Rear-wheel drive system, differential, driveshafts, axles, wheel bearings. Suspension: Front and rear suspension systems, including MacPherson struts, independent rear suspension, shock absorbers, springs, control arms, bushings, alignment specifications. Steering: Power steering system, steering rack, steering column, tie rods, steering fluid specifications. Brakes: Front and rear disc brakes (including optional ABS systems), brake fluid specifications, master cylinder, brake lines, parking brake, rotor and pad specifications. Electrical: Complete electrical system, including wiring diagrams, charging system (alternator, battery), starting system, lighting, instruments, gauges, power windows, door locks, radio, fuse box diagrams, ECU (Electronic Control Unit) information. Body: Body construction, exterior trim, doors, hood, trunk, bumpers, glass, interior trim, seats, HVAC system (heating, ventilation, air conditioning). Fuel System: Fuel tank, fuel pump, fuel lines, fuel filter, fuel injectors, fuel pressure regulator, ECI (Electronic Controlled Injection) system. Procedures Included Maintenance: Routine maintenance, oil changes, filter replacements, spark plug replacement, belt inspection and replacement, fluid level checks and top-offs, lubrication points. Troubleshooting: Comprehensive diagnostic procedures for common issues, symptom-based troubleshooting guides, wiring harness checks, sensor testing, error code interpretation (if applicable). Repair: Detailed step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, and reassembly. Installation: Procedures for installing new or reconditioned components and systems. Adjustments: Specific adjustments for engine timing, idle speed, clutch, brakes, suspension alignment, etc. Technical Depth Depth: Comprehensive, from basic maintenance to full engine and transmission rebuilds, including detailed torque specifications, clearances, and wear limits. Illustrations: Includes detailed pictorial diagrams, exploded views, drawings, and photos for visual guidance. Special Tools: References and illustrations for required special service tools. 📊 Manual Specifications File Format PDF Quality: High resolution, printable pages. Searchability: Likely text-searchable within the PDF reader, aiding quick information retrieval. Print Quality Printability: Yes, all pages are printable. Compatibility Operating Systems: Compatible with Windows, Mac, and Linux OS. Requirements Software Requirement: Adobe Reader or compatible PDF viewer. ⚙️ Engine Specifications Primary Engine Engine Code And Type: 4G63, 2.0L (1997 cc) Inline-4, SOHC and DOHC versions, turbocharged. Performance Horsepower Range: Typically ranged from approximately 145 hp (SOHC naturally aspirated) to 180-200 hp (DOHC Turbocharged), with later models potentially offering slightly more. Torque Range: Significant torque figures from the turbocharged engines, contributing to strong acceleration. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), specifically Mitsubishi's ECI system. Engine Mechanical Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: Varies by engine variant, typically around 7.6:1 to 8.0:1 for turbocharged models to handle boost. 🔧 Transmission Standard Standard Transmission: 5-speed Manual Transmission (KM132, KM211). Optional Optional Transmission: 4-speed Automatic Transmission (F4A33). Features Rear Axle Ratio: Varies by transmission and trim, often around 3.73:1 or similar for performance applications. 📐 Dimensions Exterior Wheelbase: 2465 mm (97.0 in) Length: 4335 mm (170.7 in) Width: 1735 mm (68.3 in) Height: 1295 mm (51.0 in) Weights Curb Weight: Approx. 1300-1450 kg (2866-3197 lbs), varies by equipment and engine. 🛡️ Safety Features Ratings Crash Test Performance: Information regarding official crash test ratings from the era (e.g., NHTSA) would be included in a comprehensive manual if available, though specific data for this period can be scarce. Active Features Braking System: Standard 4-wheel disc brakes; optional Anti-lock Braking System (ABS) available on some models. Passive Features Seatbelts: Standard 3-point seatbelts. Body Structure: Designed with a focus on occupant protection for its time, though safety standards have evolved significantly. 💡 Technology Features Infotainment Audio System: Factory-installed AM/FM radio with cassette player, often with optional upgraded sound systems. Driver Assistance ABS: Optional Anti-lock Braking System (ABS) was available on later models, representing early automotive electronic safety technology....
The Mitsubishi Starion (and its North American counterpart, the Dodge/Chrysler Conquest) was a rear-wheel-drive sports coupe that competed in the performance car segment of the 1980s, known for its aggressive styling and turbocharged engine options.
Competitive Analysis
Key Competitors:
Competed against vehicles like the Nissan 300ZX, Toyota Supra, Mazda RX-7, Porsche 944, and Chevrolet Camaro/Pontiac Firebird during its production run.
Key Features
Design Philosophy:
Characterized by a sharp, angular design, wide stance, pop-up headlights, and a driver-focused cockpit.
Performance Focus:
Emphasized turbocharged performance, rear-wheel drive handling, and a sporty driving experience.
📋 Manual Details
Coverage Areas
Model Years:
1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989
Global Markets:
Covers models sold worldwide including JDM (e.g., Mitsubishi Starion), Dodge/Chrysler Conquest (North America)
Coverage of manual (KM132, KM211) and automatic (F4A33) transmissions, including removal, installation, disassembly, assembly, adjustments, and fluid specifications.
Front and rear suspension systems, including MacPherson struts, independent rear suspension, shock absorbers, springs, control arms, bushings, alignment specifications.
Steering:
Power steering system, steering rack, steering column, tie rods, steering fluid specifications.
Brakes:
Front and rear disc brakes (including optional ABS systems), brake fluid specifications, master cylinder, brake lines, parking brake, rotor and pad specifications.
Electrical:
Complete electrical system, including wiring diagrams, charging system (alternator, battery), starting system, lighting, instruments, gauges, power windows, door locks, radio, fuse box diagrams, ECU (Electronic Control Unit) information.
Body:
Body construction, exterior trim, doors, hood, trunk, bumpers, glass, interior trim, seats, HVAC system (heating, ventilation, air conditioning).
Routine maintenance, oil changes, filter replacements, spark plug replacement, belt inspection and replacement, fluid level checks and top-offs, lubrication points.
Troubleshooting:
Comprehensive diagnostic procedures for common issues, symptom-based troubleshooting guides, wiring harness checks, sensor testing, error code interpretation (if applicable).
Repair:
Detailed step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, and reassembly.
Installation:
Procedures for installing new or reconditioned components and systems.
Adjustments:
Specific adjustments for engine timing, idle speed, clutch, brakes, suspension alignment, etc.
Technical Depth
Depth:
Comprehensive, from basic maintenance to full engine and transmission rebuilds, including detailed torque specifications, clearances, and wear limits.
Illustrations:
Includes detailed pictorial diagrams, exploded views, drawings, and photos for visual guidance.
Special Tools:
References and illustrations for required special service tools.
📊 Manual Specifications
File Format
PDF Quality:
High resolution, printable pages.
Searchability:
Likely text-searchable within the PDF reader, aiding quick information retrieval.
Print Quality
Printability:
Yes, all pages are printable.
Compatibility
Operating Systems:
Compatible with Windows, Mac, and Linux OS.
Requirements
Software Requirement:
Adobe Reader or compatible PDF viewer.
⚙️ Engine Specifications
Primary Engine
Engine Code And Type:
4G63, 2.0L (1997 cc) Inline-4, SOHC and DOHC versions, turbocharged.
Performance
Horsepower Range:
Typically ranged from approximately 145 hp (SOHC naturally aspirated) to 180-200 hp (DOHC Turbocharged), with later models potentially offering slightly more.
Torque Range:
Significant torque figures from the turbocharged engines, contributing to strong acceleration.
Varies by engine variant, typically around 7.6:1 to 8.0:1 for turbocharged models to handle boost.
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual Transmission (KM132, KM211).
Optional
Optional Transmission:
4-speed Automatic Transmission (F4A33).
Features
Rear Axle Ratio:
Varies by transmission and trim, often around 3.73:1 or similar for performance applications.
📐 Dimensions
Exterior
Wheelbase:
2465 mm (97.0 in)
Length:
4335 mm (170.7 in)
Width:
1735 mm (68.3 in)
Height:
1295 mm (51.0 in)
Weights
Curb Weight:
Approx. 1300-1450 kg (2866-3197 lbs), varies by equipment and engine.
🛡️ Safety Features
Ratings
Crash Test Performance:
Information regarding official crash test ratings from the era (e.g., NHTSA) would be included in a comprehensive manual if available, though specific data for this period can be scarce.
Active Features
Braking System:
Standard 4-wheel disc brakes; optional Anti-lock Braking System (ABS) available on some models.
Passive Features
Seatbelts:
Standard 3-point seatbelts.
Body Structure:
Designed with a focus on occupant protection for its time, though safety standards have evolved significantly.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM radio with cassette player, often with optional upgraded sound systems.
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) was available on later models, representing early automotive electronic safety technology.
Comfort Features
Climate Control:
Manual climate control for heating and air conditioning, often with a distinctive dashboard layout.
Power Accessories:
Power windows, power door locks, and power mirrors were common options.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 3,000-5,000 miles or 3-6 months, depending on driving conditions and oil type used (consult manual for precise interval).
Tune Up Interval:
Spark plugs, distributor cap, rotor, and ignition wires recommended for replacement at intervals specified in the manual (often around 30,000 miles).
Fluid Specifications
Engine Oil:
API SG or higher quality, SAE 10W-30 or 10W-40 recommended (specific viscosity depends on ambient temperature, refer to manual).
Coolant:
Ethylene glycol-based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Transmission Fluid Manual:
Gear oil, SAE 75W-90 or 80W-90 GL-4 specified for manual transmissions.
Transmission Fluid Automatic:
Dexron-III (or equivalent) ATF for the automatic transmission.
Known Issues
Turbocharger Reliability:
Turbocharger system components (wastegate, intercooler, hoses) can require attention; proper warm-up/cool-down is crucial for longevity.
Rust And Corrosion:
As with many 1980s vehicles, susceptibility to rust and corrosion in certain areas (wheel arches, rocker panels, chassis) is a common concern, especially in humid or winter climates.
Electronics:
Age-related failure of electrical components, sensors, and wiring can occur.
Cooling System:
Radiator, hoses, and water pump can degrade over time, requiring replacement to prevent overheating.
Fuel Delivery:
Fuel injectors, fuel pump, and fuel pressure regulator may require maintenance or replacement.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors:
Part of Mitsubishi Motors' push into the global automotive market, leveraging their engineering capabilities.
Model Evolution
Design Updates:
Facelifted models featured revised front and rear styling, wider fender flares, and updated interior features throughout its production run.
Engine Development:
The 4G63 engine became a legendary powerplant for Mitsubishi, known for its robustness and tunability, particularly in its DOHC turbo variants.
Production
Manufacturing Locations:
Primarily manufactured in Japan.
🏆 Awards & Recognition
Recognitions
Automotive Press:
While specific awards might not be widely documented, the Starion/Conquest was generally well-received by automotive press for its performance-oriented nature and styling in the 1980s.
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