Mitsubishi Galant 1993-1996 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Galant Codes Generation Code: E30/E50/E60/E70/E80 Chassis Codes Covered: E50, E60, E70, E80 (primarily E80 for this generation) 👋 Introduction Market Position Segment: Mid-size sedan. Target Audience: Owners seeking to perform their own maintenance and repairs, independent repair shops, automotive enthusiasts. Competitive Analysis Key Competitors: Honda Accord, Toyota Camry, Nissan Altima, Ford Taurus, Chevrolet Lumina, Mazda MX-6. Key Features Design Philosophy: Mitsubishi's focus on advanced engineering and a sporty driving experience within the mainstream sedan segment. Technological Advancements: For its time, offered features like multi-link suspension and sophisticated engine management systems. 📋 Manual Details Coverage Areas Years Covered: 1993, 1994, 1995, 1996 Market Coverage: North America (primarily, with potential for global variants referenced) Page Count Estimated Pages: 1500+ Manual Type Type: Workshop Service Repair Manual (Factory Service Manual Equivalent) Language Language: English Format Format: Digital Download (PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, exhaust system, cooling system, lubrication system, emissions control. Transmission: Automatic transmission (AT), manual transmission (MT) - including diagnostics, repair, and overhaul procedures. Drivetrain: Front-wheel drive (FWD) systems, including driveshafts, CV joints, differentials. Suspension: Front and rear suspension systems, including shock absorbers, struts, springs, control arms, bushings, wheel alignment specifications. Steering: Power steering system, steering gear, tie rods, steering column components, diagnostic and repair procedures. Brakes: Front and rear brake systems (disc and drum), ABS system (if equipped), brake fluid specifications, bleeding procedures, caliper and rotor replacement. Electrical System: 12V battery system, charging system (alternator), starting system (starter motor), lighting system, fuses, relays, wiring diagrams. Body And Chassis: Body panels, doors, windows, interior trim, seats, bumpers, frame structure, corrosion protection. HVAC: Heating, ventilation, and air conditioning (HVAC) system, including refrigerant handling, compressor, evaporator, condenser, blower motor. Safety Systems: Seat belts, airbags (SRS - Supplemental Restraint System) - diagnostic and component replacement (with appropriate safety precautions). Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection/replacement. Troubleshooting: Diagnostic flowcharts, symptom-based troubleshooting for engine, transmission, electrical, and HVAC issues. Repair: Step-by-step repair procedures for all major components, including engine overhaul, transmission rebuild, brake caliper replacement, suspension component replacement. Diagnostics: OBD-I (On-Board Diagnostics) codes and interpretation (as applicable for the era), sensor testing, actuator testing. Wiring: Detailed electrical wiring diagrams for all vehicle systems, component locations, and connector pinouts. Technical Depth Depth: Comprehensive: Covers everything from routine maintenance to full engine and transmission overhauls, including detailed diagnostic procedures and specifications. Diagnostic Tools: Mentions required tools and specialized equipment for diagnosis and repair. Torque Specifications: Detailed torque specifications for all critical fasteners. Clearances And Tolerances: Specific engine component clearances and assembly tolerances. 📊 Manual Specifications File Format Format: PDF Searchability: Likely text-searchable PDF, allowing for quick location of specific topics. Print Quality Quality: High resolution, suitable for printing professional-quality pages. Binding Type Binding: N/A (Digital Download - implies user printing and binding). Paper Type Paper: N/A (Digital Download - implies user printing on desired paper type). Manual Type Details Content Source: Official Factory Service Manual (FSM) data. ⚙️ Engine Specifications Primary Engine Engine Code Common: 4G63 (2.0L DOHC Turbo - found in higher trims like GSR/VR-4), 6A12 (2.0L V6 MIVEC), 6A13 (2.5L V6 MIVEC). Engine Displacement Common Na: 2.0L (1998cc), 2.5L (2498cc) Engine Configuration: Inline-4 (4G63), V6 (6A12, 6A13) Engine Aspiration: Naturally Aspirated, Turbocharged (on certain performance variants) Valve Train: DOHC (Double Overhead Camshaft), 16 Valves (4G63), DOHC, 24 Valves (V6 engines) Performance Na 2.5L V6: Approx. 170-180 hp @ 6000 rpm, 174-177 lb-ft torque @ 4500 rpm Performance Turbo 2.0L: Approx. 240-276 hp @ 6000 rpm, 260-270 lb-ft torque @ 3000 rpm (depending on specific tune, e.g., VR-4) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI), Multi-point fuel injection (MPI). Fuel Type: Unleaded Gasoline Cooling System Cooling Type: Water-cooled, pressurized system. Lubrication System Oil Type Recommended: Refer to manual - typically 5W-30 or 10W-30 API SG/SH rated oil. Engine Management ECU Type: Engine Control Unit (ECU) with integrated diagnostics (OBD-I). 🔧 Transmission Standard Transmission Type Common: 5-speed Manual Transmission (5MT), 4-speed Automatic Transmission (4AT). Optional Transmission Type Performance: All-Wheel Drive (AWD) with Active Center Differential (ACD) and viscous coupling on performance models (e.g., VR-4). Features Automatic Features: Electronically controlled automatic transmission, possibly with 'sport' or 'economy' modes on higher trims. Manual Features: Close-ratio gearing on performance variants. Fluid Specifications Automatic Transmission Fluid: Refer to manual - typically ATF SP-II or equivalent. Manual Transmission Fluid: Refer to manual - typically GL-4 or GL-5 gear oil. 📐 Dimensions Exterior Body Styles: 4-door Sedan, 2-door Coupe (some markets). Wheelbase: Approx. 2700-2740 mm (106.3-107.9 inches) depending on specific chassis/trim. Weights Curb Weight: Approx. 1400-1600 kg (3086-3527 lbs) depending on engine and configuration. 🛡️ Safety Features Ratings Crash Test Ratings: N/A specific rating for this era's US models in a standardized format like NCAP. Manual will...
Automatic transmission (AT), manual transmission (MT) - including diagnostics, repair, and overhaul procedures.
Drivetrain:
Front-wheel drive (FWD) systems, including driveshafts, CV joints, differentials.
Suspension:
Front and rear suspension systems, including shock absorbers, struts, springs, control arms, bushings, wheel alignment specifications.
Steering:
Power steering system, steering gear, tie rods, steering column components, diagnostic and repair procedures.
Brakes:
Front and rear brake systems (disc and drum), ABS system (if equipped), brake fluid specifications, bleeding procedures, caliper and rotor replacement.
Electrical System:
12V battery system, charging system (alternator), starting system (starter motor), lighting system, fuses, relays, wiring diagrams.
Scheduled maintenance, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection/replacement.
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting for engine, transmission, electrical, and HVAC issues.
Repair:
Step-by-step repair procedures for all major components, including engine overhaul, transmission rebuild, brake caliper replacement, suspension component replacement.
Diagnostics:
OBD-I (On-Board Diagnostics) codes and interpretation (as applicable for the era), sensor testing, actuator testing.
Wiring:
Detailed electrical wiring diagrams for all vehicle systems, component locations, and connector pinouts.
Technical Depth
Depth:
Comprehensive: Covers everything from routine maintenance to full engine and transmission overhauls, including detailed diagnostic procedures and specifications.
Diagnostic Tools:
Mentions required tools and specialized equipment for diagnosis and repair.
Torque Specifications:
Detailed torque specifications for all critical fasteners.
Clearances And Tolerances:
Specific engine component clearances and assembly tolerances.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely text-searchable PDF, allowing for quick location of specific topics.
Print Quality
Quality:
High resolution, suitable for printing professional-quality pages.
Binding Type
Binding:
N/A (Digital Download - implies user printing and binding).
Paper Type
Paper:
N/A (Digital Download - implies user printing on desired paper type).
Manual Type Details
Content Source:
Official Factory Service Manual (FSM) data.
⚙️ Engine Specifications
Primary Engine
Engine Code Common:
4G63 (2.0L DOHC Turbo - found in higher trims like GSR/VR-4), 6A12 (2.0L V6 MIVEC), 6A13 (2.5L V6 MIVEC).
Engine Displacement Common Na:
2.0L (1998cc), 2.5L (2498cc)
Engine Configuration:
Inline-4 (4G63), V6 (6A12, 6A13)
Engine Aspiration:
Naturally Aspirated, Turbocharged (on certain performance variants)
All-Wheel Drive (AWD) with Active Center Differential (ACD) and viscous coupling on performance models (e.g., VR-4).
Features
Automatic Features:
Electronically controlled automatic transmission, possibly with 'sport' or 'economy' modes on higher trims.
Manual Features:
Close-ratio gearing on performance variants.
Fluid Specifications
Automatic Transmission Fluid:
Refer to manual - typically ATF SP-II or equivalent.
Manual Transmission Fluid:
Refer to manual - typically GL-4 or GL-5 gear oil.
📐 Dimensions
Exterior
Body Styles:
4-door Sedan, 2-door Coupe (some markets).
Wheelbase:
Approx. 2700-2740 mm (106.3-107.9 inches) depending on specific chassis/trim.
Weights
Curb Weight:
Approx. 1400-1600 kg (3086-3527 lbs) depending on engine and configuration.
🛡️ Safety Features
Ratings
Crash Test Ratings:
N/A specific rating for this era's US models in a standardized format like NCAP. Manual will detail structural integrity and component safety.
Active Features
ABS:
Anti-lock Braking System (ABS) available as an option on many models.
Passive Features
Airbags:
Driver-side airbag standard on many models, passenger airbag optional or standard on higher trims.
Seat Belts:
3-point front seat belts with pretensioners, 3-point rear seat belts.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo cassette player, optional CD player. Basic speaker systems.
Climate Control:
Manual climate control with A/C standard or optional on most trims. Automatic climate control available on higher trims.
Driver Assistance
Cruise Control:
Available on most models.
Connectivity
External Ports:
N/A (Technology of the era predates common external connectivity ports like USB).
🔧 Maintenance
Service Intervals
Engine Oil And Filter:
Every 3,750 - 7,500 miles (6,000 - 12,000 km) or 6 months, whichever comes first (refer to specific driving conditions outlined in manual).
Air Filter:
Inspect every 15,000 miles (24,000 km), replace as needed or every 30,000 miles (48,000 km).
Spark Plugs:
Replace every 30,000 - 60,000 miles (48,000 - 96,000 km) depending on plug type (standard vs. platinum).
Timing Belt:
Crucial: Replace every 60,000 - 90,000 miles (96,000 - 144,000 km) or 5-7 years. Failure can cause catastrophic engine damage (interference engine).
Fluid Specifications
Coolant:
Refer to manual - typically a 50/50 mix of ethylene glycol-based antifreeze and distilled water.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine Performance:
Oil leaks from valve cover gaskets, intake manifold gaskets. Potential for catalytic converter failure. Ignition coil failures. Overheating due to clogged radiator or faulty thermostat.
Worn control arm bushings, ball joints, and tie rod ends leading to steering looseness and tire wear. Strut mount bearing failure.
Electrical:
Corrosion in electrical connectors, failing power window motors, headlamp switch issues, instrument cluster problems.
Maintenance Tips
Preventative Measures:
Regularly check all fluid levels, inspect belts and hoses for wear, maintain proper tire inflation, and follow the timing belt replacement schedule diligently.
📚 Vehicle History
Brand Heritage
Manufacturer Origin:
Japan
Model Evolution
Generation Details:
This generation (E80) represented a significant redesign, moving to a more aerodynamic and rounded styling. It was often praised for its handling and performance, especially the 'VR-4' variants which featured advanced AWD and turbocharged V6 or inline-4 engines.
Production
Production Years For Generation:
1992-1999 (global, with market-specific variations).
Manufacturing Locations:
Japan (primarily), with some assembly in other regions.
🏆 Awards & Recognition
Recognitions
Automotive Journal Awards:
While not consistently winning major awards like some competitors, the Galant was generally well-regarded for its styling, handling, and the performance of its VR-4 variants. Specific awards would vary by year and publication.
Choosing a selection results in a full page refresh.