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Mitsubushi GALANT 1988-1993 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Galant Model Variant: VR-4 Year Range: 1988-1993 Codes Engine Code Primary: 4G63 Engine Code Turbo: 4G63T 👋 Introduction Market Position Segment: Performance Sedan / Sport Compact Positioning: The Mitsubishi Galant VR-4, particularly the E39A chassis generation, was a performance-oriented variant of the standard Galant, known for its advanced all-wheel-drive system and potent turbocharged engine, often competing with rally-bred homologation specials. Competitive Analysis Competitors: Subaru Legacy RS, Ford Sierra RS Cosworth, Nissan Skyline GT-R (though typically in a higher performance tier), Audi Quattro. Key Features Performance Focus: Emphasis on sporty driving dynamics, turbocharged power, and all-wheel-drive traction. Advanced AWD: Sophisticated all-wheel-drive system (often referred to as 'Full-time 4WD' or 'Twin-ocyclic 4WD' depending on the specific variant and market) providing enhanced grip and handling. Engine Technology: The robust 4G63 engine, known for its durability and tunability, featured in legendary rally cars like the Lancer Evolution. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service and repair for Mitsubishi Galant VR-4, 1988-1993 model years. Engine Coverage: 2.0L 4G63 Naturally Aspirated and 2.0L 4G63T Turbocharged variants. Transmission Coverage: 4-Speed Automatic and 5-Speed Manual transmissions. Page Count Estimated Page Count: 800+ Manual Type Type: Service and Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, diagnostics, tuning, lubrication, cooling, intake, exhaust, ignition, and emission control systems. Fuel System: Fuel injection system (MPI), fuel pump, fuel filter, fuel tank, fuel lines, and associated sensors. Transmission: Automatic and manual transmission service, repair, overhaul, clutch system, gear selection, and torque converter. Drivetrain: Front-wheel drive (FWD) and All-wheel drive (AWD) systems, differential, driveshafts, CV joints, and propeller shaft. Suspension: Front and rear suspension components, struts, shocks, springs, control arms, bushings, and wheel alignment specifications. Steering: Power steering system, steering rack, tie rods, steering column, and related hydraulic components. Brakes: Hydraulic brake system, front and rear disc brakes, ABS (Anti-lock Braking System), brake lines, calipers, master cylinder, and parking brake. Electrical System: Battery, charging system (alternator), starting system (starter motor), ignition system, lighting, instrumentation, and power distribution. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant, compressor, condenser, evaporator, and climate controls. Body And Chassis: Body panels, doors, windows, interior trim, chassis structure, corrosion protection, and body repair procedures. Diagnostic Troubleshooting: Systematic troubleshooting guides, diagnostic trouble codes (DTCs) for engine management, and common fault finding. Procedures Included Maintenance: Routine maintenance, scheduled service intervals, oil changes, filter replacements, fluid checks and top-offs, tune-ups. Repair: Step-by-step repair instructions for all major vehicle systems, including component removal, installation, and adjustment. Overhaul: Detailed procedures for complete engine and transmission overhauls. Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting for electrical and mechanical issues. Specifications: Torque specifications, clearances, fluid capacities, resistance values, and other critical measurements. Technical Depth Depth: Highly detailed, covering everything from basic maintenance to complete engine rebuilds and complex electrical diagnostics. Suitable for professional technicians and advanced DIY enthusiasts. 📊 Manual Specifications File Format Format Type: PDF Searchable: Yes (Text-searchable) Printable: Yes Print Quality Quality: High-resolution scans of original factory documentation. Binding Type Binding: N/A (Digital Format) Paper Type Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Name: 4G63 (Naturally Aspirated) Displacement: 2.0 Liters (1997 cc) Configuration: Inline 4-cylinder, DOHC (Dual Overhead Camshaft), 16 valves Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.5:1 (typical) Performance Turbo Engine Name: 4G63T (Turbocharged) Turbo Displacement: 2.0 Liters (1997 cc) Turbo Configuration: Inline 4-cylinder, DOHC, 16 valves, Turbocharged and Intercooled Turbo Horsepower Approx: 195 - 240 hp (depending on market and specific model year) Turbo Torque Approx: 203 - 230 lb-ft (depending on market and specific model year) Turbo Boost Pressure: 9-12 psi (typical, may vary) Fuel System Fuel Delivery: Multi-Point Fuel Injection (MPI) for both variants. Fuel Type: Unleaded Gasoline (Octane rating specified in manual) Ignition System: Electronic ignition with distributor or distributorless ignition system (DIS) depending on specific year/market. 🔧 Transmission Standard Standard Transmission: 5-Speed Manual Transmission Optional Optional Transmission: 4-Speed Automatic Transmission Features AWD System: Full-time 4WD system with viscous coupling center differential (or electronically controlled active center differential on later models) for optimal traction distribution. Differential Type: Front: Open differential. Rear: Optional Limited Slip Differential (LSD) for VR-4 variants. Gear Ratios: Specific gear ratios for both manual and automatic transmissions are detailed within the manual. Clutch Type: Hydraulically operated single dry plate clutch for manual transmission. 📐 Dimensions Exterior Wheelbase: Approx. 2600 mm (900-930 mm range for E39A chassis) Length: Approx. 4565 - 4600 mm Width: Approx. 1700 - 1725 mm Height: Approx. 1390 - 1410 mm Weights Curb Weight Approx: 1350 - 1450 kg (depending on transmission and equipment) Gross Vehicle Weight Rating: Specifications available in the manual. 🛡️ Safety Features Ratings Crash Test Data: No specific comprehensive crash test ratings commonly available for this model year in modern formats. Manual provides...
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Mitsubushi GALANT 1988-1993 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Galant
Model Variant:
VR-4
Year Range:
1988-1993
Codes
Engine Code Primary:
4G63
Engine Code Turbo:
4G63T
👋 Introduction
Market Position
Segment:
Performance Sedan / Sport Compact
Positioning:
The Mitsubishi Galant VR-4, particularly the E39A chassis generation, was a performance-oriented variant of the standard Galant, known for its advanced all-wheel-drive system and potent turbocharged engine, often competing with rally-bred homologation specials.
Competitive Analysis
Competitors:
Subaru Legacy RS, Ford Sierra RS Cosworth, Nissan Skyline GT-R (though typically in a higher performance tier), Audi Quattro.
Key Features
Performance Focus:
Emphasis on sporty driving dynamics, turbocharged power, and all-wheel-drive traction.
Advanced AWD:
Sophisticated all-wheel-drive system (often referred to as 'Full-time 4WD' or 'Twin-ocyclic 4WD' depending on the specific variant and market) providing enhanced grip and handling.
Engine Technology:
The robust 4G63 engine, known for its durability and tunability, featured in legendary rally cars like the Lancer Evolution.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive service and repair for Mitsubishi Galant VR-4, 1988-1993 model years.
Engine Coverage:
2.0L 4G63 Naturally Aspirated and 2.0L 4G63T Turbocharged variants.
Transmission Coverage:
4-Speed Automatic and 5-Speed Manual transmissions.
Page Count
Estimated Page Count:
800+
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
Digital (PDF)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine overhaul, diagnostics, tuning, lubrication, cooling, intake, exhaust, ignition, and emission control systems.
Fuel System:
Fuel injection system (MPI), fuel pump, fuel filter, fuel tank, fuel lines, and associated sensors.
Transmission:
Automatic and manual transmission service, repair, overhaul, clutch system, gear selection, and torque converter.
Drivetrain:
Front-wheel drive (FWD) and All-wheel drive (AWD) systems, differential, driveshafts, CV joints, and propeller shaft.
Suspension:
Front and rear suspension components, struts, shocks, springs, control arms, bushings, and wheel alignment specifications.
Steering:
Power steering system, steering rack, tie rods, steering column, and related hydraulic components.
Brakes:
Hydraulic brake system, front and rear disc brakes, ABS (Anti-lock Braking System), brake lines, calipers, master cylinder, and parking brake.
Electrical System:
Battery, charging system (alternator), starting system (starter motor), ignition system, lighting, instrumentation, and power distribution.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant, compressor, condenser, evaporator, and climate controls.
Body And Chassis:
Body panels, doors, windows, interior trim, chassis structure, corrosion protection, and body repair procedures.
Diagnostic Troubleshooting:
Systematic troubleshooting guides, diagnostic trouble codes (DTCs) for engine management, and common fault finding.
Procedures Included
Maintenance:
Routine maintenance, scheduled service intervals, oil changes, filter replacements, fluid checks and top-offs, tune-ups.
Repair:
Step-by-step repair instructions for all major vehicle systems, including component removal, installation, and adjustment.
Overhaul:
Detailed procedures for complete engine and transmission overhauls.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting for electrical and mechanical issues.
Specifications:
Torque specifications, clearances, fluid capacities, resistance values, and other critical measurements.
Technical Depth
Depth:
Highly detailed, covering everything from basic maintenance to complete engine rebuilds and complex electrical diagnostics. Suitable for professional technicians and advanced DIY enthusiasts.
📊 Manual Specifications
File Format
Format Type:
PDF
Searchable:
Yes (Text-searchable)
Printable:
Yes
Print Quality
Quality:
High-resolution scans of original factory documentation.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Name:
4G63 (Naturally Aspirated)
Displacement:
2.0 Liters (1997 cc)
Configuration:
Inline 4-cylinder, DOHC (Dual Overhead Camshaft), 16 valves
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.5:1 (typical)
Performance
Turbo Engine Name:
4G63T (Turbocharged)
Turbo Displacement:
2.0 Liters (1997 cc)
Turbo Configuration:
Inline 4-cylinder, DOHC, 16 valves, Turbocharged and Intercooled
Turbo Horsepower Approx:
195 - 240 hp (depending on market and specific model year)
Turbo Torque Approx:
203 - 230 lb-ft (depending on market and specific model year)
Turbo Boost Pressure:
9-12 psi (typical, may vary)
Fuel System
Fuel Delivery:
Multi-Point Fuel Injection (MPI) for both variants.
Fuel Type:
Unleaded Gasoline (Octane rating specified in manual)
Ignition System:
Electronic ignition with distributor or distributorless ignition system (DIS) depending on specific year/market.
🔧 Transmission
Standard
Standard Transmission:
5-Speed Manual Transmission
Optional
Optional Transmission:
4-Speed Automatic Transmission
Features
AWD System:
Full-time 4WD system with viscous coupling center differential (or electronically controlled active center differential on later models) for optimal traction distribution.
Differential Type:
Front: Open differential. Rear: Optional Limited Slip Differential (LSD) for VR-4 variants.
Gear Ratios:
Specific gear ratios for both manual and automatic transmissions are detailed within the manual.
Clutch Type:
Hydraulically operated single dry plate clutch for manual transmission.
📐 Dimensions
Exterior
Wheelbase:
Approx. 2600 mm (900-930 mm range for E39A chassis)
Length:
Approx. 4565 - 4600 mm
Width:
Approx. 1700 - 1725 mm
Height:
Approx. 1390 - 1410 mm
Weights
Curb Weight Approx:
1350 - 1450 kg (depending on transmission and equipment)
Gross Vehicle Weight Rating:
Specifications available in the manual.
🛡️ Safety Features
Ratings
Crash Test Data:
No specific comprehensive crash test ratings commonly available for this model year in modern formats. Manual provides safety system details.
Active Features
ABS:
Anti-lock Braking System (ABS) often standard or optional on VR-4 models.
AWD Traction:
All-wheel-drive system enhances active safety through improved traction and stability.
Passive Features
Seat Belts:
Three-point inertia-reel seatbelts for front and rear occupants.
Airbags:
Driver's side airbag typically introduced later in the generation or as an option.
Body Structure:
Reinforced safety cell and crumple zones designed for impact energy absorption.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, often with multiple speakers. Upgrades common.
Climate Control:
Manual or automatic climate control systems depending on trim level.
Driver Assistance
Cruise Control:
Standard on many models, especially VR-4 variants.
ABS:
Anti-lock Braking System (ABS) offered significant advancements in braking control for its time.
Connectivity
Connectivity Features:
Limited by era. No modern Bluetooth or USB connectivity. Focus on core vehicle functionality.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, depending on driving conditions. Detailed schedule in manual.
Spark Plug Replacement:
Refer to manual for specific type and interval (e.g., 30,000 miles for standard, potentially longer for platinum).
Timing Belt Replacement:
Crucial for 4G63 engine. Typically every 60,000 - 90,000 miles (100,000 - 150,000 km). A non-negotiable maintenance item to prevent catastrophic engine failure.
Fluid Specifications
Engine Oil Type:
Refer to manual for specific viscosity grade (e.g., 10W-30 or 5W-30) and API service classification. Synthetic oil recommended for turbocharged models.
Engine Oil Capacity:
Approx. 4.5 Liters (4.8 US Quarts) with filter change. Check manual for exact capacity.
Coolant Type:
Ethylene glycol based coolant, typically a 50/50 mix with distilled water. Consult manual for specific OEM recommendations.
Transmission Fluid Type Auto:
Dexron II or equivalent ATF. Refer to manual for exact specification and capacity.
Transmission Fluid Type Manual:
GL-4 or GL-5 gear oil, viscosity grade as specified (e.g., 75W-90). Refer to manual.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. Refer to manual for specification.
Power Steering Fluid:
Power steering fluid or ATF Dexron II/III as specified. Refer to manual.
Known Issues
Turbo Failure:
Turbocharger seals can fail over time, leading to oil consumption or loss of boost. Proper maintenance, especially oil changes and allowing the turbo to spool down, is critical.
Engine Seals Gaskets:
Valve cover gaskets, oil pan gaskets, and rear main seals are common leak points as the vehicle ages.
Suspension Wear:
Bushings, ball joints, and strut mounts can wear out, leading to clunking noises and poor handling. AWD components also require inspection.
Electrical Gremlins:
As with many vehicles of this era, aging wiring harnesses and connectors can lead to intermittent electrical issues.
Rust Corrosion:
Underbody rust, particularly in areas prone to road salt, can be a concern. Wheel wells, rocker panels, and suspension components are areas to inspect.
📚 Vehicle History
Brand Heritage
Heritage:
Mitsubishi, a major Japanese automotive manufacturer with a history dating back to the early 20th century, known for innovation in engines and drivetrains.
Model Evolution
Generation:
This manual covers the fourth generation (E31A, E32A, E33A, E34A, E35A, E38A, E39A) Galant, produced from 1987 to 1993. The VR-4 variant (E39A) was introduced in 1987.
Vr4 Significance:
The VR-4 designation signified Mitsubishi's high-performance offering, utilizing advanced technologies to achieve sporty performance and handling.
Production
Manufacturing Locations:
Primarily Japan.
Production Years:
1988-1993 for this specific manual coverage.
🏆 Awards & Recognition
Recognitions
Motoring Awards:
While specific awards for the 1988-1993 Galant VR-4 are not as widely publicized as later models, its performance and technology were well-regarded in automotive press, often praised for its value proposition in the affordable performance sedan segment.
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