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Mitsubishi Galant 1991 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Galant Year: 1991 Chassis Code: E33A, E35A, E38A, E39A Generation Generation: Fifth Generation (E30 Series) 👋 Introduction Market Position Market Position: The 1991 Mitsubishi Galant was positioned as a capable and stylish mid-size sedan, often competing with models like the Toyota Camry, Honda Accord, and Ford Taurus. It offered a blend of comfort, performance, and advanced features for its time. Competitive Analysis Competitive Analysis: The Galant's aerodynamic styling and available V6 engine gave it an edge in performance. Its front-wheel-drive platform was standard, with all-wheel-drive available on some models, offering enhanced traction. The manual provided here covers the specific technical nuances of this generation, essential for maintaining its competitive edge in terms of reliability and performance. Key Features Key Features: Aerodynamic styling, available V6 engine, comfortable interior, advanced suspension systems (e.g., multi-link rear), optional all-wheel-drive ('4WS' in some markets). This manual is crucial for understanding and maintaining these specific features. Manual Purpose Manual Purpose: To provide detailed, step-by-step instructions for maintenance, repair, and troubleshooting, enabling owners and mechanics to effectively service the 1991 Mitsubishi Galant. Manual Value Proposition Value Proposition: Offers a cost-effective alternative to dealership service and provides the in-depth knowledge needed to maintain the long-term reliability and performance of a 1991 Mitsubishi Galant. 📋 Manual Details Coverage Areas Coverage Areas: Engine, Lubrication, Fuel, Cooling, Intake/Exhaust, Electrical, Emission Control, Clutch, Transaxles (Manual & Automatic), Axles (Front & Rear), Wheels/Tires, Mounts, Suspension (Front & Rear), Brakes (Service & Parking), Steering, Body, Exterior, Chassis Electrical, Component Locations, Configuration Diagrams, Splice Locations, Circuit Diagrams Page Count Page Count: Not Specified (but described as comprehensive) Manual Type Manual Type: Service and Repair Manual Target Audience: DIYers and professional mechanics. Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Systems Covered: Engine Mechanical, Engine Lubrication System, Fuel System (Injection), Cooling System, Intake and Exhaust Systems, Engine Electrical System, Engine Control System, Emission Control Systems, Clutch Assembly, Manual Transaxle, Automatic Transaxle, Front Axle/Drivetrain, Rear Axle/Drivetrain, Wheel and Tire Service, Power Plant Mounts, Front Suspension, Rear Suspension, Service Brakes System, Parking Brake System, Steering System, Body Construction, Exterior Components, Chassis Electrical Systems, Wiring Diagrams Chassis Electrical: Covers lighting, wipers, horn, power windows, door locks, power mirrors, instrument panel gauges, and accessory circuits. Body: Includes procedures for body panel removal/installation, interior trim, doors, hood, trunk, and glass replacement. Diagrams: Includes component location diagrams, configuration diagrams, splice locations, and detailed circuit diagrams (wiring schematics). Procedures Included Procedures Included: Routine Maintenance, Inspections, Troubleshooting, Diagnosis, Component Removal and Installation, Reassembly, Adjustment Procedures, Overhaul Procedures, Repair of Major Systems, Electrical System Diagnostics, Wiring Harness Repairs, Body Panel Alignment, Suspension Component Replacement, Brake System Servicing, Steering System Repair Troubleshooting Charts: Extensive troubleshooting guides for various systems, aiding in diagnosing common and complex problems. Technical Depth Technical Depth: Comprehensive: From basic DIY maintenance to in-depth mechanical and electrical repair procedures, suitable for both novice and experienced technicians. Includes complete disassembly and reassembly guidance. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, likely featuring hundreds of photos and illustrations, implying good visual clarity for repair procedures. Binding Type Binding Type: Digital (PDF) - implies no physical binding, but easily printable. Paper Type Paper Type: Not Applicable (Digital File) Digital Features Digital Features: Searchable text, hyperlinked sections (likely), printable pages. Compatibility Compatibility: Windows and MAC operating systems. Software Requirements Software Requirements: Adobe PDF Reader Illustrations Illustrations: Hundreds of photos and illustrations detailing procedures and components. Organization Organization: Alphabetical index for quick reference, chapter-based organization by system. ⚙️ Engine Specifications Primary Engine Engine Type: Inline 4-Cylinder Engine Displacement: 2.0 Liters (1997 cc) Engine Codes: 4G63 (DOHC and SOHC variants) Engine Horsepower: Approx. 135-140 hp (SOHC), 195 hp (DOHC Turbocharged for VR-4 models) Engine Torque: Approx. 125-130 lb-ft (SOHC), 203 lb-ft (DOHC Turbocharged) Valve Train: SOHC 12-valve or DOHC 16-valve (depending on variant) Performance Aspiration: Naturally Aspirated and Turbocharged (VR-4 model) Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) Engine Cooling Cooling Type: Water-cooled Engine Electrical Ignition System: Electronic Ignition 🔧 Transmission Standard Transmission Type: 5-Speed Manual Transaxle Optional Transmission Type: 4-Speed Automatic Transaxle Features All Wheel Drive: Available on select models, often paired with the DOHC Turbo engine and advanced AWD systems like 'Active Full-Time 4WD' or 'Super AWD' for specific trims (e.g., VR-4). Fluid Specifications Manual Transaxle Fluid: API GL-4, SAE 75W-90 or 80W-90 gear oil (Specific part numbers and capacities available in manual) Automatic Transaxle Fluid: Mitsubishi Diaqueen ATF SP-II or equivalent (Specific part numbers and capacities available in manual) 📐 Dimensions Exterior Length: Approx. 180.7 inches Width: Approx. 67.9 inches Height: Approx. 53.7 inches Wheelbase Wheelbase: Approx. 104.3 inches Weights Curb Weight: Varies by trim, approx. 3000-3300 lbs Gross Vehicle Weight: Not specified, but detailed in manual 🛡️ Safety Features Ratings NHTSA Front Impact: Not explicitly rated by modern...
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Mitsubishi Galant 1991 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Galant
Year:
1991
Chassis Code:
E33A, E35A, E38A, E39A
Generation
Generation:
Fifth Generation (E30 Series)
👋 Introduction
Market Position
Market Position:
The 1991 Mitsubishi Galant was positioned as a capable and stylish mid-size sedan, often competing with models like the Toyota Camry, Honda Accord, and Ford Taurus. It offered a blend of comfort, performance, and advanced features for its time.
Competitive Analysis
Competitive Analysis:
The Galant's aerodynamic styling and available V6 engine gave it an edge in performance. Its front-wheel-drive platform was standard, with all-wheel-drive available on some models, offering enhanced traction. The manual provided here covers the specific technical nuances of this generation, essential for maintaining its competitive edge in terms of reliability and performance.
Key Features
Key Features:
Aerodynamic styling, available V6 engine, comfortable interior, advanced suspension systems (e.g., multi-link rear), optional all-wheel-drive ('4WS' in some markets). This manual is crucial for understanding and maintaining these specific features.
Manual Purpose
Manual Purpose:
To provide detailed, step-by-step instructions for maintenance, repair, and troubleshooting, enabling owners and mechanics to effectively service the 1991 Mitsubishi Galant.
Manual Value Proposition
Value Proposition:
Offers a cost-effective alternative to dealership service and provides the in-depth knowledge needed to maintain the long-term reliability and performance of a 1991 Mitsubishi Galant.
📋 Manual Details
Coverage Areas
Coverage Areas:
Engine, Lubrication, Fuel, Cooling, Intake/Exhaust, Electrical, Emission Control, Clutch, Transaxles (Manual & Automatic), Axles (Front & Rear), Wheels/Tires, Mounts, Suspension (Front & Rear), Brakes (Service & Parking), Steering, Body, Exterior, Chassis Electrical, Component Locations, Configuration Diagrams, Splice Locations, Circuit Diagrams
Page Count
Page Count:
Not Specified (but described as comprehensive)
Manual Type
Manual Type:
Service and Repair Manual
Target Audience:
DIYers and professional mechanics.
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Systems Covered:
Engine Mechanical, Engine Lubrication System, Fuel System (Injection), Cooling System, Intake and Exhaust Systems, Engine Electrical System, Engine Control System, Emission Control Systems, Clutch Assembly, Manual Transaxle, Automatic Transaxle, Front Axle/Drivetrain, Rear Axle/Drivetrain, Wheel and Tire Service, Power Plant Mounts, Front Suspension, Rear Suspension, Service Brakes System, Parking Brake System, Steering System, Body Construction, Exterior Components, Chassis Electrical Systems, Wiring Diagrams
Chassis Electrical:
Covers lighting, wipers, horn, power windows, door locks, power mirrors, instrument panel gauges, and accessory circuits.
Body:
Includes procedures for body panel removal/installation, interior trim, doors, hood, trunk, and glass replacement.
Diagrams:
Includes component location diagrams, configuration diagrams, splice locations, and detailed circuit diagrams (wiring schematics).
Procedures Included
Procedures Included:
Routine Maintenance, Inspections, Troubleshooting, Diagnosis, Component Removal and Installation, Reassembly, Adjustment Procedures, Overhaul Procedures, Repair of Major Systems, Electrical System Diagnostics, Wiring Harness Repairs, Body Panel Alignment, Suspension Component Replacement, Brake System Servicing, Steering System Repair
Troubleshooting Charts:
Extensive troubleshooting guides for various systems, aiding in diagnosing common and complex problems.
Technical Depth
Technical Depth:
Comprehensive: From basic DIY maintenance to in-depth mechanical and electrical repair procedures, suitable for both novice and experienced technicians. Includes complete disassembly and reassembly guidance.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-resolution, likely featuring hundreds of photos and illustrations, implying good visual clarity for repair procedures.
Binding Type
Binding Type:
Digital (PDF) - implies no physical binding, but easily printable.
Paper Type
Paper Type:
Not Applicable (Digital File)
Digital Features
Digital Features:
Searchable text, hyperlinked sections (likely), printable pages.
Compatibility
Compatibility:
Windows and MAC operating systems.
Software Requirements
Software Requirements:
Adobe PDF Reader
Illustrations
Illustrations:
Hundreds of photos and illustrations detailing procedures and components.
Organization
Organization:
Alphabetical index for quick reference, chapter-based organization by system.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Inline 4-Cylinder
Engine Displacement:
2.0 Liters (1997 cc)
Engine Codes:
4G63 (DOHC and SOHC variants)
Engine Horsepower:
Approx. 135-140 hp (SOHC), 195 hp (DOHC Turbocharged for VR-4 models)
Engine Torque:
Approx. 125-130 lb-ft (SOHC), 203 lb-ft (DOHC Turbocharged)
Valve Train:
SOHC 12-valve or DOHC 16-valve (depending on variant)
Performance
Aspiration:
Naturally Aspirated and Turbocharged (VR-4 model)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Engine Cooling
Cooling Type:
Water-cooled
Engine Electrical
Ignition System:
Electronic Ignition
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual Transaxle
Optional
Transmission Type:
4-Speed Automatic Transaxle
Features
All Wheel Drive:
Available on select models, often paired with the DOHC Turbo engine and advanced AWD systems like 'Active Full-Time 4WD' or 'Super AWD' for specific trims (e.g., VR-4).
Fluid Specifications
Manual Transaxle Fluid:
API GL-4, SAE 75W-90 or 80W-90 gear oil (Specific part numbers and capacities available in manual)
Automatic Transaxle Fluid:
Mitsubishi Diaqueen ATF SP-II or equivalent (Specific part numbers and capacities available in manual)
📐 Dimensions
Exterior
Length:
Approx. 180.7 inches
Width:
Approx. 67.9 inches
Height:
Approx. 53.7 inches
Wheelbase
Wheelbase:
Approx. 104.3 inches
Weights
Curb Weight:
Varies by trim, approx. 3000-3300 lbs
Gross Vehicle Weight:
Not specified, but detailed in manual
🛡️ Safety Features
Ratings
NHTSA Front Impact:
Not explicitly rated by modern standards, but designed with crumple zones.
Active Features
Antilock Brakes:
Available on some models.
Passive Features
Airbags:
Driver-side airbag standard on most models, passenger airbag optional or unavailable for this year.
Seatbelts:
3-point front seatbelts with pretensioners on some models.
💡 Technology Features
Infotainment
Infotainment System:
Basic AM/FM stereo with cassette player, optional CD player. Manual covers basic electrical connections and speaker replacements.
Driver Assistance
Driver Assistance:
Limited by modern standards; ABS available on some trims. Manual covers ABS system diagnostics and component replacement.
Connectivity
Connectivity:
No advanced connectivity features. Manual covers wiring for power accessories and basic electrical systems.
Lighting
Lighting Systems:
Halogen headlights, manual covers bulb replacement and headlight aiming procedures.
Climate Control
Climate Control System:
Manual or automatic climate control depending on trim. Manual details HVAC system operation, component diagnosis, and refrigerant handling (if applicable).
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750-7,500 miles or 6-12 months, depending on driving conditions (Consult manual for exact recommendation based on oil type).
Air Filter Replacement:
Every 15,000-30,000 miles or as needed, based on inspection.
Spark Plug Replacement:
Every 30,000-60,000 miles, depending on plug type (copper, platinum).
Timing Belt Replacement:
Critical interval, typically 60,000-90,000 miles or 5-7 years for interference engines (4G63). Manual will specify exact interval and procedure.
Fluid Specifications
Engine Oil Type:
API SG/SH, SAE 5W-30 or 10W-30 recommended (refer to manual for exact specifications and viscosity for climate).
Coolant Type:
Ethylene Glycol based coolant, 50/50 mix with distilled water (Check manual for specific type and capacity).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (Check manual for specific type and replacement interval).
Known Issues
Known Issues:
Timing belt failure (critical on interference engines), head gasket leaks, oil leaks from valve cover and oil pan, aging electrical components (e.g., power window motors, sensors), rust on body panels and undercarriage, potential for automatic transmission issues if not maintained.
Diagnostic Trouble Codes:
Manual provides procedures for retrieving and interpreting diagnostic codes from the ECU, essential for troubleshooting engine and emissions issues.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mitsubishi Motors, a division of the Mitsubishi conglomerate, has a long history in automotive manufacturing, known for innovation and diverse product lines, including robust off-road vehicles and performance cars.
Model Evolution
Model Evolution:
The Galant has been in continuous production since the 1960s, evolving through multiple generations. The E30 series (1987-1993) represented a significant styling and technological update, with the 1991 model year being part of this modern era.
Production
Production Location:
Primarily Japan
Production Years For Generation:
1987-1993
🏆 Awards & Recognition
Recognitions
Recognitions:
While specific awards for the 1991 model year are not widely publicized, the Galant lineup generally received positive reviews for its styling and engineering during this period, often being praised as a strong competitor in its segment.
Ratings
Ratings:
Contemporary reviews often highlighted its comfortable ride and competent handling, especially for the V6 and AWD models.
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