Mitsubishi Galant 1991 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Galant Year: 1991 Codes Chassis Code: E3_A Platform: Mitsubishi Galant (E3_A) 👋 Introduction Market Position Market Position: The 1991 Mitsubishi Galant was positioned as a mid-size sedan offering a blend of European styling influence, advanced technology for its time, and reliable performance, competing with vehicles like the Toyota Camry, Honda Accord, and Ford Taurus. Competitive Analysis Competitive Analysis: The Galant of this era was known for its distinctive styling and often featured advanced drivetrain options (like optional all-wheel drive and V6 engines), setting it apart from some more conservative competitors. This manual provides the necessary in-depth information to maintain and repair these advanced features. Key Features Key Features: The 1991 Galant, particularly in higher trims, offered features like a sophisticated multi-link suspension, available V6 engines, and aerodynamic styling. This service manual covers these complex systems in detail. 📋 Manual Details Coverage Areas Coverage Areas: Comprehensive coverage for all mechanical and electrical systems of the 1991 Mitsubishi Galant. Page Count Page Count: Estimated 1500+ pages (typical for a full factory service manual of this era) Manual Type Manual Type: Factory Service Repair Manual Manual Detail Type: Comprehensive Repair Manual / Service Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Systems Covered: Engine mechanical, lubrication, fuel system, cooling system, intake and exhaust, engine electrical, engine and emission control, clutch, manual transaxle, automatic transaxle, front axle, rear axle, wheels and tires, power plant mount, front suspension, rear suspension, service brakes, parking brakes, steering, body, exterior, chassis electrical, component locations, configuration diagrams, splice locations, circuit diagrams. Procedures Included Procedures Included: Maintenance schedules, diagnostic procedures, repair procedures, component removal and installation, troubleshooting, specifications, tightening torques, wiring diagrams, exploded views. Technical Depth Technical Depth: In-depth, factory-level technical information suitable for professional mechanics and experienced DIY enthusiasts, covering everything from basic maintenance to complete engine and transmission overhauls. Specific Procedures Specific Procedures: Engine diagnostics, fuel injector testing and replacement, ignition timing adjustment, valve clearance adjustment, torque converter replacement, transmission fluid flush, ABS system troubleshooting, suspension alignment, brake caliper service, power steering system repair, body panel alignment, HVAC system diagnostics and repair. Troubleshooting Charts Troubleshooting Charts Included: Yes, extensive troubleshooting flowcharts and symptom-based diagnostic guides for common issues. Technical Data Technical Data Coverage: Includes detailed specifications for all components, tightening torque values, alignment specifications, diagnostic trouble codes (DTCs), and component resistance values. 📊 Manual Specifications File Format File Format: PDF Searchable Text: Yes, the PDF is typically searchable, allowing for quick access to specific topics. Print Quality Print Quality: High-resolution, digitally rendered for clear and legible printing of all text, diagrams, and illustrations. Binding Type Binding Type: Digital Download (PDF) - printable Paper Type Paper Type: N/A (Digital) Compatibility Compatibility: WINDOWS and MAC Requirements Requirements: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Primary Engine: 4G63 2.0L SOHC 4-cylinder (available in base models) Performance Engine 2 0L DOHc Performance: Approx. 135-145 hp, 130-140 lb-ft torque (depending on specific market and trim) Engine Options Engine Options: 6G71 2.5L SOHC V6 (available in higher trims, often designated as 'GT' or 'GTI') Engine V6 Performance Engine V6 Performance: Approx. 150-160 hp, 155-165 lb-ft torque (depending on specific market and trim) Fuel System Fuel System: Electronic Fuel Injection (EFI) Engine Codes Covered Engine Codes Covered: 4G63, 6G71 Cooling System Cooling System Capacity Approx: Approx. 6.5-7.5 liters (depending on engine and radiator size). Engine Electrical Ignition System Type: Distributorless Ignition System (DIS) on some V6 models, conventional distributor with ignition module on 4-cylinder models. 🔧 Transmission Standard Standard Transmission: 5-speed manual transaxle Optional Optional Transmission: 4-speed automatic transaxle Features Transmission Features: Some models featured optional All-Wheel Drive (AWD) system, particularly with V6 engines. Automatic Transaxle Fluid Type Automatic Transaxle Fluid Type: Typically ATF SP-II or equivalent (refer to manual for specific Mitsubishi specification). 📐 Dimensions Exterior Wheelbase: Approx. 104.7 inches (2659 mm) Length: Approx. 184.3 inches (4681 mm) Width: Approx. 68.1 inches (1730 mm) Height: Approx. 55.1 inches (1400 mm) Weights Curb Weight: Approx. 2900 - 3400 lbs (1315 - 1542 kg) depending on engine and trim Wheel Bolt Pattern: 5x114.3 mm (5x4.5 inches) Wheel Size: Typically 14 or 15 inches Interior Seating Capacity: 5 🛡️ Safety Features Ratings Safety Ratings: NHTSA ratings from this era are generally not comparable to modern standards. Refer to specific vehicle history for known issues. Active Features Active Features: Anti-lock Braking System (ABS) was optional on many models. Passive Features Passive Features: Front and rear seat belts, collapsible steering column. 💡 Technology Features Infotainment Infotainment Features: Basic AM/FM stereo with cassette player, optional CD player on higher trims. Manual covers stereo system removal and installation. Driver Assistance Driver Assistance Features: ABS (optional), and on very specific models, optional All-Wheel Steering (AWS). Connectivity Connectivity Features: N/A by modern standards. Basic diagnostics accessed via consult port. Electrical Diagrams...
The 1991 Mitsubishi Galant was positioned as a mid-size sedan offering a blend of European styling influence, advanced technology for its time, and reliable performance, competing with vehicles like the Toyota Camry, Honda Accord, and Ford Taurus.
Competitive Analysis
Competitive Analysis:
The Galant of this era was known for its distinctive styling and often featured advanced drivetrain options (like optional all-wheel drive and V6 engines), setting it apart from some more conservative competitors. This manual provides the necessary in-depth information to maintain and repair these advanced features.
Key Features
Key Features:
The 1991 Galant, particularly in higher trims, offered features like a sophisticated multi-link suspension, available V6 engines, and aerodynamic styling. This service manual covers these complex systems in detail.
📋 Manual Details
Coverage Areas
Coverage Areas:
Comprehensive coverage for all mechanical and electrical systems of the 1991 Mitsubishi Galant.
Page Count
Page Count:
Estimated 1500+ pages (typical for a full factory service manual of this era)
Manual Type
Manual Type:
Factory Service Repair Manual
Manual Detail Type:
Comprehensive Repair Manual / Service Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Systems Covered:
Engine mechanical, lubrication, fuel system, cooling system, intake and exhaust, engine electrical, engine and emission control, clutch, manual transaxle, automatic transaxle, front axle, rear axle, wheels and tires, power plant mount, front suspension, rear suspension, service brakes, parking brakes, steering, body, exterior, chassis electrical, component locations, configuration diagrams, splice locations, circuit diagrams.
In-depth, factory-level technical information suitable for professional mechanics and experienced DIY enthusiasts, covering everything from basic maintenance to complete engine and transmission overhauls.
Specific Procedures
Specific Procedures:
Engine diagnostics, fuel injector testing and replacement, ignition timing adjustment, valve clearance adjustment, torque converter replacement, transmission fluid flush, ABS system troubleshooting, suspension alignment, brake caliper service, power steering system repair, body panel alignment, HVAC system diagnostics and repair.
Troubleshooting Charts
Troubleshooting Charts Included:
Yes, extensive troubleshooting flowcharts and symptom-based diagnostic guides for common issues.
Technical Data
Technical Data Coverage:
Includes detailed specifications for all components, tightening torque values, alignment specifications, diagnostic trouble codes (DTCs), and component resistance values.
📊 Manual Specifications
File Format
File Format:
PDF
Searchable Text:
Yes, the PDF is typically searchable, allowing for quick access to specific topics.
Print Quality
Print Quality:
High-resolution, digitally rendered for clear and legible printing of all text, diagrams, and illustrations.
Binding Type
Binding Type:
Digital Download (PDF) - printable
Paper Type
Paper Type:
N/A (Digital)
Compatibility
Compatibility:
WINDOWS and MAC
Requirements
Requirements:
Adobe PDF Reader
⚙️ Engine Specifications
Primary Engine
Primary Engine:
4G63 2.0L SOHC 4-cylinder (available in base models)
Performance
Engine 2 0L DOHc Performance:
Approx. 135-145 hp, 130-140 lb-ft torque (depending on specific market and trim)
Engine Options
Engine Options:
6G71 2.5L SOHC V6 (available in higher trims, often designated as 'GT' or 'GTI')
Engine V6 Performance
Engine V6 Performance:
Approx. 150-160 hp, 155-165 lb-ft torque (depending on specific market and trim)
Fuel System
Fuel System:
Electronic Fuel Injection (EFI)
Engine Codes Covered
Engine Codes Covered:
4G63, 6G71
Cooling System
Cooling System Capacity Approx:
Approx. 6.5-7.5 liters (depending on engine and radiator size).
Engine Electrical
Ignition System Type:
Distributorless Ignition System (DIS) on some V6 models, conventional distributor with ignition module on 4-cylinder models.
🔧 Transmission
Standard
Standard Transmission:
5-speed manual transaxle
Optional
Optional Transmission:
4-speed automatic transaxle
Features
Transmission Features:
Some models featured optional All-Wheel Drive (AWD) system, particularly with V6 engines.
Automatic Transaxle Fluid Type
Automatic Transaxle Fluid Type:
Typically ATF SP-II or equivalent (refer to manual for specific Mitsubishi specification).
📐 Dimensions
Exterior
Wheelbase:
Approx. 104.7 inches (2659 mm)
Length:
Approx. 184.3 inches (4681 mm)
Width:
Approx. 68.1 inches (1730 mm)
Height:
Approx. 55.1 inches (1400 mm)
Weights
Curb Weight:
Approx. 2900 - 3400 lbs (1315 - 1542 kg) depending on engine and trim
Wheel Bolt Pattern:
5x114.3 mm (5x4.5 inches)
Wheel Size:
Typically 14 or 15 inches
Interior
Seating Capacity:
5
🛡️ Safety Features
Ratings
Safety Ratings:
NHTSA ratings from this era are generally not comparable to modern standards. Refer to specific vehicle history for known issues.
Active Features
Active Features:
Anti-lock Braking System (ABS) was optional on many models.
Passive Features
Passive Features:
Front and rear seat belts, collapsible steering column.
💡 Technology Features
Infotainment
Infotainment Features:
Basic AM/FM stereo with cassette player, optional CD player on higher trims. Manual covers stereo system removal and installation.
Driver Assistance
Driver Assistance Features:
ABS (optional), and on very specific models, optional All-Wheel Steering (AWS).
Connectivity
Connectivity Features:
N/A by modern standards. Basic diagnostics accessed via consult port.
Electrical Diagrams
Electrical Diagrams Coverage:
Comprehensive wiring diagrams for all electrical systems, including lighting, ignition, fuel injection, power windows, door locks, HVAC controls, and instrument cluster.
🔧 Maintenance
Service Intervals
Engine Oil Change Interval:
Typically every 3,000-5,000 miles or 3-6 months, depending on driving conditions (refer to manual for precise recommendation).
Timing Belt Replacement:
Crucial for 4G63 engine. Recommended replacement every 60,000 miles or 5 years. Failure can cause catastrophic engine damage.
Fluid Specifications
Engine Oil Type:
API SG or higher, viscosity grade 10W-30 recommended for most conditions (refer to manual for specific ambient temperature recommendations).
Coolant Type:
Ethylene glycol based antifreeze, 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Manual Transmission Fluid Type:
API GL-4 or GL-5 gear oil, viscosity grade 75W-90 or 80W-90 recommended (refer to manual).
Known Issues
Known Issues:
Corrosion on body panels, particularly in rust-prone areas. Suspension component wear (bushings, ball joints). Fuel injector clogging. Ignition system component failures (coil packs, distributor). Overheating due to radiator or coolant hose degradation.
Known Issues Electrical:
Fraying wiring harnesses in high-flex areas (e.g., door jambs), intermittent issues with sensors due to age, degradation of ground points.
Part Numbers Example
Timing Belt Part Number Example:
Mitsubishi OEM or equivalent for 4G63 engine (specific part numbers vary by supplier and exact engine variant).
Maintenance Schedule Coverage
Maintenance Schedule Coverage:
Detailed schedules for oil changes, filter replacements, fluid checks and flushes, timing belt inspection/replacement, spark plug replacement, brake service, suspension checks, and emissions system maintenance.
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mitsubishi Motors has a long history in automotive manufacturing, known for its engineering prowess and diverse product offerings ranging from passenger cars to off-road vehicles and industrial engines.
Model Evolution
Model Evolution:
The 1991 Galant belongs to the fifth generation (E3_A) of the model, which ran from 1987 to 1993. This generation was notable for its aerodynamic design and significant technological advancements, including independent multi-link suspension and optional four-wheel steering (4WS) on some performance variants.
Platform Variants:
The E3_A platform also underpinned the Mitsubishi Eclipse and Plymouth Laser (first generation), sharing many powertrain and chassis components.
Production
Production Years:
1987-1993 (Fifth Generation E3_A)
Manufacturing Locations:
Primarily Japan (various Mitsubishi plants).
🏆 Awards & Recognition
Recognitions
Recognitions:
The Galant platform often received praise for its design and engineering in automotive publications of the era, though specific awards for the 1991 model year vary by region.
Ratings
Ratings:
Consumer satisfaction ratings from the early 1990s would be found in historical automotive reviews. This manual aids in maintaining high satisfaction through proper care.