Mitsubishi Galant 1988-1992 Full Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Galant Model Generations Covered: E3_A, E3_3A, E3_5A Codes Chassis Codes Covered: E33A, E35A, E38A, E39A Engine Codes Covered: 4G37, 4G61, 4G63, 4G63T (likely for AWD performance models), 6G71 👋 Introduction Market Position Era Positioning: Mid-size family sedan/coupe, competing with Honda Accord, Toyota Camry, Ford Tempo, Chevrolet Celebrity Competitive Analysis Key Competitors: Honda Accord, Toyota Camry, Nissan Maxima, Ford Taurus, Chevrolet Lumina Key Features Platform Variant: Often featured advanced chassis technologies for its time, including multi-link rear suspension and optional All-Wheel Drive (AWD) Engine Options Variety: Offered a range of 4-cylinder and V6 engines, including performance-oriented turbocharged variants for some models Design Evolution: Marked a significant stylistic departure with more aerodynamic and modern styling compared to previous generations 📋 Manual Details Coverage Areas Years Covered: 1988, 1989, 1990, 1991, 1992 Page Count Estimated Page Count: 1000+ Manual Type Manual Type: Full Service & Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul, cylinder head, block assembly, lubrication, cooling, fuel, ignition, exhaust, emissions Engine Management: ECU, sensors, actuators, diagnostics, fuel injection, ignition timing Transmission Manual: Clutch, gearbox overhaul, shifting mechanisms, drive shafts Transmission Automatic: Automatic transmission overhaul, hydraulic control, torque converter, electronic control units Drivetrain AWD: Center differential, transfer case, rear differential (for AWD models) Suspension: Front and rear suspension geometry, components, alignment, shock absorbers, springs, bushings Steering: Power steering system, rack and pinion, steering column, wheel alignment Brakes: Front and rear brake systems (disc/drum), ABS (if equipped), parking brake, hydraulic components, fluid specifications Electrical System: Battery, charging system, starting system, lighting, fuses, relays, wiring diagrams, body electricals HVAC: Heating, ventilation, air conditioning system components, refrigerant, servicing Body And Interior: Body panel removal and installation, interior trim, glass, doors, latches, seats Procedures Included Scheduled Maintenance: Oil changes, filter replacements, spark plugs, timing belts, fluid checks and changes Troubleshooting: Diagnostic charts, symptom-based fault finding, common problem solutions Engine Repair: Piston ring replacement, bearing service, valve adjustments, head gasket replacement, timing belt replacement Transmission Overhaul: Complete disassembly and reassembly of manual and automatic transmissions Brake Service: Brake pad/shoe replacement, rotor/drum resurfacing or replacement, caliper overhaul, bleeding procedures Electrical Diagnostics: Using multimeters, oscilloscopes, tracing short circuits, open circuits, diagnosing sensor failures Suspension Alignment: Adjustment procedures for camber, caster, toe Ac Service: Refrigerant charging, leak detection, component replacement Bodywork Repair: Panel replacement, dent repair, rust treatment Technical Depth Depth: Comprehensive: from basic maintenance to full engine and transmission rebuilds, detailed electrical schematics Diagnostic Information: Detailed diagnostic trouble codes (DTCs) and troubleshooting flows Torque Specifications: Precise torque values for all critical fasteners Tolerances: Engine and transmission component wear tolerances for rebuilding Wiring Diagrams: Complete and detailed electrical system wiring diagrams 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content Print Quality Printability: Printable pages Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine 1 Code: 4G63 Engine 1 Type: 2.0L DOHC 16-valve Inline-4 (Naturally Aspirated and Turbocharged) Engine 1 Displacement Cc: 1997 Engine 1 Hp Na: ~140-155 hp Engine 1 Hp Turbo: ~190-200 hp (GSi/GT models) Engine 1 Torque Nm Na: ~175-185 Nm Engine 1 Torque Nm Turbo: ~255-260 Nm Optional Engine Engine 2 Code: 6G71 Engine 2 Type: 2.5L SOHC 24-valve V6 Engine 2 Displacement Cc: 2496 Engine 2 Hp: ~150-160 hp Engine 2 Torque Nm: ~200-210 Nm Performance Performance Engine Options: Available with naturally aspirated 4-cylinder, turbocharged 4-cylinder (4G63T), and V6 engines Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) Fuel Type: Unleaded Gasoline Octane Rating Recommended: 87 AKI (for NA engines), 91 AKI (for Turbocharged engines) 🔧 Transmission Standard Standard Transmission: 5-speed Manual Optional Optional Transmission: 4-speed Automatic (with Lock-up) Features AWD Availability: Available on certain trim levels, typically with the 4G63T engine (e.g., AWD GSR/GT models) Clutch Type: Hydraulically actuated dry single plate clutch 📐 Dimensions Exterior Length Mm: ~4545 - 4610 Width Mm: ~1710 - 1735 Height Mm: ~1395 - 1415 Wheelbase Mm: ~2600 Track Width Front Mm: ~1450 Track Width Rear Mm: ~1455 Weights Curb Weight Kg: ~1250 - 1450 Gross Vehicle Weight Rating Kg: ~1750 - 1900 🛡️ Safety Features Ratings NHTSA Ratings: Not extensively tested by modern standards; likely had basic front impact protection. Active Features ABS: Optional Anti-lock Braking System (ABS) on some models Passive Features Airbags: Driver-side airbag standard on later models (1991/1992), optional earlier. Seatbelts: Three-point seatbelts with pretensioners (driver/passenger) Rollover Protection: Reinforced body structure 💡 Technology Features Infotainment Audio System: Factory AM/FM stereo with cassette player, optional CD player on higher trims Speaker Configuration: Typically 4 or 6 speaker systems Driver Assistance Cruise Control: Standard on many trim levels Anti Lock Brakes: Optional, as mentioned in safety Connectivity No Modern Connectivity: No Bluetooth, USB, or smartphone integration; analog systems only. 🔧 Maintenance Service Intervals Engine Oil...
Comprehensive: from basic maintenance to full engine and transmission rebuilds, detailed electrical schematics
Diagnostic Information:
Detailed diagnostic trouble codes (DTCs) and troubleshooting flows
Torque Specifications:
Precise torque values for all critical fasteners
Tolerances:
Engine and transmission component wear tolerances for rebuilding
Wiring Diagrams:
Complete and detailed electrical system wiring diagrams
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content
Print Quality
Printability:
Printable pages
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine 1 Code:
4G63
Engine 1 Type:
2.0L DOHC 16-valve Inline-4 (Naturally Aspirated and Turbocharged)
Engine 1 Displacement Cc:
1997
Engine 1 Hp Na:
~140-155 hp
Engine 1 Hp Turbo:
~190-200 hp (GSi/GT models)
Engine 1 Torque Nm Na:
~175-185 Nm
Engine 1 Torque Nm Turbo:
~255-260 Nm
Optional Engine
Engine 2 Code:
6G71
Engine 2 Type:
2.5L SOHC 24-valve V6
Engine 2 Displacement Cc:
2496
Engine 2 Hp:
~150-160 hp
Engine 2 Torque Nm:
~200-210 Nm
Performance
Performance Engine Options:
Available with naturally aspirated 4-cylinder, turbocharged 4-cylinder (4G63T), and V6 engines
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Octane Rating Recommended:
87 AKI (for NA engines), 91 AKI (for Turbocharged engines)
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual
Optional
Optional Transmission:
4-speed Automatic (with Lock-up)
Features
AWD Availability:
Available on certain trim levels, typically with the 4G63T engine (e.g., AWD GSR/GT models)
Clutch Type:
Hydraulically actuated dry single plate clutch
📐 Dimensions
Exterior
Length Mm:
~4545 - 4610
Width Mm:
~1710 - 1735
Height Mm:
~1395 - 1415
Wheelbase Mm:
~2600
Track Width Front Mm:
~1450
Track Width Rear Mm:
~1455
Weights
Curb Weight Kg:
~1250 - 1450
Gross Vehicle Weight Rating Kg:
~1750 - 1900
🛡️ Safety Features
Ratings
NHTSA Ratings:
Not extensively tested by modern standards; likely had basic front impact protection.
Active Features
ABS:
Optional Anti-lock Braking System (ABS) on some models
Passive Features
Airbags:
Driver-side airbag standard on later models (1991/1992), optional earlier.
Seatbelts:
Three-point seatbelts with pretensioners (driver/passenger)
Rollover Protection:
Reinforced body structure
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, optional CD player on higher trims
Speaker Configuration:
Typically 4 or 6 speaker systems
Driver Assistance
Cruise Control:
Standard on many trim levels
Anti Lock Brakes:
Optional, as mentioned in safety
Connectivity
No Modern Connectivity:
No Bluetooth, USB, or smartphone integration; analog systems only.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,000-5,000 miles or 6 months, whichever comes first (using recommended oil type)
Engine Oil Filter Replacement:
With every oil change
Timing Belt Replacement:
Every 60,000 miles or 4 years (critical for 4G63/6G71 engines to prevent catastrophic failure)
Spark Plug Replacement:
Every 30,000-60,000 miles depending on plug type (e.g., platinum vs. standard)
Coolant Flush:
Every 2 years or 30,000 miles
Transmission Fluid Change:
Manual: Every 60,000 miles; Automatic: Every 30,000-50,000 miles (depending on driving conditions)
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 5W-30 or 10W-30 (check owner's manual for specific viscosity based on temperature)
Engine Oil Capacity Liters:
~4.0 - 4.5 (depending on engine)
Coolant Type:
Ethylene Glycol based antifreeze (e.g., Mitsubishi DiaQueen Super Long Life Coolant or equivalent)
Brake Fluid Type:
DOT 3 or DOT 4
Power Steering Fluid Type:
Dexron II or equivalent ATF
Manual Transmission Fluid Type:
API GL-4, SAE 75W-90 (or specified viscosity)
Automatic Transmission Fluid Type:
Dexron II or equivalent ATF
Known Issues
Engine:
Timing belt failure (critical maintenance), oil leaks from seals, some issues with ignition system components (e.g., distributor cap/rotor on older models).
Suspension:
Worn ball joints, tie rod ends, and bushings due to age and mileage; strut mounts can degrade.
Common rust areas include wheel wells, rocker panels, and subframes, especially in areas with harsh winters.
Part Numbers
Timing Belt Kit Example:
e.g., Gates TCK186 (verify for specific engine)
Oil Filter Example:
e.g., Fram PH5793 or Wix 51515 (verify for specific engine)
📚 Vehicle History
Brand Heritage
Mitsubishi History:
Mitsubishi Motors, a division of the Mitsubishi Group, has a long history in automotive manufacturing known for innovation and reliability.
Model Evolution
Previous Generation:
E10 Series Galant (1983-1987)
Subsequent Generation:
8th Generation Galant (1993-1998)
Design Inspiration:
The E30 Galant featured aerodynamic styling heavily influenced by the Lancer FTO concept car and shared platforms with other Mitsubishi models.
Production
Production Period:
1987-1993
Manufacturing Plants:
Primarily Japan (e.g., Mizushima Plant), with some assembly in other global locations.
🏆 Awards & Recognition
Recognitions
Awards History:
While specific major awards are scarce for this particular generation, the Galant series consistently received praise for its value and reliability in its class.
Ratings
Consumer Ratings:
Generally positive for its era, often cited for solid engineering and durable powertrains, especially the 4G63 engine.