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Mitsubushi GALANT 1993-1998 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Galant Model Generation: Eighth Generation (E3_A, E5_A, E6_A, E7_A, E8_A) Year Range Covered: 1993-1998 Codes Chassis Codes Covered: E5_A, E6_A, E7_A, E8_A 👋 Introduction Market Position Segment: Mid-size sedan, often positioned as a sporty and well-equipped option. Competitive Analysis Competitors: Toyota Camry, Honda Accord, Nissan Altima, Ford Taurus, Chevrolet Lumina. Key Features Styling: Distinctive aerodynamic styling, often with a coupe-like profile, particularly in later models. Engines: Diverse engine options including reliable 4-cylinder and potent V6 engines. Performance: Offered a balance of comfort and sporty driving dynamics, with some variants featuring all-wheel drive. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive workshop service and repair for all applicable systems. Region Coverage: Global (specifications may vary by market). Page Count Estimated Page Count: 1000+ Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital (likely PDF) 📖 Manual Coverage Systems Covered Engine: Detailed diagnosis, repair, and overhaul procedures for 4G63 SOHC, 4G93 SOHC, 6G73 DOHC, 6A12 DOHC, and 4D68 SOHC engines. Fuel System: Fuel injection systems, fuel pump, fuel lines, fuel filter replacement, and diagnosis. Ignition System: Ignition timing, spark plugs, ignition coils, distributor (if applicable), and related components. Cooling System: Radiator, coolant, water pump, thermostat, cooling fan, and hoses. Exhaust System: Exhaust manifold, catalytic converter, muffler, pipes, and emissions control. Transmission: Service and repair for 5-speed manual transmissions. Includes clutch, gearbox, and related components. Drivetrain: Front-wheel drive (FWD) and all-wheel drive (AWD) systems, CV joints, drive shafts, and differential. Suspension: Front and rear suspension components, shock absorbers, springs, control arms, and alignment specifications. Steering: Power steering system, steering rack, tie rods, and steering column. Brakes: Front and rear disc brakes, brake pads, rotors, calipers, brake lines, master cylinder, and ABS systems (if equipped). Electrical System: Battery, charging system (alternator), starting system (starter), wiring diagrams, fuses, relays, and lighting. Body And Chassis: Body panels, doors, windows, interior trim, bumpers, and structural components. HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair. Body Electronics: Power windows, door locks, mirrors, alarm systems, and interior accessories. Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, fluid checks, tune-ups. Troubleshooting: Diagnostic procedures, symptom-based troubleshooting guides, common fault identification. Repair: Step-by-step instructions for component replacement and repair of all covered systems. Overhaul: Complete engine and transmission overhaul procedures, including disassembly, inspection, and reassembly. Diagnostics: On-board diagnostics (OBD-I) information, diagnostic trouble codes (DTCs), and diagnostic tool usage. Electrical Diagnostics: Detailed wiring diagrams, circuit testing, and component testing procedures. Technical Depth Depth: Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures. 📊 Manual Specifications File Format Format Details: Digital PDF, typically optimized for searchability and printing. Print Quality Quality: High-resolution scanned pages ensuring legibility of text, diagrams, and illustrations. Binding Type Binding: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Options: 2.0L 4G63 SOHC, 1.8L 4G93 SOHC, 2.5L 6G73 DOHC, 2.0L 6A12 DOHC, 2.0L 4D68 SOHC Diesel. Performance 4G63 Sohc (Example): Displacement: 1997 cc, Bore x Stroke: 85.0 x 88.0 mm, Compression Ratio: 9.5:1, Power: ~135 hp @ 6000 rpm, Torque: ~120 lb-ft @ 4000 rpm. 6G73 DOHc V6 (Example): Displacement: 2497 cc, Bore x Stroke: 74.1 x 77.0 mm, Compression Ratio: 9.0:1, Power: ~160-170 hp @ 5500-6000 rpm, Torque: ~175-185 lb-ft @ 4500-5000 rpm. Fuel System System Type: Electronic Multi-Point Fuel Injection (MPI). Fuel Type: Unleaded gasoline (for gasoline engines), Diesel (for 4D68). Maintenance Spark Plug Gap: Typically 0.039-0.043 inches (1.0-1.1 mm), refer to specific engine specs in manual. Timing Belt Replacement: Recommended every 60,000-90,000 miles or 4-5 years, depending on engine and driving conditions (refer to manual for exact intervals). 🔧 Transmission Standard Type Standard: 5-speed Manual Transmission (5MT). Optional Type Optional: Automatic Transmission (4-speed INVECS-II was common). Features Manual Clutch: Hydraulic clutch actuation. Manual Fluid Type: API GL-4 SAE 75W-90 or 75W-85 gear oil (verify with manual for exact specification). AWD System: Active Sport (A.S.C.) All-Wheel Drive system available on some models, often with viscous coupling or electronically controlled center differential. 📐 Dimensions Exterior Length: Approximately 183.7 inches (4666 mm). Width: Approximately 69.5 inches (1765 mm). Height: Approximately 54.9 inches (1395 mm). Wheelbase: Approximately 104.7 inches (2659 mm). Track Width Front: Approximately 59.1 inches (1501 mm). Track Width Rear: Approximately 58.7 inches (1491 mm). Weights Curb Weight: Approximately 3100-3400 lbs (1400-1540 kg) depending on engine and trim. Gross Vehicle Weight Rating: Varies by model and configuration, consult manual. Towing Capacity: Not typically specified for this vehicle class, consult manual if applicable. Wheelbase AWD Vs FWD: Generally the same, but check specific model for confirmation. 🛡️ Safety Features Ratings NHTSA Front Crash Test: Refer to NHTSA archives for specific model year ratings. Early 1990s vehicles generally had lower ratings than modern standards. IIHS Side Impact Test: Refer to IIHS...
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Mitsubushi GALANT 1993-1998 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Galant
Model Generation:
Eighth Generation (E3_A, E5_A, E6_A, E7_A, E8_A)
Year Range Covered:
1993-1998
Codes
Chassis Codes Covered:
E5_A, E6_A, E7_A, E8_A
👋 Introduction
Market Position
Segment:
Mid-size sedan, often positioned as a sporty and well-equipped option.
Competitive Analysis
Competitors:
Toyota Camry, Honda Accord, Nissan Altima, Ford Taurus, Chevrolet Lumina.
Key Features
Styling:
Distinctive aerodynamic styling, often with a coupe-like profile, particularly in later models.
Engines:
Diverse engine options including reliable 4-cylinder and potent V6 engines.
Performance:
Offered a balance of comfort and sporty driving dynamics, with some variants featuring all-wheel drive.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive workshop service and repair for all applicable systems.
Region Coverage:
Global (specifications may vary by market).
Page Count
Estimated Page Count:
1000+
Manual Type
Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Digital (likely PDF)
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnosis, repair, and overhaul procedures for 4G63 SOHC, 4G93 SOHC, 6G73 DOHC, 6A12 DOHC, and 4D68 SOHC engines.
Fuel System:
Fuel injection systems, fuel pump, fuel lines, fuel filter replacement, and diagnosis.
Ignition System:
Ignition timing, spark plugs, ignition coils, distributor (if applicable), and related components.
Cooling System:
Radiator, coolant, water pump, thermostat, cooling fan, and hoses.
Exhaust System:
Exhaust manifold, catalytic converter, muffler, pipes, and emissions control.
Transmission:
Service and repair for 5-speed manual transmissions. Includes clutch, gearbox, and related components.
Drivetrain:
Front-wheel drive (FWD) and all-wheel drive (AWD) systems, CV joints, drive shafts, and differential.
Suspension:
Front and rear suspension components, shock absorbers, springs, control arms, and alignment specifications.
Steering:
Power steering system, steering rack, tie rods, and steering column.
Brakes:
Front and rear disc brakes, brake pads, rotors, calipers, brake lines, master cylinder, and ABS systems (if equipped).
Electrical System:
Battery, charging system (alternator), starting system (starter), wiring diagrams, fuses, relays, and lighting.
Body And Chassis:
Body panels, doors, windows, interior trim, bumpers, and structural components.
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system diagnosis and repair.
Body Electronics:
Power windows, door locks, mirrors, alarm systems, and interior accessories.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks, tune-ups.
Troubleshooting:
Diagnostic procedures, symptom-based troubleshooting guides, common fault identification.
Repair:
Step-by-step instructions for component replacement and repair of all covered systems.
Overhaul:
Complete engine and transmission overhaul procedures, including disassembly, inspection, and reassembly.
Diagnostics:
On-board diagnostics (OBD-I) information, diagnostic trouble codes (DTCs), and diagnostic tool usage.
Electrical Diagnostics:
Detailed wiring diagrams, circuit testing, and component testing procedures.
Technical Depth
Depth:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including detailed electrical schematics and diagnostic procedures.
📊 Manual Specifications
File Format
Format Details:
Digital PDF, typically optimized for searchability and printing.
Print Quality
Quality:
High-resolution scanned pages ensuring legibility of text, diagrams, and illustrations.
Binding Type
Binding:
N/A (Digital Format)
Paper Type
Paper Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Options:
2.0L 4G63 SOHC, 1.8L 4G93 SOHC, 2.5L 6G73 DOHC, 2.0L 6A12 DOHC, 2.0L 4D68 SOHC Diesel.
Performance
4G63 Sohc (Example):
Displacement: 1997 cc, Bore x Stroke: 85.0 x 88.0 mm, Compression Ratio: 9.5:1, Power: ~135 hp @ 6000 rpm, Torque: ~120 lb-ft @ 4000 rpm.
6G73 DOHc V6 (Example):
Displacement: 2497 cc, Bore x Stroke: 74.1 x 77.0 mm, Compression Ratio: 9.0:1, Power: ~160-170 hp @ 5500-6000 rpm, Torque: ~175-185 lb-ft @ 4500-5000 rpm.
Fuel System
System Type:
Electronic Multi-Point Fuel Injection (MPI).
Fuel Type:
Unleaded gasoline (for gasoline engines), Diesel (for 4D68).
Maintenance
Spark Plug Gap:
Typically 0.039-0.043 inches (1.0-1.1 mm), refer to specific engine specs in manual.
Timing Belt Replacement:
Recommended every 60,000-90,000 miles or 4-5 years, depending on engine and driving conditions (refer to manual for exact intervals).
🔧 Transmission
Standard
Type Standard:
5-speed Manual Transmission (5MT).
Optional
Type Optional:
Automatic Transmission (4-speed INVECS-II was common).
Features
Manual Clutch:
Hydraulic clutch actuation.
Manual Fluid Type:
API GL-4 SAE 75W-90 or 75W-85 gear oil (verify with manual for exact specification).
AWD System:
Active Sport (A.S.C.) All-Wheel Drive system available on some models, often with viscous coupling or electronically controlled center differential.
📐 Dimensions
Exterior
Length:
Approximately 183.7 inches (4666 mm).
Width:
Approximately 69.5 inches (1765 mm).
Height:
Approximately 54.9 inches (1395 mm).
Wheelbase:
Approximately 104.7 inches (2659 mm).
Track Width Front:
Approximately 59.1 inches (1501 mm).
Track Width Rear:
Approximately 58.7 inches (1491 mm).
Weights
Curb Weight:
Approximately 3100-3400 lbs (1400-1540 kg) depending on engine and trim.
Gross Vehicle Weight Rating:
Varies by model and configuration, consult manual.
Towing Capacity:
Not typically specified for this vehicle class, consult manual if applicable.
Wheelbase AWD Vs FWD:
Generally the same, but check specific model for confirmation.
🛡️ Safety Features
Ratings
NHTSA Front Crash Test:
Refer to NHTSA archives for specific model year ratings. Early 1990s vehicles generally had lower ratings than modern standards.
IIHS Side Impact Test:
Refer to IIHS archives. Side airbags were not standard in early models.
Active Features
ABS:
Anti-lock Braking System (ABS) available on higher trims or as an option.
Traction Control:
Traction control system (TCS) available on some models, often paired with AWD.
Passive Features
Airbags:
Driver and front passenger airbags standard. Side airbags not common for this generation.
Seatbelts:
Three-point front and rear seatbelts, with pre-tensioners on front belts.
Crumple Zones:
Designed with front and rear crumple zones for energy absorption.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, optional CD player on higher trims. Speaker configurations varied.
Driver Assistance
Cruise Control:
Standard on many trims, often electronically controlled.
Connectivity
Power Accessories:
Power windows, power door locks, and power mirrors were common options.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,750 - 7,500 miles or 6 months, depending on oil type and driving conditions (refer to manual for exact recommendation).
Air Filter Replacement:
Every 15,000 - 30,000 miles or as needed based on driving environment.
Cabin Air Filter Replacement:
If equipped, typically every 12,000 - 15,000 miles or annually.
Coolant Flush:
Every 30,000 - 60,000 miles or 2-3 years.
Fluid Specifications
Engine Oil Type:
API SG or SH, SAE 5W-30 or 10W-30 recommended (check manual for specific viscosity and classification).
Engine Oil Capacity:
Approximately 4.0-4.5 quarts (3.8-4.3 liters) with filter, for 4-cylinder engines. V6 engines will have slightly higher capacity. Verify in manual.
Coolant Type:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Use Asian vehicle specific coolant.
Power Steering Fluid:
Typically Dexron III/Mercon compatible ATF or a specific Mitsubishi power steering fluid.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine Idle Instability:
Can be caused by dirty throttle body, idle air control (IAC) valve issues, or vacuum leaks.
Oil Leaks:
Valve cover gasket and crankshaft/camshaft seals can degrade over time, leading to leaks.
Suspension Wear:
Ball joints, tie rod ends, and bushings can wear out, leading to clunking noises and steering looseness.
Automatic Transmission Issues:
While this manual focuses on manual, automatic transmissions of this era could experience solenoid issues or torque converter problems if not maintained.
Rust:
Rust can be an issue on certain body panels, especially in areas with salt exposure. Check wheel wells, rocker panels, and undercarriage.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors History:
Mitsubishi Motors is a Japanese multinational automotive manufacturer with a history dating back to the early 20th century, known for innovation and durable vehicles.
Model Evolution
Galant History Overview:
The Galant has a long history, evolving from a compact to a mid-size sedan. The 1993-1998 generation (E80) marked a significant design and engineering update, featuring sleeker styling and improved performance, including the introduction of the acclaimed 2.5L V6 and AWD systems.
Production
Manufacturing Location:
Primarily manufactured in Japan, with some production possibly occurring in other global facilities.
Production Years:
Eighth generation produced from 1992 (for the 1993 model year) to 1998.
🏆 Awards & Recognition
Recognitions
Car And Driver Ten Best:
While not consistently on this list, certain Galant models, particularly V6 variants, were recognized for their value and performance by automotive publications.
Jd Power Ratings:
J.D. Power initial quality and dependability ratings varied by year and specific model, generally competitive for its class during its production run.
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