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Mitsubishi Galant 1990-2000 Factory Service Repair Manual

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This comprehensive manual covers the Galant, encompassing models from 1990 through 2000, including various chassis codes such as E33A, E35A, E38A, E39A, and E30. This generation of the Galant, known...
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Mitsubishi Galant 1990-2000 Factory Service Repair ManualMitsubishi Galant 1990-2000 Factory Service Repair ManualMitsubishi Galant 1990-2000 Factory Service Repair ManualMitsubishi Galant 1990-2000 Factory Service Repair Manual
This comprehensive manual covers the Galant, encompassing models from 1990 through 2000, including various chassis codes such as E33A, E35A, E38A, E39A, and E30. This generation of the Galant, known for its distinctive aerodynamic styling and performance-oriented variants like the VR-4, offered advanced features for its time, including available All-Wheel Drive and turbocharged engines. The Galant was positioned as a competitive mid-size sedan, often lauded by publications, and offered in diverse trim levels such as ES, LS, GSX, and the acclaimed GSR and VR-4. This factory service manual provides in-depth technical information essential for the maintenance, repair, and troubleshooting of all Galant models within the specified years and regions. It details procedures for every major system, including engine mechanicals, fuel and ignition systems, transmissions (manual and automatic), drivetrain components like AWD systems, suspension, steering, brakes, and the electrical system. With over 1000 pages of factory-level content, it includes detailed repair instructions, diagnostic flowcharts, torque specifications, wiring diagrams, and information on special tools, making it an invaluable resource for DIY mechanics, professional technicians, and enthusiast owners.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Galant
Generation:
E3_A/E3_A (E33A, E35A, E38A, E39A, E30)
Codes
Platform Code:
E30
Chassis Codes Covered:
E33A, E35A, E38A, E39A, E30
👋 Introduction
Market Position
Market Segment:
Mid-size sedan (sedan and coupe body styles available in different markets)
Competitive Analysis
Key Competitors:
Toyota Camry, Honda Accord, Nissan Altima, Ford Taurus, Chevrolet Lumina
Key Features
Performance Orientation:
Offered performance-oriented variants like the Galant VR-4 with AWD and turbocharged engines, competing in a more enthusiast-driven segment
Styling:
Distinctive aerodynamic styling for its era, particularly the VR-4 model
Manual Value
Target Audience:
DIY mechanics, professional technicians, enthusiast owners seeking in-depth knowledge
📋 Manual Details
Coverage Areas
Years Covered:
1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000
Regions Covered:
Global (North America, Europe, Asia, Australia)
Trim Levels Covered:
All trim levels including SOHC and DOHC variants, GSR, VR-4, ES, LS, GSX
Page Count
Estimated Page Count:
1000+
Manual Type
Manual Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine overhaul, cylinder head, block, crankshaft, pistons, connecting rods, timing components, lubrication system, cooling system
Engine Performance:
Fuel injection system (MPI/GDI), ignition system, emissions control, turbocharger systems (where applicable)
Transmission Manual:
Manual transmission overhaul, clutch system, shift linkage
Transmission Automatic:
Automatic transmission overhaul, torque converter, valve body, electronic controls
Drivetrain:
All-Wheel Drive (AWD) systems (e.g., Viscous Coupling Unit, Center Differential, Rear Differential), Front-Wheel Drive (FWD) axle shafts, CV joints
Suspension:
Front and rear suspension systems, shock absorbers, struts, springs, control arms, ball joints, bushings, alignment specifications
Steering:
Power steering system, steering rack, steering column, steering wheel, hydraulic pump
Brakes:
Brake system diagnostics, hydraulic lines, calipers, rotors, drums, master cylinder, ABS system (where applicable), parking brake
Electrical System:
Battery, charging system (alternator), starting system (starter motor), lighting, wiring diagrams, fuses, relays
Body And Trim:
Body panel removal and installation, interior trim, glass, doors, latches, hinges, exterior trim
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system, A/C compressor, evaporator, condenser, refrigerant, climate control units
Safety Systems:
Airbag system (SRS) diagnostics and replacement procedures, seat belts
Procedures Included
General Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, battery maintenance
Diagnostic Troubleshooting:
Step-by-step troubleshooting flowcharts for common and uncommon issues, symptom-based diagnostics
Repair And Rebuild:
Detailed instructions for component removal, repair, reassembly, and installation for all major systems
Torque Specifications:
Precise torque values for all critical fasteners across all systems
Wiring Diagrams:
Comprehensive and detailed electrical wiring diagrams for all circuits and components
Special Tools:
Identification and usage instructions for factory-specified special tools required for certain repairs
Technical Depth
Depth Level:
Comprehensive Factory Level
Diagnostic Capabilities:
Advanced diagnostic procedures, including OBD-I and OBD-II (for later models) codes, sensor data interpretation, and circuit testing
Rebuild Procedures:
Full engine and transmission rebuild procedures with detailed sub-assembly instructions
📊 Manual Specifications
File Format
File Format:
PDF
Searchability:
Fully searchable text
Print Quality
Print Quality:
High-resolution, printable pages
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Codes:
4G63 (2.0L Turbo I4), 4G64 (2.4L SOHC I4), 6A12 (2.0L V6 SOHC/DOHC), 6A13 (2.5L V6 SOHC/DOHC)
Performance
4G63T (Vr-4):
Approx. 237-241 hp @ 6000 rpm, 250-254 lb-ft @ 3000 rpm (depending on market and year)
6A13 (V6):
Approx. 168-189 hp @ 6000 rpm, 170-184 lb-ft @ 4500 rpm (depending on DOHC/SOHC and market)
4G64 (2.4L):
Approx. 140-156 hp @ 5500-6000 rpm, 154-167 lb-ft @ 3500-4500 rpm
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), Multi-Point Injection (MPI) / Gasoline Direct Injection (GDI) on some later V6 variants
Fuel Type:
Unleaded gasoline (premium recommended for turbocharged models)
Engine Management
ECU Type:
Engine Control Unit (ECU) / Powertrain Control Module (PCM)
🔧 Transmission
Standard
Standard Transmission:
5-speed manual transmission
Optional
Optional Transmission:
4-speed automatic transmission
Features
AWD System:
Full-time All-Wheel Drive (AWD) with Active Yaw Control (AYC) on VR-4 models
Transfer Case:
Viscous coupling center differential on AWD models
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 (check manual for specific variant)
Automatic Transmission Fluid:
Mitsubishi DiaQueen ATF SP-II / SP-III or equivalent (check manual for specific variant)
📐 Dimensions
Exterior
Wheelbase:
Approx. 104.5 inches (2654 mm)
Length:
Approx. 183.7 inches (4666 mm)
Width:
Approx. 69.3 inches (1760 mm)
Height:
Approx. 54.9 inches (1395 mm) (sedan) / 54.3 inches (1380 mm) (coupe)
Weights
Curb Weight:
Approx. 3,200 - 3,500 lbs (1450 - 1590 kg), varies significantly by engine and drivetrain
🛡️ Safety Features
Ratings
NHTSA Ratings:
Specific NHTSA ratings for this era are not readily available or consistent across all models and years. Generally considered a safe vehicle for its time.
Active Features
ABS:
Anti-lock Braking System (ABS) available as an option on most trims, standard on VR-4
Passive Features
Airbags:
Driver and passenger airbags became more common through the generation, check specific model year for availability.
Seat Belts:
Three-point inertia-reel seat belts
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM cassette or CD players, optional premium sound systems. Basic analog controls.
Driver Assistance
Cruise Control:
Standard on most trims.
Connectivity
OBD Ii:
OBD-I standard on earlier models, transitioning to OBD-II on later models within this range. Manual covers diagnostic procedures for both.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 3,750 - 5,000 miles (6,000 - 8,000 km) or 6 months, whichever comes first (refer to manual for specific engine)
Timing Belt Replacement:
Recommended every 60,000 miles (96,000 km) or 5 years for 4G6x engines. V6 engines may have different intervals or timing chains. Critical to follow manual.
Spark Plug Replacement:
Varies by plug type: standard ~30,000 miles, platinum ~60,000 miles, iridium ~100,000 miles.
Fluid Specifications
Engine Oil Type:
API SG or SH, ILSAC GF-2. Viscosity 5W-30 or 10W-30 (refer to manual for exact specification and ambient temperature range).
Coolant Type:
Ethylene glycol based antifreeze (green) mixed 50/50 with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine:
Head gasket failures (especially on early 4G63), oil leaks, turbocharger issues on VR-4 (if applicable), carbon buildup on intake valves.
Drivetrain:
Wear in AWD system components (viscous coupler, center diff), automatic transmission solenoid issues.
Suspension:
Worn bushings, ball joints, and tie rod ends leading to clunks and poor handling.
Electrical:
Corrosion on wiring connectors, intermittent power to various components, failure of power window regulators.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors Legacy:
Mitsubishi Motors has a history of innovative engineering, particularly in performance and all-wheel-drive technology, evident in models like the Lancer Evolution and Galant VR-4.
Model Evolution
Eighth Generation E30:
The E30 generation (1987-1993 in Japan, 1990-1993 in North America) was a significant redesign, introducing advanced features and the iconic VR-4 performance variant. This manual covers the latter half of this generation and its transition into the subsequent E50/E70/E80 generation.
Production
Manufacturing Locations:
Primarily Japan (Mizushima Plant)
Production Span For Manual:
Covers models produced from 1990 through the end of the 1990-2000 model run which likely includes the E50, E70, and E80 generations depending on market introduction dates.
🏆 Awards & Recognition
Recognitions
Car And Driver:
The Galant VR-4 was often featured on Car and Driver's '10Best' lists during its production years for its performance and technology.
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