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Mitsubushi GALANT Full Service & Repair Manual 1989-1993

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This manual covers the Mitsubishi Galant, produced from 1989 to 1993, across its E30/E40 series generations and various chassis codes including E31A through E49A. Known for its aerodynamic styling and...
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Mitsubushi GALANT Full Service & Repair Manual 1989-1993
This manual covers the Mitsubishi Galant, produced from 1989 to 1993, across its E30/E40 series generations and various chassis codes including E31A through E49A. Known for its aerodynamic styling and driver-focused interior, the Galant offered a range of engine options from efficient 1.3L and 1.5L units to more powerful 2.0L naturally aspirated and turbocharged engines, as well as V6 variants. Notable features included optional All-Wheel Drive (AWD) on performance models like the Galant VR-4, which received acclaim for its handling and technology. This generation represented a significant engineering update for the Galant line, a nameplate with a long history of evolution in the mid-size sedan and coupe segment. This comprehensive Factory Service & Repair Workshop Manual provides detailed information for maintaining and repairing the Mitsubishi Galant. It covers all major systems, including engine mechanicals, lubrication, cooling, fuel, ignition, emission control, and engine management for various engine codes such as 4G63, 4G63T, 4G13, 4G15, 6G71, and 6G72. Transmission coverage includes manual and automatic transmissions, drivetrain components, suspension, brakes, steering, and electrical systems. The manual also details body and interior work, HVAC systems, and chassis components. It includes routine maintenance procedures, repair and overhaul instructions, troubleshooting guides, alignment specifications, and diagnostic procedures, offering factory-level detail with torque specifications, clearances, assembly sequences, and numerous illustrations to assist owners and technicians.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Galant
Generation:
E30/E40 Series
Production Years Covered:
1989-1993
Codes
Chassis Codes:
E31A, E32A, E33A, E34A, E35A, E37A, E38A, E39A, E41A, E42A, E43A, E44A, E45A, E47A, E49A
👋 Introduction
Market Position
Segment:
Mid-size sedan and coupe, known for its sporty handling and distinctive styling in its era
Competitive Analysis
Competitors:
Honda Accord, Toyota Camry, Nissan Maxima, Ford Taurus, Chevrolet Lumina
Key Features
Design:
Aerodynamic styling, often featuring pop-up headlights in earlier models of this generation, and a driver-focused interior
Performance Variants:
Availability of turbocharged (GSR, VR-4) performance variants offering significantly enhanced power and handling
AWD:
Optional All-Wheel Drive (AWD) system, particularly in the performance-oriented Galant VR-4, enhancing traction and stability
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service & Repair Workshop Manual
Language:
English
Format Delivery:
Instant Download (Digital)
Licensing:
No expiry dates, no extra fees
📖 Manual Coverage
Systems Covered
Engine:
4G63, 4G63T, 4G13, 4G15, 6G71, 6G72 (Engine mechanical, lubrication, cooling, fuel, ignition, emission control, engine management systems)
Transmission:
Manual (W5M33, KM210-2) and Automatic (F4A21, F4A22, F4A23, V4A51) transmission overhaul, diagnostics, and repair
Drivetrain:
Front-Wheel Drive (FWD) and All-Wheel Drive (AWD) systems, including differentials, driveshafts, and CV joints
Suspension:
Front MacPherson strut, Rear multi-link suspension system component overhaul, alignment, and troubleshooting
Brakes:
Front disc (ventilated and solid), Rear disc and drum brake systems, ABS (Anti-lock Braking System) diagnostics and repair
Steering:
Power assisted rack and pinion steering system overhaul, diagnostics, and fluid service
Electrical:
Full electrical schematics, wiring diagrams, component testing, starter, alternator, battery system service, lighting, and accessory circuits
Body And Interior:
Body panel replacement, door mechanisms, glass, interior trim, seat adjustments, and exterior trim components
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system diagnostics, refrigerant service, blower motor, and climate control unit repair
Chassis And Frame:
Frame inspection, collision repair guidelines, and chassis component replacement
Procedures Included
Maintenance:
Routine scheduled maintenance, oil changes, filter replacements, tune-ups, fluid level checks and changes
Repair:
Component-level repair and replacement for all covered systems, including engine, transmission, brakes, suspension, and electrical
Troubleshooting:
Diagnostic procedures, fault code interpretation (where applicable), symptom-based troubleshooting guides
Overhaul:
Complete engine and transmission overhaul procedures, including disassembly, inspection, and reassembly specifications
Alignment:
Wheel alignment specifications and procedures for front and rear suspensions
Diagnostics:
In-depth diagnostic steps for engine performance, electrical faults, and mechanical issues
Technical Depth
Scope:
Comprehensive factory-level detail suitable for professional technicians and advanced DIY enthusiasts
Detail Level:
Includes torque specifications, clearances, assembly sequences, and diagnostic flowcharts
Illustrations:
Contains numerous diagrams, exploded views, and illustrations to aid in understanding procedures
📊 Manual Specifications
File Format
Format:
PDF (Portable Document Format)
Searchability:
Searchable text for quick access to specific topics and components
Printability:
Printable pages for offline use and workshop convenience
Print Quality
Resolution:
High-resolution scans ensuring clarity of text and diagrams
Binding Type
Physical Format:
Not Applicable (Digital Download)
Paper Type
Physical Format:
Not Applicable (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code Options:
4G63 (2.0L DOHC), 4G63T (2.0L DOHC Turbocharged), 4G15 (1.5L SOHC), 4G13 (1.3L SOHC), 6G71 (2.5L V6 SOHC), 6G72 (3.0L V6 SOHC)
Performance
4G63 Horsepower:
Approx. 140-150 hp (Naturally Aspirated), Approx. 195-205 hp (Turbocharged GSR/VR-4)
6G71 Horsepower:
Approx. 140-150 hp
Torque Specifications:
Varies significantly by engine; e.g., 4G63T approx. 203 lb-ft (Turbocharged)
Fuel System
Injection Type:
Multi-point Fuel Injection (MPI) / Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (Octane rating recommendations available in manual)
Emission Control
Systems:
Catalytic converter, EGR (Exhaust Gas Recirculation), O2 sensors, and electronic engine control units (ECU)
🔧 Transmission
Standard
Type Options:
5-speed Manual Transmission (5MT) and 4-speed Automatic Transmission (4AT)
Optional
AWD Transmission:
All-Wheel Drive (AWD) system available, often paired with specific engine/trim levels (e.g., VR-4 models)
Features
Automatic Modes:
Some automatic transmissions may feature sport or economy modes
Fluid Specifications
Manual Transmission Fluid:
API GL-4 or GL-5 gear oil, SAE 75W-90 recommended (refer to manual for exact spec)
Automatic Transmission Fluid:
DIA QUEEN ATF SP-III or equivalent (refer to manual for exact spec)
📐 Dimensions
Exterior
Wheelbase:
Approximately 100.4 inches (2550 mm)
Length:
Approximately 175.8 - 177.2 inches (4465 - 4490 mm)
Width:
Approximately 67.3 - 67.7 inches (1710 - 1720 mm)
Height:
Approximately 53.7 - 54.7 inches (1365 - 1390 mm)
Weights
Curb Weight:
Approximately 2700 - 3300 lbs (1225 - 1500 kg), varies by model and drivetrain
🛡️ Safety Features
Ratings
NHTSA Ratings:
Limited historical data for this specific era; later models and similar vehicles from this period generally received average to good ratings for their time.
Active Features
ABS:
Anti-lock Braking System (ABS) available on select models and trims
Passive Features
Seatbelts:
Three-point retractable front seatbelts, lap belts for rear passengers
Airbags:
Driver's side airbag became more common towards the end of this generation, optional on some models.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, often with optional CD player or premium sound systems (e.g., Mitsubishi-branded units).
Display:
Basic analog gauges and warning lights. Climate control displays are typically analog or simple digital readouts.
Driver Assistance
Cruise Control:
Electronic cruise control available on many models.
Connectivity
Mobile Integration:
No integrated Bluetooth or smartphone connectivity; aftermarket solutions are required.
Lighting
Headlights:
Halogen headlights, with pop-up (retractable) headlights featured on some styling variants of this generation.
🔧 Maintenance
Service Intervals
Oil Change:
Recommended every 3,000-5,000 miles (5,000-8,000 km) or 3-6 months, depending on driving conditions (refer to manual for specifics)
Timing Belt Replacement:
Crucial for interference engines (like 4G63/4G63T). Recommended every 60,000-90,000 miles (96,000-145,000 km) or 5-7 years. Refer to manual for specific engine.
Fluid Specifications
Engine Oil:
SAE 5W-30, 10W-30, or 10W-40 depending on climate. API SG or higher. (Consult manual for precise recommendation)
Coolant:
Ethylene glycol-based antifreeze/coolant, 50/50 mix with distilled water. Mitsubishi Super Long Life Coolant (or equivalent) recommended.
Brake Fluid:
DOT 3 or DOT 4 brake fluid
Known Issues
Engine:
Timing belt failure on interference engines can cause catastrophic damage. Oil leaks from valve cover gasket and oil pan gasket are common. Overheating due to aging cooling system components.
Transmission:
Automatic transmission clutch wear and failure, especially in high-mileage or hard-driven vehicles. Manual transmission synchro wear.
Electrical:
Corrosion in wiring harnesses and connectors. Faulty power window regulators, aging sensors (e.g., O2, MAP).
Suspension And Steering:
Worn ball joints, tie rod ends, and bushings leading to clunking noises and poor handling. Power steering pump leaks.
Rust:
Corrosion is a common issue for vehicles of this age, particularly in rust-belt regions. Check wheel wells, rocker panels, and underbody.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors:
Mitsubishi Motors Corporation is a Japanese multinational automotive manufacturer, founded in 1970, with a history of innovation and diverse product lines.
Model Evolution
Galant Lineage:
The Galant nameplate has been used since 1969, evolving through numerous generations and body styles, consistently positioned as a family sedan with performance options.
E30 E40 Era:
This generation (E30/E40) represented a significant styling and engineering update, introducing aerodynamic designs and advanced features like AWD on performance models.
Production
Manufacturing Locations:
Primarily manufactured in Japan, with some assembly potentially occurring in other global locations depending on market.
🏆 Awards & Recognition
Recognitions
Performance Awards:
The Galant VR-4, in particular, received critical acclaim for its innovative all-wheel-drive and turbocharged technology, often praised in automotive publications for its handling and performance for its class.
Ratings
Reliability Reputation:
Generally considered to have average to good reliability for its era, though maintenance and timely repairs are crucial, especially for the turbocharged models.
Certifications
Emissions Compliance:
Designed to meet emissions standards of the late 1980s and early 1990s, with detailed emission system repair procedures in the manual.
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