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    Mitsubishi Galant 1989-1993 Service Repair Manual

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    This manual covers the Galant, specifically the E30/E40 generation produced from 1989 to 1993. Known for its stylish, aerodynamic design and European-influenced aesthetics, the Galant offered a compelling alternative in...
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    This manual covers the Galant, specifically the E30/E40 generation produced from 1989 to 1993. Known for its stylish, aerodynamic design and European-influenced aesthetics, the Galant offered a compelling alternative in the compact to mid-size sedan segment. This generation featured a range of engine options, including the robust 4G63 2.0L (SOHC and DOHC) and the performance-oriented 4G63T 2.0L turbocharged engine, powering models like the GSR. The vehicle was engineered for a balance of comfort and responsive handling, making it a versatile choice for daily commuting and spirited driving. This comprehensive factory service repair manual provides detailed information for all models and configurations of the Galant from 1989 to 1993. It encompasses extensive coverage of all major mechanical and electrical systems, including detailed diagnostics, repair procedures, and technical specifications for engines, transmissions, suspension, brakes, and more. The manual is designed to assist owners, mechanics, and technicians in performing routine maintenance, troubleshooting complex issues, and executing thorough repairs, ensuring the longevity and optimal performance of the vehicle.
    🏷️ Basic Information
    Identification
    Make:
    Mitsubishi
    Model:
    Galant
    Generation:
    E30/E40
    Production Years Covered:
    1989-1993
    Codes
    Chassis Codes:
    E31, E32, E33, E34, E35, E38, E39, E43, E44, E45, E46, E47, E48
    👋 Introduction
    Market Position
    Segment:
    Compact to mid-size sedan, known for its advanced styling and European-influenced design.
    Competitive Analysis
    Competitors:
    Honda Accord, Toyota Camry, Nissan Altima, Mazda 626, Ford Tempo, Chevrolet Corsica.
    Key Features
    Design Philosophy:
    Stylish, aerodynamic, and comfortable interior, often featuring advanced (for its time) technology and handling.
    Performance Variants:
    The availability of the turbocharged GSR model provided a performance-oriented option.
    📋 Manual Details
    Coverage Areas
    Primary Coverage:
    All models and configurations of Mitsubishi Galant from 1989 to 1993
    Engine Coverage:
    4G37 1.8L, 4G63 2.0L (SOHC & DOHC), 4G63T 2.0L Turbocharged, 6A10 1.6L V6 (JDM), 6A11 1.8L V6 (JDM), 6A12 2.0L V6 (JDM)
    Transmission Coverage:
    5-speed manual transaxle, 4-speed automatic transaxle
    Page Count
    Estimated Page Count:
    Extensive (Factory Service Manuals are typically 1000+ pages)
    Manual Type
    Type:
    Factory Service Repair Manual (FSM)
    Language
    Language:
    English
    Format
    Digital Format:
    PDF
    Archival Format:
    WinRAR
    📖 Manual Coverage
    Systems Covered
    Engine:
    Detailed diagnostics, repair, overhaul procedures, component testing for all engine variants, including timing belt replacement, valve adjustments, and turbocharger systems.
    Fuel:
    Fuel injection system (MPI, GDI where applicable), fuel pump, injectors, pressure regulator, fuel filter replacement, and fuel tank service.
    Cooling:
    Radiator, water pump, thermostat, cooling fan operation, hoses, and coolant flush procedures.
    Intake And Exhaust:
    Intake manifold, throttle body, exhaust manifold, catalytic converter, muffler, and emissions control components.
    Emission Control:
    EGR system, PCV system, evaporative emission control (EVAP), and oxygen sensor diagnostics.
    Clutch:
    Clutch disc, pressure plate, release bearing, hydraulic clutch system, adjustment, and replacement.
    Manual Transaxle:
    Internal component inspection, gear engagement, synchronizers, seals, fluid changes, and clutch-related transaxle removal/installation.
    Automatic Transaxle:
    Transmission fluid type and capacity, valve body diagnostics, torque converter, shift solenoid operation, and complete overhaul procedures.
    Propeller Shaft:
    Driveshaft, universal joints, constant velocity (CV) joints (if applicable), and balancing.
    Front Axle:
    CV shafts, wheel bearings, steering knuckle, and hub assembly.
    Rear Axle:
    Suspension components, trailing arms, control arms, wheel bearings, and differential (if applicable).
    Wheel And Tire:
    Tire pressure recommendations, rotation, wheel balancing, alignment specifications, and wheel bolt torque.
    Power Plant Mount:
    Engine and transmission mount inspection and replacement.
    Front Suspension:
    MacPherson struts, control arms, ball joints, tie rod ends, sway bar, and alignment procedures.
    Active Electronic Control Suspension:
    Diagnostic and repair procedures for electronically controlled suspension systems (if equipped on specific trims/markets).
    Control Suspension:
    Standard suspension component diagnosis and repair.
    Rear Suspension:
    Multi-link independent suspension (common on this generation), shock absorbers, springs, bushings, and alignment.
    Service Brakes:
    Front disc brakes, rear drum or disc brakes, brake pad/shoe replacement, rotor/drum resurfacing/replacement, brake fluid type and bleeding procedures, ABS system diagnostics (if equipped).
    Parking Brakes:
    Parking brake system operation, adjustment, and cable replacement.
    Alphabetical Index:
    Complete index for quick reference to specific topics and components.
    Procedures Included
    General Maintenance:
    Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement.
    Troubleshooting:
    Systematic diagnostic flowcharts and symptom-based troubleshooting for various mechanical and electrical issues.
    Repair Procedures:
    Step-by-step instructions for component removal, installation, and adjustment for all covered systems.
    Diagnostic Codes:
    Explanation and interpretation of diagnostic trouble codes (DTCs) for electronically managed systems (OBD-I).
    Technical Depth
    Depth:
    Comprehensive factory-level detail suitable for professional mechanics and advanced DIY enthusiasts.
    Electrical Diagrams:
    Inclusion of wiring diagrams for all major electrical systems, including engine management, lighting, HVAC, and accessories.
    Specifications And Tolerances:
    Precise technical data, torque values, clearances, and wear limits for all serviceable components.
    📊 Manual Specifications
    File Format
    Digital Format:
    PDF (searchable and bookmarked)
    Print Quality
    Page Printability:
    All pages printable
    Binding Type
    Digital Binding:
    None (Digital Download)
    Paper Type
    Digital Paper Type:
    N/A (Digital Document)
    File Organization
    Bookmarking:
    Completely bookmarked for easy navigation
    Searchability:
    Complete searchable text
    File Origin
    Authenticity:
    Real files, not scans
    ⚙️ Engine Specifications
    Primary Engine
    Common Engine Options:
    2.0L 4G63 (SOHC and DOHC), 2.0L 4G63T (Turbocharged DOHC)
    Performance
    4G63 DOHc Hp:
    Approximately 135-150 hp (naturally aspirated)
    4G63T Gsr Hp:
    Approximately 195 hp (turbocharged)
    4G63 Torque:
    Varies by variant, e.g., ~125 lb-ft for NA DOHC, ~203 lb-ft for turbo
    Fuel System
    Injection Type:
    Multi-Point Fuel Injection (MPI)
    Fuel Type:
    Unleaded Gasoline (87 octane minimum, 91+ recommended for turbo models)
    Engine Management
    ECU Type:
    OBD-I (On-Board Diagnostics, First Generation)
    🔧 Transmission
    Standard
    Manual Transmission:
    5-speed manual transaxle (e.g., KM210, KM211 variants)
    Optional
    Automatic Transmission:
    4-speed automatic transaxle (e.g., F4A21, F4A22 variants)
    Features
    Manual Transaxle Fluid:
    API GL-4, SAE 75W-90 or 80W-90 gear oil (specific type may vary, consult manual)
    Automatic Transaxle Fluid:
    Mitsubishi Genuine ATF SP or equivalent
    📐 Dimensions
    Exterior
    Wheelbase:
    Approx. 100.4 inches (2550 mm)
    Length:
    Approx. 176.8 inches (4490 mm)
    Width:
    Approx. 68.1 inches (1730 mm)
    Height:
    Approx. 54.7 inches (1390 mm)
    Weights
    Curb Weight:
    Approx. 2800-3200 lbs (1270-1450 kg), depending on engine and trim
    Gross Vehicle Weight Rating:
    Refer to vehicle specific label or manual
    🛡️ Safety Features
    Ratings
    NHTSA Rating:
    Varies by model year and specific crash test configurations; generally considered safe for its era.
    Active Features
    ABS:
    Anti-lock Braking System (optional on some models, standard on higher trims/later years)
    Passive Features
    Airbags:
    Driver-side airbag (optional/standard depending on year and trim), Passenger airbag not typically available on early models.
    Seatbelts:
    Three-point front seatbelts with pretensioners, three-point rear seatbelts.
    💡 Technology Features
    Infotainment
    Audio System:
    Factory AM/FM/Cassette player, with options for CD players on higher trims or later models. Speaker configurations vary.
    Driver Assistance
    Cruise Control:
    Available on most models as standard or optional.
    Climate Control:
    Manual or automatic climate control systems, depending on trim level.
    🔧 Maintenance
    Service Intervals
    Engine Oil Change:
    Every 3,000-5,000 miles (4,800-8,000 km) or 6 months, using recommended oil type.
    Timing Belt Replacement:
    Every 60,000 miles (96,000 km) or 4 years for 4G63 engines (critical interval to prevent catastrophic engine damage).
    Coolant Flush:
    Every 30,000 miles (48,000 km) or 2 years.
    Fluid Specifications
    Engine Oil Viscosity:
    SAE 5W-30 or 10W-30 (check manual for specific temperature ranges)
    Engine Oil Capacity:
    Approx. 4.2-4.5 quarts (4.0-4.2 liters) with filter change, depending on engine.
    Brake Fluid Type:
    DOT 3 or DOT 4
    Known Issues
    Common Wear Items:
    CV boots, motor mounts, strut mounts, exhaust system components, O2 sensors, and water pumps can be common wear items.
    Turbo Specific Issues:
    Turbocharger health, oil feed/return lines, and intercooler integrity are critical for GSR models.
    Electrical Aging:
    As with any vehicle of this age, wiring harness degradation, corroded connectors, and failing sensors can occur.
    📚 Vehicle History
    Brand Heritage
    Mitsubishi Motors:
    Mitsubishi Motors has a history dating back to 1917, with automotive production beginning in the 1960s. Known for innovation and diverse product lines.
    Model Evolution
    Galant Generations:
    The 1989-1993 models represent the fifth generation (E30/E40 series), a significant redesign from its predecessor, emphasizing styling and performance.
    Production
    Manufacturing Locations:
    Primarily Japan (Mizushima Plant), with some assembly in other international locations depending on market.
    🏆 Awards & Recognition
    Recognitions
    Car And Driver 10Best:
    While not explicitly listed for the 1989-1993 models, the Galant line has historically been recognized for its value and engineering.
    Ratings
    Consumer Reports:
    Consumer Reports evaluations for this era generally pointed to good reliability for the powertrain but some average or below-average ratings for certain interior components and body integrity, typical for the time.
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