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Mitsubishi Galant 1990 Service Repair Manual

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The Mitsubishi Galant, produced for the 1990 model year, represents a mid-size sedan renowned for its aerodynamic styling and advanced engineering. This generation, belonging to the fifth model series, offered...
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Mitsubishi Galant 1990 Service Repair Manual
The Mitsubishi Galant, produced for the 1990 model year, represents a mid-size sedan renowned for its aerodynamic styling and advanced engineering. This generation, belonging to the fifth model series, offered a compelling blend of comfortable ride quality and sporty handling, particularly in its performance-oriented VR-4 variants. Differentiating itself with available Front-Wheel Drive (FWD) and All-Wheel Drive (AWD) systems, and powered by a range of inline-four cylinder engines including the potent turbocharged 2.0L 4G63B, the Galant was a strong contender in its market segment. Its design philosophy emphasized passenger comfort and incorporated technological features that were notable for the late 1980s and early 1990s. This comprehensive Service and Repair Manual provides detailed guidance for maintaining and repairing the 1990 Mitsubishi Galant. It covers all essential systems, including engine diagnostics and overhaul for gasoline and diesel variants, transmission service for both manual and automatic transmissions, drivetrain components, suspension, steering, brakes, and the electrical system. The manual also details procedures for fuel and cooling systems, exhaust, HVAC, and bodywork. With over 1500 pages of professional-level information, including factory specifications, torque values, troubleshooting charts, and complete rebuild instructions, this English-language resource is an indispensable tool for owners, mechanics, and technicians seeking to ensure the optimal performance and longevity of their vehicle.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Galant
Year:
1990
Codes
Chassis Code:
E31A, E32A, E33A, E35A, E38A, E39A
Engine Codes:
4G33, 4G37, 4G61, 4G63, 4G67, 4G37 (Diesel)
👋 Introduction
Market Position
Market Segment:
Mid-size sedan, known for its comfortable ride, sporty handling (especially on performance variants), and advanced features for its era.
Competitive Analysis
Competitors:
Competed against vehicles like the Honda Accord, Toyota Camry, Nissan Maxima, and Ford Taurus.
Key Features
Design Philosophy:
Aerodynamic styling, emphasis on passenger comfort and advanced technology for the late 1980s/early 1990s.
Available Drivetrains:
Offered both Front-Wheel Drive (FWD) and Full-Time All-Wheel Drive (4WD/AWD) systems, a significant differentiator.
Performance Variants:
Included performance-oriented models like the Galant VR-4, featuring turbocharged engines and advanced AWD systems.
📋 Manual Details
Coverage Areas
Primary Coverage:
Comprehensive service and repair procedures for the 1990 Mitsubishi Galant.
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine:
Detailed diagnostics, repair, overhaul, and specifications for all gasoline and diesel engines offered (4G33, 4G37, 4G61, 4G63, 4G67).
Transmission:
Service and repair for manual (F5M21, F5M33) and automatic (F4A33, F4A42) transmissions.
Drivetrain:
Front-wheel drive (FWD) and All-wheel drive (AWD) systems, including CV joints, driveshafts, and differentials.
Suspension:
Front and rear suspension systems, including struts, shock absorbers, control arms, bushings, and alignment procedures.
Steering:
Power steering system diagnosis and repair, steering gear, column, and tie rods.
Brakes:
Front and rear brake systems (disc and drum), ABS (Anti-lock Braking System) components and diagnosis, hydraulic lines, master cylinder, and caliper/wheel cylinder repair.
Electrical:
Comprehensive wiring diagrams, starter, alternator, battery, ignition system, lighting, instrumentation, and accessory circuits.
Fuel System:
Fuel injection systems (MPI, ECI), fuel pumps, injectors, fuel pressure regulator, fuel filter replacement, and EVAP system.
Cooling System:
Radiator, thermostat, water pump, cooling fan operation, and coolant specifications.
Exhaust System:
Catalytic converter, mufflers, exhaust manifold, and pipe replacement.
HVAC:
Air conditioning system, heater core, blower motor, controls, and refrigerant handling procedures.
Body And Frame:
Body panel repair, door and window mechanisms, interior trim, and structural component identification.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, fluid level checks, spark plug replacement, belt adjustments, and tire rotation.
Troubleshooting:
Diagnostic charts and flowcharts for common problems across all major systems.
Engine Repair:
Engine overhaul, piston ring replacement, valve stem seal replacement, timing belt/chain service, and cylinder head gasket replacement.
Transmission Repair:
Transmission fluid changes, clutch replacement (manual), torque converter replacement (automatic), and internal component overhaul.
Brake Service:
Brake pad/shoe replacement, rotor/drum resurfacing/replacement, brake fluid bleeding, and ABS component replacement.
Electrical Diagnostics:
Testing of sensors, actuators, control modules, and troubleshooting using wiring diagrams.
Body Repair:
Panel alignment, rust repair, glass replacement, and interior component removal/installation.
Ignition System:
Distributor, ignition coils, spark plug wires, spark plugs, ignition timing adjustments, and electronic ignition system components.
Emission Control:
Components like the EGR valve, catalytic converter, and oxygen sensors; diagnosis and service related to emission standards.
Body And Interior:
Removal and installation of interior panels, seats, dashboard components, door panels, glass, and exterior trim.
Technical Depth
Depth:
Professional-level detail, including factory specifications, torque values, diagnostic procedures, and complete rebuild instructions.
📊 Manual Specifications
File Format
Quality:
High-resolution PDF, ensuring clear text and legible diagrams for printing.
Searchable:
Yes, text-searchable for quick access to specific information.
Print Quality
Printability:
Fully printable, allowing for creation of a physical copy for workshop use.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Options:
Range of inline-four cylinder engines: 1.8L (4G33, 4G37), 1.6L (4G61), 2.0L (4G63, 4G67), and a 1.8L Turbo Diesel (4D65).
Performance
Vr4 Engine:
2.0L 16-valve DOHC Turbocharged 4G63B (intercooled turbo) producing approximately 195-204 PS (143-150 kW) and 203-210 lb-ft (275-285 Nm) of torque.
Naturally Aspirated Engines:
Naturally aspirated variants ranged from 80 PS (59 kW) to 130 PS (96 kW) depending on displacement and technology (e.g., multi-point fuel injection).
Fuel System
Injection Type:
Electronic Fuel Injection (EFI), including Multi-Point Fuel Injection (MPI) and Electronic Controlled Injection (ECI) on various models.
Fuel Type:
Unleaded gasoline (Octane rating recommendations will be detailed in the manual).
Engine Management
ECU:
Engine Control Unit (ECU) for managing fuel injection, ignition timing, and emission control.
Turbocharging
Turbo Details:
Variable nozzle turbo (VNT) on some later models, wastegate control, and intercooling on performance variants.
🔧 Transmission
Standard
Standard Transmission:
5-speed manual transmission (e.g., F5M21, F5M33).
Optional
Optional Transmission:
4-speed automatic transmission (e.g., F4A33, F4A42).
Features
AWD Transmission:
Specific AWD transmissions (e.g., F5M33 manual, F4A33 automatic) often featured a viscous coupling center differential.
Sport Mode:
Some automatic transmissions may offer a 'sport' mode for more aggressive shifting.
📐 Dimensions
Exterior
Length:
Approx. 4,550-4,640 mm (179.1-182.7 inches) depending on body style and trim.
Width:
Approx. 1,695-1,710 mm (66.7-67.3 inches).
Height:
Approx. 1,390-1,430 mm (54.7-56.3 inches).
Weights
Curb Weight:
Ranges from approximately 1,200 kg to 1,500 kg (2,645 lbs to 3,307 lbs) depending on engine, transmission, and drivetrain.
Wheelbase:
Approx. 2,600 mm (102.4 inches).
🛡️ Safety Features
Ratings
Crash Test Data:
Limited standardized crash test data publicly available for this specific year and model, but generally met prevailing safety standards of the time.
Active Features
ABS:
Anti-lock Braking System (ABS) available as an option or standard on higher trims, particularly VR-4 models.
Passive Features
Seat Belts:
Front and rear seat belts; potential for front seat belt pretensioners on some models.
Airbags:
Driver's side airbag may have been available as an option on some trims, but not universally standard.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM stereo with cassette player; optional CD player on higher trims. Speaker configurations varied by trim level.
Driver Assistance
ABS Availability:
ABS was a notable driver assistance feature available on certain models.
Connectivity
Connectivity Features:
Limited by modern standards; primarily focused on basic vehicle functions. No integrated Bluetooth or USB ports.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-5,000 miles (5,000-8,000 km) or 6 months, depending on driving conditions. Consult manual for exact intervals.
Timing Belt Replacement:
For 4G63 engines, typically recommended every 60,000 miles (96,000 km) or 5 years. Crucial for engine longevity.
Fluid Specifications
Engine Oil Type:
API SG or higher, viscosity typically 10W-30 or 10W-40, depending on climate. Refer to manual for specific grades.
Coolant Type:
Ethylene glycol based coolant, typically a 50/50 mix with distilled water. Refer to manual for specific type (e.g., long-life).
Transmission Fluid Type:
Manual: Gear oil (e.g., GL-4 75W-90); Automatic: ATF SP-II or equivalent (refer to manual for exact specification).
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid.
Known Issues
Engine Common Issues:
Timing belt failure if not replaced on schedule (can cause catastrophic engine damage), oil leaks, carbon build-up on intake valves (especially turbo models).
Transmission Common Issues:
Wear in manual transmission synchros, automatic transmission solenoid issues, and potential for cooler leaks.
Electrical Common Issues:
Corrosion in electrical connectors, aging wiring harness insulation, failure of climate control units.
Suspension Common Issues:
Worn bushings, leaking struts/shocks, and ball joint wear.
📚 Vehicle History
Brand Heritage
Mitsubishi History:
Mitsubishi Motors has a long history in automotive manufacturing, with roots tracing back to the early 20th century, known for innovation in automotive technology.
Model Evolution
Galant Generations:
The 1990 model belongs to the fifth generation (1987-1993) of the Mitsubishi Galant, which was a significant redesign featuring more aerodynamic styling and advanced technologies like optional AWD.
Vr4 Introduction:
The high-performance VR-4 variant, featuring the 4G63T engine and full-time AWD, was a key highlight of this generation, establishing a performance lineage.
Production
Production Years:
1987-1993 for the fifth generation.
Manufacturing Location:
Primarily Japan.
🏆 Awards & Recognition
Recognitions
Performance Recognition:
The Galant VR-4 was often praised for its handling and performance, earning respect in performance car circles and appearing on 'best of' lists for its era.
Ratings
Industry Ratings:
Generally received positive reviews for ride comfort, handling, and technological advancements at the time of its release.
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