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Mitsubishi Galant 1994 Service Repair Manual

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Welcome to the comprehensive service manual for the 1994 Mitsubishi Galant. This vehicle, built on the robust fourth-generation E30/E50/E60/E70/E80 platform, offers a compelling blend of sporty handling, distinctive styling, and...
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Mitsubishi Galant 1994 Service Repair Manual
Welcome to the comprehensive service manual for the 1994 Mitsubishi Galant. This vehicle, built on the robust fourth-generation E30/E50/E60/E70/E80 platform, offers a compelling blend of sporty handling, distinctive styling, and value, making it a notable competitor in the mid-size sedan market of its time. Available with a range of efficient 4-cylinder and powerful V6 engines, and offering both front-wheel drive and all-wheel drive configurations, the Galant was engineered to provide a dynamic driving experience and reliable performance for a variety of uses. This factory service manual provides extensive coverage for all systems of your 1994 Mitsubishi Galant, designed for both professional technicians and dedicated enthusiasts. Within these pages, you will find detailed procedures for routine maintenance, major repairs, and component replacement, covering everything from engine mechanicals and fuel systems to transmissions, suspension, brakes, and the electrical system. This manual also includes comprehensive troubleshooting guides, diagnostic information, technical specifications, and essential safety guidelines, ensuring you have the knowledge to maintain, repair, and optimize your vehicle effectively.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Galant
Year:
1994
Generation Code:
E30/E50/E60/E70/E80
👋 Introduction
Market Position
Segment:
Mid-size Sedan
Key Competitors:
Toyota Camry, Honda Accord, Nissan Altima, Ford Taurus, Chevrolet Lumina.
Competitive Analysis
Galant Strengths 1994:
Sporty handling (especially V6 models), distinctive styling, good value proposition, available AWD on some trims.
Key Features
Platform:
Fourth Generation E30/E50/E60/E70/E80 platform.
Body Styles:
4-door Sedan, 2-door Coupe (less common in North America for this year).
Available Engines:
4-cylinder and V6 options.
Drivetrain Options:
Front-Wheel Drive (FWD), All-Wheel Drive (AWD) on select models (e.g., GSR).
📋 Manual Details
Coverage Areas
All Systems:
Yes
Engine Mechanical:
Complete
Engine Performance:
Complete
Fuel System:
Complete
Ignition System:
Complete
Cooling System:
Complete
Exhaust System:
Complete
Transmission Manual:
Complete
Transmission Automatic:
Complete
Clutch System:
Complete
Drivetrain:
Complete
Suspension Front:
Complete
Suspension Rear:
Complete
Steering System:
Complete
Brake System:
Complete
Wheels And Tires:
Complete
Body And Frame:
Complete
Electrical System:
Complete
Lighting System:
Complete
Instrument Panel:
Complete
HVAC System:
Complete
Safety Restraints:
Complete
Audio System:
Complete
Wiring Diagrams:
Comprehensive
Troubleshooting:
Extensive
Page Count
Estimated Pages:
1500+
Manual Type
Type:
Factory Service Manual
Purpose:
Professional Technician & Enthusiast
Language
Language:
English
Format
Format:
PDF (Digital Download)
📖 Manual Coverage
Systems Covered
Engine Mechanical Diagnostics:
Compression testing, valve timing, piston/ring inspection, cylinder head removal/installation, crankshaft/connecting rod service.
Engine Electronic Controls:
ECU diagnosis, sensor testing (MAP, TPS, O2, CKP, CMP), actuator testing (injectors, IAC), emissions control systems.
Fuel Injection System:
Fuel pressure testing, injector cleaning/replacement, fuel pump diagnosis, fuel filter replacement, fuel rail service.
Cooling And Heating:
Radiator and component testing, thermostat replacement, water pump service, heater core diagnosis, A/C system component service (refrigerant handling requires EPA certification).
Manual Transmission:
Clutch inspection and replacement, gear synchro diagnosis, bearing service, shift linkage adjustment, transmission fluid service.
Automatic Transmission:
Torque converter diagnosis, valve body service, transmission fluid and filter change, transmission control module (TCM) diagnosis, shift solenoid testing.
Suspension And Steering:
Shock absorber/strut replacement, ball joint and tie rod end inspection, power steering pump and rack service, wheel alignment specifications.
Brake System Overhaul:
Disc and drum brake service, caliper and wheel cylinder rebuilding, brake fluid flush and bleed, ABS system diagnosis (if equipped).
Electrical Diagnostics:
Starter motor and alternator testing, battery service, fuse and relay identification, lighting circuit troubleshooting, accessory circuits.
Body And Trim Service:
Panel removal and installation, interior trim component replacement, door and window regulator service, bumper repair and replacement.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements (oil, air, fuel), spark plug replacement, fluid checks and top-offs, belt inspection and replacement.
Major Repairs:
Engine overhaul, transmission rebuild, suspension component replacement, brake caliper/rotor replacement, exhaust system repair.
Troubleshooting Guide:
Systematic diagnosis of common drivability issues, electrical faults, and mechanical problems with flowcharts and symptom-based guides.
Component Replacement:
Detailed step-by-step instructions for replacing virtually all mechanical and electrical components.
Special Tools Required:
Identification and usage of specific tools needed for certain procedures.
Torque Specifications:
Precise torque values for critical fasteners throughout the vehicle.
Technical Depth
Depth Level:
Comprehensive (from basic maintenance to complete engine/transmission rebuilds).
Diagnostic Capabilities:
Advanced diagnostic procedures, including electrical circuit analysis and sensor data interpretation.
Rebuild Procedures:
Detailed instructions for overhauling engines, transmissions, and other major components.
📊 Manual Specifications
File Format
File Type:
PDF
Searchable:
Yes
Printable:
Yes
Print Quality
Image Resolution:
High-resolution, clear images and diagrams.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code 4Cyl:
4G63 (2.0L DOHC Turbocharged - performance variant like GSR), 4G64 (2.4L SOHC).
Engine Code V6:
6A12 (2.0L V6 DOHC), 6A13 (2.5L V6 SOHC).
Performance
Horsepower 4Cyl Naturally Aspirated:
Approx. 130-140 HP (4G64).
Horsepower 4Cyl Turbocharged:
Approx. 200-220 HP (4G63 Turbo).
Horsepower V6 2.0L:
Approx. 140-150 HP (6A12).
Horsepower V6 2.5L:
Approx. 160-170 HP (6A13).
Torque 4Cyl Naturally Aspirated:
Approx. 130-135 lb-ft (4G64).
Torque 4Cyl Turbocharged:
Approx. 200-205 lb-ft (4G63 Turbo).
Torque V6 2.0L:
Approx. 130-135 lb-ft (6A12).
Torque V6 2.5L:
Approx. 155-160 lb-ft (6A13).
Fuel System
Injection Type:
Multi-Point Fuel Injection (MPI) or Electronic Fuel Injection (EFI).
Fuel Type:
Unleaded Gasoline.
Fuel Octane Rating:
87 Octane Minimum (check specific models, performance variants may recommend higher).
🔧 Transmission
Standard
Standard Transmission:
5-Speed Manual Transmission (various models).
Optional
Optional Transmission:
4-Speed Automatic Transmission (available on most models).
Features
AWD System:
Optional 'Active Four' All-Wheel Drive system (often paired with 4G63 turbo engine).
📐 Dimensions
Exterior
Length:
Approx. 182.9 inches (4645 mm) for sedan.
Width:
Approx. 69.7 inches (1770 mm).
Height:
Approx. 54.1 inches (1375 mm) for sedan.
Wheelbase:
Approx. 104.7 inches (2660 mm).
Weights
Curb Weight:
Varies by model and engine, typically 3000-3400 lbs (1360-1540 kg).
🛡️ Safety Features
Ratings
NHTSA Frontal Impact:
Not rated or limited data available for this model year.
IIHS Crash Tests:
Limited data available; generally considered average for its era.
Active Features
ABS:
Available on higher trims or as an option.
Passive Features
Airbags:
Driver-side airbag standard on most models; passenger airbag optional or unavailable.
Seatbelts:
3-point front seatbelts, 2-point rear seatbelts (some models may have 3-point rear belts).
💡 Technology Features
Infotainment
Audio System Features:
Standard AM/FM radio, cassette player. Optional CD player available on higher trims.
Speaker Configuration:
Typically 4 to 6 speakers depending on trim level.
Driver Assistance
Cruise Control:
Available on most models.
Connectivity
Bluetooth:
Not available (standard for the era).
Usb Ports:
Not available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles (4,800-8,000 km) or 6 months, whichever comes first (refer to manual for specific engine).
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on conditions.
Spark Plug Replacement:
Every 30,000-60,000 miles (48,000-96,000 km) depending on plug type (copper, platinum).
Timing Belt Replacement:
Crucial for 4G63/4G64 engines. Recommended every 60,000-90,000 miles (96,000-144,000 km). Failure can cause severe engine damage.
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 5W-30 or 10W-30 recommended (check manual for temperature variations).
Engine Oil Capacity:
Approx. 4.0-5.0 quarts (3.8-4.7 liters) with filter, depending on engine.
Coolant Type:
Ethylene glycol-based antifreeze (green) mixed 50/50 with distilled water.
Transmission Fluid Manual:
API GL-4 Gear Oil, SAE 75W-90 or 80W-90.
Transmission Fluid Automatic:
Mitsubishi Diamond SP-II or SP-III (or equivalent Dexron III/Mercon).
Brake Fluid Type:
DOT 3 or DOT 4.
Known Issues
Engine Mounts:
Can degrade over time, leading to increased vibration and engine noise.
Automatic Transmission Shifting:
Some models may experience rough shifting or delayed engagement due to valve body issues or worn solenoids.
Radiator Leaks:
Common wear item; leaks can occur at the end tanks.
Power Steering Pump Leaks:
Leaking seals or hoses can lead to reduced power steering assist.
Window Regulators:
Can become stiff or fail, preventing windows from operating smoothly.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors Origin:
Founded in 1970, emerging from Mitsubishi Shipbuilding Co., Ltd. Known for engineering prowess and innovative technologies.
Model Evolution
Galant Introduction:
First generation introduced in 1969. The 1994 model represents the fourth generation (E30 series) which debuted in 1987 and underwent facelifts and powertrain updates.
Production
Manufacturing Locations:
Primarily Japan (Mizushima Plant), with some assembly in other countries depending on market.
🏆 Awards & Recognition
Recognitions
Car And Driver Ten Best:
The Galant was often lauded for its engineering and driving dynamics, though not a consistent 'Ten Best' recipient.
Ratings
Consumer Reports Reliability:
Varies by year and specific component; generally considered average to above average for its class in this era, but specific model years and powertrains should be researched.
Certifications
Emissions Compliance:
Designed to meet EPA emissions standards for 1994 model year.
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