Mitsubushi GALANT 1990-1996 Service Repair Manual

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This manual covers the Galant, specifically the E3x Series chassis codes including E33A, E38A, E39A, E35A, and E37A, for the model years 1990 through 1996. The Galant is a mid-size...

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Tipo: Car

Proveedor:

SKU: 124020

Etiquetas: 1990 1991 1992 1993 1994 1995 1996 Car GALANT Mitsubushi

Variantes de producto

Descripción

This manual covers the Galant, specifically the E3x Series chassis codes including E33A, E38A, E39A, E35A, and E37A, for the model years 1990 through 1996. The Galant is a mid-size sedan renowned for its sporty handling and advanced engineering, offering a range of engine variants from efficient 1.8L and 2.0L naturally aspirated options to the powerful 2.0L turbocharged 4G63 and the smooth 2.5L V6 6G71. Notable features include available All-Wheel Drive (AWD) and All-Wheel Steering (AWS) on performance-oriented VR-4 models, sophisticated suspension systems, and a strong reputation for reliability. This generation of the Galant was recognized for its competitive edge against other prominent sedans of its time. This comprehensive service and repair manual provides essential information for maintaining and repairing your Galant. It details a wide array of systems, including the powertrain, transmission and drivetrain, suspension and steering, brakes, and electrical/electronic components. Coverage extends to body and chassis work, with thorough explanations of maintenance procedures, systematic troubleshooting guides, and in-depth repair and rebuild instructions. The manual also includes technical specifications, diagnostic procedures, and safety guidelines, making it an indispensable resource for DIY enthusiasts, mechanics, and technicians aiming to ensure the optimal performance and longevity of their vehicle.

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Galant

Generation:

E30/E33A/E38A/E39A/E35A/E37A (E3x Series)

Codes

Chassis Codes Covered:

E33A, E38A, E39A, E35A, E37A

👋 Introduction

Market Position

Segment:

Mid-size sedan, known for its sporty handling and advanced features, particularly the AWD VR-4 variant.

Competitive Analysis

Competitors:

Honda Accord, Toyota Camry, Nissan Maxima, Mazda MX-6.

Key Features

Engineering Emphasis:

Front-wheel drive (FWD) and advanced All-Wheel Drive (AWD) systems, sophisticated multi-link rear suspension on AWD models, powerful turbocharged engine options (VR-4).

Target Audience

Manual Users:

DIY enthusiasts, independent repair shops, and owners seeking in-depth knowledge of their vehicle's maintenance and repair.

📋 Manual Details

Coverage Areas

Model Years Covered:

1990, 1991, 1992, 1993, 1994, 1995, 1996

Trim Levels Covered:

All trims including GS, LS, ES, SP, GT, VR-4 (with specific notes where differences apply)

Engine Variants Covered:

4G63 2.0L DOHC Turbo, 4G63 2.0L SOHC, 6G71 2.5L SOHC V6, 4G93 1.8L SOHC

Page Count

Estimated Page Count:

Over 1500 pages (typical for comprehensive service manuals of this era)

Manual Type

Type:

Comprehensive Service & Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF) - Searchable and Printable

📖 Manual Coverage

Systems Covered

Powertrain:

Engine mechanical, fuel system (EFI, carbureted where applicable), ignition system, lubrication system, cooling system, exhaust system, engine management (ECU diagnosis), turbocharged systems (VR-4).

Transmission Drivetrain:

Manual transmission (W5M33, KM210), Automatic transmission (F4A33, W4A33), transfer case (4WD/AWD systems), differential (front and rear), driveshafts, CV joints, clutch system, torque converter.

Suspension Steering:

Front suspension (MacPherson strut), rear suspension (Multi-link beam, Independent for AWD models), shock absorbers, springs, bushings, steering gear, power steering system, steering linkage, wheel alignment specifications.

Brakes:

Front disc brakes (ventilated/solid), rear disc brakes (solid/ventilated), ABS system (where equipped), parking brake, brake system bleeding procedures, master cylinder, calipers, brake pads, rotors.

Electrical Electronics:

Battery, starting system, charging system (alternator, starter), lighting system (headlights, taillights, interior), instrumentation cluster, gauges, power windows, power locks, mirrors, horn, wiper system, audio system, HVAC controls, ECU pinouts, wiring diagrams for all major systems.

Body Chassis:

Body panel removal and installation, door mechanisms, interior trim, seats, glass, exterior trim, bumper systems, chassis components, rust prevention and repair notes.

Procedures Included

Maintenance:

Oil change, filter replacement, fluid level checks and top-offs, tire rotation and pressure checks, spark plug replacement, air filter replacement, battery maintenance, brake pad inspection.

Troubleshooting:

Systematic diagnostic procedures for common and uncommon drivability issues, electrical faults, starting problems, braking concerns, and HVAC malfunctions.

Repair Rebuild:

Detailed step-by-step instructions for engine rebuilds, transmission overhaul, suspension component replacement, brake caliper rebuilding, starter/alternator replacement, and body panel repairs.

Diagnostics:

On-board diagnostic (OBD) system interpretation (where applicable for the era), troubleshooting flowcharts, component testing procedures, sensor resistance and voltage checks.

Technical Depth

Depth:

Comprehensive, covering basic owner maintenance to full engine and transmission rebuilds, including advanced electrical diagnostics and chassis repair.

📊 Manual Specifications

File Format

Digital Format:

Searchability:

Fully searchable text for quick information retrieval.

Printability:

Printable pages, allowing users to print specific sections or the entire manual.

Print Quality

Image Resolution:

High-resolution for clear diagrams and illustrations.

Binding Type

Physical Equivalent Binding:

Spiral-bound or perfect-bound (for print versions, digital equivalent offers easy navigation).

Paper Type

Physical Equivalent Paper:

Heavy-duty, coated paper for durability in a workshop environment.

⚙️ Engine Specifications

Primary Engine

Engine 1 Name:

Engine 1 Type:

2.0L Inline-4 DOHC Turbocharged (VR-4), 2.0L Inline-4 SOHC Naturally Aspirated (Base/ES/GS)

Engine 1 Displacement:

1997cc

Engine 1 Horsepower Turbo:

237-245 hp @ 6000 rpm (varies by year and market)

Engine 1 Torque Turbo:

255-261 lb-ft @ 3000-3500 rpm (varies by year and market)

Engine 1 Horsepower Naturally Aspirated:

135-145 hp @ 6000 rpm (varies by year and market)

Engine 1 Torque Naturally Aspirated:

125-135 lb-ft @ 4000-5000 rpm (varies by year and market)

Other Engines

Engine 2 Name:

Engine 2 Type:

2.5L V6 SOHC Naturally Aspirated

Engine 2 Displacement:

2497cc

Engine 2 Horsepower:

170-175 hp @ 6000 rpm

Engine 2 Torque:

174-180 lb-ft @ 4500-5000 rpm

Fuel System

Fuel Delivery:

Multi-point Electronic Fuel Injection (MPI)

Recommended Fuel:

87 Octane (NA), 91 Octane Recommended for Turbocharged (VR-4)

🔧 Transmission

Standard

Base Transmission:

5-speed Manual (FWD models)

Optional

Optional Transmission:

4-speed Automatic with Overdrive

Awd Transmission

Vr4 Transmission:

5-speed Manual (W5M33) or 4-speed Automatic (V4A51) with advanced All-Wheel Drive (AWD) and Active Yaw Control (AYC) on some later models.

Features

Clutch Type:

Hydraulically operated, single dry plate clutch.

Fluid Specifications

Manual Transmission Fluid:

API GL-4, SAE 75W-90 or SAE 80W-90 gear oil.

Automatic Transmission Fluid:

Diamond SP-III ATF (or equivalent)

📐 Dimensions

Exterior

Length:

Approx. 180-184 inches (varies slightly by body style)

Width:

Approx. 69.1 inches

Height:

Approx. 54.5-55.5 inches (varies by body style)

Weights

Curb Weight:

Approx. 3000-3500 lbs (varies significantly by model and drivetrain)

Gross Vehicle Weight Rating Gvwr:

Typically around 4000-4500 lbs

Wheel Dimensions

Wheelbase:

104.7 inches

Track Width Front:

Approx. 59.3 inches

Track Width Rear:

Approx. 59.1 inches (FWD) / 59.3 inches (AWD)

🛡️ Safety Features

Passive Features

Airbags:

Driver and passenger airbags standard on later models (optional/unavailable on early models).

Seat Belts:

Three-point front and rear seat belts.

Active Features

Anti-lock Braking System (ABS) available as an option on many models, standard on VR-4.

Traction Control:

Available on later VR-4 models, especially those with AWD.

Ratings

NHTSA Ratings:

Ratings vary by year and specific test protocols. Likely received moderate ratings typical of vehicles from this era.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM cassette player, optional CD player. Speaker configuration varies by trim.

Driver Assistance

Cruise Control:

Standard on most models.

Climate Control:

Manual or automatic climate control systems depending on trim level.

Performance Tech

Vr4 Technologies:

All-Wheel Drive (AWD), All-Wheel Steering (AWS) on early VR-4 models, Active Yaw Control (AYC) on later AWD models, electronically controlled suspension (ECS) on some models.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,750 to 7,500 miles or 6 months, depending on driving conditions and oil type used.

Timing Belt Replacement:

Crucial: 60,000 miles or 5 years for 4G63/4G93 engines. Failure can cause severe engine damage. V6 engines have a timing chain.

Spark Plug Replacement:

Every 30,000 to 60,000 miles depending on plug type (copper vs. platinum).

Fluid Specifications

Engine Oil Type:

API Service SG or SH, viscosity 5W-30, 10W-30, or 10W-40 depending on ambient temperature.

Coolant Type:

Ethylene glycol based antifreeze, typically a 50/50 mix with distilled water.

Brake Fluid Type:

DOT 3 or DOT 4.

Power Steering Fluid:

Dexron II ATF or equivalent.

Known Issues

Engine Turbo:

Oil leaks, turbocharger wear, boost control issues on VR-4 models.

Suspension:

Worn ball joints, control arm bushings, and strut mounts; especially common on AWD models with multi-link rear suspension.

Electrical:

Corroded electrical connectors, faulty window regulators, aging dashboard illumination, ABS sensor failures.

Transmission:

Automatic transmission solenoid issues, clutch wear on manuals, AWD coupling unit service.

Rust:

Prone to rust in wheel wells, rocker panels, and around the rear differential on AWD models if not properly maintained.

📚 Vehicle History

Brand Heritage

Mitsubishi History:

Mitsubishi Motors Corporation, a Japanese multinational automotive manufacturer, known for its engineering prowess and innovation, particularly in powertrain and AWD technology.

Model Evolution

Galant Evolution 1990-1996:

This generation (E3x) marked a significant shift in styling and technology. It introduced the high-performance VR-4 variant with AWD and a potent turbocharged engine, setting benchmarks for sporty sedans. It evolved through facelifts and feature updates during its production run.

Production

Manufacturing Locations:

Primarily Japan.

Production Years For This Generation:

1987-1993 (globally, with specific market relevance for 1990-1996).

🏆 Awards & Recognition

Recognitions

Car And Driver:

The Galant VR-4 was often featured on Car and Driver's '10Best' lists during its production run for its performance and technology.

Motor Trend:

Received positive reviews from automotive publications like MotorTrend for its handling and driving dynamics, especially the VR-4.

Certifications

Epa Fuel Economy:

EPA estimates varied by engine and transmission, generally ranging from 18-22 MPG city and 24-28 MPG highway for 4-cylinder models, and lower for V6 and VR-4 variants.