1991 Mitsubishi Galant Service & Repair Manual Software

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UGS: 139469

Mots clés: 1991 Car Cars Galant Misc Mitsubishi

Variantes de produits

Description

The 1991 Mitsubishi Galant is a mid-size sedan renowned for its sporty handling and advanced engineering, particularly the performance-oriented GSX models which offered turbocharged engines and all-wheel drive. This generation, produced from 1987 to 1993, competed effectively against established rivals by providing a compelling blend of sharp styling, sophisticated multi-link suspension systems, and engaging driving dynamics. Available with 1.8L or 2.0L engines, including the potent 2.0L DOHC Turbocharged (4G63T), the Galant offered an exciting alternative in its segment, distinguishing itself with features that emphasized driver engagement and technological innovation for its era. This comprehensive factory service manual covers all mechanical and electrical systems of the 1991 Mitsubishi Galant. It provides detailed maintenance procedures, troubleshooting guides, diagnostic strategies, and repair instructions for the engine, drivetrain, brakes, steering, suspension, and electrical systems. Owners, technicians, and mechanics will find in-depth coverage of engine repair, transmission overhaul, electrical diagnostics, and bodywork, along with essential technical specifications, torque values, and wiring diagrams, ensuring thorough understanding and effective maintenance of the vehicle.

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Galant

Year:

Codes

Chassis Code:

E33A (for certain engine/drivetrain configurations)

Engine Codes Common:

4G63 (2.0L DOHC), 4G63T (2.0L DOHC Turbo), 4G37 (1.8L SOHC)

👋 Introduction

Market Position

Market Position:

The 1991 Mitsubishi Galant represented a significant evolution in the model's history, aiming to compete in the mid-size sedan market with a focus on sporty handling and advanced features for its time, particularly with the performance-oriented GSX model.

Competitive Analysis

Competitive Analysis:

Competed against rivals such as the Honda Accord, Toyota Camry, Nissan Maxima, Ford Taurus, and Chevrolet Lumina. The Galant distinguished itself with available all-wheel drive and turbocharged engines, offering a sportier alternative in a segment often dominated by comfort and fuel economy.

Key Features

Key Features:

Advanced multi-link suspension, active four-wheel steering (optional in some markets, but a key tech for the generation), aerodynamic design, emphasis on driver engagement.

📋 Manual Details

Coverage Areas

Coverage Areas:

All mechanical and electrical systems, bodywork, maintenance, troubleshooting, diagnostics, repair procedures, specifications.

Diagnostic Trouble Codes:

Coverage of diagnostic trouble codes (DTCs) for engine management and other electronic systems, with troubleshooting flowcharts.

Page Count

Page Count:

Estimated 1000+ pages (typical for comprehensive service manuals of this era, software format may vary).

Manual Type

Manual Type:

Official Factory Service Manual (Software Edition)

Language

Language:

English

Format

Format:

Digital Software (likely PDF or proprietary format)

📖 Manual Coverage

Systems Covered

Systems Covered:

Engine (mechanical, lubrication, cooling, fuel, ignition, emissions), Drivetrain (manual & automatic transmissions, differentials, axles, driveshafts), Brakes (hydraulic, parking brake, ABS if equipped), Steering & Suspension (power steering, alignment, suspension components), Electrical System (battery, charging, starting, lighting, instrumentation, body electrical, ECU diagnosis), HVAC (heating, ventilation, air conditioning), Body & Chassis (body construction, doors, windows, interior trim, collision repair basics), Fuel Tank & Lines, Exhaust System, Wheels & Tires.

Advanced Systems:

Electronic Control Unit (ECU) and sensor diagnostics, multiplex communication systems (if applicable), cruise control system, anti-lock braking system (ABS) diagnosis.

Bodywork:

Detailed diagrams for interior and exterior trim removal and installation, door panel disassembly, mirror replacement, bumper cover repair.

Procedures Included

Procedures Included:

Engine torque specifications for critical components (head bolts, main bearings, rod caps), piston ring and bearing clearance specifications, valve clearance adjustment procedures.

Technical Depth

Technical Depth:

Includes detailed torque sequences, component measurements, troubleshooting trees based on symptoms, and repair illustrations.

📊 Manual Specifications

File Format

File Format:

Digital (e.g., PDF, searchable text for ease of navigation)

Searchability:

Likely features searchable text, allowing users to quickly find specific topics or components.

Print Quality

Print Quality:

N/A (Digital Format)

Binding Type

Binding Type:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Primary Engine:

2.0L DOHC 16-Valve Inline-4 (4G63)

Performance

Horsepower 4G63:

Approximately 135-140 hp @ 6000 rpm

Torque 4G63:

Approximately 125-130 lb-ft @ 4000 rpm

Horsepower 4G63T Gsx:

Approximately 195 hp @ 6000 rpm

Torque 4G63T Gsx:

Approximately 203 lb-ft @ 3500 rpm

Compression Ratio 4G63:

9.5:1

Compression Ratio 4G63T:

8.5:1

Fuel System

Fuel System:

Electronic Fuel Injection (EFI)

Fuel Type Recommended:

Unleaded gasoline (87 octane for naturally aspirated, 91 octane for turbocharged models)

Fuel Pump Pressure:

Approximately 36-44 psi (for EFI systems).

Engine Variants

Engine Variants:

1.8L SOHC 16-valve (4G37), 2.0L DOHC 16-valve (4G63), 2.0L DOHC 16-valve Turbocharged (4G63T).

Engine Displacement 1 8L:

1830 cc

Engine Displacement 2 0L:

1997 cc

🔧 Transmission

Standard

Standard Transmission:

5-speed Manual Transmission

Optional

Optional Transmission:

4-speed Automatic Transmission (with lock-up torque converter)

Features

AWD Availability:

Available on GSX models, often paired with the turbocharged engine and manual transmission.

Transmission Fluid Type:

Manual: API GL-4 (e.g., Mitsubishi DiaQueen Super Synthetic Gear Oil) or equivalent. Automatic: ATF SP-III or equivalent.

Drivetrain

Drivetrain Options:

Front-Wheel Drive (FWD), All-Wheel Drive (AWD) available on select models (GSX).

📐 Dimensions

Exterior

Length:

Approximately 181.9 inches

Width:

Approximately 69.1 inches

Height:

Approximately 55.1 inches

Wheelbase:

Approximately 104.3 inches

Weights

Curb Weight Base Model:

Approximately 2,800 - 3,000 lbs

Curb Weight Gsx Model:

Approximately 3,100 - 3,300 lbs

Gross Vehicle Weight Rating Gvwr:

Varies by model, typically around 4,200-4,500 lbs.

Interior

Seating Capacity:

5-passenger

🛡️ Safety Features

Ratings

NHTSA Crash Test Results:

Limited public data available for this specific model year from NHTSA. Vehicles of this era generally had lower safety standards than modern vehicles.

Active Features

Active Safety Features:

Anti-lock Braking System (ABS) available on higher trims (e.g., GSX).

Passive Features

Passive Safety Features:

Driver and front passenger airbags (optional or standard depending on trim), three-point seat belts, collapsible steering column.

Seatbelt Pretensioners:

Front seatbelts with pretensioners.

Child Seat Anchors:

LATCH system not standard on 1991 models; traditional seatbelt installation is the method.

💡 Technology Features

Infotainment

Infotainment System:

Factory fitted AM/FM stereo cassette player with optional CD player. Analog climate controls.

Driver Assistance

Driver Assistance Features:

Limited by modern standards. Primarily focused on mechanical systems. ABS was an option on higher trims.

Connectivity

Connectivity Features:

N/A (No integrated Bluetooth or USB connectivity)

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 3,000-5,000 miles or 3-6 months, depending on driving conditions (consult manual for specific recommendations).

Engine Oil Type:

API SG or SH, SAE 5W-30 or 10W-30 (refer to owner's manual for specific viscosity based on temperature).

Timing Belt Replacement:

Typically every 60,000 miles or 5 years for the 4G63 engine. Critical maintenance item.

Transmission Fluid Change Interval:

Automatic: Every 30,000-60,000 miles. Manual: Check for leaks, fluid replacement typically at higher mileage or if contamination is suspected.

Fluid Specifications

Coolant Type:

Ethylene glycol-based antifreeze (50/50 mix with distilled water). Consult manual for specific coolant type/color.

Brake Fluid Type:

DOT 3 or DOT 4.

Power Steering Fluid:

Dexron II or equivalent.

Transfer Case Fluid AWD:

API GL-4 or GL-5 Gear Oil (consult specific manual for Mitsubishi recommended type).

Differential Fluid AWD:

API GL-5 Gear Oil (check manual for front/rear specific recommendations).

Known Issues

Known Issues:

Drive belt tensioner pulley bearing failure, power window motor failure, AC compressor clutch failure, dashboard cracking/deterioration due to UV exposure.

Maintenance Part Numbers:

Oil Filter: MD345571 (or equivalent like Fram PH3593A, Wix 51516). Air Filter: MD618438 (or equivalent like Fram CA3229, Wix 42034). Spark Plugs: NGK BPR6ES or equivalent.

📚 Vehicle History

Brand Heritage

Brand Heritage:

Mitsubishi Motors has a long history in automotive manufacturing, known for its diverse product lines and engineering prowess, including rally racing heritage and innovative technologies.

Model Evolution

Model Evolution:

The 1991 Galant (eighth generation) marked a significant redesign, moving away from its previous angular styling to a more aerodynamic and modern appearance. It introduced advanced features like all-wheel drive and four-wheel steering (on some markets/trims not necessarily US '91) to the Galant line.

Production

Production Years:

1987-1993 (E30 series for this generation)

Manufacturing Location:

Japan

Trim Levels

Trim Levels Common Usdm:

LS (base), GS, GSX (performance flagship).

🏆 Awards & Recognition

Recognitions

Recognitions:

The 1991 Galant received positive reviews for its handling and performance, particularly the GSX model, often cited for its value and sporty credentials.

Ratings

Ratings:

Considered a strong performer in its class, especially with the turbo AWD variant, often lauded by automotive journalists for its engineering.

Certifications

Certifications: