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Mitsubishi Starion 1982-1989 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Starion Generation: A180/A187 Production Years Covered: 1982-1989 👋 Introduction Market Position Historical Context: The Mitsubishi Starion (and its North American counterpart, the Dodge/Chrysler...
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Mitsubishi Starion 1982-1989 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Starion
Generation:
A180/A187
Production Years Covered:
1982-1989
👋 Introduction
Market Position
Historical Context:
The Mitsubishi Starion (and its North American counterpart, the Dodge/Chrysler Conquest) was a rear-wheel-drive sports coupe that competed in the performance car segment of the 1980s, known for its aggressive styling and turbocharged engine options.
Competitive Analysis
Key Competitors:
Competed against vehicles like the Nissan 300ZX, Toyota Supra, Mazda RX-7, Porsche 944, and Chevrolet Camaro/Pontiac Firebird during its production run.
Key Features
Design Philosophy:
Characterized by a sharp, angular design, wide stance, pop-up headlights, and a driver-focused cockpit.
Performance Focus:
Emphasized turbocharged performance, rear-wheel drive handling, and a sporty driving experience.
📋 Manual Details
Coverage Areas
Model Years:
1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989
Global Markets:
Covers models sold worldwide including JDM (e.g., Mitsubishi Starion), Dodge/Chrysler Conquest (North America)
Page Count
Page Count:
700+
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
File Format:
PDF
Download Type:
Instant Download
📖 Manual Coverage
Systems Covered
Engine:
Detailed coverage of 4G63 2.0L SOHC & DOHC Turbocharged engines, including turbocharger system, fuel injection, ignition system, cooling system, lubrication system, engine mechanical (disassembly, assembly, specifications).
Transmission:
Coverage of manual (KM132, KM211) and automatic (F4A33) transmissions, including removal, installation, disassembly, assembly, adjustments, and fluid specifications.
Drivetrain:
Rear-wheel drive system, differential, driveshafts, axles, wheel bearings.
Suspension:
Front and rear suspension systems, including MacPherson struts, independent rear suspension, shock absorbers, springs, control arms, bushings, alignment specifications.
Steering:
Power steering system, steering rack, steering column, tie rods, steering fluid specifications.
Brakes:
Front and rear disc brakes (including optional ABS systems), brake fluid specifications, master cylinder, brake lines, parking brake, rotor and pad specifications.
Electrical:
Complete electrical system, including wiring diagrams, charging system (alternator, battery), starting system, lighting, instruments, gauges, power windows, door locks, radio, fuse box diagrams, ECU (Electronic Control Unit) information.
Body:
Body construction, exterior trim, doors, hood, trunk, bumpers, glass, interior trim, seats, HVAC system (heating, ventilation, air conditioning).
Fuel System:
Fuel tank, fuel pump, fuel lines, fuel filter, fuel injectors, fuel pressure regulator, ECI (Electronic Controlled Injection) system.
Procedures Included
Maintenance:
Routine maintenance, oil changes, filter replacements, spark plug replacement, belt inspection and replacement, fluid level checks and top-offs, lubrication points.
Troubleshooting:
Comprehensive diagnostic procedures for common issues, symptom-based troubleshooting guides, wiring harness checks, sensor testing, error code interpretation (if applicable).
Repair:
Detailed step-by-step instructions for component removal, disassembly, cleaning, inspection, repair, and reassembly.
Installation:
Procedures for installing new or reconditioned components and systems.
Adjustments:
Specific adjustments for engine timing, idle speed, clutch, brakes, suspension alignment, etc.
Technical Depth
Depth:
Comprehensive, from basic maintenance to full engine and transmission rebuilds, including detailed torque specifications, clearances, and wear limits.
Illustrations:
Includes detailed pictorial diagrams, exploded views, drawings, and photos for visual guidance.
Special Tools:
References and illustrations for required special service tools.
📊 Manual Specifications
File Format
PDF Quality:
High resolution, printable pages.
Searchability:
Likely text-searchable within the PDF reader, aiding quick information retrieval.
Print Quality
Printability:
Yes, all pages are printable.
Compatibility
Operating Systems:
Compatible with Windows, Mac, and Linux OS.
Requirements
Software Requirement:
Adobe Reader or compatible PDF viewer.
⚙️ Engine Specifications
Primary Engine
Engine Code And Type:
4G63, 2.0L (1997 cc) Inline-4, SOHC and DOHC versions, turbocharged.
Performance
Horsepower Range:
Typically ranged from approximately 145 hp (SOHC naturally aspirated) to 180-200 hp (DOHC Turbocharged), with later models potentially offering slightly more.
Torque Range:
Significant torque figures from the turbocharged engines, contributing to strong acceleration.
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI), specifically Mitsubishi's ECI system.
Engine Mechanical
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
Varies by engine variant, typically around 7.6:1 to 8.0:1 for turbocharged models to handle boost.
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual Transmission (KM132, KM211).
Optional
Optional Transmission:
4-speed Automatic Transmission (F4A33).
Features
Rear Axle Ratio:
Varies by transmission and trim, often around 3.73:1 or similar for performance applications.
📐 Dimensions
Exterior
Wheelbase:
2465 mm (97.0 in)
Length:
4335 mm (170.7 in)
Width:
1735 mm (68.3 in)
Height:
1295 mm (51.0 in)
Weights
Curb Weight:
Approx. 1300-1450 kg (2866-3197 lbs), varies by equipment and engine.
🛡️ Safety Features
Ratings
Crash Test Performance:
Information regarding official crash test ratings from the era (e.g., NHTSA) would be included in a comprehensive manual if available, though specific data for this period can be scarce.
Active Features
Braking System:
Standard 4-wheel disc brakes; optional Anti-lock Braking System (ABS) available on some models.
Passive Features
Seatbelts:
Standard 3-point seatbelts.
Body Structure:
Designed with a focus on occupant protection for its time, though safety standards have evolved significantly.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM radio with cassette player, often with optional upgraded sound systems.
Driver Assistance
ABS:
Optional Anti-lock Braking System (ABS) was available on later models, representing early automotive electronic safety technology.
Comfort Features
Climate Control:
Manual climate control for heating and air conditioning, often with a distinctive dashboard layout.
Power Accessories:
Power windows, power door locks, and power mirrors were common options.
🔧 Maintenance
Service Intervals
Oil Change:
Typically every 3,000-5,000 miles or 3-6 months, depending on driving conditions and oil type used (consult manual for precise interval).
Tune Up Interval:
Spark plugs, distributor cap, rotor, and ignition wires recommended for replacement at intervals specified in the manual (often around 30,000 miles).
Fluid Specifications
Engine Oil:
API SG or higher quality, SAE 10W-30 or 10W-40 recommended (specific viscosity depends on ambient temperature, refer to manual).
Coolant:
Ethylene glycol-based coolant with corrosion inhibitors, typically a 50/50 mix with distilled water.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Transmission Fluid Manual:
Gear oil, SAE 75W-90 or 80W-90 GL-4 specified for manual transmissions.
Transmission Fluid Automatic:
Dexron-III (or equivalent) ATF for the automatic transmission.
Known Issues
Turbocharger Reliability:
Turbocharger system components (wastegate, intercooler, hoses) can require attention; proper warm-up/cool-down is crucial for longevity.
Rust And Corrosion:
As with many 1980s vehicles, susceptibility to rust and corrosion in certain areas (wheel arches, rocker panels, chassis) is a common concern, especially in humid or winter climates.
Electronics:
Age-related failure of electrical components, sensors, and wiring can occur.
Cooling System:
Radiator, hoses, and water pump can degrade over time, requiring replacement to prevent overheating.
Fuel Delivery:
Fuel injectors, fuel pump, and fuel pressure regulator may require maintenance or replacement.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors:
Part of Mitsubishi Motors' push into the global automotive market, leveraging their engineering capabilities.
Model Evolution
Design Updates:
Facelifted models featured revised front and rear styling, wider fender flares, and updated interior features throughout its production run.
Engine Development:
The 4G63 engine became a legendary powerplant for Mitsubishi, known for its robustness and tunability, particularly in its DOHC turbo variants.
Production
Manufacturing Locations:
Primarily manufactured in Japan.
🏆 Awards & Recognition
Recognitions
Automotive Press:
While specific awards might not be widely documented, the Starion/Conquest was generally well-received by automotive press for its performance-oriented nature and styling in the 1980s.
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