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1990-2000 Mitsubishi Galant Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Galant Generation: Eighth Generation (E33A, E34A, E35A, E38A, E39A, E53A, E54A, E55A, E64A, E74A, E77A, E84A, E88A) Model Years Covered: 1990-2000 Codes Chassis...
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Sku: 114655
1990-2000 Mitsubishi Galant Service Repair Manual1990-2000 Mitsubishi Galant Service Repair Manual1990-2000 Mitsubishi Galant Service Repair Manual1990-2000 Mitsubishi Galant Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Galant
Generation:
Eighth Generation (E33A, E34A, E35A, E38A, E39A, E53A, E54A, E55A, E64A, E74A, E77A, E84A, E88A)
Model Years Covered:
1990-2000
Codes
Chassis Codes:
E33A, E34A, E35A, E38A, E39A, E53A, E54A, E55A, E64A, E74A, E77A, E84A, E88A
👋 Introduction
Market Position
Vehicle Segment:
Mid-size sedan and wagon, competing with models like the Toyota Camry, Honda Accord, and Ford Taurus.
Competitive Analysis
Strengths:
Known for its sporty handling (especially AWD models), distinctive styling, and optional powerful V6 engines. Often offered good value compared to competitors.
Key Features
Drivetrain Options:
Available in Front-Wheel Drive (FWD) and All-Wheel Drive (AWD) configurations.
Body Styles:
Offered primarily as a 4-door sedan, with some markets receiving a 5-door station wagon variant.
Manual Value Proposition
Benefits Of Digital Manual:
Eliminates wear and tear on original paper manuals, provides quick access to information, allows for printing of specific pages, and consolidates multiple manuals into one accessible format.
📋 Manual Details
Coverage Areas
Systems Covered Overview:
Comprehensive coverage including Engine, Transmission, Drivetrain, Brakes, Suspension, Steering, Electrical, HVAC, Body, Fuel, Cooling, Exhaust, Safety Systems, and more.
Page Count
Estimated Page Count:
Varies by specific edition, but comprehensive factory manuals for this generation typically exceed 1500 pages.
Manual Type
Type:
Service and Repair Manual
Language
Language:
English
Format
Format:
PDF (Digital Download)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed coverage of 4G63 (2.0L SOHC/DOHC), 4G64 (2.4L SOHC), and 6G72 (3.0L SOHC V6) engines, including disassembly, assembly, torque specifications, valve clearance, timing belt/chain replacement, and internal component diagnostics.
Engine Control:
Engine Control System (ECU), sensors (MAP, TPS, O2, Crankshaft Position, Camshaft Position, Knock, MAF), actuators, fuel injection, ignition timing, emissions control systems (SFI, EGR, Charcoal Canister), and diagnostic trouble codes (DTCs).
Transmission Automatic:
Automatic Transaxle (e.g., F4A33, F4A23), including shift control, valve body operation, torque converter, fluid specifications, troubleshooting, and rebuild procedures.
Transmission Manual:
Manual Transaxle Systems (e.g., W5MG1, W4A32), including clutch operation, shift linkages, gear ratios, fluid specifications, and component servicing.
Brakes:
Brake System (Front/Rear Disc Brakes, ABS), including hydraulic components (master cylinder, booster, calipers, wheel cylinders), brake fluid specifications, bleeding procedures, pad/rotor replacement, parking brake system, and ABS sensor diagnostics.
Suspension:
Front and Rear Suspension Systems (MacPherson struts front, Multi-link rear on some models), including shock absorbers, springs, control arms, ball joints, bushings, sway bars, wheel alignment specifications (front and rear), and component replacement.
Steering:
Steering System (Power Steering, Rack and Pinion), including steering column, power steering pump, rack assembly, fluid specifications, steering angle sensors, and tie rod end replacement.
Electrical Lighting:
Lighting System (Headlamps, Tail Lamps, Fog Lamps, Interior Lights), including bulb types, wiring schematics, switch operation, and component testing.
Electrical Power Windows:
Power Window Control System, including motors, regulators, switches, and wiring diagrams for driver and passenger windows.
Electrical Audio:
Audio and Visual System, including radio receiver, speakers, amplifiers, antenna systems, and wiring.
HVAC:
Heater and Air Conditioning System, including refrigerant cycles, blower motor, evaporator, condenser, heater core, climate controls, and diagnostic procedures.
Body Exterior:
Body Repair, including front/rear bumpers, fenders, hood, doors, glass (windshield, door, quarter), sunroof systems, trim mouldings, and weatherstripping.
Body Interior:
Instrument Panel, seats, seat belts, roof headlining, door panels, and interior trim components.
Safety Airbag:
Supplemental Restraint System (SRS), including front airbags, side airbags, curtain airbags, airbag sensors (front, side, rear), control module, and seat belt warning systems.
Procedures Included
Maintenance:
Routine maintenance procedures such as oil changes, filter replacements, fluid checks and changes, spark plug replacement, drive belt inspection and replacement.
Troubleshooting:
Systematic diagnostic procedures for common and complex issues, often including symptom-based troubleshooting guides and wiring diagram interpretation.
Repair Rebuild:
Detailed step-by-step instructions for component removal, disassembly, inspection, repair, reassembly, and installation for major vehicle systems.
Wiring Diagrams:
Comprehensive wiring diagrams for all major electrical systems, including power distribution, engine control, lighting, audio, HVAC, and safety systems.
Technical Specifications:
All essential technical specifications, torque values, clearances, fluid capacities, electrical specifications, and diagnostic data required for accurate service.
Technical Depth
Depth:
Factory-level technical depth, suitable for professional technicians and advanced DIY mechanics. Covers everything from basic fluid checks to complete engine and transmission overhauls.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Printability:
Printable pages, allowing users to print specific sections as needed for clean use in the workshop.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
Software Compatibility
Operating Systems:
Compatible with all PC and Mac-based operating systems.
Searchability
Search Functionality:
Searchable PDF format for quick access to specific topics and repair procedures.
⚙️ Engine Specifications
Primary Engine
Engine Options:
4G63 (2.0L DOHC I4), 4G64 (2.4L SOHC I4), 6G72 (3.0L SOHC V6)
Performance
Horsepower Range:
Approximately 135 hp (2.0L SOHC) to 195 hp (3.0L V6), with performance variants exceeding this.
Torque Range:
Approximately 135 lb-ft (2.0L SOHC) to 205 lb-ft (3.0L V6).
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI) or Sequential Fuel Injection (SFI) depending on engine and year.
Cooling System
Coolant Type:
Typically requires a 50/50 mixture of ethylene glycol-based antifreeze and distilled water.
Lubrication System
Oil Capacity:
Varies by engine; typically 4-5 quarts (3.8-4.7 liters).
Oil Viscosity:
Commonly SAE 5W-30 or 10W-30, consult manual for specific recommendations based on climate.
🔧 Transmission
Standard
Manual Transmission:
Available 5-speed manual transmission on select models.
Optional
Automatic Transmission:
Available 4-speed automatic transmission on most models.
Features
Sportronic Shiftronic:
Some later models and performance variants may feature manual-shift capabilities on the automatic transmission.
Fluid Specs
Automatic Transaxle Fluid:
Typically requires Mitsubishi DiaQueen SPIII or equivalent ATF.
📐 Dimensions
Exterior
Length:
Approximately 183-185 inches (4650-4700 mm) for sedan.
Width:
Approximately 69-70 inches (1750-1780 mm).
Height:
Approximately 54-55 inches (1370-1400 mm).
Weights
Curb Weight:
Approximately 3000-3400 lbs (1360-1540 kg) depending on configuration.
Wheelbase:
Approximately 104.5 inches (2654 mm).
🛡️ Safety Features
Ratings
NHTSA Ratings:
Safety ratings varied by model year and testing agency; early models may not have comprehensive modern crash test data readily available.
Active Features
ABS:
Anti-lock Braking System (ABS) available on many models.
AWD:
All-Wheel Drive (AWD) system available, enhancing traction and stability.
Passive Features
Airbags:
Driver and passenger airbags standard on later models; side and curtain airbags introduced on some later trims.
Seat Belts:
Front and rear seat belts, with pre-tensioners on front belts.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM cassette or CD players with multiple speaker configurations.
Driver Assistance
Cruise Control:
Electronic cruise control system available on most trims.
Connectivity
Power Accessories:
Power windows, power door locks, and power mirrors standard on many models.
Comfort Features
Climate Control:
Manual or automatic climate control systems.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,750 to 7,500 miles (6,000 to 12,000 km) or 6 to 12 months, depending on oil type and driving conditions. Consult manual for specific recommendations.
Timing Belt Replacement:
For 4G63 and 4G64 engines, the timing belt typically requires replacement every 60,000 to 90,000 miles (96,000 to 145,000 km). Critical for preventing engine damage.
Fluid Specifications
Brake Fluid:
DOT 3 or DOT 4 brake fluid recommended.
Power Steering Fluid:
Typically uses ATF Dexron II or equivalent.
Coolant Capacity:
Varies by engine, typically 6-8 quarts (5.7-7.6 liters).
Known Issues
Common Wear Items:
CV joints, struts/shocks, power steering pumps, catalytic converters, and occasional transmission control module issues.
Engine Specific Concerns:
4G63 timing belt integrity is paramount; ensure it's replaced at recommended intervals. Some early models may have oil consumption concerns.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors:
Mitsubishi Motors Corporation, a Japanese multinational automotive manufacturer with a history of producing reliable and innovative vehicles.
Model Evolution
Galant Generations:
The 1990-2000 Galant represents the eighth generation, a significant redesign from previous models, featuring sleeker styling and advanced technology for its time.
Production
Manufacturing Locations:
Primarily manufactured in Japan, with some assembly potentially occurring in other global locations.
🏆 Awards & Recognition
Recognitions
Car And Driver:
The Galant often received positive reviews from automotive publications like Car and Driver for its driving dynamics and styling during its production run.
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