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Mitsubishi Galant 1991 Factory Service Repair Manual

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The Mitsubishi Galant, model year 1991, chassis code E3_A, is a mid-size sedan recognized for its distinctive aerodynamic styling and comfortable ride. As part of its fifth generation, this vehicle...
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Mitsubishi Galant 1991 Factory Service Repair Manual
The Mitsubishi Galant, model year 1991, chassis code E3_A, is a mid-size sedan recognized for its distinctive aerodynamic styling and comfortable ride. As part of its fifth generation, this vehicle offered a compelling balance of performance and value, positioning itself against key competitors such as the Honda Accord and Toyota Camry. Buyers appreciated its available V6 engines and the overall engineering quality that characterized Mitsubishi’s automotive offerings during this period. This model represents a solid choice for those seeking a reliable and well-engineered sedan from the early 1990s. This comprehensive factory service manual provides complete information for the maintenance and repair of the 1991 Mitsubishi Galant. It covers all essential vehicle systems, including engine mechanicals, drivetrain, suspension, steering, brakes, and electrical systems, along with detailed procedures for scheduled maintenance, troubleshooting, and component repair. The manual includes vital technical specifications, diagnostic flowcharts, wiring diagrams, and special tool requirements, making it an indispensable resource for owners, mechanics, and technicians aiming to ensure the optimal performance and longevity of their vehicle.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Galant
Year:
1991
Codes
Chassis Code:
E3_A
👋 Introduction
Market Position
Positioning:
Mid-size sedan offering a balance of comfort, performance, and value, competing against models like the Honda Accord, Toyota Camry, and Ford Taurus.
Competitive Analysis
Key Rivals:
Honda Accord, Toyota Camry, Nissan Altima, Ford Taurus, Chevrolet Lumina.
Key Features
Vehicle Features:
Known for its distinctive aerodynamic styling (for its era), comfortable ride, and available V6 engines.
Manual Value Proposition:
Provides dealer-level technical information, empowering owners and independent mechanics for effective maintenance and repair.
📋 Manual Details
Coverage Areas
Primary Coverage:
Complete Factory Service and Repair
Secondary Coverage:
Diagnostic Procedures, Wiring Diagrams, Torque Specifications, Fluid Capacities
Page Count
Estimated Page Count:
High volume, typically over 1000 pages for a full factory service manual
Manual Type
Type:
Factory Service Manual (FSM)
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine mechanical, lubrication, cooling, fuel delivery, intake and exhaust, emission control, ignition
Drivetrain Systems:
Clutch, manual transaxle, automatic transaxle, propeller shaft, front axle, rear axle
Suspension Steering Brakes:
Front suspension, rear suspension, wheels and tires, power plant mount, service brakes, parking brakes
Electrical Systems:
Electrical diagrams, lighting, instruments, engine control systems, body electrical
Body Chassis:
Body construction, exterior trim, interior trim
Emission Control Systems:
Catalytic converter, EGR system, O2 sensors, evaporative emission control (EVAP) systems.
Procedures Included
Maintenance:
Scheduled maintenance, oil changes, filter replacements, fluid checks and changes, spark plug replacement
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting for various systems
Repair Rebuild:
Detailed step-by-step instructions for component removal, disassembly, inspection, repair, and reassembly
Diagnostics:
Component testing, diagnostic trouble codes (DTCs) if applicable to the era, sensor readings
Wheel Tire Service:
Tire pressure checks, rotation, wheel alignment procedures, wheel bearing service.
Technical Depth
Depth:
Comprehensive, covering basic to advanced repair and diagnostic procedures
Level Of Detail:
Detailed instructions with step-by-step diagrams and illustrations
Special Tools:
Lists specific special tools required for certain procedures
Torque Specs:
Includes precise torque specifications for critical fasteners
Electrical Diagrams:
Complete wiring diagrams for all vehicle systems
Refrigerant Handling:
Procedures for A/C system service, including refrigerant type (likely R12 for this era, requiring specialized handling).
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Likely text-searchable if originally created digitally or scanned with OCR
Zoom:
Yes, zoom in/out functionality
Compatibility:
All versions of Windows & Mac
Requirements:
Adobe PDF Reader & WinZip (for extraction)
Print Quality
Quality:
High resolution for clear diagrams and text
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code And Type:
4G63 (2.0L SOHC I4), 6G71 (3.0L SOHC V6) - Specific engine dependent on trim level.
Performance
Horsepower 2.0L:
Approx. 105-110 hp (varies slightly by market and tuning)
Horsepower 3.0L:
Approx. 140-150 hp
Torque 2.0L:
Approx. 120-125 lb-ft
Torque 3.0L:
Approx. 160-170 lb-ft
Fuel System
Fuel Delivery Type:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline
Other Engine Features
Ignition System:
Electronic ignition with distributor (Distributorless Ignition System - DIS on some later models, but likely distributor for 1991)
Timing Drive:
Timing belt (4G63), Timing belt (6G71)
🔧 Transmission
Standard
Transmission Type Standard:
5-speed Manual Transaxle
Optional
Transmission Type Optional:
4-speed Automatic Transaxle with Overdrive
Features
Automatic Transmission Features:
Electronically controlled, Lock-up torque converter
Fluid Specifications
Manual Transmission Fluid:
API GL-4, SAE 75W-90 or SAE 80W-90 gear oil (refer to manual for exact specification)
Automatic Transmission Fluid:
Mitsubishi Genuine ATF-SP II (or equivalent DEXRON II/III compatible fluid)
📐 Dimensions
Exterior
Length:
Approx. 176.8 inches (4490 mm)
Width:
Approx. 69.1 inches (1755 mm)
Height:
Approx. 55.1 inches (1400 mm)
Wheelbase:
Approx. 100.8 inches (2560 mm)
Weights
Curb Weight:
Approx. 2800-3200 lbs (1270-1450 kg), varies by engine and equipment.
Gross Vehicle Weight Rating:
Typically around 3800-4000 lbs
Cargo
Trunk Volume:
Approximately 14.5 cubic feet (varies)
🛡️ Safety Features
Ratings
NHTSA Ratings:
Data for 1991 models can be scarce; generally, cars of this era had lower safety standards than modern vehicles. No specific 5-star ratings typical.
Active Features
Brakes:
Front disc brakes, Rear drum brakes standard. Optional front and rear disc brakes on higher trims.
ABS:
Anti-lock Braking System (ABS) typically optional, especially on V6 models.
Passive Features
Airbags:
Driver-side airbag often optional or not available on all trims for 1991.
Seatbelts:
3-point front seatbelts, 2-point or 3-point rear seatbelts depending on seating position.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM cassette player, with optional CD player on some higher trims. Basic speaker systems.
Climate Control:
Manual climate control with A/C standard or optional depending on trim. Automatic climate control was rare.
Driver Assistance
Cruise Control:
Optional on most trims.
Connectivity
Connectivity Features:
No modern connectivity features like Bluetooth or USB. Radio antenna is analog.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 - 5,000 miles or 3-6 months, whichever comes first (refer to manual for precise recommendation).
Timing Belt Replacement:
Recommended every 60,000 - 90,000 miles or 5-7 years due to potential for catastrophic engine damage if it fails.
Spark Plug Replacement:
Typically every 30,000 - 60,000 miles depending on plug type (copper vs. platinum).
Fluid Specifications
Engine Oil Specification:
API SG or SH, SAE 10W-30 recommended for most ambient temperatures. Refer to manual for exact viscosity and API rating.
Coolant Specification:
Ethylene glycol based antifreeze, 50/50 mix with distilled water. Green color coolant typical for the era.
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Wear Items:
Suspension bushings, CV joints, oxygen sensors, exhaust components, ignition components (plugs, wires, distributor cap/rotor).
Engine Issues:
Oil leaks from valve cover gaskets or oil pan, timing belt tensioner issues if not replaced on schedule.
Transmission Issues:
Automatic transmission can develop slipping or harsh shifts if fluid is neglected. Clutch wear on manual transmissions.
📚 Vehicle History
Brand Heritage
Mitsubishi Heritage:
Mitsubishi Motors Corporation has a long history in automotive manufacturing, dating back to the 1930s, known for reliable and innovative vehicles.
Model Evolution
Galant Generation:
This 1991 model is part of the fifth generation (E3_A) of the Mitsubishi Galant, which ran from 1987 to 1993. It introduced a more aerodynamic and contemporary design.
Production
Manufacturing Location:
Primarily Japan, with some assembly in other global locations.
🏆 Awards & Recognition
Recognitions
Automotive Press Reviews:
Received positive reviews for styling, ride comfort, and available V6 engine performance for its time. Not a recipient of major 'Car of the Year' awards globally, but respected in its segment.
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