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Mitsubishi Galant 1993-1996 Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Galant Year: 1993-1996 Codes Chassis Codes: E33A, E34A, E35A, E38A, E39A, E55A, E75A, E77A, E88A Platform: Galant E30 Series (often referred to as...
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Mitsubishi Galant 1993-1996 Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Galant
Year:
1993-1996
Codes
Chassis Codes:
E33A, E34A, E35A, E38A, E39A, E55A, E75A, E77A, E88A
Platform:
Galant E30 Series (often referred to as the E30 chassis, though specific sub-designations apply)
👋 Introduction
Market Position
Segment:
Mid-size Sedan / Coupe
Target Audience:
Consumers seeking a reliable, practical, and often performance-oriented vehicle for daily driving and spirited use.
Competitive Analysis
Key Competitors:
Toyota Camry, Honda Accord, Nissan Altima, Ford Taurus, Chevrolet Lumina, Mazda 626.
Key Features
Powertrain Options:
Available in both fuel-efficient 4-cylinder and potent V6 engine configurations, often with all-wheel drive (AWD) on higher trims.
Design Philosophy:
Aerodynamic styling, comfortable interior, and a balance of performance and practicality.
📋 Manual Details
Coverage Areas
Systems Covered:
Engine Mechanical, Engine Fuel & Emission Control, Engine Cooling, Engine Lubrication, Ignition System, Starting System, Charging System, Clutch, Manual Transmission, Automatic Transmission, Front Axle, Rear Axle, Driveshafts, Suspension (Front & Rear), Steering System, Brake System (Front & Rear), Parking Brake, Wheels & Tires, Body (Exterior & Interior), Electrical System (Wiring Diagrams, Lighting, Accessories), HVAC System, Cruise Control, Safety Systems (SRS Airbag if equipped), Diagnosis and Troubleshooting.
Page Count
Estimated Page Count:
Approximately 1500-2000 pages (typical for comprehensive factory service manuals of this era)
Manual Type
Manual Type:
Factory Service Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF
File Format:
PDF
Print Quality:
High-resolution scans suitable for printing, ensuring legibility of text and diagrams.
Binding Type:
N/A (Digital PDF Format)
Paper Type:
N/A (Digital PDF Format)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed overhaul procedures, cylinder head, block assembly, crankshaft, connecting rods, pistons, camshafts, valve train, timing belt/chain replacement, torque specifications.
Fuel And Emission Control:
Fuel injection system (MPI), fuel pump, injectors, fuel pressure regulator, throttle body, exhaust system, catalytic converter, oxygen sensors, evaporative emission control (EVAP).
Electrical System:
Complete wiring diagrams for all circuits, lighting, power windows, locks, mirrors, wipers, horn, audio system, fuses, relays, battery, starter, alternator.
Procedures Included
Maintenance Procedures:
Scheduled maintenance intervals, oil changes, filter replacements, spark plug replacement, coolant flush, brake fluid change, accessory belt replacement, tire rotation and balancing.
Repair Procedures:
Engine rebuild, transmission overhaul, suspension component replacement, brake caliper and rotor replacement, steering rack repair, body panel repair, electrical component diagnosis and replacement.
Troubleshooting Guides:
Systematic diagnostic flowcharts for common drivability issues, electrical faults, cooling system problems, and transmission performance.
Technical Depth
Diagnostic Capabilities:
Advanced diagnostics, including OBD-I codes (for applicable models/years) and detailed interpretation of sensor data, circuit testing with multimeters and oscilloscopes.
Rebuild Procedures:
Complete engine and transmission rebuild instructions with detailed component specifications, clearances, and torque values for critical fasteners.
⚙️ Engine Specifications
Primary Engine
Engine 1 Code:
4G63 (2.0L SOHC)
Engine 1 Displacement:
1997 cc
Engine 1 Configuration:
Inline-4, DOHC
Engine 1 Horsepower:
Approx. 135-145 hp @ 6000 rpm (depending on market and specific tune)
Engine 1 Torque:
Approx. 130-140 lb-ft @ 4000 rpm
Engine 1 Fuel System:
Multi-Point Fuel Injection (MPI)
Optional Engine
Engine 2 Code:
6G72 (3.0L SOHC V6)
Engine 2 Displacement:
2972 cc
Engine 2 Configuration:
V-6, SOHC
Engine 2 Horsepower:
Approx. 160-170 hp @ 5500 rpm
Engine 2 Torque:
Approx. 175-185 lb-ft @ 4500 rpm
Engine 2 Fuel System:
Multi-Point Fuel Injection (MPI)
🔧 Transmission
Standard
Transmission Type Std:
5-Speed Manual Transmission
Optional
Transmission Type Opt:
4-Speed Automatic Transmission with Lock-up Torque Converter
Features
AWD Option:
Available on select models and trims (e.g., VR-4, AWD variants), utilizing Mitsubishi's 'Advanced All-Wheel Drive' system.
📐 Dimensions
Exterior
Length:
Approx. 4660-4730 mm (183.5-186.2 in) (depending on body style and market)
Width:
Approx. 1700-1720 mm (66.9-67.7 in)
Height:
Approx. 1380-1400 mm (54.3-55.1 in)
Wheelbase:
Approx. 2600 mm (102.4 in)
Weights
Curb Weight:
Approx. 1300-1500 kg (2866-3307 lbs) (depending on engine and drivetrain)
🛡️ Safety Features
Ratings
NHTSA Driver Side Impact:
Not extensively rated by NHTSA for these specific years in most markets. Early airbag systems were optional or standard on higher trims.
Passive Features
Airbags:
Driver-side airbag (standard on later models/trims, optional on earlier ones). Passenger airbag generally not available or very rare.
Seatbelts:
3-point front seatbelts with pretensioners (on some models/years), 3-point rear seatbelts.
Body Structure:
Reinforced safety cell, front and rear crumple zones.
💡 Technology Features
Infotainment
Audio System:
Factory-installed AM/FM stereo with cassette player. Optional CD player available on some trims. Basic speaker configurations.
Climate Control:
Manual climate control with A/C and heater. Automatic climate control might have been available on premium trims.
Driver Assistance
Cruise Control:
Electronically controlled cruise control system available on most models.
Anti Lock Brakes:
Anti-lock Braking System (ABS) available as an option or standard on higher trims.
Connectivity
Original Connectivity:
Limited to basic radio and cassette/CD playback. No integrated Bluetooth or smartphone connectivity.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first, depending on driving conditions and oil type.
Engine Oil Filter Replacement:
At every oil change.
Air Filter Replacement:
Every 15,000-30,000 miles (24,000-48,000 km) or as needed based on driving environment.
Spark Plug Replacement:
Every 30,000-60,000 miles (48,000-96,000 km) depending on plug type (copper vs. platinum).
Timing Belt Replacement:
Every 60,000-90,000 miles (96,000-144,000 km) or 5-7 years for 4G63 engines (critical replacement interval to prevent catastrophic engine damage).
Fluid Specifications
Engine Oil Type:
API SG or higher; Viscosity: SAE 10W-30 or 10W-40 recommended. Consult manual for specific temperature ranges.
Coolant Type:
Ethylene glycol based antifreeze, mixed 50/50 with distilled water. Typically green coolant.
Automatic Transmission Fluid Type:
Dexron II or equivalent.
Power Steering Fluid Type:
Dexron II or equivalent.
Brake Fluid Type:
DOT 3.
Known Issues
Common Problem Engine Mounts:
Degradation of engine and transmission mounts leading to increased vibration and noise.
Common Problem Suspension Components:
Wear in ball joints, tie rod ends, and bushings due to age and mileage, affecting handling and ride quality.
Common Problem Cooling System:
Leaking radiators, hoses, and water pumps due to material degradation over time.
Common Problem Electrical Connectors:
Corrosion in electrical connectors, especially those exposed to moisture, leading to intermittent faults.
Common Problem Timing Belt Failure:
Critical to replace the timing belt and tensioner/idler pulleys at recommended intervals on the 4G63 engine to avoid severe internal engine damage (interference engine).
📚 Vehicle History
Brand Heritage
Mitsubishi Motors Legacy:
Mitsubishi Motors has a long history of engineering innovation, particularly in areas like four-wheel drive technology (e.g., Pajero) and performance vehicles (e.g., Lancer Evolution).
Model Evolution
E30 Generation:
The E30 generation Galant (1987-1993 in most markets, with overlap into 1993 for some regions) was a significant departure from its predecessors, featuring more aerodynamic styling and advanced technology. The 1993-1996 models represent a facelift and continuation of this E30 platform with updated styling and features. Note: Some markets might transition to the E33/E34/E35/E38/E39 chassis code for this period.
Facelift:
The 1993-1996 period often refers to the facelifted E30 series, which introduced revised front and rear styling, updated interior trim, and potentially new feature packages. It's crucial to distinguish this from the subsequent E33/E50 series Galant introduced in late 1992 for the 1993 model year in North America, which had a completely different chassis.
Production
Manufacturing Locations:
Primarily Japan (e.g., Mizushima Plant).
Production Years Global:
1987-1993 (E30 generation globally, with variations in model year introduction/end dates).
🏆 Awards & Recognition
Recognitions
Performance Awards:
While the standard Galant models were generally praised for reliability and value, performance-oriented variants (like the potential early precursors to the VR-4) garnered attention for their handling and powertrain technology.
Ratings
Consumer Reports Reliability:
Generally rated as average to good for reliability during its production run, though specific issues like timing belts and certain electrical components required attention.
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