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Mitsubishi Galant 1988-1992 Full Service Repair Manual

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The Mitsubishi Galant, spanning generations E3_A, E3_3A, and E3_5A with chassis codes E33A, E35A, E38A, and E39A, represents a significant entry in the mid-size sedan and coupe market from 1988...
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Mitsubishi Galant 1988-1992 Full Service Repair ManualMitsubishi Galant 1988-1992 Full Service Repair ManualMitsubishi Galant 1988-1992 Full Service Repair ManualMitsubishi Galant 1988-1992 Full Service Repair Manual
The Mitsubishi Galant, spanning generations E3_A, E3_3A, and E3_5A with chassis codes E33A, E35A, E38A, and E39A, represents a significant entry in the mid-size sedan and coupe market from 1988 to 1992. This vehicle offered a range of engine options, including the robust 4G63 (naturally aspirated and turbocharged) and the smooth 6G71 V6, paired with either a 5-speed manual or 4-speed automatic transmission. Known for its aerodynamic styling and advanced chassis technologies for its time, such as optional All-Wheel Drive, the Galant competed effectively with contemporaries like the Honda Accord and Toyota Camry. Its engineering quality and the availability of performance-oriented variants, particularly those featuring the turbocharged 4G63T engine, contributed to its appeal. This comprehensive service and repair manual, presented in English, covers the Mitsubishi Galant models from 1988 through 1992. With over 1000 pages of detailed information, it serves as an indispensable resource for owners, technicians, and mechanics. The manual provides in-depth guidance on scheduled maintenance, engine and transmission overhauls, brake and suspension servicing, and electrical system diagnostics. It includes essential technical specifications, troubleshooting procedures, detailed wiring diagrams, torque values, and component tolerances, enabling effective diagnosis, repair, and maintenance to ensure the longevity and optimal performance of the vehicle.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Galant
Model Generations Covered:
E3_A, E3_3A, E3_5A
Codes
Chassis Codes Covered:
E33A, E35A, E38A, E39A
Engine Codes Covered:
4G37, 4G61, 4G63, 4G63T (likely for AWD performance models), 6G71
👋 Introduction
Market Position
Era Positioning:
Mid-size family sedan/coupe, competing with Honda Accord, Toyota Camry, Ford Tempo, Chevrolet Celebrity
Competitive Analysis
Key Competitors:
Honda Accord, Toyota Camry, Nissan Maxima, Ford Taurus, Chevrolet Lumina
Key Features
Platform Variant:
Often featured advanced chassis technologies for its time, including multi-link rear suspension and optional All-Wheel Drive (AWD)
Engine Options Variety:
Offered a range of 4-cylinder and V6 engines, including performance-oriented turbocharged variants for some models
Design Evolution:
Marked a significant stylistic departure with more aerodynamic and modern styling compared to previous generations
📋 Manual Details
Coverage Areas
Years Covered:
1988, 1989, 1990, 1991, 1992
Page Count
Estimated Page Count:
1000+
Manual Type
Manual Type:
Full Service & Repair Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine overhaul, cylinder head, block assembly, lubrication, cooling, fuel, ignition, exhaust, emissions
Engine Management:
ECU, sensors, actuators, diagnostics, fuel injection, ignition timing
Transmission Manual:
Clutch, gearbox overhaul, shifting mechanisms, drive shafts
Transmission Automatic:
Automatic transmission overhaul, hydraulic control, torque converter, electronic control units
Drivetrain AWD:
Center differential, transfer case, rear differential (for AWD models)
Suspension:
Front and rear suspension geometry, components, alignment, shock absorbers, springs, bushings
Steering:
Power steering system, rack and pinion, steering column, wheel alignment
Brakes:
Front and rear brake systems (disc/drum), ABS (if equipped), parking brake, hydraulic components, fluid specifications
Electrical System:
Battery, charging system, starting system, lighting, fuses, relays, wiring diagrams, body electricals
HVAC:
Heating, ventilation, air conditioning system components, refrigerant, servicing
Body And Interior:
Body panel removal and installation, interior trim, glass, doors, latches, seats
Procedures Included
Scheduled Maintenance:
Oil changes, filter replacements, spark plugs, timing belts, fluid checks and changes
Troubleshooting:
Diagnostic charts, symptom-based fault finding, common problem solutions
Engine Repair:
Piston ring replacement, bearing service, valve adjustments, head gasket replacement, timing belt replacement
Transmission Overhaul:
Complete disassembly and reassembly of manual and automatic transmissions
Brake Service:
Brake pad/shoe replacement, rotor/drum resurfacing or replacement, caliper overhaul, bleeding procedures
Electrical Diagnostics:
Using multimeters, oscilloscopes, tracing short circuits, open circuits, diagnosing sensor failures
Suspension Alignment:
Adjustment procedures for camber, caster, toe
Ac Service:
Refrigerant charging, leak detection, component replacement
Bodywork Repair:
Panel replacement, dent repair, rust treatment
Technical Depth
Depth:
Comprehensive: from basic maintenance to full engine and transmission rebuilds, detailed electrical schematics
Diagnostic Information:
Detailed diagnostic trouble codes (DTCs) and troubleshooting flows
Torque Specifications:
Precise torque values for all critical fasteners
Tolerances:
Engine and transmission component wear tolerances for rebuilding
Wiring Diagrams:
Complete and detailed electrical system wiring diagrams
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text content
Print Quality
Printability:
Printable pages
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Quality:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine 1 Code:
4G63
Engine 1 Type:
2.0L DOHC 16-valve Inline-4 (Naturally Aspirated and Turbocharged)
Engine 1 Displacement Cc:
1997
Engine 1 Hp Na:
~140-155 hp
Engine 1 Hp Turbo:
~190-200 hp (GSi/GT models)
Engine 1 Torque Nm Na:
~175-185 Nm
Engine 1 Torque Nm Turbo:
~255-260 Nm
Optional Engine
Engine 2 Code:
6G71
Engine 2 Type:
2.5L SOHC 24-valve V6
Engine 2 Displacement Cc:
2496
Engine 2 Hp:
~150-160 hp
Engine 2 Torque Nm:
~200-210 Nm
Performance
Performance Engine Options:
Available with naturally aspirated 4-cylinder, turbocharged 4-cylinder (4G63T), and V6 engines
Fuel System
Fuel Delivery:
Multi-point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Octane Rating Recommended:
87 AKI (for NA engines), 91 AKI (for Turbocharged engines)
🔧 Transmission
Standard
Standard Transmission:
5-speed Manual
Optional
Optional Transmission:
4-speed Automatic (with Lock-up)
Features
AWD Availability:
Available on certain trim levels, typically with the 4G63T engine (e.g., AWD GSR/GT models)
Clutch Type:
Hydraulically actuated dry single plate clutch
📐 Dimensions
Exterior
Length Mm:
~4545 - 4610
Width Mm:
~1710 - 1735
Height Mm:
~1395 - 1415
Wheelbase Mm:
~2600
Track Width Front Mm:
~1450
Track Width Rear Mm:
~1455
Weights
Curb Weight Kg:
~1250 - 1450
Gross Vehicle Weight Rating Kg:
~1750 - 1900
🛡️ Safety Features
Ratings
NHTSA Ratings:
Not extensively tested by modern standards; likely had basic front impact protection.
Active Features
ABS:
Optional Anti-lock Braking System (ABS) on some models
Passive Features
Airbags:
Driver-side airbag standard on later models (1991/1992), optional earlier.
Seatbelts:
Three-point seatbelts with pretensioners (driver/passenger)
Rollover Protection:
Reinforced body structure
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player, optional CD player on higher trims
Speaker Configuration:
Typically 4 or 6 speaker systems
Driver Assistance
Cruise Control:
Standard on many trim levels
Anti Lock Brakes:
Optional, as mentioned in safety
Connectivity
No Modern Connectivity:
No Bluetooth, USB, or smartphone integration; analog systems only.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 3,000-5,000 miles or 6 months, whichever comes first (using recommended oil type)
Engine Oil Filter Replacement:
With every oil change
Timing Belt Replacement:
Every 60,000 miles or 4 years (critical for 4G63/6G71 engines to prevent catastrophic failure)
Spark Plug Replacement:
Every 30,000-60,000 miles depending on plug type (e.g., platinum vs. standard)
Coolant Flush:
Every 2 years or 30,000 miles
Transmission Fluid Change:
Manual: Every 60,000 miles; Automatic: Every 30,000-50,000 miles (depending on driving conditions)
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 5W-30 or 10W-30 (check owner's manual for specific viscosity based on temperature)
Engine Oil Capacity Liters:
~4.0 - 4.5 (depending on engine)
Coolant Type:
Ethylene Glycol based antifreeze (e.g., Mitsubishi DiaQueen Super Long Life Coolant or equivalent)
Brake Fluid Type:
DOT 3 or DOT 4
Power Steering Fluid Type:
Dexron II or equivalent ATF
Manual Transmission Fluid Type:
API GL-4, SAE 75W-90 (or specified viscosity)
Automatic Transmission Fluid Type:
Dexron II or equivalent ATF
Known Issues
Engine:
Timing belt failure (critical maintenance), oil leaks from seals, some issues with ignition system components (e.g., distributor cap/rotor on older models).
Suspension:
Worn ball joints, tie rod ends, and bushings due to age and mileage; strut mounts can degrade.
Electrical:
Corroded ground points, aging wiring harnesses, failing window regulators, HVAC blower motor resistor failures.
Rust:
Common rust areas include wheel wells, rocker panels, and subframes, especially in areas with harsh winters.
Part Numbers
Timing Belt Kit Example:
e.g., Gates TCK186 (verify for specific engine)
Oil Filter Example:
e.g., Fram PH5793 or Wix 51515 (verify for specific engine)
📚 Vehicle History
Brand Heritage
Mitsubishi History:
Mitsubishi Motors, a division of the Mitsubishi Group, has a long history in automotive manufacturing known for innovation and reliability.
Model Evolution
Previous Generation:
E10 Series Galant (1983-1987)
Subsequent Generation:
8th Generation Galant (1993-1998)
Design Inspiration:
The E30 Galant featured aerodynamic styling heavily influenced by the Lancer FTO concept car and shared platforms with other Mitsubishi models.
Production
Production Period:
1987-1993
Manufacturing Plants:
Primarily Japan (e.g., Mizushima Plant), with some assembly in other global locations.
🏆 Awards & Recognition
Recognitions
Awards History:
While specific major awards are scarce for this particular generation, the Galant series consistently received praise for its value and reliability in its class.
Ratings
Consumer Ratings:
Generally positive for its era, often cited for solid engineering and durable powertrains, especially the 4G63 engine.
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