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Mitsubishi Galant 1990-2000 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Galant Model Generations Covered: Eighth Generation (1993-2003), specifically the years 1990-2000 which encompass the later part of the Seventh Generation (E80/E90, 1987-1993) and...
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Mitsubishi Galant 1990-2000 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Galant
Model Generations Covered:
Eighth Generation (1993-2003), specifically the years 1990-2000 which encompass the later part of the Seventh Generation (E80/E90, 1987-1993) and the initial years of the Eighth Generation.
Codes
Chassis Codes Primarily Covered:
E80 series (Seventh Gen), E84A, E74A, E77A, E75A (Eighth Gen pre-facelift)
Engine Codes Primarily Covered:
4G63 (2.0L SOHC/DOHC MPI), 4G64 (2.4L SOHC MPI), 6A12 (2.0L V6 SOHC MPI), 6A13 (2.5L V6 SOHC MPI)
👋 Introduction
Market Position
Vehicle Class:
Mid-size sedan (family car)
Target Audience:
Families seeking reliable, comfortable, and reasonably priced transportation with optional sporty performance (especially AWD variants).
Competitive Analysis
Key Competitors:
Honda Accord, Toyota Camry, Nissan Altima, Mazda 626, Ford Taurus, Chevrolet Malibu.
Competitive Advantage:
Often offered optional all-wheel drive (AWD) and powerful V6 engines, providing performance and all-weather capability that some competitors lacked or offered at higher price points.
Key Features
Notable Features:
Optional V6 engines, available AWD, comfortable and spacious interior, good value for money, distinctive styling for its era.
Trim Levels Common:
DE, GSL, LS, GS, ES, VR-4 (performance variant, especially on AWD models).
📋 Manual Details
Coverage Areas
Manual Type:
Workshop Service Repair Manual
Language:
English
Format:
PDF
Completeness:
Comprehensive for repair and overhaul
Page Count
Estimated Page Count:
Variable, typically 1500-3000+ pages for full coverage across all engine/trim variants. (Specific count not provided in product info, but based on scope.)
📖 Manual Coverage
Systems Covered
Engine Repair Overhaul:
Yes, including engine mechanicals, cooling, lubrication, fuel injection, ignition, emissions control, and engine diagnostics.
Transmission Repair Overhaul:
Yes, covering both manual (W5M33, F5M33) and automatic (F4A41, F4A42, V4A51) transmissions, including overhaul procedures and hydraulic control.
Drivetrain And Axles:
Yes, including front-wheel drive (FWD) and optional all-wheel drive (AWD) systems, driveshafts, CV joints, and differentials.
Suspension And Steering:
Yes, detailing front (MacPherson strut) and rear (multi-link) suspension components, shock absorbers, springs, bushings, power steering system, and alignment specifications.
Brakes:
Yes, including hydraulic system, ABS (if equipped), brake discs, calipers, pads, master cylinder, and brake fluid specifications.
Electrical System:
Yes, comprehensive coverage of starting and charging system, battery, alternator, starter, lighting, wipers, horn, power windows, mirrors, and comfort features.
Body And Chassis:
Yes, including body panels, doors, hood, trunk, bumpers, glass, interior trim, and basic structural repair considerations.
Heating Ventilation And Air Conditioning:
Yes, covering HVAC system components, refrigerant handling, blower motor, heater core, evaporator, and climate control operation.
Fuel System:
Yes, including fuel tank, fuel pump, fuel lines, fuel filter, fuel injectors, and pressure regulation.
Exhaust System:
Yes, covering exhaust manifolds, catalytic converter, mufflers, and exhaust pipes.
Procedures Included
Routine Maintenance:
Yes, oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection/replacement.
Troubleshooting Diagnostics:
Yes, including diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, and testing procedures for various components.
Major Repair And Rebuild:
Yes, detailed procedures for engine rebuilds, transmission overhauls, and component replacement.
Component Removal Installation:
Yes, step-by-step instructions for removing and installing virtually all major mechanical and electrical components.
Wiring Diagrams:
Yes, typically includes comprehensive electrical wiring diagrams for all systems.
Technical Depth
Depth Of Coverage:
Extremely detailed, covering everything from basic owner maintenance checks to complete engine and transmission rebuilds, including torque specifications, tolerances, and diagnostic procedures.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Typically text-searchable PDF for efficient information retrieval.
Printability:
Printable for physical use in a workshop environment.
Print Quality
Image Clarity:
High resolution images, diagrams, and schematics (dependent on source quality).
Binding Type
Binding Type:
Not applicable (digital format)
Paper Type
Paper Type:
Not applicable (digital format)
⚙️ Engine Specifications
Primary Engine
Base Engine Option:
2.4L 4G64 I4 SOHC MPI
Common Engine Options:
2.0L 4G63 I4 SOHC MPI, 2.0L 6A12 V6 SOHC MPI, 2.5L 6A13 V6 SOHC MPI
Performance Engine Option:
2.5L V6 (6A13) and sportier 4G63 variants (especially in AWD models)
Performance
Horsepower Range:
Approx. 130 HP (2.4L I4) to 175 HP (2.5L V6), with higher outputs for turbocharged variants (e.g., 4G63 in some markets/performance trims).
Torque Range:
Approx. 135 lb-ft (2.4L I4) to 170 lb-ft (2.5L V6).
Fuel System
Fuel Delivery:
Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline (Octane rating as per owner's manual)
Emissions Control:
Catalytic Converter, EGR, EVAP system.
🔧 Transmission
Standard
Standard Transmission Type:
5-speed Manual Transmission (e.g., F5M33, W5M33)
Optional
Optional Transmission Type:
4-speed Automatic Transmission (e.g., F4A41, F4A42, V4A51)
Features
Drivetrain Options:
Front-Wheel Drive (FWD) standard, All-Wheel Drive (AWD) optional on select models/trims.
Transmission Fluid Type:
Refer to manual for specific grades (e.g., DiaQueen ATF SP-III for automatics, GL-4 or GL-5 gear oil for manuals).
📐 Dimensions
Exterior
Length:
Approx. 185-188 inches (depending on specific model/trim)
Width:
Approx. 69-70 inches
Height:
Approx. 56-57 inches
Weights
Curb Weight Range:
Approx. 3100-3500 lbs (depending on engine and drivetrain)
Wheelbase:
Approx. 105-107 inches
Cargo
Trunk Capacity:
Approx. 15-16 cubic feet (typical for mid-size sedan)
🛡️ Safety Features
Ratings
NHTSA Crash Test Ratings:
Information varies by year and specific test configuration. Early 90s standards differ from later years. The manual will detail vehicle-specific safety features but not necessarily aggregated NHTSA ratings.
Active Features
ABS:
Available on most models, especially higher trims and later years.
Traction Control:
Less common, but potentially available on higher performance AWD models.
Passive Features
Airbags:
Driver and passenger airbags became standard during this generation. Manual will cover their systems.
Seat Belts:
3-point seat belts with pretensioners available.
Child Seat Anchors:
LATCH systems were not standard in this era; manual will detail any ISOFIX or equivalent provisions.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM/Cassette or CD player, often with optional premium sound systems (e.g., Rockford Fosgate on some trims).
Display Systems:
Basic analog gauges, climate control display. No integrated navigation or complex digital displays of the era.
Driver Assistance
Cruise Control:
Standard on most models.
Anti Lock Brakes:
Optional on many models, standard on higher trims/later years.
Connectivity
Phone Integration:
None from factory. Aftermarket solutions available.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,750 to 7,500 miles or 6-12 months, depending on oil type and driving conditions (refer to manual for precise recommendations).
Air Filter Replacement:
Recommended every 15,000-30,000 miles or as needed based on inspection.
Spark Plug Replacement:
Typically 60,000-100,000 miles for iridium/platinum plugs, less for standard copper plugs. Manual will specify type and interval.
Timing Belt Replacement:
Crucial for 4G6x engines. Recommended every 60,000-90,000 miles or 5-7 years. Failure can cause catastrophic engine damage.
Fluid Specifications
Engine Oil Capacity:
Approx. 4.5-5.5 quarts (4.3-5.2 liters) for 4-cylinder, 5.0-6.0 quarts (4.7-5.7 liters) for V6, depending on engine. Manual specifies exact amounts.
Engine Oil Viscosity:
Commonly 5W-30 or 10W-30, depending on climate and engine. Refer to manual for precise specification.
Coolant Type:
Ethylene glycol-based coolant (e.g., green or a specified Mitsubishi pink/red coolant). Manual will detail capacity and type.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid. Manual specifies exact type and capacity.
Known Issues
Common Problems Engine:
Timing belt failure (if not replaced), oil leaks from valve cover or oil pan gaskets, occasional head gasket issues on high-mileage units.
Common Problems Transmission:
Automatic transmission solenoid failures, torque converter issues. Manual transmission clutch wear.
Common Problems Suspension Steering:
Worn ball joints, tie rod ends, and control arm bushings due to age and mileage. Power steering pump leaks.
Common Problems Electrical:
Window regulator failures, dashboard warning light issues, minor sensor failures (e.g., crank/cam position sensors).
Part Numbers Example
Timing Belt Kit Part Number:
Example: Mitsubishi Part Number MD182280 (timing belt for 4G63). Manual will list exact PNs.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors History:
Mitsubishi Motors is a Japanese multinational automotive manufacturer, known for its diverse range of vehicles from small cars to trucks and SUVs. The Galant has been a significant model in its lineup for decades.
Model Evolution
Seventh Gen To Eighth Gen Transition:
The 1990-2000 period covers the tail end of the E80/E90 (Seventh Generation) and the beginning of the E80/E90 (Eighth Generation, launched in 1993). The manual bridges this important generational shift.
Eighth Gen Design:
The Eighth Generation Galant (starting 1993) featured a more rounded and aerodynamic design compared to its predecessor.
Production
Manufacturing Locations:
Primarily Japan, with some assembly in other international locations.
Market Focus:
Strong presence in North America, Europe, and Asia.
🏆 Awards & Recognition
Recognitions
Decade Discounts:
While specific awards for the 1990-2000 Galant are less prominent than later models, it was generally well-regarded for its value, comfort, and available AWD system in its segment.
Ratings
Consumer Reports Reputation:
Varied by year, but generally seen as a solid, reliable option with some competitive advantages in performance for the price point.
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