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Mitsubishi Galant 1992-1998 Workshop Service Repair Manual

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The Mitsubishi Galant, produced from 1992 to 1998, represents a significant era in mid-size sedan design, known for its aerodynamic styling and spacious interior. This generation, spanning chassis codes E50...
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Mitsubishi Galant 1992-1998 Workshop Service Repair ManualMitsubishi Galant 1992-1998 Workshop Service Repair ManualMitsubishi Galant 1992-1998 Workshop Service Repair ManualMitsubishi Galant 1992-1998 Workshop Service Repair Manual
The Mitsubishi Galant, produced from 1992 to 1998, represents a significant era in mid-size sedan design, known for its aerodynamic styling and spacious interior. This generation, spanning chassis codes E50 through E80 series, offered a range of efficient 4-cylinder and smooth V6 engines, including the robust 4G63 and 6A12 variants, paired with either a 5-speed manual or an advanced 4-speed INVECS-II automatic transmission. High-performance models like the VR-4, lauded for their handling and technology, earned accolades such as Car and Driver's '10Best' list. The Galant was engineered with a focus on comfort and quietness, making it a competitive choice against contemporaries like the Toyota Camry and Honda Accord, and was manufactured globally in Japan and the USA. This comprehensive workshop service and repair manual provides detailed guidance for the Mitsubishi Galant models from 1992 to 1998. It covers essential maintenance procedures, from routine oil changes and filter replacements to critical timing belt service, along with in-depth troubleshooting and diagnostic strategies for engine, transmission, suspension, brakes, and electrical systems. The manual includes step-by-step repair instructions for component overhaul, electrical testing, and wheel alignment, supported by crucial technical specifications, torque values, and fluid recommendations. This resource is designed to assist owners, mechanics, and technicians in effectively maintaining, diagnosing, and repairing their Galant, ensuring optimal performance and longevity.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Galant
Model Years:
1992, 1993, 1994, 1995, 1996, 1997, 1998
Codes
Chassis Codes:
E50, E60, E70, E80 series
👋 Introduction
Market Position
Segment:
Mid-size sedan
Target Audience:
Families, professionals seeking reliable and comfortable transportation
Competitive Analysis
Key Competitors:
Toyota Camry, Honda Accord, Ford Taurus, Chevrolet Lumina, Nissan Altima
Key Features
Design Philosophy:
Aerodynamic styling, spacious interior, emphasis on comfort and quietness
Powertrain Options:
Choice of efficient 4-cylinder and smooth V6 engines, available with automatic or manual transmissions
Platform Advancements:
Introduction of Mitsubishi's INVECS-II (Intelligent and Innovative Control System) for automatic transmissions on some models
📋 Manual Details
Coverage Areas
Continents Covered:
Global (primarily North America, Europe, Asia)
Regions Covered:
USA, Canada, Europe, Japan, Australia
Page Count
Estimated Pages:
Approximately 1500-2000 (typical for comprehensive service manuals covering multiple years and variants)
Manual Type
Manual Classification:
Workshop Service and Repair Manual
Language
Language:
English
Format
File Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, piston and connecting rod, crankshaft and main bearings, lubrication system, cooling system, fuel system (MPI), ignition system, emission control systems
Engine Performance:
Engine tuning, troubleshooting, diagnostics, performance modifications (basic)
Transmission Manual:
Clutch, manual transmission (5-speed), internal components, removal and installation, overhaul
Transmission Automatic:
Automatic transmission (4-speed INVECS-II), hydraulic control system, valve body, torque converter, removal and installation, overhaul, troubleshooting
Drivetrain:
Front wheel drive, drive shafts, universal joints, differential (integrated with transmission)
Suspension:
Front suspension (MacPherson strut), rear suspension (multi-link), springs, shock absorbers, control arms, bushings, alignment specifications
Steering:
Power steering system, steering gear, steering column, tie rods, power steering fluid specifications
Brakes:
Front disc brakes, rear drum or disc brakes, ABS system (if equipped), brake lines, master cylinder, brake fluid specifications, bleeding procedures
Electrical System:
Battery, charging system (alternator), starting system (starter motor), ignition system, lighting system, horn, wipers, power windows, power mirrors, central locking
Engine Control System:
ECU, sensors (MAP, TPS, O2, ECT, knock), actuators (injectors, idle air control), diagnostic trouble codes (DTCs), OBD-I/OBD-II (early implementation)
Body Interior:
Interior trim, seats, dashboard, door panels, headliner, HVAC controls
Body Exterior:
Body panels, doors, hood, trunk lid, bumpers, glass, seals, exterior trim, corrosion protection
Heating Ventilation Air Conditioning:
HVAC system components, refrigerant, charging, troubleshooting, blower motor, evaporator, condenser
Procedures Included
Routine Maintenance:
Oil changes, filter replacements (oil, air, fuel), spark plug replacement, coolant checks and flushes, brake fluid checks, tire rotations
Troubleshooting Diagnostics:
Systematic fault finding, diagnostic charts, common problem diagnosis, DTC interpretation
Repair Procedures:
Step-by-step instructions for component removal, installation, and overhaul (engine, transmission, suspension, brakes, etc.)
Component Overhaul:
Detailed disassembly and reassembly instructions for major components like engines and transmissions
Electrical Component Testing:
Testing of sensors, actuators, relays, motors, wiring harness continuity checks, voltage and resistance measurements
Wheel Alignment:
Front and rear wheel alignment specifications (camber, caster, toe), adjustment procedures
Body Repair:
Panel replacement, dent repair, rust treatment (basic guidance)
Technical Depth
Depth Of Information:
Comprehensive, suitable for professional technicians and advanced DIY enthusiasts
Diagnostic Tools:
Information on using basic diagnostic tools (multimeter, scan tools for early OBD)
Specifications Data:
Detailed torque specifications, clearances, fluid capacities, electrical values, and diagnostic data
📊 Manual Specifications
File Format
PDF Quality:
High-resolution, searchable text with clear diagrams
Print Quality
Printable:
Yes, designed for printing individual sections or the entire manual
Binding Type
Digital Binding:
N/A (Digital PDF)
Paper Type
Digital Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code Usdm 4Cyl:
4G63 (2.0L SOHC/DOHC)
Engine Code Usdm V6:
6A12 (2.5L V6 SOHC/DOHC)
Engine Code Other Markets 4Cyl:
4G93 (1.8L SOHC/DOHC), 4G63 (2.0L SOHC/DOHC)
Engine Displacement 2.0L:
1997 cc (2.0 Liters)
Engine Displacement 2.5L:
2498 cc (2.5 Liters)
Engine Cylinders Configuration 4Cyl:
Inline 4-cylinder
Engine Cylinders Configuration V6:
V6
Performance
Horsepower 2.0L Sohc:
Approx. 113-135 hp (varies by market and tuning)
Horsepower 2.0L DOHc:
Approx. 145-150 hp (e.g., Galant GS)
Horsepower 2.5L V6 Sohc:
Approx. 160-170 hp
Horsepower 2.5L V6 DOHc:
Approx. 180-200 hp (e.g., Galant VR-4, performance variants)
Torque 2.0L Sohc:
Approx. 125-135 lb-ft
Torque 2.5L V6 Sohc:
Approx. 150-160 lb-ft
Fuel System
Fuel Delivery:
Multi-Point Fuel Injection (MPI)
Fuel Type:
Unleaded Gasoline
Compression Ratio 2.0L:
Approx. 9.5:1 to 10.0:1 (varies by engine variant)
Compression Ratio 2.5L V6:
Approx. 9.0:1 to 9.5:1 (varies by engine variant)
🔧 Transmission
Standard
Standard Transmission Type:
5-Speed Manual
Optional
Optional Transmission Type:
4-Speed Automatic (INVECS-II)
Features
AWD Option:
Yes, available on VR-4 and some other AWD models (e.g., E70 chassis)
Invecs Ii Features:
Adaptive shift control, manual mode (on some high-trim models), sporty shift patterns
Manual Transmission Fluid:
API GL-4 or GL-5, viscosity typically 75W-90 or 80W-90 (Refer to manual for exact spec)
Automatic Transmission Fluid:
Mitsubishi DiaQueen ATF SP-II or equivalent (Refer to manual for exact spec)
📐 Dimensions
Exterior
Length:
Approx. 4720 - 4800 mm (varies by model and market)
Width:
Approx. 1750 - 1780 mm (varies by model and market)
Height:
Approx. 1390 - 1430 mm (varies by model and market)
Wheelbase:
Approx. 2700 mm
Weights
Curb Weight:
Approx. 1350 - 1650 kg (depending on engine and trim)
🛡️ Safety Features
Ratings
NHTSA Front Crash Test:
No specific rating available for all model years/configurations in all markets. Generally considered safe for its era.
Active Features
ABS:
Available on higher trims and optional on many models
Traction Control:
Limited availability on very high-performance models (e.g., AWD variants)
Passive Features
Airbags:
Driver airbag standard on later models, passenger airbag optional or standard on certain trims. Side airbags were not common for this generation.
Seatbelts:
3-point front seatbelts with pretensioners (standard), 3-point rear seatbelts
Child Seat Anchors:
Lower Anchors and Tethers for Children (LATCH) system was not widely implemented in this era, ISOFIX equivalent typically absent.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player and CD player (optional on higher trims). Speaker count varies by trim.
Climate Control:
Manual or Automatic Climate Control (ACC) on higher trims.
Driver Assistance
Cruise Control:
Standard on most trims, optional on base models.
Keyless Entry:
Available on higher trim levels, often as an optional feature.
Connectivity
OBD Interface:
OBD-I (On-Board Diagnostics) system, transitioning to early OBD-II compliance in later model years. The manual will cover diagnostic procedures for both.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000 miles or 6 months (whichever comes first) using synthetic or high-quality conventional oil.
Oil Filter Replacement:
With every oil change
Air Filter Replacement:
Every 15,000 - 30,000 miles or as needed based on driving conditions.
Fuel Filter Replacement:
Every 30,000 - 60,000 miles (depending on fuel quality and type).
Spark Plug Replacement:
Every 30,000 - 60,000 miles for standard plugs, or 60,000 - 100,000 miles for platinum/iridium plugs (refer to manual for specific plug type).
Coolant Flush:
Every 30,000 - 60,000 miles or 2-4 years (using appropriate coolant type).
Timing Belt Replacement:
Every 60,000 - 90,000 miles or 5-7 years (CRITICAL for interference engines like 4G63/6A12). Include tensioner and idler pulleys.
Fluid Specifications
Engine Oil Viscosity:
5W-30 or 10W-30 (API SH or higher). Consult manual for severe service recommendations.
Coolant Type:
Ethylene Glycol based, typically Asian Red or Green (ensure compatibility with original fill). A 50/50 mix with distilled water.
Brake Fluid Type:
DOT 3 or DOT 4. Always use fresh, sealed fluid.
Power Steering Fluid:
ATF Dexron II or III, or specific power steering fluid (check manual).
Known Issues
Engine Mounts:
Can degrade over time, leading to vibration and noise, especially under acceleration.
Automatic Transmission:
INVECS-II transmissions can develop shift quality issues or solenoid problems if not maintained with proper fluid changes.
Suspension Bushings:
Worn control arm bushings can cause steering wander and uneven tire wear.
Radiator And Hoses:
Aging rubber components can lead to coolant leaks and overheating. Regular inspection is crucial.
Power Window Motors:
Motors can fail, leading to unresponsive windows.
Cv Axle Boots:
Torn boots can lead to grease leakage and premature CV joint failure.
📚 Vehicle History
Brand Heritage
Mitsubishi Reputation:
Known for robust engineering, rally heritage (Lancer Evolution), and technological innovation (e.g., GDI, INVECS)
Model Evolution
Generation:
6th Generation Galant (1992-1998)
Platform:
Mitsubishi E Platform (shared with Mitsubishi Eclipse and Eagle Talon in North America)
Key Variants:
LS, ES, GS (performance oriented), VR-4 (high-performance AWD twin-turbo V6)
Production
Production Years Global:
1992-1998
Manufacturing Locations:
Japan (Okazaki Plant), USA (Normal, Illinois Plant - for North American market)
🏆 Awards & Recognition
Recognitions
Car And Driver 10Best:
The Galant VR-4 (all-wheel drive, turbocharged variant) was a frequent contender and recipient of Car and Driver's '10Best' list during its production run for its performance and handling.
Ratings
Consumer Reports Reliability:
Reliability ratings varied by model year and specific engine/transmission combination. The 2.5L V6 and certain transmissions generally received moderate to good ratings, while earlier 4-cylinder models could be very reliable.
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