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1989 Mitsubishi Galant Service Repair Manual.pdf
1. BACKUP
Service Manual
GRLRNT
1989-1990-1991-1992-1993
Volume 1
Chassis & Mechanical
FOREWORD
This Service Manual has been prepared with the
latest service information available at the time of
publication. It is subdivided into various group cate-
gories and each section contains diagnostic, dis-
assembly, repair, and installation procedures along
with complete specifications and tightening ref-
erences. Use of this manual will aid in properly per-
forming any servicing necessary to maintain or res-
tore the high levels of performance and reliability
designed into these outstanding vehicles.
This BACKUP DSM manual is to be used DNLY as a SACKUP. please DIJ NOT REDISTRIBUTE
WHOLE SECTIONS. This BACKUP was sold to you under the fact that you do indeed DWN
a GENUINE DSM MANUAL. It CANNOT BE considered a REPLACEMENT (Unless your original
manual was lost or destroyed.)
Please See README.TXT or README.HTML for additional information.
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WE SUPPORT
VOLUNTARY TECHNICIAN
CERTIFICATION THROUGH
Nallonal lnsrltule for
AU~~~v3~;VPCT:VE
EXCELLENCE
naiLcorn
MITSUBISHI
MOTOR SALES OF AMERICA. Inc.
Mltsublshl Motors Corporat!on reserves the right to make changes in
design or to make additions to or Improvements In Its products wlthout
~mposng any obllgatlons upon Itself to install them on its products
previously manufactured
0 1992 Mitsubishi Motors Corporation RcprintedinUSA
GROUP INDEX MOOAA-
General .........................................................
Engine ...........................................................
Fuel ................................................................
Cooling .........................................................
Intake and Exhaust ..............................
Emission Control ....................................
Clutch ............................................................
Manual Transaxle ..................................
Automatic Transaxle ............................
Propeller Shaft ........................................
Front Axle ..................................................
Rear Axle ....................................................
Wheel and Tire .......................................
Power Plant Mount ..............................
Front Suspension ...................................
Active-Electronic
Control Suspension
..............................
m
A
Rear Suspension .................................... &
Service Brakes .........................................
Parking Brakes ........................................
Alphabetical Index .................................
NOTE: Electrical system Information is contained in
Volume 2 “Electrical” of this paired Service Manual.
For overhaul procedures of engines or transmissions,
refer to the separately issued Engine Service Manual
or Manual/Automatic Transmission Service Manual.
2. 00-l
GENERAL
CONTENTS
GENERAL DATA AND SPECIFICATIONS ..... 23
HOW TO USE THIS MANUAL ...................... 3
Definition of Terms ...................................... 3
Explanation of Circuit Diagrams .................. 7
Explanation of Manual Contents ................. 4
Explanation of the Troubleshooting
Guide ............................................................. 6
Model Indications ......................................... 3
Scope of Maintenance, Repair and
Servicing Explanations .................................. 3
Troubleshooting ............................................. 3
LUBRICATION AND MAINTENANCE ............ 34
MAINTENANCE SERVICE ........ ....................... 39
Air Cleaner Element ..................................... 39
Automatic Transaxle ..................................... 43
Ball Joint and Steering Linkage Seals ........ 45
Brake Hoses ................................................. 45
Disc Brake Pads ........................................... 44
Drive Belt (For Water Pump and
Generator) ....................................................... 41
Drive Shaft Boots ......................................... 45
Engine Coolant ............................................. 44
Engine Oil ..................................................... 41
Engine Oil Filter ........................................... 41
Exhaust System ............................................ 45
Fuel Hoses ................................................... 39
Fuel System ................................................. 39
Manual Transaxle .......................................... 42
Rear Axle ...................................................... 45
Rear Drum Brake Linings and
Rear Wheel Cylinders .................................. 44
Spark Plugs ................................................... 40
Timing Belt ................................................... 40
MASTER TROUBLESHOOTING ..................... 28
PRECAUTIONS BEFORE SERVICE ................ 15
RECOMMENDED LUBRICANTS AND
LUBRICANT CAPACITIES TABLE .................. 35
SCHEDULED MAINTENANCE TABLE ........... 38
SPECIAL HANDLING INSTRUCTIONS
FOR AWD MODELS ....................................... 20
TABLE OF MAIN SEALANTS
AND ADHESIVES ............................................ 46
TIGHTENING TORQUE ................................... 27
TOWING AND HOISTING .............................. 17
VEHICLE IDENTIFICATION ............................. 8
Chassis Number ........................................... 11
Engine Model Stamping ............................... 12
Theft Protection ............................................ 12
Vehicle Identification Code Chart Plate.. ..... 8
Vehicle Identification Number List .............. 8
Vehicle Identification Number Location ....... 8
Vehicle Information Code Plate ................... 1 1
Vehicle Safety Certification Label ................ 12
3. GENERAL - How to Use This Manual 00-3
HOW TO USE THIS MANUAL MOOBMTO
SCOPE OF MAINTENANCE, REPAIR AND DEFINITION OF TERMS
SERVICING EXPLANATIONS STANDARD VALUE
This manual provides explanations, etc. concerning
procedures for the inspection, maintenance, repair
and servicing of the subject model. Unless other-
wise specified, each service procedure covers all
models. Procedures covering specific models are
identified by the model codes, or similar designation
(engine type, transaxle type, etc.). A description of
these designations is covered in this unit under
“VEHICLE IDENTIFICATION”.
SERVICE ADJUSTMENT PROCEDURES
“Service Adjustment Procedures” are procedures
for performing inspections and adjustments of
particularly important locations with regard to the
construction and for maintenance and servicing, but
other inspections (for looseness, play, cracking,
damage, etc.) must also be performed.
SERVICE PROCEDURES
The service steps are arranged in numerical order
and attentions to be paid in performing vehicle
service are described in detail in SERVICE POINTS.
TROUBLESHOOTING
Troubleshootinqs are classified into master trou-
bleshooting and group troubleshooting and located
as follows:
The master troubleshooting is prepared when the
trouble symptom relates to two or more groups and
given in MASTER TROUBLESHOOTING.
The group troubleshooting guide is prepared for
causes of problems related to that individual group
only; a troubleshooting guide is prepared for each
appropriate group.
Indicates the value used as the standard for judging
the quality of a part or assembly on inspectian or the
value to which the part or assembly is corrected and
adjusted. It is given by tolerance.
LIMIT
Shows the standard for judging the quality of a part
or assembly on inspection and means the maximum
or minimum value within which the part or assembly
must be kept functionally or in strength. It is a value
established outside the range of standard value.
REFERENCE VALUE
Indicates the adjustment value prior to starting the
work (presented in order to facilitate assembly and
adjustment procedures, and so they can be com-
pleted in a shorter time).
CAUTION
Indicates the presentation of information particularly
vital to the worker during the performance of
maintenance and servicing procedures in order to
avoid the possibility of injury to the worker; or
damage to component parts, or a reduction of
component or vehicle function or performance, etc.
MODEL INDICATIONS
The following abbreviations are used in this manual for classification of model types.
M/T . Indicates the manual transaxle, or models equipped with the manual transaxle.
A/T: indicates the automatic transaxle, or models equipped with the automatic transaxle.
MFI: Indicates the multiport fuel injection, or engines equipped with the multiport fuel injection.
SOHC: Indicates an engine with the single overhead camshaft, or a model equipped with such an
engine.
DOHC: Indicates an engine with the double overhead camshaft, or a model equipped with such an
engine.
Turbo: Indicates an engine with turbocharger, or a model equipped with such an engine.
Non-Turbo: Indicates an engine without turbocharger, or a model equipped with such an engine.
FWD: Indicates the front wheel drive vehicles.
AWD: Indicates the all wheel drive vehicles.
ABS: Indicates the anti-lock braking system or models equipped with the anti-lock braking system.
4. 00-4 GENERAL - How to Use This Manual
EXPLANATION OF MANUAL CONTENTS
Indicates procedures to
be performed before the
work in that section is
started, and procedures
to be performed after
the work in that section
is finished.
Maintenance and Servicing Procedures
(1) A diagram of the component parts is
provided near the front of each section in
order to give the reader a better under-
standing of the installed condition of
component parts.
(2) The numbers provided within the diagram
indicate the sequence for maintenance
and servicing procedures; the symbol m
indicates a non-reusable part; the tighten-
ing torque is provided where applicable.
l Removal steps:
The part designation number corres-
ponds to the number in the illustration
to indicate removal steps.
l Disassembly steps:
The part designation number corres-
ponds to the number in the illustration
to indicate disassembly steps.
l Installation steps:
Specified in case installation is impossi-
ble in reverse order of removal steps.
Omitted if installation is possible in
reverse order of removal steps.
8 Reassembly steps:
Specified in case reassembly is im-
possible in reverse order of disassem-
bly steps.
Omitted if reassembly is possible in
reverse order of disassembly steps.
Classifications of Major Maintenance/
Service Points
When there are major points relative to mainte-
nance and servicing procedures (such as essential
maintenance and service points, maintenance and
service standard values, information regarding the
use of special tools, etc.), these are arranged
together as major maintenance and service points
and explained in detail.
*+ : Indicates that there are essential points for
removal or disassembly.
I)+ : Indicates that there are essential points for
installation or reassembly.
necessary. In this exam-
ple, sealant is applied
(where indicated) to the
I---
Symbols for Lubrication, Sealants and
Adhesives
4 . . . . . Grease
(multipurpose grease unless there is
Information concerning the locations for lubrica-
tion and for application of sealants and adhesives
is provided, by using symbols, in the diagram of
component parts or on the page following the
component parts page, and explarned.
a brand or type specified)
4 . . . . Sealant or adhesive
a
..... Brake fluid. automatic transmission
fluid or air conditioner compressor oil
a . . . . . Engine oil or gear oil
. . . Adhesive tape or butyl rubber tape
5. GENERAL - How to Use This Manual
QfitIIICQ CTEEQINC CFAR RnY ..^-
TV..&” Y.LLI.II.Y Y_.. w-1.
REMOVAL AND INSTALLATION
1, Jpn assemble and gear box connecting
2 Connectlo” for return tube
3 Connectm for pressure hose
4 cotter P!”
6 T!e-rod end and knuckle connecting
I
J rl”.#l ~“,. dLlrr_. ..__
10. Center member rear mouniing bou
11, Front exhaust p’pe
4. H 12. Gear box assembly
. . 13. Mounting rubber
Denotes non-re-
p
u s a b l e p a r t .
Y.T-*c As..
- 6
Repair kit or set parts are shown.
(Only very frequently used parts
Operating procedures, cautions,
I
I
-’ iY,W1
1 ’
etc. on removal, installation, dis-
se&an: 3rM&rr&paNo.~3W
[scribed, ,
~ 1
assembly and reassembly are de-
37A-24 STEERING - NINA Steering Gear Box
-
SERVICE POINTS OF REMOVALJ ll37?kM
6. DlSCONNECllON OF TIEROD END
Using the special tool, disconnect the tie rod from the
knuckle.
ceurion
1 . Besretotiethewrdofthespeciaitodtomen
P-.
2. Loosenthenutbutdonotremoveit.
12. REMOVAL OF GEAR BOX ASSEMBLY
Thus number corresponds to the
number ?pyi:,“~&‘R~;;?I
steps”,
“Installation s t e p s ” o r “Reas-
semblv steps”.
/ LUBRlCATlON AND SEALING POINTS-
The title of the page (fOilOWing
the page on which the diagram of
component parts is presented)
indicating the locations of lubnca-
tion and sealing procedures.
6. 00-6 GENERAL - How to Use This Manual
EXPLANATION OF THE TROUBLESHOOTING GUIDE
Indicates con-
nector’s termi-
nal number.
3. Checking the pasmngw compartment-twnpwatu* UnSO!. ~ F, ah-
thermo8tat sensor and refdgwant-tempnaturs sensor ufalits
Indicates the
circuit diagram
(including the
interface of the
air conditioning
control unit).
number. Num-
bers are used
temperawe of the Sensor pm to resistance
e a c h sensor t? order to convest lb+ amben
The sense, power-supply l2.W of The atrcOnd,f,oner control unit s aD&d~to each SmSOt snd lhe
voltages of te,mmaIs 116). (151. (17) and (51 are dwded by the reslstme va!ueS.of each ““F
reelstance R ..
TmuMnhooting hints *
Dtagnoss
in the opera-
tion descrip-
tions only as
necessary, and
these numbers
correspond to
the numbers
used in har-
ness and com-
ponent layout
diagrams.
Provides the
necessary de-
scription of cir-
curt operation
for basic under-
( s t a n d i n g .
N O 1, The passenger cPrrlpmme”l-lemperatu4 -r tnput sigrml is hid to
Z’C (77-F). ,, “”
N O 1’2 The ou~sde.ar sensor inpu srgnal IS held to WC (5IpF). .
_ N O 13 The air#t,?,mpSf~ SenSO, VlPut SlgMl 6 t+ 10 4% G33-F) : I
-Airwndtlimluconhdunittwmirutwtmge
~~
I
16
I lYle *“MI
Passenger com,wnme”t-tawa. 1 sensor Parr lem,mat”r~ 25-c OFFI 7 to WV 1
,‘W . _: ,. L. .L
I
17 A~r.,hermos,at sewor sensor Pm remoeraure 2% 177%
WM” m cQndlt*Ow IS O F F 1 Lo
, o-‘l,W ,
terminals to be
4 _ .: ._. 4
-h i
Indicates the
conditions un-
der which the
check should
be made.
Provides hints
(including
standards for
I--
judgement)
when trouble-
shooting pro-
cedures are fol-
lowed.
Indicates the on-
board diagnostic
L:
output code No.
and the system
conditions dur-
ina output.
Indicates the specification to
be used for judgement of
the check results.
If there is no particular men-
tion of conditions in the
‘Conditions” column, the
column shows the specifica-
:ion under normal condi-
:ions.
7. GENERAL - How to Use This Manual 00-7
EXPLANATION OF CIRCUIT DIAGRAMS
The symbols used in circuit diagrams are used as NOTE
described below. For detailed information concerning the reading of
, circuit diagrams, refer to GROUP 54lCircuit Dia-
grams.
Indicates a
I
The input/output (direr
of current flow) relativ
the electronic control
is indicated by sym
(A.V).
The (A) symbol indic
that current flows in
upward direction.
output
The broken (-.
line indicates the
t -
/ r
same connector.
The connector
symbol indicates
the device side
connector (for an
intermediate con-
nector, the male
side connectorj
as seen from the
terminal fronl
( t h e connectois
rnnnection face).
RELAY
devce side con-
I MOTOR
Indicates
that the con-
nector is the
direct-inser-
tion tvoe.
The direction of cu.r-
reht flow is indicat-
ed by the arrow.
In this instance, the
current flow is in
both directions. UP
8. 00-8 GENERAL - Vehicle Identification
VEHICLE IDENTIFICATION MOOCA-
VEHICLE IDENTIFICATION NUMBER LOCATION
The vehicle identification number (V.I.N.) is located on a plate
attached to the left top side of the instrument panel.
/ OOAOOSO
VEHICLE IDENTIFICATION CODE CHART P+zE
All vehicle identification numbers contain 17 digits. The vehicle
number is a code which tells country, make, vehicle type, etc.
L . u
5th 6th 7th
r
8th 9th 10th
Digit Digit Digit Digit Digit Digit
I
3rd
Digit
/
4th
Digit
/
2nd
Digit
Line
H-
Galant
FWD
1 St
Digit
Body
6-
4 door
Sedan
Price
class
4-
High
5-
Premium
Engine
Check
digits*
Model
year
Make
Vehicle
type
Others Plant
Serial
number
Country
Okazaki
Plant
D-
2.0 dm3
(122
cu.in.)
[SOHC-
MFI]
E-
2.0 dm3
(122
cu.in.)
[DOHC-
MFI]
K-
1989
Year
L-
1990
Year
M-
1991
Year
N-
1992
Year
P-
1993
Year
J-
Japan
A-
Mitsu-
bishr
3-
Passen-
9er Car
c-
Auto-
matic
Seat Belt
D-
Manual
Seat Belt
NOTE l “Check digit” means a single number or letter x used to verify the accuracy of transcription of vehicle identification number.
VEHICLE IDENTIFICATION NUMBER LIST Mlmcc-
<I989 MODELS>
VEHICLES FOR FEDERAL
V.I.N. (except sequence number) Brand Engine Displacement Models Code
JA3BR46VnKZ Mitsubishi Galant 2.0 dm3 (122 cu.in.) E33ASNHEL2M/RHEL2M
JA3BR56VaKZ
[SOHC-MFI]
E33ASNXEL2MlFiXEL2M
JA3B R56RaKZ
/
2.0 dm3 ( 7 22 cu.in.)
[DOHC-MFI]
E33ASNGMLZM
TSB Revision
11. GENERAL - Vehicle Identification 00-l 1
VEHICLES FOR CALIFORNIA
V.I.N. (except sequence number)
JA3DH46DmPZ
JA3DH56DnPZ
JA3DH56EOPZ
Brand
Mitsubishi
Galant <FWD>
Engine Displacement
2.0 dm3 (122 cu.in.)
[SOHC-MFI]
2.0 dm3 (122 cu.in.)
[DOHC-MFI]
Models Code
E33ASNHEL7M/RHEL7M
b;$,,%&EL7M/NGEL7M/
E33ASNXML7M
VEHICLE INFORMATION CODE PLATE MOOCD-
Vehicle information code plate is riveted onto the bulkhead in
the engine compartment.
The plate shows model code, engine model, transaxle model,
and body color code.
1. MODEL
2. ENGINE
3. EXT
4. TRANSAXLE
5. COLOR,
INT OPT
E33AS RGELZM
-LzI~~~~~S$)y&
4G63
( Engine model
CA6
IExterior co&
F5M22
L Transaxle model
R82 87V 03V
-p+cf~~l;;
CHASSIS NUMBER MOOCE-
STAMPING LOCATION
The chassis number is stamped on the top Center of the
firewall located in the engine compartment.
CHASSIS NUMBER CODE CHART
E33AKZOOOOl
T?T!
1. Vehicule line
E-GALANT
2. Engine displacement
33- 2.0 dm3 (122 cu.in.) engine
3. Body type
A-4-door Sedan
4, R e f e r t o 10th thru 17th digits of V.I.N. Plate.
K- 1989 models p-l 993 models
L- 1990 models
M-1991 models
N- 199'2 modes
12. GENERAL - Vehicle Identification
OOA0192
Theft protection label
For orIgInal parts
OOK619
For replacement parts
OOK621
VEHICLE SAFETY CERTIFICATION LABEL MWCF-
1. The vehicle safety certification label is attached to face of
left door pillar.
2. This label indicates Gross Vehicle Weight Rating (G.V.
W.R.), Gross Axle Weight Rating (G.A.W.R.) front, rear and
Vehicle Identification Number (V.I.N.).
ENGINE MODEL STAMPING M6ocG-.
1. The engine model number is stamped at the front side on
the top edge of the cylinder block as shown in the
following.
Engine model Engine displacement
4G63 2.0 dm3 (122 cu.in.)
2. The engine serial number is stamped near the engine
model number, and the serial number cycles, as shown
below.
THEFT PROTECTION MwclA9
In order to protect against theft, a Vehicle ldentificatlon
Number (VIN) is stamped in, or attached as a label to, the
following major parts of the engine and transaxle. as well as
main outer panels:
Engine cylinder block, Transaxle housing, Fender, Door, Quar-
ter panel, Hood, Trunk lid, Bumpers
In addition, a theft-protection label is attached to replacement
parts for the body outer panel main components, and the same
data are stamped into replacement parts for the engine and the
transaxle.
Cautions regarding panel repairs
1. When repainting original parts, do so after first mask-
ing the theft-protection label, and, after painting, be
sure to peel off the masking tape.
2. The theft-protection label for replacement parts is
covered by masking tape, so such parts can be painted
as is. The masking tape should be removed after
painting is finished.
3. The theft-protection label should not be removed from
original parts or replacement par-&
13. GENERAL - Vehicle Identification 00-13
LOCATIONS
Part
Engine
*ansaxle
.
Target area : for original equipment parts
LZZB : for replacement parts
SOHC-Up to 1992 models SOHC-l 993 models
DOHC
Manual transaxle Automatic transaxle
<FWD>
<AWD> 17
1 TSB Revision
14. GENERAL - Vehicle Identification
@g : for replacement parts
inner side of the parts shown
OOA0065
The illustration indicates left hand side, outer.
Right hand side is symmetrically opposite.
OOA0056
OOAOO59
inner side of the parts shown
in the figure.
The illustration indicates left hand side, outer.
TSB Revision
15. GENERAL - Vehicle Identification/Precautions before Service
OOA0063
inner side of the parts shown
PRECAUTIONS BEFORE SERVICE reomu~
SERVICING ELECTRICAL SYSTEM
1.
2.
Note the following before proceeding with work on the
electrical system.
Note that the following must never be done:
Unauthorized modifications of any electrical device or
wiring, because such modifications might lead to a vehicle
malfunction, over-capacity or short-circuit that could result
in a fire in the vehicle.
When servicing the electrical system, disconnect the
negative cable terminal from the battery.
TSB Revision
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