Page 1

BACKUP Service Manual

GRLRNT

GROUP INDEX

MOOAA-

General ......................................................... Engine ........................................................... Fuel ................................................................ Cooling .........................................................

1989-1990-1991-1992-1993

Intake and Exhaust ..............................

Volume 1 Chassis & Mechanical

Emission Control ....................................

This Service Manual has been prepared with the latest service information available at the time of publication. It is subdivided into various group categories and each section contains diagnostic, disassembly, repair, and installation procedures along with complete specifications and tightening references. Use of this manual will aid in properly performing any servicing necessary to maintain or restore 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. kyou. - Gjmpiemym_ay&?h

Manual Transaxle .................................. Automatic Transaxle ............................

FOREWORD

1

Clutch ............................................................

Propeller Shaft ........................................ Front Axle .................................................. Rear Axle .................................................... Wheel and Tire ....................................... Power Plant Mount .............................. A Front Suspension ................................... Active-Electronic .............................. Control Suspension m & Rear Suspension ....................................

naiLcorn

Service Brakes ......................................... A

Parking Brakes ........................................

.

Alphabetical Index .................................

.” @ WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION THROUGH Nallonal lnsrltule for

AU~~~v3~;VPCT:VE EXCELLENCE

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

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.


00-l

GENERAL CONTENTS GENERAL DATA AND SPECIFICATIONS ..... 23

Rear Axle ......................................................

45

HOW TO USE THIS MANUAL ......................

Rear Drum Brake Linings and Rear Wheel Cylinders ..................................

44

3

Definition of Terms ......................................

3

Explanation of Circuit Diagrams .................. Explanation of Manual Contents .................

7

Explanation of the Troubleshooting Guide ............................................................. Model Indications ......................................... Scope of Maintenance, Repair and Servicing Explanations .................................. Troubleshooting .............................................

4

40 Spark Plugs ................................................... Timing Belt ................................................... 40

MASTER TROUBLESHOOTING ..................... 28 6 3 3 3

PRECAUTIONS BEFORE SERVICE ................ 15 RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE .................. 35 SCHEDULED MAINTENANCE TABLE ........... 38

LUBRICATION AND MAINTENANCE ............ 34 MAINTENANCE SERVICE ........ . ...................... Air Cleaner Element ..................................... Automatic Transaxle .....................................

39

SPECIAL HANDLING INSTRUCTIONS FOR AWD MODELS .......................................

39 43

TABLE OF MAIN SEALANTS AND ADHESIVES ............................................ 46

Ball Joint and Steering Linkage Seals ........ 45 Brake Hoses ................................................. 45 Disc Brake Pads ........................................... 44 Drive Belt (For Water Pump and Generator) ....................................................... Drive Shaft Boots ......................................... Engine Coolant ............................................. Engine Oil ..................................................... Engine Oil Filter ...........................................

41 45 44 41

41 Exhaust System ............................................ 45

Fuel Hoses ................................................... 39 Fuel System ................................................. 39 Manual Transaxle .......................................... 42

20

TIGHTENING TORQUE ...................................

27

TOWING AND HOISTING ..............................

17

VEHICLE IDENTIFICATION .............................

8

11 Chassis Number ........................................... Engine Model Stamping ............................... 12 12 Theft Protection ............................................ Vehicle Identification Code Chart Plate.. ..... 8 Vehicle Identification Number List .............. Vehicle Identification Number Location .......

8 8

Vehicle Information Code Plate ................... 1 1 Vehicle Safety Certification Label ................ 12


GENERAL - How to Use This Manual

HOW TO USE THIS MANUAL SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair and servicing of the subject model. Unless otherwise 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

00-3 MOOBMTO

DEFINITION OF TERMS STANDARD VALUE 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.

“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.

Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly and adjustment procedures, and so they can be completed in a shorter time).

SERVICE PROCEDURES

CAUTION

The service steps are arranged in numerical order and attentions to be paid in performing vehicle service are described in detail in SERVICE POINTS.

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.

TROUBLESHOOTING Troubleshootinqs are classified into master troubleshooting 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.

REFERENCE VALUE

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.


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 understanding 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 tightening torque is provided where applicable.

l

l

l

Removal steps: The part designation number corresponds to the number in the illustration to indicate removal steps. Disassembly steps: The part designation number corresponds to the number in the illustration to indicate disassembly steps. Installation steps: Specified in case installation is impossible 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 impossible in reverse order of disassembly steps. Omitted if reassembly is possible in reverse order of disassembly steps.

Classifications Service Points

of Major Maintenance/

When there are major points relative to maintenance 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.

Symbols for Lubrication, Sealants and Adhesives Information concerning the locations for lubrication 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.

necessary. In this example, sealant is applied (where indicated) to the

I---

4 . . . . . Grease (multipurpose grease unless there is 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


GENERAL - How to Use This Manual

QfitI ICQ TV..&”

CTEEQINC Y.LLI.II.Y

CFAR Y_..

RnY w-1.

..^-

REMOVAL AND INSTALLATION

p

u Y.T-*c As..

s

a

b

l

e

p

Denotes non-rea r t .

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

I I

-6

-’

se&an:

Repair kit or set parts are shown. (Only very frequently used parts

iY,W1

3rM&rr&paNo.~3W

1

Operating procedures, cautions, etc. on removal, installation, disassembly and reassembly are de[scribed, ~ , 1

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

STEERING - NINA Steering Gear Box

37A-24 /

LUBRlCATlON

Thus number corresponds to the number ?pyi:,“~&‘R~;;?I steps”, “Installation s t e p s ” o r “Reassemblv steps”.

AND

SEALING POINTS-

The title of the page (fOilOWing the page on which the diagram of component parts is presented) indicating the locations of lubncation and sealing procedures.


00-6

GENERAL - How to Use This Manual

EXPLANATION OF THE TROUBLESHOOTING GUIDE

3. Checking the pasmngw compartment-twnpwatu* thermo8tat

Indicates connector’s terminal number.

sensor and refdgwant-tempnaturs

UnSO!. ~ F, ahsensor ufalits

the Indicates circuit diagram (including the interface of the air conditioning control unit).

Provides the necessary description of circurt operation for basic under(standing.

e a c h sensor t? order to convest lb+ amben temperawe of the Sensor pm to resistance 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 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 17

Passenger com,wnme”t-tawa. I lYle *“MI A~r.,hermos,at

sewor

1 sensor Parr lem,mat”r~ 25-c OFFI 7 to WV

,‘W

.

_:

,.

L.

sensor Pm remoeraure 2% 177% WM” m cQndlt*Ow IS O F F 1 Lo

4

_

.:

1

.L

, o-‘l,W

._. 4

,

I

number. Numbers are used in the operation descriptions only as necessary, and these numbers correspond to the numbers used in harness and component layout diagrams.

I--

Provides hints (including standards for judgement) when troubleshooting procedures are followed.

L: Indicates the onboard diagnostic output code No. and the system conditions durina output.

-h

terminals to be

i

Indicates the conditions under which the check should be made.

Indicates the specification to be used for judgement of the check results. If there is no particular mention of conditions in the ‘Conditions” column, the column shows the specifica:ion u n d e r n o r m a l condi:ions.


00-7

GENERAL - How to Use This Manual EXPLANATION OF CIRCUIT DIAGRAMS The symbols used in circuit diagrams are used as described below.

Indicates a

NOTE For detailed information concerning the reading of , circuit diagrams, refer to GROUP 54lCircuit Diagrams.

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.

I

output

The broken (-. line indicates the same connector. t

/

r

-

RELAY

I

MOTOR \ \

connector The symbol indicates the device side

The direction of cu.rreht flow is indicated by the arrow. In this instance, the current flow is in both directions. UP

connector (for an

intermediate connector, the male side connectorj as seen from the fronl terminal ( t h e connectois rnnnection face).

devce side con-

Indicates that the connector is the direct-insertion tvoe.


00-8

GENERAL - Vehicle Identification

MOOCA-

VEHICLE IDENTIFICATION

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.

1 St Digit Country

I

\ \\ u \ . / L

2nd Digit

3rd Digit

4th Digit

Make AMitsubishr

JJapan

NOTE

/

l

Vehicle

Others

type 3Passen9er Car

5th Digit

Line

c-

HGalant FWD

Automatic Seat Belt DManual Seat Belt

6th Digit

7th Digit

Price class 4High 5Premium

r

10th 9th 8th Digit Digit Digit \

Body

Engine

64 door Sedan

D2.0 dm3 (122 cu.in.) [SOHCMFI] E2.0 dm3 (122 cu.in.) [DOHCMFI]

Check digits*

Model year K1989 Year L1990 Year M1991 Year N1992 Year P1993 Year

Plant

Serial number

Okazaki Plant

“Check digit” means a single number or letter x used to verify the accuracy of transcription of vehicle identification number.

Mlmcc-

VEHICLE IDENTIFICATION NUMBER LIST <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.) [SOHC-MFI]

E33ASNHEL2M/RHEL2M

JA3BR56VaKZ

E33ASNXEL2MlFiXEL2M

2.0 dm3 ( 7 22 cu.in.)

JA3B R56RaKZ /

TSB Revision

[DOHC-MFI]

E33ASNGMLZM


00-9

GENERAL - Vehicle Identification VEHICLES FOR CALIFORNIA V.I.N. (except sequence number)

Brand

Engine Displacement

Models Code

JA3BR46VnKZ

Mitsubishi Galant

2.0 dm3 (122 cu.in.1 [SOHC-MFI]

E33ASNHEL7MIRHEL7M

JA3BR56VnKZ

I

E33ASNXEL7MlRXEL7M

JA3BR56RC]KZ

2.0 dm3 (122 cu.in.) [DOHC-MFI]

E33ASNGML7M

<I990 MODELS> VEHICLES FOR FEDERAL V.I.N. (except sequence number)

Brand

Engine Displacement

Models Code

JASCR46VOl-Z

Mitsubishi Galant <FWD>

2.0 dm3 (122 cu.in.1 [SOHC-MFI]

E33ASNHEL2MIRHEL2M

JA3CR56VOLZ

E33ASNXEL2MIRXEL2M

JA3CR56RnLZ JA3CX56RnLZ

2.0 dm3 (122 cuin.) [DOHC-MFI] Mitsubishi Galant tAWD>

E33ASNGML2M E38ASNGML2M

VEHICLES FOR CALIFORNIA V.I.N. (except sequence number)

Brand

Engine Displacement

Models Code

JA3CR46VC]LZ

Mitsubishi Galant <FWD>

2.0 dm3 (122 cuin.) [SOHC-MFI]

E33ASNHEL7MlRHEL7M E33ASNXEL7MIRXEL7M

JA3CR56VC]LZ 2.0 dm3 (122 cuin.) [DOHC-MFI]

JA3CR56RnLZ JA3CX56ROLZ

E33ASNGML7M E38ASNGML7M

Mitsubishi Galant <AWD>

<I991 MODELS> VEHICLES FOR FEDERAL V.I.N. (except sequence number)

Brand

Engine Displacement

Models Code

JA3CR46VC]MZ

Mitsubishi Galant <FWD>

2.0 dm3 (122 cu.in.1 [SOHC-MFI]

E33ASNHEL2MlRHEL2M

2.0 dm3 (122 cu.in.1 [DOHC-MFI]

E33;;$ML2MIRGML2Ml

E33ASRXEL2M

JA3CR56VnMZ JA3CR56RnMZ JA3CX56RnMZ

E38ASNGML2MlRGML2M

Mitsubishi Galant <AWD>

E39ASNPFL2M

2.0 dm3 (122 cuin.) [DOHC-MFI-Turbo1

JA3CX56UOMZ

TSB Revision

I


00-l 0

GENERAL - Vehicle Identification

VEHICLES FOR CALIFORNIA V.I.N. (except sequence number)

Brand

Engine Displacement

Models Code

JA3CR46VnMZ

Mitsubishi Galant <FWD>

2.0 dm3 (122 cuin.) [SOHC-MFI]

E33ASNHEL7MIRHEL7M E33ASRXEL7M

JA3CR56VuMZ

I 11 ““nUPi”WD> 200.0~‘~~~22x~.)

2.0 dm3 (122 cuin.) [DOHC-MFI]

JA3CR56RnMZ

I

:::::?:;IRGMVM . ,

I

1

FX3;;$ML7MIRGML7M/ I

J

<1992 MODELS> VEHICLES FOR FEDERAL V.I.N. (except sequence number) JA3CR46VaNZ

Brand Mitsubishi 1 Galant <FWD>

Engine Displacement 2.0 dm3 (122 cu.in.) [SOHC-MFI]

E33ASNHEL2MIRHEL2M E33ASRXEL2M

JA3CR56VuNZ 2.0 dm3 (122 cu.in.) [DOHC-MFI]

JA3CR56RONZ JA3CX56R[ZlNZ

1 Models Code

Mitsubishi Galant <AWD>

JA3CX56UnNZ

E3gf2N$ML2M/AGML2M/ E38ASNGML2M/RGML2M

2.0 dm3 (122 cu.in.) [DOHC-MFI-Turbo]

E39ASNPFL2M

2 . 0 dm3 (122 cu.in.) [DOHC-MFI]

E33ASNGML7M/RGML7M/ NXML7M

2.0 dms (122 cu.in.) [DOHC-MFI-Turbo]

E39ASNPFL7M

Models Code

VEHICLES FOR CALIFORNIA V.I.N. (except sequence number)

~

I

JA3CR56RnNZ

j1 Mw;wm;;:

g;;gwo,

< 1993 MODELS> VEHICLES FOR FEDERAL V.I.N. (except sequence number)

Brand

Engine Displacement

JA3DH46DnPZ

Mitsubishi Galant <FWD>

2.0 dm3 (122 cu.in.) [SOHC-MFI]

JA3DH56DnPZ

2.0 dm3 (122 win.)

J,A3DH56EOPZ

[DOHC-MFI]

TSB Revision

E33ASNXML2M


GENERAL - Vehicle Identification

00-l 1

VEHICLES FOR CALIFORNIA V.I.N. (except sequence number)

Brand

Engine Displacement

Models Code

JA3DH46DmPZ

Mitsubishi Galant <FWD>

2.0 dm3 (122 cu.in.) [SOHC-MFI]

E33ASNHEL7M/RHEL7M b;$,,%&EL7M/NGEL7M/

JA3DH56DnPZ 2.0 dm3 (122 cu.in.) [DOHC-MFI]

JA3DH56EOPZ

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

E33AS RGELZM -LzI ~~~~~S$)y&

2. E N G I N E

4G63 ( Engine model

3. EXT 4. TRANSAXLE

5. COLOR, INT OPT

CA6 I Exterior co& F5M22 L Transaxle model R82 87V 03V -p+cf~~l;;

MOOCE-

CHASSIS NUMBER 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 t h r u 17th d i g i t s o f V.I.N. Plate. K- 1989 models

L- 1990 models M-1991 models N- 199'2 mode\s

p-l 993 models


GENERAL - Vehicle Identification 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.).

OOA0192

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

Theft protection label For orIgInal

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:

parts

Engine cylinder block, Transaxle housing, Fender, Door, Quarter panel, Hood, Trunk lid, Bumpers OOK619

For replacement

parts

OOK621

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 masking 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-&


00-13

GENERAL - Vehicle Identification LOCATIONS Part

Target area

Engine

SOHC-Up to 1992 models

: for original equipment parts LZZB : for replacement parts SOHC-l 993 models

DOHC

*ansaxle

Manual transaxle

Automatic transaxle <FWD>

. <AWD>

1 TSB Revision

17


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


GENERAL - Vehicle Identification/Precautions before Service

OOA0063

inner side of the parts shown

PRECAUTIONS BEFORE SERVICE reomu~ SERVICING ELECTRICAL SYSTEM 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. 2. When servicing the electrical system, disconnect the negative cable terminal from the battery. 1.

TSB Revision


Thank you very much for your reading. Please Click Here Then Get More Information.

1989 Mitsubishi Galant Service Repair Manual  
1989 Mitsubishi Galant Service Repair Manual  
Advertisement