galant vr4 88-93 chassis and mechanical.pdf

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1989-1993 GALANT Chassis & Mechanical V1

BACKUP

Service Manual

GROUP INDEX

MOOAA-

General .........................................................

GRLRNT

Engine ...........................................................

Fuel ................................................................

Cooling .........................................................

1989-1990-1991-1992-1993

Volume 1

Chassis & Mechanical

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

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

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

Manual Transaxle ..................................

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.)

Automatic Transaxle ............................

Propeller Shaft ........................................

Front Axle ..................................................

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

Wheel and Tire .......................................

Power Plant Mount ..............................

Front Suspension ...................................

Active-Electronic

Control Suspension

A

..............................

m

Please See README.TXT or README.HTML for additional information.

Rear Suspension .................................... &

1

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Service Brakes .........................................

A

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

.

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WE SUPPORT

VOLUNTARY TECHNICIAN

CERTIFICATION THROUGH

Nallonal lnsrltule for

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EXCELLENCE

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

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

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.

0 1992 Mitsubishi Motors Corporation

RcprintedinUSA

@

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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

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

LUBRICATION AND MAINTENANCE ............ 34

SPECIAL HANDLING INSTRUCTIONS

FOR AWD MODELS ....................................... 20

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

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

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00-z

NOTES

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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.

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.

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.

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.

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