suspension MITSUBISHI GALANT 1989 Service Repair Manual

BACKUP
Service Manual
GRLRNT
1989-1990-1991-1992-1993
Volume 1
Chassis & Mechanical
FOREWORD
This Service Manual has been prepared with thelatest 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 REDISTRIBUTEWHOLE SECTIONS. This BACKUP was sold to you under the fact that you do indeed
DWNa 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 forAU~~~v3~;VPCT:VE
EXCELLENCE naiLcorn
MITSUBISHIMOTOR SALES OF AMERICA. Inc.
Mltsublshl Motors Corporat!on reserves the right to make changes indesign or to make additions to or Improvements In Its products
wlthout~mposng any obllgatlons upon Itself to install them on its productspreviously manufactured
0 1992 Mitsubishi Motors CorporationRcprintedinUSA
GROUP INDEXMOOAA-
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.

00-l 8GENERAL - Towing and Hoisting
SAFETY PRECAUTIONS
The following precautions should be taken when towing thevehicle.
1.DO NOT LIFT OR TOW THE VEHICLE BY ATTACHING TO
OR WRAPPING AROUND THE BUMPER.
2. Any loose or protruding parts of damaged vehicle such as hoods, doors, fenders, trim, etc., should be secured prior to
moving the vehicle.
3.Operator should refrain from going under a vehicle while it
is lifted by the towing equipment, unless the vehicle in
adequately supported by satefy stands.
4. Never allow passengers to ride in a towed vehicle. 5. State and local rules and regulations must be followed when towing a vehicle.

Refer to the section “Special Handling Instructions for AWD
Models”.
Frame contact support location
I
: 1,020 mm (40.2 in.)
: 1,120 mm (44.1 in.)OOAOO47
ReartAWD>I
HOISTING
POST TYPE
Special care should be taken when raising the vehicle on a
frame contact type hoist. The hoist must be equipped with the
proper adapters in order to support the vehicle at the proper
locations.
Caution
When service procedures require removing rear suspen-
sion, fuel tank, spare tire and lift gate, place additional
weight on rear end of vehicle or anchor vehicle to hoist to
prevent tipping of center of gravity changes.
FLOOR JACK
The usual type of floor jack is used at the following locations.
Front:
Under the mid point of centermember
tAWD> Under the mid point of crossmember
Rear:
Under the jack up bracket of rear floor pan
Under the rear differential
Cautions
1. Never use a jack at the lateral rod or rear suspension
assembly.
2.In order to prevent scarring the centermember
or crossmember ,
place a piece of cloth on the
jack’s contact surface (to prevent corrosion caused by
damage to the coating).
3. A floor jack must never be used on any part of the
underbody.
4.Do not attempt to raise one entire side of the vehicle by
placing a jack midway between front and rear wheels.
This practice may result in permanent damage to the
body.
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00-24GENERAL - General Data and Specifications
ItemsFWDAWD
SOHC Engine DOHC Engine DOHC Engine DOHC Engine
(Non-Turbo)
(Turbo)
Vehicle weight
kg (Ibs.)
Curb weightsMIT
1.2 10 (2.668)1.290 (2,844) or 1.405 (3.097).1,495 (3.296)1.3 10 (2.8881e2
/-v-r1,230 (2.7 12) or
1,300 (2,866) 1,425 (3.142)
1,270
(2.800)”
Gross vehicle weight rating 1,700 (3,747) 1,780 (3,923)1,900 (4,189)
1,900 (4,189)
Gross axle weight rating Front 900 (I ,984)
960 (2,116) 960 (2,116)
980 (2.161)
Rear800 (1.763)820 (1,807)940 (2.072)920 (2.028)
Seating capacity5 55 5
Engine
Model No.
4G634G63 4G634G63
Transaxle
Model No.Manual transaxle F5M22 F5M3
1 W5M31 W5M33
Automatic transaxle
F4A22F4A22 W4A32-
Clutch
Type
Dry-single disc
Dry-single disc
Dry-single disc Dry-single disc &
diaphragm & diaphragm & diaphragm &
diaphragm
spring spring spring
springChassis
Tire
185/7OR14 87s 195/60R15 86i-i 195/60R15 86ti195/60R15 86H
or
195/65R14 89H
Front suspension Type
Independent Independent
Independent
Independent
strut strut strut
strut
Rear suspension Type
3L$k Torsion3$k Torsion Double-
Double-
wishbone wishbone
Brake Type
Front
DiscDisc Disc
Disc
RearDrum
Disc Disc
Disc
Steering
Gear type Rack and pinion Rack and pinion Rack and pinion
Rack and pinion
Gear ratio
cc00m03
Fuel tank
Capacity
dm3(gals.) 60 (16)60 (16) 62 (16.3)
62 (16.3)
NOTE+’ : E33ASRXEL2Mi7M~2:
E33ASNXML2Mi7M
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00-263ms
GENERAL -General Data and Specifications
FWD
iassis
Tire
Front suspension Type
Rear suspension Type
Brake
Type
Steering Gear type
Gear ratio
Fuel tank
Capacity
Front
Rear
dm3 (gals.)
L
SOHC EngineDOHC Engine
185/7ORl4 87s 195/60R15
86H
Independent strut independent strut 3-Link
Torsion axle 3-Link
Torsion axle
Disc
Drum Disc
Disc
Rack and pinion
cc
60 (16)
Rack and pinion
/cu
60 (16)
ENGINE SPECIFICATIONS Items Type
Number of cylinders
Bore
StrokePiston displacement
Compression ratio
Firing order 4G63-SOHC
In line,
Front Transverse
4
mm (in.) 85 (3.35)
mm (in.) 88 (3.46)
cm3 (win.) 1,997 (122)
8.5
1-3-4-2
TRANSAXLE SPECIFICATIONS
Items
Type
Gear ratio
1 st
2nd
3rd 4th
5th
Reverse
Transaxle
Pnmary reduction ratio
Secondary reductron ratio
Transfer F5M22
F5M3
1 5-speed
M/T W5M31
EFd
5-speed
M/T
F4A2 2 4-speed
A/T 4-speed
A/T
3.363 2.846 2.846 2.846
1.947 1.833
1.684 1.684 1.285
1.217
1.115 1.115
0.9390.8880.8330.833
0.7560.73 10.6900.666
3.0833.166
3.166
3.166 2.846 2.846
1.581
1.581
1 .ooo 1.000
0.6850.685
--
2.1762.176
4.02 14.9131.6801.2754.007
1.228
---3.1003.8663.600
---1.0901.090
1.0904G63-DOHC
(Non-Turbo) 4G63-DOHC
(Turbo)
In line, In line,
Front Transverse Front Transverse
44
85 (3.35) 85 (3.35)
88 (3.46) 88 (3.46)
1,997 (I

22)1,997 (I 22)
9.0
7.8
1-3-4-21-3-4-2
W5M33W4A3 2
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GENERAL - Master Troubleshooting
00-31
POOR RETURN OF STEERING WHEEL TO CENTER
Symptom
Probable cause Reference page
’Poor return of steering wheel to
Improper front wheel alignment33A-5center
Improper tire pressure31-3
Excessive tightened rack support cover 37A-35, 36, 37
Damaged front wheel bearing
26-9
POOR RIDING
Symptom
Poor riding Probable cause
Reference page or remedy
Improper tire pressure
31-3
lmbalanced wheelsRepair
Improper front or rear wheel alignment33A-5
34-5, 11, 23, 35
Malfunctioning shock absorber Malfunctioning
electronic control suspension
33B-90system
Broken or worn stabilizer
33A-6. 13, 1734-l 1, 35, 37
Broken or worn coil spri#ng
Loose suspension secuiring bolt(s)
Retighten
Worn lower arm bushing
33A-10
Worn suspension arm bushing 33A-IO
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ABNORMAL TIRE WEAR
Symptom
Abnormal tire wear Probable cause
Improper front or rear wheel alignment Reference page
33A-534-5, 23
131-3
lmbalanced wheelsII
Loose wheel bearings
27-3, 15
Malfunctioning shock absorber
33A-634-l 1, 35

FUEL SYSTEM - Fuel Tank13-111
03R0297
Vapor hose
mmin.)Fillerhose
i2.l
B
3FOO7
A
1
Flare nut
Skure side
03Yo43
9. CONNECTION OF VAPOR HOSE/8. FILLER HOSE
(1) The vapor hose should be connected all the way at the tank, and approximately 40 mm (1.6 in.) at the fuel tank
filler tube.
(2) The end of the filler hose with the shorter straight pipe
part should be connected at the tank side.
7. CONNECTION OF HIGH PRESSURE HOSE TO FUEL PUMP
Temporarily tighten the flare nut by hand, and then tightenit to the specified torque, being careful that the fuel hose
does not become twisted.
Caution
When tightening flare nut, be careful not to bend or
twist line to prevent damage to fuel pump low connec-
tion.
FUEL PUMP REPLACEMENT
(1) Disconnect the fuel pump connector.
(2) Remove the fuel tank filler tube cap.
(3) Drain the fuel. MllGFAC
(4)
Disconnect the fuel high pressure hose and main pipe.
Caution
Cover the hose connection with rags to prevent splash
of fuel that could be caused by some residual pressure in the
fuel. pipe line.
(5) Loosen the self-locking nuts to the end of the stud bolt.
(6) Disconnect the lateral rod right side body coupling; then lower the lateral rod and use wire or similar material to
suspend from the axle beam.
(7) For models equipped with the ACTIVE-Electronic Control Suspension
(E.C.S.) disconnect the rear height sensor and
the lateral rod. (Refer to GROUP
33B-Service Adjustment
Procedures.)

13-320FUEL SYSTEM - Fuel Tank
03RO297
V/apor hose
mmin.)
3FOO7
Filler
hoseB
A Flare nut
\Secure side 03YO43
Ll
9. CONNECTION OF VAPOR HOSE/8. FILLER HOSE
(1) The vapor hose should be connected all the way at the
tank, and approximately 40 mm (1.6 in.) at the fuel tank
filler tube.
(2) The end of the filler hose with the shorter straight pipe part should be connected at the tank side.
7. CONNECTION OF HIGH PRESSURE HOSE TO FUEL
PUMP
Temporarily tighten the flare nut by hand, and then tighten
it to the specified torque,
bein,g careful that the fuel hose
does not become twisted.
Caution
When tightening flare nut, be careful not to bend or
twist line to prevent damage to fuel pump low connec-
tion.
FUEL PUMP REPLACEMENT
(1) Disconnect the fuel pump connector.
(2) Remove the fuel tank filler tube cap.
(3) Drain the fuel.
Ml3GFAt.X
(4) Disconnect the fuel high pressure hose and main pipe.
Caution
Cover the hose connection with rags to prevent splash
of fuel that could be caused by some residual pressure
in the fuel pipe line.
(5) Loosen the self-locking nuts to the end of the stud bolt.
(6) Disconnect the lateral rod right side body coupling; then
lower the lateral rod and use wire or similar material to
suspend from the axle beam.
(7) For models equipped with the ACTIVE-Electronic Control Suspension
(E.C.S.) disconnect the rear height sensor and
the lateral rod. (Refer to GROUP
33B-Service Adjustment
Procedures.)
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13-408AUTO-CRUISE CONTROL SYSTEM - Auto-cruise Control
AUTO-CRUISE CONTROL
REMOVAL AND INSTALLATION
1 4-6
Nm3-4 ft.lbs.
Post-installation Operationa Accelerator Cable Adwstment (Referto P. 13-398.)
,**.“qy “y ,,,,ezls:’ 3 -. .- ,*%L’J
01
,\@&&,
-<28- E+c- - - --.c,
T
$$y= *g i ;g+j$T
-3
18
Removal steps of actuator
1. Protector
2. Accelerator cable B adjusting nut
3. Accelerator cable A adjusting nut
4. Actuator side inner cable 5. Actuator connector
6. Actuator
7. Air hoses
8. Bracket
Removal steps of sensor and switches 9. Accelerator switch
10. Stop light switch11. Clutch pedal position switch
12. Park/neutral position switch
13. Vehicle speed sensor (Refer to GROUP
54-Met&sand Gauges.)
14. Auto-cruise control switch (Refer to GROUP
54-Column Switch.)
Removal steps of control unit
15. Instrument under cover
16. Lap shower duct and foot shower nozzle
17. Control unit
18. Auto-cruise control indicator light (Refer to
GROUP
54-Meters and Gauges.)
9’ -L.-lI I07A0024
falQA0237
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15-2INTAKE AND EXHAUST - Specifications
SPECIFICATIONS
GENERAL SPECIFICATIONSMEch-
Items
Air cleaner
Element
Exhaust systemFront exhaust pipe
Front exhaust pipe
Muffler
Coupling
Suspension system
Turbocharger
Type
Identification No.
intake charge pressure control
Intercooler
Type Specifications
Unwoven cloth type
Dual type
Single type Expansion resonance type
Flat coupling
Rubber hangers and O-rings
Exhaust gas turbine type
TD05H-14B-6
Turbocharger waste gate actuator and valve
Air cooled type
SERVICE SPECIFICATIONS
Items
Intake and exhaust manifolds
StandardLimit
Distortion of cylinder head contacting surface mm (in.) Less than 0.15 (0059)0.3 (.012)
Turbocharger waste gate solenoid terminal resistance[at 20°C (68”F)l5-2 36-4
4
Turbocharger
Supercharging pressurekPa (psi) 31-70 (4.4-10.1)
TORQUE SPECIFICATIONS
Items
Air cleaner
Air cleaner to body
Air duct
Resonator
Branch tube
Charge air cooler
Air hose B
Air pipe A Air pipe
B
Turbocharger by-pas valve to air pipe B
Charge air cooler
Nmft.lbs.
8-106-
7
8-106-7
8-106-

7
8-106-

7
8-106-

7
12-15 9-11
12-15 9-11
15-22 11-16 12-15
9-11
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26-4FRONT AXLE- Special Tools
TdNumberNameI Use. .-. .------.
CD
MB990890-01
Rear suspension Press-fitting of the wheel bearing and oil seal
bushing base
OPTIONAL: AVAILABLE FROM O.T.C. MB990883-01
Rear suspension
arbor
/
OPTIONAL: AVAILABLE FROM O.T.C.
\
J!D
GENERALAxle puller Removal of the drive shaft
SERVICE TOOL
000
1 MB991 248 or
Inner shaft remover
Removal of the inner shaft MD998801
GENERAL
SERVICE TOOLBearing and oil seal
installer set
Removal of wheel bearing
H MB990938-01
Handle
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