length MITSUBISHI GALANT 1989 Service Repair Manual

GENERAL - General Data and Specifications00-23
GENERAL DATA AND SPECIFICATIONSMOOHA-
3
I TT I
8
GENERAL SPECIFICATIONS
Items
FWD
AWD
SOHC EngineDOHC EngineDOHC Engine
DOHC Engine(Non-Turbo) (Turbo)
Vehicle dimensions
mm (in.)
Overall length
14,670 (183.9) 4,670 (183.9)4,670 (183.9) 4,670 (183.9)
Overall width
21,695 (66.7) 1,695 (66.7)1,695 (66.7) 1,695 (66.7)
Overall height
31,425 (56.1) 1.425 (56.1)1,435 (56.5) 1,435 (56.5)
1,410 (55.5)"
Wheel base
42,600 (102.4) 2,600 (102.4)2,600 (102.4) 2,600 (102.4)
TreadFront51,460 (57.5)1,460 (57.5)1,460 (57.5) 1,460 (57.5)
Rear61,450 (57.1)1,450 (57.1)1,450 (57.1) 1,450 (57.1)
Overhang Front
7980 (38.6)980 (38.6)980 (38.6) 980 (38.6)
Rear81,090 (42.9)1,090 (42.9)1,090 (42.9) 1,090 (42.9)
Height at curb mass (wt.) Front bumper toground
9240 (9.4)
250 (9.8)255 (10.0) 255 (10.0)
Rear bumper toground
10215 (8.5)
290 (11.4)230 (9.1) 230 (9.1)
Minimum running ground
clearance
11115 (4.5) 155 (6.1)100 (4.0)100 (4.0)
Angle of approach 12 18.5
"
19"21"21"
Angle of departure
13 12"17"12.5"
12.5"
NOTEl ’ : E33ASNXML2M/L7M
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GENERAL - General Data and Specifications00-25
(1993 models
>
Items
FWD
SOHC Engine DOHC Engine
Vehicle dimensionsmm (in.)
Overall length14,670 (183.9)
4,670 (183.9)
Overall width21,695 (66.7)1,695 (66.7)
Overall height31,425 (56.1)1,425 (56.1) I,41
0
(55.5)*’
Wheel base4
2,600 (102.4)
2,600 (102.4)
Tread Front51,460 (57.5)1,460 (57.5)
Rear
61,450 (57.1) 1,450 (57.1)
Overhang Front7980 (38.6)980 (38.6)
Rear
81,090 (42.9) 1,090 (42.9)
Height at curb mass (wt.)
Front bumper to ground
9240 (9.4) 250 (9.8)
Rear bumper to ground10215 (8.5)290 (11.4)
Minimum running ground
clearance11115 (4.5)155 (6.1)
Angle of approach 12 18.5”19”
Angle of departure13 12”17”
lehicle weightkg (tbs.)
Curb weights
M/T
1,230 (2,712) or1,250 (2,755)*’I,31
0 (2,888)
A/T1,250 (2,755) or1,285(2,833)*3or1,270 (2,800)*4
Gross vehicle weight rating1,700 (3,747) 1,780 (3,923)
Gross axle weight rating Front900 (1,984)960 (2,116)
Rear 800 (1,763)
820 (1,807)
ieating capacity55lngine
Model No.
4G634G63 -ransaxle
Model No. Manual transaxle
F5M22 F5M22
Automatic transaxle
F4A22 lutch
Type
Dry-single disc & diaphragm spring
Dry-single disc &
diaphragm spring
d
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NOTE*l : E33ASNXML2MlL7M*2 : E33ASNGEL2MI7M*3 :
E33ASRXEL2M/7M*4 :
E33ASRGEL2M/7M

00-34GENERAL- Lubrication and Maintenance
LUBRICATION AND
MAINTE-
NANCEMOOPA-
Maintenance and lubrication service recommenda-
tions have been compiled to provide maximum protection for the vehicle owner’s investment
against all reasonable types of driving conditions. Since these conditions vary with the individual
vehicle owner’s driving habits, the area in which the
vehicle is operated and the type of driving to which
the vehicle is subjected, it is necessary to prescribe lubrication and maintenance service on a time
frequency as well as mileage interval basis.
Oils, lubricants and greases are classified and
graded according to standards recommended by the Society of Automotive Engineers (SAE), the Amer-
ican Petroleum Institute (API) and the National
Lubricating Grease Institute (NLGI).
MAINTENANCE SCHEDULES Information for service maintenance is provided
under “SCHEDULED MAINTENANCE TABLE”.
Three schedules are provided; one for “Required Maintenance”, one for “General Maintenance” and
one for “Severe Usage Service”.
The item numbers used in the “SCHEDULED MAINTENANCE TABLE” correspond to th
e
“MAINTENANCE SERVICE” section numbers.
SEVERE SERVICE
Vehicles operating under severe service conditions
will require more frequent service. Component service information
isIncluded i
n
appropriate units for vehicles operating under one or
more of the following conditrons:
1.Trailer towing or police, taxi, or
commerciai
type
operation
2. Operation of Vehicle (1) Short-trip operation at freezing temperature(engine not thoroughly warmed up)
(2) More than 50% operation in heavy city traffic during hot weather above
32°C (90°F)
(3) Extensive idling
(4) Driving in sandy areas
(5) Driving in salty areas
(6) Driving in dusty conditions
ENGINE OIL
The SAE grade number indicates the viscosity of engine oils, for example, SAE 30, which is a single
grade oil. Engine oils are also identified by a dual number, for example, SAE 1
OW-30, which Indicates
a multigrade oil.
The API classification system defines oil perform- ance in terms of engine usage. Only engine oil
designed “For Service SG” or “For Service
SGKD”,
when available, should be used. These oils contain
sufficient chemical additives to provide maximum
engine protection. Both the SAE grade and the API
designation can be found on the container.
Caution
Test results submitted to EPA have shown that
laboratory animals develop skin cancer after
prolonged contact with used engine oil. Accor-
dingly, the potential exists for humans to de-
velop a number of skin disorders, including
cancer, from such exposure to used engine oil.
Care should be taken, therefore, when changing engine oil, to minimize the amount and length of
exposure time to used engine oil on your skin.
Protective clothing and gloves, that cannot be
penetrated by oil, should be worn. The skin
should be thoroughly washed with soap and
water, or use waterless hand cleaner, to remove
any used engine oil. Do not use gasoline,
thinners, or solvents.
GEAR LUBRICANTS
The SAE grade number also indicates the viscosity of Multi-Purpose Gear Lubricants.
The API classfication
system defines gear lubricants
in terms of usage. Typically gear lubricants conform-
ing to API
GL-4 or GL-5 with a viscosity of SAE 75W-85W
are recommended for manual transaxle.
LUBRICANTS
- GREASES
Semi-solid lubricants, bear the
NLGI designation and
are further classified as grades 0, 1, 2, 3 etc.
Whenever “Chassis Lubricant” is specified,
Multi-
Purpose Grease, NLGI grade 2 should be used.
FUEL USAGE STATEMENT
Your vehicle must use unleaded gasoline only.
This vehicle has a fuel filler tube especially designed
to accept only the smaller-diameter unleaded gaso- line
dispensrng nozzle.
Caution
Using leaded gasoline in your vehicle will damage
the catalytic converter, and affect the warranty
coverage validity.
All vehicles except those with DOHC engines
Your vehicle is designed to operate on unleaded
gasoline having a minimum octane rating of 87 or
91 RON (Research Octane Number).
Vehicles equipped with DOHC engines
Your vehicle is designed to operate on premiumunleaded gasoline having a minimum
octane rating
of 91 or 95 RON (Research Octane Number).
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14KO24
OOA0186
GENERAL - Maintenance Service00-45
2.Inspect the wheel cylinder boots for evidence of a brake
fluid leak. Visually check the boots for cuts, tears or heat cracks. (A slight amount of fluid on the boot may
not be a leak, but may be preservative fluid used at
assembly.)
Checking the Brake Shoes for Wear. Thiclkness
of lining (B)
Limit: 1.0 mm
(.04 in.)
14.BRAKEI HOSES (Check for deterioration or
leaks)MOOSBHA
Inspection of brake hoses and tubing should be included in
all brake service operations.
The hoses should be checked for: 1. Correct length, severe surface cracking, pulling, scuf- fing or worn spots. (If the fabric casing of the hoses is
exposed by cracks of abrasion in the rubber hose cover,
the hoses should be replaced. Eventual deterioration of hose may occur with possible bursting failure.)
2. Faulty installation, casing twisting or interference with wheel, tire of chassis.
15.BALL ,IOINT AND STEERING LINKAGE SEALS
(Inspect for grease leaks and damage)
MOOSBJAa
I, These components, which are permanently lubricated at the factory, do not require periodic lubrication.Damaged seals and boots should be replaced to
prevent leakage or contamination of the grease.
2. Inspect the dust cover and boots for proper sealing, leakage and damage. Replace them if defective. 16.DRIVE SHAFT BOOTS (Inspect for grease leaks
and damage) MOOSWAb
1. The.se components, which are permanently lubricated
at the factory, do not require periodic lubrication.
Damaged boots should be replaced to prevent leakage
or contamination of the grease.
2. Inspect the boots for proper sealing, leakage and damage. Replace it if defective.
17.REAR AXLE (Inspect oil level)-AWD MOOSBPQ
Remove the filler plug and inspect the oil level at bottom of
filler hole. If the oil level is slightly below the filler hole, it is
in satisfactory condition. 18.EXHAIJST
SYSTEM (CONNECTION PORTION
OF MUFFLER, PIPING AND CONVERTER HEAT
SHIELDS) (Check and service as
require$LsBU
1. Check for holes and gas leaks due to damage, corro- sion, etc.
2.Check the joints and connections for looseness and gas
leaks.
3. Check the hanger rubber and brackets for damage.
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ENGINE - Cvlinder Head GasketII-33
Identification markr3
Intake
side “4G63K”
Front of
Exhaust side
OlA0669
Front of engine
I)Intake side
Exhaust side
OlR0391
Ei;. -Qmm (in.)0140674 (2) Place the cylinder head gasket on top of the cylinder
block so that the identification mark is facing upwards
as in the illustration.
Caution
The cylinder head gasket is easy to mis-install, so
be sure to check it. If it is mis-installed, malfunc-
tions such as no oil rising to the cylinder head will
occur.
32. INSTALLATION OF CYLINDER HEAD ASSEMBLYI31.
CYLINDER HEAD BOLT
(1) Use a scraper to clean the gasket surface of the cylin-
der head assembly.
Caution
Take care that no foreign material gets into the
engine coolant passages or oil passages.
(2) When installing the cylinder head bolts, check that theshank length of each bolt meets the limit. If the limit is
exceeded, replace the bolt.
Limit: Max. 99.4 mm (3.91 in.)
(3) Apply engine oil to the threaded part of the bolt and the
washer.
(4) According to the tightening sequence, tighten the bolts to the specified torque 80 Nm (58 ftlbs.).
(5) Loosen bolts completely.
(6) Torque bolts to 20 Nm (14.5
ft.lbs.).
(7) Tighten bolts l/4 turns (90”) more.
(8) Tighten bolts
l/4 turns (90”) additionally.
25. INSTALLATION OF WATER INLET FITTING, THERMOSTAT AND THERMOSTAT CASE ASSEMBLY
(1) Loosen the water inlet pipe bolt shown in the illustra-tion.
(2) Apply specified sealant to the thermostat case assem- bly as shown in the illustration.
Specified sealant: MITSUBISHI GENUINE PART
No.MD970389 or equivalent
(3) Apply a small amount of water to the O-ring of the
water inlet pipe, and press the thermostat case assem-bly onto the water inlet pipe.
(4) Install the thermostat case assembly mounting bolt.
(5) Tighten the water inlet pipe bolt.
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ENGINE - Timina Belt11-41
I
I
(3) Turn the crankshaft clockwise by two teeth of the
camshaft sprocket.
Caution
As the purpose of this procedure is to apply the
proper amount of tension on the timing belt, be sure
not to rotate the crankshaft counter-clockwise or
place pressure on the belt to check the amount of
tension.
Tensioner
spacer
OlR0404
(4) Apply force on tensioner toward turning direction, (inthe direction of the arrow) such that no portion of the
belt raises out in portion A, place the belt on the
camshaft sprocket such that the belt sprocket teeth
are fully engaged.
(5) Tighten the tensioner installation bolt and tensioner spacer in that order.
Caution
If the tensioner spacer is tightened first, the ten-
sioner will rotate with it and belt tension be thrown
out of adjustment. Always tighten the bolt first.
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(6) Check to see that the clearance between the outside of the belt and the cover are within the standard value
by grasping the tension side (between the camshaft
sprocket and oil pump sprocket) of the centre part of
the timing belt between the thumb and index finger.
Standard value: 14 mm
(.55 in.)
6 x 20(23 x .78)
6 x 20(23 x .78)
6 x 25t.23 x ,981
11. INSTALLATION OF TIMING BELT FRONT LOWER COV- ER/9.
TIMING BELT FRONT UPPER COVER
Note that the timing belt lower and upper cover attaching
bolts differ in size from one place to another.
Bolt diameter
x length
mm (in.)6x 20t.23 x ,781011672

ENGINE - Cylinder Head Gasket11-79
Front of engine I)Intake side
Exhaust side
OlR0391
Fuel rail/
Hig; pressure \
O-ring
hose
03Aoo79
< 1993 models>
(1) Use a scraper to clean the gasket surface of the cylin- der head assembly.
Caution
Take care that no foreign material gets into the
coolant passages or oil passages.
(2) When installing the cylinder head bolts, check that the shank length of each bolt meets the limit. If the limit is
exceeded, replace the bolt.
Limit: Max. 99.4 mm (3.91 in.)
(3) Apply engine oil to the threaded part of the bolt and the washer.
(4) According to the tightening sequence, tighten the bolts
to the specified torque 80 Nm (58 ftlbs.).
(5) Loosen bolts completely.
(6) Torque bolts to 20 Nm (14.5 ftlbs.).
(7) Tighten bolts
l/4 turns (90”) more.
(8) Tighten bolts
l/4 turns (90”) additionally.
TSB Revision 21. CONNECTION OF HIGH-PRESSURE FUEL HOSE
When connecting the high-pressure fuel hose to the fuelrail, apply a coating of engine oil to the hose union, and in-
sert so that the O-ring is not damaged.

(8) Install the rubber plug to the timing belt rear cover.
ENGINE
- Timing Belt
*‘: Up to 1990 models*>. Up to 1992 models A*
B+2

C*’
Thread diameterx thread length
A: 6x
16 1.24x.63)B: 6x22
(.24?87j*‘, 6x18 (.24~.70)*~,*~C: 6x20
(.24x.79)*‘,
6x25 (.24x.98)*2,*3D: 6x28 (.24x1.10)
mm (in.)OlA0681
11. INSTALLATION OF TIMING BELT LOWER COVER/
10. TIMING BELT UPPER COVER
The dimensions of the installation bolts for the timing covers differ according to the installation location, so be
sure not to install the bolts in the incorrect locations.
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13-90 FUEL SYSTEM - On-Vehicule Inspection of MFI Components
INJECTORS
Fuel
Connector
Solenoid coil
Plunger
Needle valve -----I
InjectionFilter6FUO514
M13rrAA
Multiport
fuel injection relay
No.1 &j No.2& No.3& No,4+
tI
lFUO642
Engine control module connector
CJ=JW=U-I
0 1 LO636
OPERATION
l The
injectorsare electromagnetic-valve-
equipped injection nozzles that function to inject
fuel based upon injection signals from the
engine control module.
lBecause the surface area of the injection ports is
fixed and because the pressure of the fuel
relative to the pressure within the manifold is
also regulated to a fixed pressure, the amount of
fuel injection by injectors is determined by the
TROUBLESHOOTING HINTS
Hint 1:
If there is a problem with starting while the engine is
warm, perform the combustion test and check for leakage of the injectors.
Hint
2,
If the engine can’t be started, and the injectors are
not activated during cranking, the cause is probably
a malfunction such as described below, not with the
injectors.
(I) Malfunction of the circuit for supply of power to the engine control module, or of the ground cir-
cuit.
(2) Malfunction of the multiport fuel injection relay.
(3) Malfunction of the crankshaft position sensor and/or the camshaft position sensor.
Hint
3.
If there is a cylinder for which the idling condition
does not change when, during idling, the fuel length of time that the needle valve is open, or,
in other words, by the length of time of current
~-
flow to the solenoid coil.
lBattery power supply is supplied, by way of the
multiport fuel injection relay, to the injectors.
When the engine control module switches ON
the power transistor within the unit and current
flows to the solenoid coil, the injectors open and
fuel is injected.
injection of the injectors is cut off in sequence,
check that cylinder as described below.
(1) Check the injector and harness.
(2) Check the spark plugs and the high-tension
cable.
(3) Check the compression pressure. Hint 4:
If the injector activation time deviates from the
standard value even though the results of the
checking of the injector’s harness and of the injector itself are normal, the cause may be pressumed to
be one of the following,
(1) Incomplete combustion within the cylinder. (Malfunction of the spark plugs, the ignition coil,
the compression pressure, etc.)
(2) Incomplete close contact of the EGR valve seat.
(3) Increased engine resistance.
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FUEL SYSTEM -On-Vehicle Inspection
of
MFI
Components13-295
Filter
Connector
Solenoid coil
Plunger
Needle valve -&$
lnjedtion6FUO51
Multiport
fuel injection relayMIBvrbA1
I
The area enclosed with ~~~~ is@I Harness side
applicable onlv for Turbo.
connector
Enginecofitrolmodule
Engine control module connectorI6FU1547
OlLo63
OPERATION
l The injectorsare electromagnetic-valve-
equipped injection nozzles that function to inject
fuel based upon injection signals from the engine control module.
lBecause the surface area of the injection ports is
fixed and because the pressure of the fuel relative to the pressure within the manifold is
also regulated to a fixed pressure, the amount of
fuel injection by injectors is determined by the
TROUBLESHOOTING HINTS
Hint 1:
If there is a problem with starting while the engine is
warm, perform the combustion test and check for leakage of the injectors.Hint 2:
If the engine can’t be started, and the injectors are
not activated during cranking, the cause is probably
a malfunction such as described below, not with the injectors.
(1) Malfunction of the circuit for supply of power to
the engine control module, or of the ground cir-
cuit.
(2) Malfunction of the multiport fuel injection relay.
(3) Malfunction of the crankshaft position sensor and/or the camshaft position sensor.
Hint 3:
If there is a cylinder for which the idling condition
does not change when, during idling, the fuelinjection of the injectors is cut off in sequence,
length of time that the needle valve is open, or,
in other words, by the length of time of current
flow to the solenoid coil.
lBattery power supply is supplied, by way of the
multiport fuel injection relay, to the injectors.
When the engine control module switches ON
the power transistor within the unit and current
flows to the solenoid coil, the injectors open and
fuel is injected.
check that cylinder as described below.
(1) Check the injector and harness.
(2) Check the spark plugs and the high-tension
cable.
(3) Check the compression pressure. Hint 4:
if the injector activation time deviates from the
standard value even though the results of the
checking of the injector’s harness and of the injector
itself are normal, the cause may be pressumed to
be one of the following,
(1) Incomplete combustion within the cylinder.
(Malfunction of the spark plugs, the ignition coil,
the compression pressure, etc.)
(2) Incomplete close contact of the EGR valve seat.
(3) Increased engine resistance.
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