1989 MITSUBISHI GALANT brake

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
GENERAL
CONTENTS
GENERAL DATA AND SPECIFICATIONS.....23
HOWTOUSETHISMANUAL......................
3
Definition of Terms ......................................3
ExplanationofCircuitDiagrams..................7
Explanation of
ManualContents .................4
Explanation of the Troubleshooting
Guide .............................................................
6
Model
Indications .........................................3
Scope of Maintenance, Repair and
Servicing Explanations
..................................
3
Troubleshooting .............................................3
LUBRICATIONANDMAINTENANCE............
34
MAINTENANCE SERVICE............................... 39
AirCleanerElement
.....................................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
FuelHoses
...................................................39
Fuel System
.................................................39
Manual Transaxle ..........................................42
RearAxle......................................................45
Rear Drum Brake Linings and
RearWheel Cylinders
..................................44
Spark
Plugs...................................................40
Timing Belt...................................................40
MASTER
TROUBLESHOOTING.....................28
PRECAUTIONS
BEFORESERVICE................15
RECOMMENDED LUBRICANTS AND
LUBRICANT CAPACITIESTABLE..................35
SCHEDULED
MAINTENANCETABLE ...........38
SPECIAL HANDLING INSTRUCTIONS
FOR AWD MODELS
.......................................20
TABLE OF MAIN SEALANTS
AND
ADHESIVES ............................................46
TIGHTENING TORQUE
................................... 27
TOWING
ANDHOISTING ..............................17
VEHICLE
IDENTIFICATION .............................8
Chassis Number ...........................................
11
EngineModel
Stamping
...............................12
Theft Protection ............................................12
Vehicle Identification Code Chart Plate.......
8
Vehicle Identification Number List
..............8
Vehicle Identification Number Location .......
8
Vehicle Information
CodePlate...................1 1
Vehicle SafetyCertificationLabel................12

00-4GENERAL - How to Use This Manual
EXPLANATION OF MANUAL CONTENTSIndicates 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
mindicates 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.
Classificationsof 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 forinstallation 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

GENERAL - Towina and Hoisting
00-l 7
Sling type
Wheel lift type
Flat bed type
Sling type
Wheel lift type
Flat bed type TOWING AND HOISTING
WRECKER TOWING RECOMMENDATION

FRONT TOWING PICKUP
Caution
This vehicle cannot be towed by a wrecker using sling-type
equipment to prevent the bumper from deformation.
If this vehicle is towed, use wheel lift or flat bed
equipment.
The vehicle may be towed on its rear wheels for extended
distances provided the parking brake is released. It is recom-
mended that vehicles be towed using the front pickup
whenever possible.
REAR TOWING PICKUP
Caution
This vehicle cannot be towed by a wrecker using sling-type
equipment to prevent the axle beam from deformation. If this vehicle is towed, use wheel lift or flat bed
equipment.
Manual transaxle vehicles may be towed on the front wheels,
provided the transaxle is in neutral and the drive-line has not
been damaged. The steering wheel must be clamped in the
straight-ahead position with a steering wheel clamping device
designed for towing service use.
Caution
Do not use steering column lock to secure front wheel
position for towing.
Automatic transaxle vehicle may be towed on the front wheels at speeds not to exceed
50 km/h (30 mob) for a distances not
to exceed 30 km (18 miles).
Caution
If these limits cannot be met, the front wheels must be
placed on a tow dolly.
TOWING WHEN KEYS ARE NOT AVAILABLE
When a locked vehicle must be towed and keys are not available, the vehicle may be lifted and towed from the front.provided the parking brake is released. If not released, the rear
wheels should be placed on a tow dolly.
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00-20GENERAL - Special Handling Instructions for AWD Models
SPECIAL HANDLING INSTRUCTIONS
FOR AWD MODELS
TOWIN
G
MomMA
Towing methods
If a tow truck is used Lifting method for 4 wheels-Good Remarks
l For AWD models, the basic principle is that
all four wheels are to be raised before
towing.
l The shift lever should be set to 1
st gear and
the parking brake should be applied. >
l The selector lever should be set to “P” position and the parking brake should be
applied.

OOA0032
Front wheels lifted-No good l The vehicle must not be towed by placing
only its front wheels or only the rear wheels
on a rolling dolly, because to do so willresult in deterioration of the viscous
coupling and result in the viscous coupling
causing the vehicle to jump forward
suddenly.
OOA0034
Front wheels lifted-No good l
If only the front wheels or only the rear
wheels are lifted for towing, the bumper
will be damaged. In addition, lifting of the rear wheels causes
the oil to flow forward, and may result in
heat damage to the rear bushing of the
transfer, and so should never be done.
Rear wheels lifted-No good
OOA0033
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GENERAL - Special Handling Instructions for AWD Models00-21
Free roller
OOPO038
Axle stand
OOPOO37
Towino hook
Tenslon
bar
Front
eJ
Anchor plate
&-16PO209 14AO198
OOP003E
SPEEDOMETER TEST
IF A FREE ROLLER IS USED
1.Set the free roller on the floor (at the rear wheels) so that it
is aligned with the vehicle’s wheelbase and the rear tread.
2.Carefully move the vehicle onto the tester and free roller.
3. Set the speedometer tester in place.
4. Perform the speedometer test. For information concerning the measurement of speed and
the allowable error, refer to GROUP
54-Meters and
Gauges.
Caution
Do not operate the clutch suddenly, or increase or
reduce speed suddenly during the work.
IF THE REAR WHEELS ARE JACKED UP
1. Move the vehicle onto the speedometer tester.
2. Jack up the rear wheels, and place axle stands at the designated part of the side sill.
3. Perform the speedometer test. For information concerning the measurement of speed and
the allowable error, refer to GROUP
54-Meters and
Gauges.
Caution
Do not operate the clutch suddenly, or increase or
reduce speed suddenly during the work.
Front wheel side slip
To prevent the front wheels from moving from side to side, attach tension bars to the towing hooks, and secure both ends
at anchor plates.
Accident prevention procedures (1) Attach a chain or wire to the rear traction hook. Make sure the end of the wire or chain is secured firmly.
(2) Take all other necessary precautions.
BRAKE TEST In order to stabilize the viscous coupling’s dragging force, the
brake test should always be conducted after the speedometer
test.
FRONT WHEEL MEASUREMENTS
1. Place the front wheels on the brake tester.
2. Perform the brake test.
Caution
The rear wheels should remain on the ground.
3. If the brake dragging force exceeds the specified value, jack up the vehicle and manually rotate each wheel tocheck the rotation condition of each wheel.
NOTE
If the brake dragging force exceeds the specified value, the
cause may be the effect of the viscous coupling’s dragging
force, so jack up the front wheels and check the rotation condition of the wheels in this state for no effect by the
viscous coupling’s dragging force.
,
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00-22GENERAL - Special Handling Instructions for AWD Models
REAR WHEEL MEASUREMENTS
After placing the rear wheels on the brake tester, follow thesame procedures as for the front wheel measurements.
WHEEL BALANCE
FRONT WHEEL MEASUREMENTS
1. Jack up the rear wheels, and place an axle stand at the designated part of the side sill.
2. Jack up the front wheels and set a pick-up stand and balancing machine in place.
Caution
1.Set so that the front and rear of the vehicle are at
the same height. Balancing
machlne
OOA0046
Balancw
Pick-up stand
0010024
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2. Release the parking brake.
3. Rotate each wheel manually and check to be sure
that there is no dragging.
3. Use the engine to drive the tires, and then make the measurement.
Caution
1.If an error is indicated in the state of engine drive,
motor drive can be used concurrently.
2.Do not operate the clutch suddenly, or increase or
reduce speed suddenly during the work.
REAR WHEEL MEASUREMENTS
1. Jack up the front wheels, and place an axle stand at the
designated part of the side sill.
2. Jack up the rear wheels, and then, after setting a pick-up stand and balancing machine in place, follow the same
procedure as for front wheel measurements.

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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