Mitsubishi Galant 1983-2012 Workshop Repair Service Manual PDF with Wiring Diagrams - MMTBSGLT8312OPES.zip

A full factory-level repair guide featuring Electrical Wiring Diagrams for the Mitsubishi Galant covering 1983 through 2012, packed with every detail you need to service, troubleshoot, fix, and rebuild the vehicle the way a professional technician would.

Inside the Mitsubishi Galant 1983-2012 workshop service repair manual, you'll find:

* Numbered table of contents easy to use so that you can find the information you need fast.

* Detailed sub-steps expand on repair procedure information

* Numbered instructions guide you through every repair procedure step by step.

* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.

* Notes, cautions and warnings throughout each chapter pinpoint critical information.

* Bold figure number help you quickly match illustrations with instructions.

* Detailed illustrations, drawings and photos guide you through every procedure.

* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:

Total Pages: 33,224 pages

File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)

Language: English

TABLE OF CONTENTS

'01..1

00..1

GENERAL BODY AND CHASSIS..2

HOW TO USE THIS MANUAL..4

MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS..4

ON-VEHICLE SERVICE..4

SERVICE PROCEDURES..4

DEFINITION OF TERMS..4

STANDARD VALUE..4

LIMIT..4

REFERENCE VALUE..4

DANGER, WARNING, AND CAUTION..4

TIGHTENING TORQUE INDICATION..4

SPECIAL TOOL NOTE..4

MODEL INDICATIONS..4

TROUBLESHOOTING GUIDELINES..8

VERIFY THE COMPLAINT..8

DETERMINE POSSIBLE CAUSES..8

FIND THE PROBLEM..8

REPAIR THE PROBLEM..8

VERIFY THE REPAIR..8

HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS..8

TROUBLESHOOTING CONTENTS..8

1. STANDARD FLOW OF DIAGNOSTIC TROUBLESHOOTING..8

2. SYSTEM OPERATION AND SYMPTOM VERIFICATION TESTS..8

3. DIAGNOSTIC FUNCTION..8

4. DIAGNOSTIC TROUBLE CODE CHART..8

5. SYMPTOM CHART..9

6. DIAGNOSTIC TROUBLE CODE PROCEDURES..9

7. SYMPTOM PROCEDURES..9

8. SERVICE DATA REFERENCE TABLE..9

9. CHECK AT ECU TERMINALS..9

Terminal Voltage Checks..9

Terminal Resistance and Continuity Checks..9

10. INSPECTION PROCEDURES USING AN OSCILLOSCOPE..9

HOW TO USE THE INSPECTION PROCEDURES..9

HARNESS INSPECTION..11

MEASURES TO TAKE AFTER REPLACING THE ECU..11

CONNECTOR MEASUREMENT SERVICE POINTS..12

IF INSPECTING WITH THE CONNECTOR CONNECTED (WITH CIRCUIT IN A CONDITION OF CONTINUITY)..12

IF INSPECTING WITH THE CONNECTOR DISCONNECTED..12

CONNECTOR INSPECTION SERVICE POINTS..14

VISUAL INSPECTION..14

CONNECTOR PIN INSPECTION..14

CONNECTOR ENGAGEMENT INSPECTION..14

HOW TO COPE WITH INTERMITTENT MALFUNCTIONS..15

TO COPE WITH INTERMITTENT MALFUNCTION; 1. Ask the customer about the malfunction..15

2. Determine the conditions from the customer's responses..15

3. Use simulation test..15

4. Verify the intermittent malfunction is eliminated..15

SIMULATION TESTS..16

INSPECTION SERVICE POINTS FOR A BLOWN FUSE..17

VEHICLE IDENTIFICATION..17

VEHICLE IDENTIFICATION NUMBER LOCATION..17

VEHICLE IDENTIFICATION CODE CHART PLATE..18

VEHICLE IDENTIFICATION NUMBER LIST..18

VEHICLE IDENTIFICATION CODE PLATE..19

VEHICLE SAFETY CERTIFICATION LABEL..19

ENGINE MODEL STAMPING..20

THEFT PROTECTION..20

PRECAUTIONS BEFORE SERVICE..22

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)..22

SERVICING ELECTRICAL SYSTEM..23

VEHICLE WASHING..24

APPLYING ANTI-CORROSION AGENT OR OTHER UNDERCOAT AGENTS..24

SCAN TOOL (MUT-II)..24

TOWING AND HOISTING..25

WRECKER TOWING RECOMMENDATION..25

FRONT TOWING PICKUP..25

REAR TOWING PICKUP..25

TOWING WHEN KEYS ARE NOT AVAILABLE..25

SAFETY PRECAUTIONS..26

LIFTING, JACKING SUPPORT LOCATION..27

FLOOR JACK..27

POST TYPE..27

GENERAL DATA AND SPECIFICATIONS..28

TIGHTENING TORQUE..30

LUBRICATION AND MAINTENANCE..31

MAINTENANCE SCHEDULES..31

SEVERE SERVICE..31

ENGINE OIL..31

LUBRICANTS AND GREASES..31

FUEL USAGE STATEMENT..32

GASOLINES CONTAINING ALCOHOL..32

GASOLINES CONTAINING METHY TERTIARY BUTYL ETHER (MTBE)..32

MATERIALS ADDED TO FUEL..32

RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE..32

LUBRICANT SELECTION..33

ENGINE OIL..33

Oil Viscosity..34

SELECTION OF COOLANT..34

COOLANT..34

SCHEDULED MAINTENANCE TABLE..34

MAINTENANCE SERVICE..37

1. FUEL SYSTEM - TANK, PIPE LINES, CONNECTIONS AND FUEL TANK FILLER TUBE CAP (CHECK FOR LEAKS)..37

2. FUEL HOSES (CHECK CONDITION)..37

3. AIR CLEANER ELEMENT (REPLACE)..38

4. EVAPORATIVE EMISSION CONTROL SYSTEM - EXCEPT EVAPORATIVE EMISSION CANISTER (CHECK FOR LEAKS AN...38

5. SPARK PLUGS (REPLACE)..38

6. IGNITION CABLES (REPLACE)..39

7. DISTRIBUTOR CAP AND ROTOR (CHECK) 3.0L ENGINE..39

DISTRIBUTOR CAP AND ROTOR INSPECTION..39

8. TIMING BELT (REPLACE)..39

9. DRIVE BELTS - FOR GENERATOR, WATER PUMP, POWER STEERING PUMP (CHECK CONDITION)..39

Water Pump2.4L ENGINE, A/C Compressor 3.0L ENGINE and Generator Drive Belt Tension Check and ...40

When using scan tool MB991502..40

When using the tension gauge..41

Belt deflection check..42

Generator Drive Belt Tension Adjustment 2.4L ENGINE..42

Generator and A/C Compressor Drive Belt Tension Adjustment 3.0L ENGINE..43

Power Steering Oil Pump and A/C Compressor 2.4L ENGINE Drive Belt Tension Check and Adjustment..44

When using scan tool MB991502..44

When using a tension gauge..44

Belt deflection check..44

2.4L ENGINE..45

3.0L ENGINE..45

10. ENGINE OIL (CHANGE)..45

11. ENGINE OIL FILTER (CHANGE)..46

ENGINE OIL FILTER SELECTION..46

OIL FILTER REPLACEMENT..47

12. AUTOMATIC TRANSAXLE FLUID (CHECK FLUID LEVEL AND CHANGE)..48

Check Fluid Level..48

Change Fluid..49

13. ENGINE COOLANT (CHANGE)..50

Changing Coolant..50

14. DISC BRAKE PADS (CHECK FOR WEAR)..51

15. REAR DRUM BRAKE LININGS AND REAR WHEEL CYLINDERS (CHECK FOR WEAR AND LEAKS)..52

16. BRAKE HOSES (CHECK FOR DETERIORATION OR LEAKS)..52

17. BALL JOINT AND STEERING LINKAGE SEALS (CHECK FOR GREASE LEAKS AND DAMAGE)..53

18. DRIVE SHAFT BOOTS (CHECK FOR GREASE LEAKS AND DAMAGE)..53

19. SRS MAINTENANCE (SRS COMPONENT CHECK FOR DAMAGE, FUNCTION, CONNECTION TO WIRING HARNESS, ETC)..54

SRS Warning Light Check..54

SRS Component Visual Check..55

Side Impact Sensors..55

SRS Air Bag Control Unit (SRS-ECU)..56

Air Bag Module, Steering Wheel and Clock Spring..56

Front Seatback Assembly with Side Air Bag Module..58

20. EXHAUST SYSTEM - CONNECTION PORTION OF MUFFLER, MUFFLER PIPES AND CONVERTER HEAT SHIELDS (CHE...59

21. TIRES (ROTATE)..60

22. AIR PURIFIER FILTER (REPLACE)..60

MAIN SEALANT AND ADHESIVE TABLE..60

GENERAL..1

00E..63

GENERAL ELECTRICAL..63

HARNESS CONNECTOR INSPECTION..64

CONNECTOR CONTINUITY AND VOLTAGE TEST..64

IMPROPER TERMINAL ENGAGEMENT CHECK..64

CONNECTOR TERMINAL ENGAGEMENT AND DISENGAGEMENT..65

COMPUTER CONNECTOR..65

ROUND WATERPROOF CONNECTOR..66

RECTANGULAR WATERPROOF CONNECTOR..66

INJECTOR CONNECTOR..67

HOW TO DIAGNOSE..67

INSPECTION..69

INSPECTION INSTRUMENTS..69

CHECKING SWITCHES..71

CHECKING RELAYS..72

CHECKING FUSES..73

CAUTIONS IN EVENT OF BLOWN FUSE..73

CABLES AND WIRES CHECK..74

BATTERY HANDLING..74

GENERAL ELECTRICAL SYSTEM CHECK..75

STEP 1. Remove the blown fuse and connect the test light across the fuse terminals (Switch: OFF)...75

STEP 2. Switch on the switch and disconnect the illumination light connector...76

11A..79

ENGINE MECHANICAL 2.4L..80

GENERAL DESCRIPTION..81

ENGINE DIAGNOSIS..81

SPECIAL TOOLS..82

ON VEHICLE SERVICE..84

DRIVE BELT TENSION CHECK AND ADJUSTMENT..84

IGNITION TIMING CHECK..84

IDLE MIXTURE CHECK..85

CURB IDLE SPEED CHECK..86

COMPRESSION PRESSURE CHECK..86

MANIFOLD VACUUM CHECK..87

LASH ADJUSTER CHECK..88

Bleeding lash adjuster system..89

ENGINE ASSEMBLY..91

REMOVAL SERVICE POINTS..93

A POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL..93

B A/C COMPRESSOR REMOVAL..93

C ENGINE MOUNT BRACKET REMOVAL..93

D ENGINE ASSEMBLY REMOVAL..94

INSTALLATION SERVICE POINTS..94

A ENGINE ASSEMBLY INSTALLATION..94

B ENGINE MOUNT STOPPER INSTALLATION..94

C ENGINE MOUNT BRACKET INSTALLATION..94

D HIGH-PRESSURE FUEL HOSE INSTALLATION..94

CAMSHAFT AND CAMSHAFT OIL SEAL..95

REMOVAL SERVICE POINTS..96

A CAMSHAFT SPROCKET REMOVAL..96

B ROCKER ARM AND SHAFT ASSEMBLY REMOVA..96

INSTALLATION SERVICE POINTS..96

A ROCKER ARM AND SHAFT ASSEMBLY INSTALLATION..96

B CAMSHAFT OIL SEAL INSTALLATION..97

C CAMSHAFT SPROCKET INSTALLATION..97

OIL PAN..98

REMOVAL SERVICE POINT..99

A OIL PAN REMOVAL..99

INSTALLATION SERVICE POINTS..99

A OIL PAN INSTALLATION..99

B DRAIN PLUG GASKET INSTALLATION..99

INSPECTION..100

CRANKSHAFT FRONT OIL SEAL..100

REMOVAL SERVICE POINT..101

A CRANKSHAFT SPROCKET REMOVAL..101

INSTALLATION SERVICE POINTS..101

A CRANKSHAFT FRONT OIL SEAL INSTALLATION..101

B CRANKSHAFT SPROCKET B/CRANKSHAFT SENSING BLADE/CRANKSHAFT SPROCKET INSTALLATION..101

CRANKSHAFT REAR OIL SEAL..102

REMOVAL SERVICE POINT..102

A ADAPTER PLATE/DRAIVE PLATE REMOVAL..102

INSTALLATION SERVICE POINTS..103

A CRANKSHAFT REAR OIL SEAL INSTALLATION..103

B DRIVE PLATE/ADAPTER PLATE INSTALLATION..103

CYLINDER HEAD GASKET..103

REMOVAL SERVICE POINTS..106

A POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL..106

B CYLINDER HEAD ASSEMBLY REMOVAL..106

INSTALLATION SERVICE POINTS..106

A CYLINDER HEAD GASKET INSTALLATION..106

B CYLINDER HEAD ASSEMBLY INSTALLATION..106

C HIGH-PRESSURE FUEL HOSE INSTALLATION..107

TIMING BELT..108

REMOVAL SERVICE POINT..109

A TIMING BELT REMOVAL..109

INSTALLATION SERVICE POINTS..109

A AUTO-TENSIONER INSTALLATION..109

B TIMING BELT INSTALLATION..110

C TIMING BELT TENSION ADJUSTMENT..111

TIMING BELT B..112

REMOVAL SERVICE POINTS..112

A CRANKSHAFT SPROCKET REMOVAL..112

B TIMING BELT B REMOVAL..113

INSTALLATION SERVICE POINTS..113

A TIMING BELT B INSTALLATION..113

B CRANKSHAFT SENSING BLADE/CRANKSHAFT SPROCKET INSTALLATION..113

C TIMING BELT B TENSION ADJUSTMENT..114

SPECIFICATIONS..114

ENGINE..79

11B..117

ENGINE OVERHAUL 2.4L..117

SPECIAL TOOLS..118

GENERATOR AND IGNITION SYSTEM..122

INSTALLATION SERVICE POINT..123

A CAMSHAFT POSITION SENSOR SUPPORT INSTALLATION..123

TIMING BELT..124

REMOVAL SERVICE POINTS..125

A TIMING BELT REMOVAL..125

BOIL PUMP SPROCKET REMOVAL..125

C CRANKSHAFT BOLT LOOSENING..126

D CRANKSHAFT SPROCKET REMOVAL..126

E TIMING BELT "B" REMOVAL..126

F COUNTERBALANCE SHAFT SPROCKET REMOVAL..126

G CRANKSHAFT SPROCKET"B" REMOVAL..127

H CAMSHAFT SPROCKET REMOVAL..127

INSTALLATION SERVICE POINTS..127

A CAMSHAFT SPROCKET INSTALLATION..127

B ENGINE SUPPORT BRACKET INSTALLATION..127

C SPACER INSTALLATION..128

D COUNTERBALANCE SHAFT SPROCKET INSTALLATION..128

E TIMING BELT"B" INSTALLATION..128

F CRANKSHAFT BOLT TIGHTENING..129

G OIL PUMP SPROCKET INSTALLATION..129

H AUTO-TENSIONER INSTALLATION..130

I TIMING BELT INSTALLATION..130

INSPECTION..133

TIMING BELT..133

AUTO-TENSIONER..134

FUEL AND EMISSION PARTS..135

INSTALLATION SERVICE POINTS..136

A INJECTORS INSTALLATION..136

B FUEL PRESSURE REGULATOR INSTALLATION..136

C THROTTLE BODY GASKET INSTALLATION..137

INTAKE MANIFOLD..138

INSTALLATION SERVICE POINTS..138

A INTAKE MANIFOLD STAY INSTALLATION..138

B WATER INLET PIPE/O-RING INSTALLATION..139

C THERMOSTAT HOUSING INSTALLATION..139

D THERMOSTAT INSTALLATION..139

E SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE GAUGE UNIT..140

F SEALANT APPLICATION TO ENGINE COOLANT TEMPERATURE SENSOR..140

EXHAUST MANIFOLD..141

INSTALLATION SERVICE POINT..141