Mitsubishi Galant & 4G5/4G6 1990–1996 Repair Manual Set (P/N PWEE9037)

The paired Galant volumes cover vehicle servicing and electrical diagnosis, while the separate engine and automatic-transmission sections provide internal repair procedures for their listed units. The Chilton chapters add maintenance and repair coverage for the three vehicle lines.

Coverage varies by publication. The factory Galant volumes cover 1989–1993; the broader year range comes from the Chilton material and separate component publications. The Galant volumes direct internal engine and transmission overhaul to separate manuals; a dedicated manual-transaxle overhaul manual is not included.

PDF Search, Bookmarks and File Layout

Search and diagram detail: Text search is available in the Galant volumes, Chilton chapters, E-W engine manual, and engine supplement. The 4G5, W-E engine, and two automatic-transmission PDFs lack usable text search. The Mitsubishi files have section bookmarks; the Chilton files do not. Small wiring labels require zooming in the inspected diagrams.

The ZIP contains 20 printable English PDFs totaling 3,364 pages. Chilton occupies 12 files, the Galant volumes and automatic-transmission sections occupy two files each, and the engine material occupies four files. The total includes 68 notes pages, 19 blank pages, and both Galant cover pages; 18 of the blank pages occur within Volume 1’s automatic-transaxle section.

Engine Overhaul, Vehicle Service and Circuit Diagnosis

This selected content overview highlights the main repair areas. Other included topics include body-panel adjustment and heater-component removal.

• Engine overhaul: Step-by-step procedures for cylinder-head and valve work, piston and connecting-rod service, crankshaft inspection, and flywheel or drive-plate installation.

• Timing and balance shafts: Timing-chain and timing-belt procedures, tensioner inspection, silent-shaft installation, and configuration-specific timing illustrations.

• Fuel and engine controls: MFI component testing, fuel-injector checks, emissions diagnosis, and separate GDI fuel-system assembly procedures.

• Automatic transmissions: Internal disassembly and assembly, clutch inspection, valve-body service, differential work, and selective-fit adjustment tables.

• Chassis and brakes: Clutch hydraulics, halfshafts and CV joints, wheel bearings, suspension, steering, brake bleeding, and ABS diagnosis.

• Electrical fault tracing: Starting and charging tests, connector checks, circuit diagrams, and diagnostic information for body electrical systems.

The engine and transmission overhaul material suits readers experienced with precision measurement and specialist tooling; the Chilton chapters also explain routine service for DIY owners.

Engine Inspection and Configuration Differences

Engine sectional views distinguish assemblies with and without silent shafts. The 4G5 lubrication diagrams identify involute-gear and trochoid oil-pump layouts, while separate rocker-arm sections address hydraulic lash adjusters, mechanical valve adjustment, and jet valves.

The 4G6 publications distinguish single- and double-camshaft assemblies, front- and rear-wheel-drive installations, and MPI and GDI components. Inspection data cover valve timing angles, cylinder bore sizing, piston-ring end gaps, and bearing clearances. Plastic-area bolt tightening and form-in-place gasket application receive separate treatment.

The timing-belt section warns that locking a camshaft sprocket with a tool can damage the sprocket. The valve-spring section also identifies stem-seal damage caused by excessive spring compression.

When working with heavy engine components, proper lifting equipment and secure engine stands are essential to prevent personal injury or structural damage during teardown.

Transmission Assembly and Selective-Fit Data

Exploded assemblies show oil pumps, clutch packs, planetary gears, valve bodies, and transfer components. Pressure-plate, snap-ring, and spacer identification tables support clearance adjustment during reassembly.

Hydraulic control diagrams explain the transmission circuits. The W4A32/W4A33 sections extend into center-differential and transfer-unit repair, rather than stopping at transmission removal.

MFI Testing and Electrical Troubleshooting

The Galant fuel-system sections combine scan-tool data, oscilloscope waveforms, and connector-level checks. These references help distinguish sensor faults from power-supply or harness faults before components are replaced.

Named diagrams include the Power Distribution Circuit, MFI Circuit, and Anti-Lock Braking System Circuit. Connector views and harness configuration diagrams support circuit tracing, with separate information for applicable FWD, AWD, ECS, and four-wheel-steering configurations.

Selected Cylinder-Head and Internal-Clearance Data

For the 4G5 cylinder head, gasket-surface flatness is listed at 0.05 mm standard, with a 0.2 mm service limit.

The 4G63 eight-valve SOHC engine’s No. 1 piston-ring side clearance is 0.02–0.06 mm. The E-W 4G6 manual lists crankshaft end play at 0.05–0.25 mm standard, with a 0.40 mm limit.