Mitsubishi MOTORS GALANT 1990 User manual

BACKUP
Service Manual
Gl=lLRNT
1989-1990-1991-1992-1993
Volume 2
Body & Electrical
FOREWORD
This Service Manual has been prepared with the
latest service information available at the time of
publication. It is subdivided into various group
categories and each section contains diagnostic,
disassembly, repair, atid installation prbcedures
along with complete specifications and tightening
references. Use of this manual will aid in properly
performing any servicing necessary to maintain or
restore the high levels of performance and reliability
designed into these outstanding vehicles.
This BACKUP DSM manual IS to be used ONLY as a BACKUP. Please DO NOT REDISTRIBUTE
WHOLE SECTIONS. This BACKUP was sold to you under the fact that you do indeed OWN
a GENUINE DSM MANUAL. It CANNOT BE considered a REPLACEMENT (Unless your original
manual was lost or destroyed.)
Please See README.N or README.HTML for addItIonal InformatIon.
Thank you. G~mm~emymanual@hotma~l.com
WE SUPPORT
VOLUNTARY TECHNICIAN
CERTIFICATION THROUGH
A
MITSUBISHI
PlOlDRSALESOFAMERlCAIllC.
Mltsubishl Motors Corporation reserves the right to make changes in
design or to make addltlons to or Improvements In Its products wlthout
lmposmg any obllgatlons upon Itself to mstall them on Its products
previously manufactured
0 1992 Mitsubishi Motors Corporation
ReprinWdinUSA
GROUP INDEX
General ...............................................
Fusible Link and
Fuse Location
...........
Inspection Terminal
Location ...............
Grounding Location ...............................
Diode Location .......................................
Junction Block ........................................
Centralized Junction
..............................
Inspection of Harness Connector..
.......
Configuration
Diagrams ........................
Circuit Diagrams .....................................
Steering ...................................................
4 Wheel Steering
System
.......................
VW
Body .........................................................
Exterior
Heater,
Air
Conditioning
. . . . . . . . . . . . . . . . . . . . . . . .
and Ventilation
Ia
Engine Electrical
. . . . . . . . . . . . . ..*...............
Chassis Electrical .............................
Alphabetic Index
...............................
NOTE:
I
For information concerning all components
other than the electrical system and on-
vehicle service procedures for engines and
transmissions, refer to Volume 1 “Chassis
& Body” of this paired Service Manual.
For overhaul procedures of engines or
transmissions, refer to the separately issued
Engine Service Manual or Manual/Auto-
matic Transmission Service Manual.

2
GENERAL - Fusible Link and Fuse Location
FUSIBLE LINK AND FUSE LOCATION
M16BA-
<Engine compartment>
cm a
13A0218
Name
Dedicated fuse block
Symbol
B
Fusible link box (main fusible links and sub
NOTE
(I) For details of fusible link and fuse, refer to P.12.
(2) ;rhdee;‘Name” column is arranged in alphabetical
<Up to 1990 models (vehicles with
ABS)> <From 1990.5 models>
B
q \ i
\
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GENERAL - Inspection Terminal Location
3
I
INSPECTION TERMINAL LOCATION
Name Symbol Name Symbol
Engine speed detection connector* <DOHC>
C
Oxgen sensor check connector <DOHC>
D
Fuel pump check connector AData link connector
E
Ignition timing adjustment connector
NOTE
B
I
(1) *: <From 1990 models>
(2) The “Name” column is arranged in alphabetical
order.
<Engine comuartment>
I-
I
<Interior>
Oxgen sensor
check connector
13A0218

4GENERAL
-
Grounding Location
GROUNDING LOCATION
<Engine compartment>
c
#
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e - Grounding Location
5
Anterior>
1340218
MFI control unit
WA0535
<DOHC-FM/D>

6
GENERAL - Grounding Location
From 1990 models
<Luggage compartment>
<DOHC-MD>
<DOHC>
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GENERAL - Diqde Location 7:
DIODE LOCATION
I
I
1
I
Name
1 Symbol
Name
1 Symbol 1
Diode (4WS fluid level warning light circuit)
A
Diode (ABS circuit)
B
1 Diode (ACTIVE-ESC circuit)
I c
Diode (auto-cruise control circuit)
<up to 1990 models>
A
Diode (sunroof circuit) <From 199 1 models>
C
Diode (AJT fluid temperature warning
light circuit) <AWD-AR>
NOTE
L Diode (theft-alarm system circuit)
A
AC
The “Name” column is arranged in alphabetical order.
<Interior>
<From 1991 models>
<Up to 1990 models>
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8
GENERAL - Junction Block
JUNCTION BLOCK
MlWG.
:Up to 1990 models>
I
T
I
t
-
-
I
t
Vote
1) The alphabetical symbols used for connectors correspond to the alphabetical symbols for connectors on next page.
‘2) The ( ) indicates the connection terminal at the harness side.
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I
. .

GENERAL - Junction Block
To front
harness
No -
connection
-To roof
harness
To instrument
panel harness
Heater
relay
Fuse block
(Multipurpose
fuse)
c !!
II
I
-
-
\@)I
\ I
I,
16A6661
16A0002
To body
harness
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10
GENERAL - Junction Block
<From 1991 models>
r
i
-
-
-
-
-
I I
-
-
-
-
f
0
5
U-J
Kx35-AC-w1701-I
NOTE
(1) The alphabetical symbols used for connectors correspond to the alphabetical symbols for connectors on next page.
(2) The (
) indicates the connection terminal at the harness side.
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GENERAL - Junction ~Block
71
No
connection
1 Front side 1
-To roof
harness
To front
harness
To instrument
panel harness
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I
WA1236
Fuse block
(Multipurpose
fuse)
1 Reverse side 1
To body
* harness

12
GENERAL - Centralized Junction
CENTRALIZED JUNCTION
M16BB-
MAIN FUSIBLE LINK (direct connection to battery’s positive 0 terminal)
No. Circuit
Housing color Rated capacity
(A)
1
Generator circuit
Black*‘, BIue*2 80*‘,
1 oo*2
2 ABS circuit (control unit power supply)
Blue
20
3 ABS circuit (hydraulic unit power supply)
Yellow
60
NOTE
*I: <I989 models>
*‘: <From 1990 models>
<Vehicles without ABS>
1989 models 1990 models From 1990.5 models
16A1092
<Vehicles with ABS>
1989 models
From 1990 models
16A1093
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GENERAL - Centralized Junction
SUB FUSIBLE LfNK (relay box inside engine compartment, fusible link box)
No.
Circuit
Housing color Rated capacity
(Al
1
Junction block (Multipurpose fuse @,@,@I, 0, @, 0.0)
A/C circuit Yellow
60
2
Power window circuit
Pink 30
3
ACTIVE-ECS circuit Green
40
4
Defogger circuit
Pink 30
5
ignition switch and generator circuit
Pink 30
6 Radiator fan motor and condenser fan motor circuit
Pink 30
7
Headlight and tail light circuit
Green 40
8
MFI circuit
Blue 20
9
Automatic seatbelt circuit <From
1990
models>
Pink
30
I
-W/Y
I
-ii
83
El
q
El
1
a
I
J
Sub fusible link
16AO567
<Vehicles without ABS>
1990 models
16A1092
From 1990.5 models
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I
<Vehicles with ABS>
16A1093

14
GENERAL - Centralized Junction
MULTI-PURPOSE FUSE (inside junction block)
Power supply circuit No.
Rated capacity (A) Load circuit
Ignition IG2 1
IO EPS control unit
switch
210
Heater relay, blower switch, defogger timer, power window
relay (Vehicles without ETACS), sunroof power relay (Vehicles
without ETACS), ABS power relay, ACTIVE-ECS power relay
Sattery
‘gnition
switch
ACC 3
4
5
IG2 6
10
15
15
10
Clock, motor antenna, radio, ETACS control unit*4
Remote-controlled mirror switch, cigarette lighter
Door lock relay
Power/Economy change over switch <A/T>, over drive
switch <A/T>, park/neutral position switch <A/T>, ELC
4-speed automatic transaxle control module, auto-cruise con-
trol unit <A/T>
ACC 7
15
810
IG1 9
10
Wiper and washer, ETACS control unit*3, wiper relay
Headlight relay, horn
Combination meter, auto-cruise control switch, motor antenna,
ETACS control unit, seat belt timer*‘, clutch pedal position switch
3attery
Jnition
witch
10 10
Hazard switch
11 20
ACTIVE-ECS power relay
12 20
-
13
20 Sunroof relay
14 30 Heater relay
15 15
Stop light, auto-cruise control unit <M/T>
IGl 16
10
Back-up light <M/T>, park/neutral position switch <A/T>
lattery 17
IO
,’
18 IO
MFI control unit, clock, dome light, luggage compartment light,
door light, map light (Vehicles without sunroof), radio, ETACS
control unit, sunroof relay (Vehicles with ETACS), combination
meter, ELC 4-speed automatic transaxle control module, key re-
minder switch, automatic seatbelt control unit*’
-
NOTE
*” <I989 models>
*2’ <From 1990 models>
*3’ <Up to 1990 models>
*41 <From 1991 models>
Multipurpose
’ fuse
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I

GENERAL - Centralized Junction
15
DEDICATED FUSE (relay box inside engine compartment)
Power supply circuit
Battery
Taillight relay (Battery)
Headlight relay (Battery)
No. Rated capacity (A) Housing color
Circuit
1
10
Red Hazard light circuit
210
Red Taillight circuit
1 3 (
Battery
141 15 I
Blue
I
ECS circuit
I
Headlight relay (Battery)
510
6
25,30*
715
Red
transparent
Blue
A/C compressor circuit
Condenser fan motor circuit
Fog light circuit
NOTE
* : DOHC <From 1992 models>
I Deciiczd fuse
03
El
m
El
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16
GENERAL - Centralized Junction
CENTRALIZED RELAY
Classification
Relay box in-
A-01X
side engine
compartment A-02X
A-03X
A-04X
A-05X
A-06X
A-07X
A-07-1X
Name
Headlight relay
Taillight relay
Radiator fan motor relay (HI)
Radiator fan motor relay (LO)
Generator relay
ACTIVE-ECS solenoid valve
power relay
A/C compressor clutch relay
Fog light relay
NOTE
*I: <1989 models>
*2: <From 1991 models>
<Relay box inside engine compartment>
Classification Name
Passenger
C-72X Power window relay
compartment
relay box
c-73x
Door lock relay
c-75x
Defogger timer
I
16AO667
IOD or STORAGE CONNECTOR <From 1991 models>
<Passenger
compartment
relay box>
^-74X
El
:-73x
I
Y
:-72X
El
16A0566
Classification
Relay box inside engine compartment A-07-2X
Name
IOD or Storage Connector
NOTE
IOD: Ignition Off Draw
<Relay box inside engine compartment>
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GENERAL - Inspection of Harness Connector
17
INSPECTION OF HARNESS CONNEC-
TOR
mwcAAA
CONTINUITY AND VOLTAGE TEST FOR CONNEC-
TOR
Following procedures shall be followed for testing continuity and
voltage at connector in order to prevent improper contact and
deterioration of waterproof in connector.
CONVENTIONAL (NON-WATERPROOF) CONNECTOR
Check shall be done by inserting a probing needle from harness
side.
WATER PROOF CONNECTOR
Caution
Do not insert probing needle from harness side as it will de-
teriorates waterproof and cause for rusting. To inspect the
energized circuit, use the ECI checker.
fi:CK FOR IMPROPER ENGAGEMENT OF TERMI-
When terminal stopper of connector is out of order, engagement
of male and female terminals becomes improper even when con-
nector itself is engaged perfectly and terminal sometimes slips out
to rear side of connector. Ascertain, therefore, that each terminal
does not come off connector by pulling each harness wire.
ENGAGING AND DISENGAGING OF CONNECTOR
TERMINAL
Connector which gives loose engagement shall be rectified by
removing female terminal from connector housing and raise its
lance to establish securer engagement. Removal of connector
housing and raise its lance to establish securer engagement. Re
moval of connector terminal used for ECI and ELC 4 AK control
circuit shall be done in the following manner.
COMPUTER CONNECTOR
(1) Insert screwdriver il.4 mm (06 in.) width] as shown in the
figure, disengage front holder and remove it.

18
GENERAL - Inspection of Harness Connector
Housing lance
16R1321
tr
Needle
16R1322
Housing lance
16R1323
B
16R1324
J
(2) Insert harness of terminal to be rectified deep into connector
from harness side and hold it there.
(3) Insert tip of screwdriver [1.4 mm (06 in.) width] into connector
in a manner as shown in the figure, raise housing lance slightly
with it and pull out harness.
Caution
Tool No. 753787-l supplied by AMP can be used instead of
screwdriver.
(4) Insert needle through a hole provided on terminal and raise
contact point of male terminal.
ROUND WATERPROOF CONNECTOR
(1) Remove waterproof cap by using a screwdriver.
(2) Insert tip of screwdriver (1.4 mm (06 in.) or 2.0 mm (.08 in.)
width] into connector in a manner as shown in the figure, raise
housing lance slightly with it and pull out harness.
(3) Inset-t screwdriver through a hole provided on terminal and
raise contact point of male terminal.
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GENERAL - Inspection of Harness Connector
19
I \\ I 16R1326
RECTANGULAR WATERPROOF CONNECTOR
(1) Disengage front holder by using a screwdriver and remove it.
tiousing lance
16R1326
I
(3) Press contact point of male terminal down by holding a screw-
driver [1.4 mm (.06 in.) width] in a manner as shown in the
figure.
(2) Insert tip of screwdriver (“0.8 mm (.03 in.) width] into connec-
tor in a manner as shown in the figure, push it lightly to raise
housing lancer and pull out harness.
*If right size screwdriver is not available, convert a conven-
tional driver to suit the size.
Terminal lance
,wmSO
\
I
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INJECTOR CONNECTOR
(1) Remove waterproof cap.
(2) Insert tip of screwdriver (1.4 mm (06 in.) width] into connector
in a manner as shown in the figure, press in terminal lance and
pull out harness.
(3) Press contact point of male terminal down by holding a screw-
driver [1.4 mm (06 in.) width] in a manner as shown in the
figure.
Caution
Correct lancer to be in proper condition before terminal is
inserted into connector.
I

20
GENERAL - ‘How to Diagnose
HOW TO DIAGNOSE
M16DMC
The most important point in troubleshooting is to determine “Probable Causes”. Once the probable causes are
determined, parts to be checked can be limited to those associated with such probable causes. Therefore, unnec-
essary checks can be eliminated. The determination of the probable causes must be based on a theory and be
supported by facts and must not be based on intuition only.
TROUBLESHOOTING STEPS
If an attempt is made to solve a problem without going through correct steps for troubleshooting, the problem
symptoms could become more complicated, resulting in failure to determine the causes correctly and making
incorrect repairs. The four steps below should be followed in troubleshooting.
1 Observation of Problem Symptoms
2 Determination of Probable Causes
I I
Checking of Parts Associated with
3 Probable Causes and Determination
of Faultv Parts
I
I I
4 Repair and Confirmation
Observe the symptom carefully. Check if there are also other
problems.
In determining the probable causes, it is necessary to check the
wiring diagram to understand the circuit as a system. Knowledge
of switches, relays and other parts is necessary for accurate de-
termination. The causes of similar problems in the past must be
taken into account.
Troubleshooting is carried out by making step by step checks until
the true cause is found. Always go through the procedures con-
sidering what check is to be made where for the best results.
After the problems are corrected, be sure to check that the sys-
tem operates correctly. Also check that new problems have not
been caused by the repair.
INFORMATION FOR DIAGNOSTIC
This manual contains the cable diagrams as well as the individual circuit drawings, operational explanations,
and troubleshooting hints for each component required to facilitate the task of troubleshooting. The
information is compiled in the following manner:
(1) Cable diagrams show the connector positions, etc., on the actual vehicle as well as the harness path.
(2) Circuit drawings show the configuration of the circuit with all switches in their normal positions.
(3) Operational explanations include circuit drawings of voltage flow when the switch is operated and how
the component operates in reaction.
(4) Troubleshooting hints include numerous examples of problems which might occur, traced backward in a
common-sense manner to the origin of the trouble. Problems whose origins may not be found in this
manner are pursued through the various system circuits.
NOTE
Components of ECI, ETACS, ECS, etc. with ECU do not include 3 and 4 above. For this information, refer
to a manual which includes details of these components.
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