Service Manuals, User Guides, Schematic Diagrams or docs for : . Car Manuals Mitsubishi Galant 1989-1993 Approved service repair manuals 89-93BE
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GROUP INDEX
Service Manual General ...............................................
Gl=lLRNT
Fusible Link and Fuse Location ...........
Inspection Terminal Location ...............
Grounding Location ...............................
1989-1990-1991-1992-1993
Diode Location .......................................
Volume 2
Junction Block ........................................
Body & Electrical
Centralized Junction ..............................
FOREWORD
This Service Manual has been prepared with the Inspection of Harness Connector.. .......
latest service information available at the time of
publication. It is subdivided into various group
categories and each section contains diagnostic, Configuration Diagrams ........................
disassembly, repair, atid installation prbcedures
along with complete specifications and tightening Circuit Diagrams .....................................
references. Use of this manual will aid in properly
performing any servicing necessary to maintain or
restore the high levels of performance and reliability Steering ...................................................
designed into these outstanding vehicles.
4Wheel Steering System .......................
VW
Body .........................................................
Exterior
WE SUPPORT
VOLUNTARY TECHNICIAN
CERTIFICATION THROUGH
Heater, Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . Ia
and Ventilation
Engine Electrical . . . . . . . . . . . . . ..*...............
Chassis Electrical .............................
Alphabetic Index ...............................
A MITSUBISHI
I
PlOlDRSALESOFAMERlCAIllC.
NOTE:
For information concerning all components
other than the electrical system and on-
Mltsubishl M o t o r s Corporation r e s e r v e s t h e right t o m a k e c h a n g e s in
design or to make addltlons to or Improvements In Its p r o d u c t s wlthout
vehicle service procedures for engines and
lmposmg a n y obllgatlons u p o n Itself to mstall t h e m o n Its p r o d u c t s transmissions, refer to Volume 1 "Chassis
previously m a n u f a c t u r e d & Body" of this paired Service Manual.
For overhaul procedures of engines or
transmissions, refer to the separately issued
0 1992 Mitsubishi Motors Corporation ReprinWdinUSA Engine Service Manual or Manual/Auto-
matic Transmission Service Manual.
2 GENERAL - Fusible Link and Fuse Location
FUSIBLE LINK AND FUSE LOCATION M16BA-
Name Symbol
cm a
Dedicated fuse block 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
q \\ i
B
13A0218
TSB Revision
GENERAL - Inspection Terminal Location 3
I
INSPECTION TERMINAL LOCATION
Name Symbol Name Symbol
Engine speed detection connector* C Oxgen sensor check connector D
Fuel pump check connector A Data link connector E
Ignition timing adjustment connector B
I
NOTE
(1) *:
(2) The "Name" column is arranged in alphabetical
order.
I - I
13A0218
Oxgen sensor
connector
check
4 GENERAL - Grounding Location
GROUNDING LOCATION
c
#
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e - Grounding Location 5
Anterior>
1340218
MFI control unit
WA0535
6 GENERAL - Grounding Location
From 1990 models
1 TSB Revision
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 (auto-cruise control circuit)
A
Diode (ABS circuit) B
IL Diode (theft-alarm system circuit)
c
Diode (sunroof circuit) C
1 Diode (ACTIVE-ESC circuit)
AC
Diode (AJT fluid temperature warning
light circuit) A
NOTE
The "Name" column is arranged in alphabetical order.
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8 GENERAL - Junction Block
JUNCTION BLOCK MlWG.
:Up t o 1990 models>
I
T I
I t
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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. .
GENERAL - Junction Block
To front
harness
-To roof
harness
To instrument
panel harness
To body
harness
No - Heater
connection relay
Fuse block
(Multipurpose
fuse)
c !! - II - I
\@)I
\ I I ,
16A6661 16A0002
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10 GENERAL - Junction Block
r
I I i
-
-
- -
-
-
-
- -
0
f 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
1 Front side 1 1 Reverse side 1
-To roof
harness
To front
harness
To instrument
panel harness
To body
* harness
No
connection
Fuse block
(Multipurpose
fuse)
WA1236
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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:
*`:
1989 models 1990 models From 1990.5 models
16A1092
1989 models From 1990 models
16A1093
1 TSB Revision
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 Pink 30
I
-W/Y
I
-ii
El El
I
83 q a
1 J
Sub fusible link 16AO567
1990 models From 1990.5 models
16A1092
16A1093
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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
2 10 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
ACC 3 10 Clock, motor antenna, radio, ETACS control unit*4
4 15 Remote-controlled mirror switch, cigarette lighter
Sattery 5 15 Door lock relay
`gnition IG2 6 10 Power/Economy change over switch , over drive
switch switch , park/neutral position switch , ELC
4-speed automatic transaxle control module, auto-cruise con-
trol unit
ACC 7 15 Wiper and washer, ETACS control unit*3, wiper relay
8 10 Headlight relay, horn
IG1 9 10 Combination meter, auto-cruise control switch, motor antenna,
ETACS control unit, seat belt timer*`, clutch pedal position switch
10 10 Hazard switch
3attery 11 20 ACTIVE-ECS power relay
12 20 -
13 20 Sunroof relay
14 30 Heater relay
15 15 Stop light, auto-cruise control unit
Jnition IGl 16 10 Back-up light , park/neutral position switch
witch
lattery 17 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*'
18 IO -
NOTE
*"
*2'
*3'
*41
Multipurpose
' fuse
1 TSB Revision I
GENERAL - Centralized Junction 15
DEDICATED FUSE (relay box inside engine compartment)
Power supply circuit No. Rated capacity (A) Housing color Circuit
Battery 1 10 Red Hazard light circuit
Taillight relay (Battery) 2 10 Red Taillight circuit
Headlight relay (Battery) 1 3 (
Battery 141 15 I Blue I ECS circuit I
5 10 Red A/C compressor circuit
6 25,30* transparent Condenser fan motor circuit
Headlight relay (Battery) 7 15 Blue Fog light circuit
NOTE
* : DOHC
I Deciiczd f u s e
03 m El
El
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16 GENERAL - Centralized Junction
CENTRALIZED RELAY
Classification Name Classification Name
Relay box in- A-01X Headlight relay Passenger C-72X Power window relay
side engine compartment
compartment A-02X Taillight relay relay box c-73x Door lock relay
A-03X Radiator fan motor relay (HI)
A-04X Radiator fan motor relay (LO)
c-75x Defogger timer I
A-05X Generator relay
A-06X ACTIVE-ECS solenoid valve
power relay
A-07X A/C compressor clutch relay
A-07-1X Fog light relay
NOTE
*I: <1989 models>
*2:
compartment
relay box>
^-74X
El
:-73x
I
Y
:-72X
El
16AO667
16A0566
IOD or STORAGE CONNECTOR
Classification Name
Relay box inside engine compartment A-07-2X IOD or Storage Connector
NOTE
IOD: Ignition Off Draw
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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
(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.
Housing lance
Caution
Tool No. 753787-l supplied by AMP can be used instead of
screwdriver.
16R1321
(4) Insert needle through a hole provided on terminal and raise
contact point of male terminal.
tr Needle
16R1322
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.
Housing lance
16R1323
(3) Inset-t screwdriver through a hole provided on terminal and
raise contact point of male terminal.
B 16R1324
J
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GENERAL - Inspection of Harness Connector 19
RECTANGULAR WATERPROOF CONNECTOR
(1) Disengage front holder by using a screwdriver and remove it.
I \\ 16R1326 I
(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.
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.
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.
Terminal lance ,wmSO \
I
\ TSB Revision 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.
Observe the symptom carefully. Check if there are also other
1 Observation of Problem Symptoms problems.
In determining the probable causes, it is necessary to check the
2 Determination of Probable Causes 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.
II Checking of Parts Associated with Troubleshooting is carried out by making step by step checks until
3 Probable Causes and Determination the true cause is found. Always go through the procedures con-
of Faultv Parts I sidering what check is to be made where for the best results.
II
4 Repair and Confirmation
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.
TSB Revision
GENERAL - How to Diagnose 21
INSPECTION
1. Visual and aural checks
Check relay operation, blower motor rotation, light illumina-
tion, etc. visually or aurally. The flow of current is invisible but
can be checked by the operation of the parts.
2. Simple checks
For example, if a headlight does not come on and a faulty fuse
or poor grounding is suspected, replace the fuse with a new
one or ground the light to the body by a jumper wire to deter-
mine which part is responsible for the problem.
1680222
I
3. Checking with instruments
$!?I
Pointer Use an appropriate instrument in an adequate range and read
the indication correctly. You must have sufficient knowledge
D and experience to handle instruments correctly.
C so -
V - \ OCV
\
50
`1
#z
Changeover knob 1 1680224
INSPECTION INSTRUMENTS
In inspection, make use of the following instruments.
1. Test lights
A test light consists of a 12V bulb and lead wires. It is used
to check voltages or shortcircuits.
1660225
2. Self-power test light
A self-power test light consists of a bulb, batten/ and lead.
wires connected in series. It is used to check continuity or
grounding.
1660226
r
-
1 TSB Revision
22 GENERAL - How to Diagnose
3. Jumper wire
A jumper wire is used to close an open circuit. Never use one
to connect a power supply directly to a load.
1660227
\
b Power line
4. Voltmeter
A voltmeter is used to measure the circuit voltage. Normally,
the positive (red lead) probe is applied to the point of voltage
measurement and the negative (black lead) probe to the body
ground.
Ground -
1680228
5. Ohmmeter
An ohmmeter is used to check continuity or measure resis-
tance of a switch or coil. If the measuring range has been
changed. the zero point must be adjusted before measure-
ment.
Normal open (NO) type' CHECKING SWITCHES
OFF ON In a circuit diagram, a switch is represented by a symbol and in the
idle state.
1. Normal open or normal close switch
in
-1 x
Switches are classified into those which make the circuit open
and those which make the circuit closed when off.
Current does not flow Curren; flows
Normal cllOI;e (NC) type
OFF ON
ai a in
1
x
Current flows Current does not flow
16A0255
I
1 TSB Revision I
GENERAL - How to Diagnose 23
2. SWITCH CONNECTION
This figure illustrates a complex switch. The continuity
between terminals at each position is as indicated in the
table below.
OFF
1 st stage 0 I n 0
I 4
2nd stage
3rd staae
4th stage
16A0253
NOTE
W denotes continuity between terminals.
10W698
CHECKING RELAYS
Cover
1. When current flows through the coil of a relay, its core is
Coil + Spring magnetized to attract the iron piece, closing (ON) the contact
Iron
at the tip of the iron piece. When the coil current is turned off,
core the iron piece is made to return to its original position by a
Iron spring, opening the contact (OFF).
piece,
Contact
1680231 I
2. By using a relay, a heavy current can be turned on and off
Power supply
by a switch of small capacity. For example, in the circuit
I I shown here, when the switch is turned on (closed), current
flows to the coil of the relay. Then, its contact is turned on
Relay (closed) and the light comes on. The current flowing at this
time to the switch is the relay coil current only and is very
small.
1 r 16A0254
Normal open (NO) type 3. The relays may be classified into the normal open type and the
Deenergized state 1 Energized state
normal close type by their contact construction.
NOTE
The deenergized state means that no current is flowing
through the coil and the energized state means that current is
flowing through the coil.
Current does not flow Current flows
16A0256
I -
1 TSB Revision
24 GENERAL - How to Diagnose
00
-a
Normal close (NC) type
Deenergized state Energized state
When a normal close type relay as illustrated here is checked,
there should be continuity between terminals (1) and (2) and
between terminals 3 and 4 when the relay is deenergized,
00
and the continuity should be lost between terminals 3 and 4
when the batten/ voltage is applied to the terminals 1 and 2. A
u
x
relay can be checked in this manner and it cannot be deter-
mine if a relay is okay or faulty by checking its state only when
it is deenergized (or energized).
Current flows Current does not flow
16AO257
CHECKING FUSES
A blade type fuse has test taps provided to allow checking of
the fuse itself without removing it from the fuse block. The
fuse is okay if the test light comes on when its one lead is
connected to the test taps (one at a time) and the other lead is
grounded. (Change the ignition switch position adequately so
that the fuse circuit becomes live.)
16BO235
State of fuse blown due to overcurrent CAUTIONS IN EVENT OF BLOWN FUSE
When a fuse is blown, there are two probable causes as follows
: One is that it is blown due to flow of current exceeding its rating.
The other is that it is blown due to repeated on/off current flowing
through it. Which of the two causes is responsible can be easily
determined by visual check as described below.
(1) Fuse blown due to current exceeding rating
The illustration shows the state of a fuse blown due to this
cause. In this case, do not replace the fuse with a new one
1660237
hastily since a current heavy enough to blow the fuse has
flowed through it. First, check the circuit for shorting and
check for abnormal electric parts. Only after the correction of
such shorting or parts, fuse of the same capacity should be
used as a replacement. Never use a fuse of lager capacity than
the one that has blown. If such a fuse is used, electric parts or
wirings could be damaged before the fuse blows in the event
an overcurrent occurs again.
(2) Fuse blown due to repeated current on/off
The illustration shows the state of a fuse blown due to re
peated current on/off. Normally, this type of problem occurs
after fairly long period of use and hence is less frequent than
the above type. In this case, you may simply replace with a
new fuse of the same capacity.
TSB Revision
GENERAL - How to Diagnose 25
CHECKING CABLES AND WIRES
1. Check connections for looseness, rust and stains.
2. Check terminals and wires for corrosion by battery electrolyte,
etc.
3. Check terminals and wires for open circuit or impending open
circuit.
4. Check wire insulation and coating for damage, cracks and de-
grading.
5. Check conductive parts of terminals for contact with other
metallic parts (vehicle body and other parts).
6. Check grounding parts to verify that there is complete conti-
nuity between attaching bolt(s) and vehicle body.
7. Check for incorrect wiring.
8. Check that wirings are so clamped as to prevent contact with
sharp corners of the vehicle body, etc. or hot parts (exhaust
manifold, pipe, etc.).
9. Check that wirings are clamped firmly to secure enough clear-
ance from the fan pulley, fan belt and other rotating or moving
parts.
10. Check that the wirings between the fixed parts such as the
vehicle body and the vibrating parts such as the engine are
made with adequate allowance for vibrations.
HANDLING ON-VEHICLE BATTERY
When checking or servicing does not require power from the on-
vehicle battery, be sure to disconnect the cable from the battery
(-) terminal. This is to prevent problems that could be caused by
shorting of the circuit. Disconnect the (-1 terminal first and recon-
nect it last.
Caution
1. Before connecting or disconnecting the negative cable,
be sure to turn off the ignition switch and the lighting
switch.
(If this is not done, there is the possibility of semicon-
ductor parts being damaged.)
2. For MFI-equipped models, after completion of the work
steps [when the battery's negative (-) terminal is
connected], warm up the engine and allow it to idle for
approximately five minutes under the conditions des-
cribed below, in order to stabilize engine control
conditions, and then check to be sure that the idling is
satisfactory.
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