1988 Mitsubishi Starion Repair Manual

The 1988 Mitsubishi Starion is a rear-wheel drive sports coupe featuring turbocharged 2.6L 4-cylinder engine, 5-speed manual or 3-speed automatic transmission, independent rear suspension, and advanced fuel injection system. This comprehensive repair manual covers engine mechanical, fuel system, electrical, brakes, suspension, steering, transmission, and body repair procedures for proper maintenance and troubleshooting.

1. Vehicle Specifications 2. Engine Repair 3. Fuel System 4. Electrical System 5. Brake System 6. Suspension & Steering 7. Transmission 8. Cooling System 9. Body & Interior 10. Maintenance Schedule 11. Troubleshooting

Vehicle Specifications

Technical specifications for 1988 Mitsubishi Starion models.

Specification	Details
Engine	2.6L 4-cylinder turbocharged (G54B)
Horsepower	176 hp @ 5000 rpm
Torque	223 lb-ft @ 3500 rpm
Transmission	5-speed manual or 3-speed automatic
Drivetrain	Rear-wheel drive
Fuel System	Electronic Fuel Injection (EFI)
Brakes	Front disc, rear drum with optional ABS
Suspension	Independent front and rear
Wheelbase	96.9 inches
Curb Weight	2,900 lbs

Engine Repair

Complete engine service and repair procedures for G54B turbo engine.

Engine removal: Disconnect battery, drain fluids, remove accessories and mounts.
Cylinder head: Torque sequence 65-72 ft-lbs in proper pattern.
Timing balance shaft: Align marks at TDC compression stroke.
Turbocharger: Inspect for shaft play, replace seals if leaking oil.
Valve adjustment: Set clearance to 0.008" intake, 0.010" exhaust (cold).

WARNING! Allow engine to cool completely before servicing. Use proper lifting equipment.

Fuel System

Fuel injection system maintenance and repair.

Fuel pressure test: Should be 36-38 psi at idle.
Injector replacement: Release fuel pressure before disconnecting lines.
Fuel pump: Located in fuel tank, access through trunk floor.
Throttle body: Clean with approved cleaner, do not damage TPS sensor.
Air flow meter: Test resistance 200-600 ohms between terminals.

CAUTION! Always relieve fuel system pressure before servicing. No smoking or open flames.

Electrical System

Battery: Group 58, 550 CCA minimum.
Alternator: 75 amp output, test voltage 13.5-14.5V.
Starter: 1.4 kW, draw current 130-160 amps.
Ignition System: Electronic distributor, 0.8-1.0 mm gap.
Fuse Box: Located under dashboard driver side.
Wiring Diagrams: Color-coded for easy troubleshooting.
ECU: Located behind glove compartment.
Spark Plugs: NGK BPR6ES, gap 0.028-0.031".

Brake System

Hydraulic brake system service and repair procedures.

Front Disc Brakes: Rotor minimum thickness 0.882", pad wear limit 0.079". Rear Drum Brakes: Drum maximum diameter 9.06", shoe wear limit 0.039".

Bleeding sequence: Right rear, left rear, right front, left front. Master cylinder: Bench bleed before installation. ABS system: Special diagnostic tool required for service.

Suspension & Steering

Front MacPherson strut and rear independent suspension service.

Front strut replacement: Support control arm, remove three top nuts.
Ball joints: Check for play, replace if movement exceeds 0.125".
Wheel alignment: Toe-in 0.08±0.08", camber -0.25°±0.5°.
Power steering: Fluid type Dexron II, check for leaks at rack.
Steering gear: Adjust worm bearing preload if loose.

Tip: Always use jack stands when working under vehicle.

Transmission

Manual and automatic transmission service procedures.

Manual transmission: KM132 5-speed, fluid capacity 2.1 quarts 75W-90.
Clutch replacement: Disc wear limit 0.012", pressure plate check for cracks.
Automatic transmission: 3-speed, fluid capacity 6.3 quarts Dexron II.
Shift linkage: Adjust for proper gate alignment.
Differential: Final drive ratio 3.54:1, fluid capacity 1.6 pints.
Driveshaft: Check U-joints for play, replace if worn.
Shift forks: Inspect for wear in manual transmission.
Torque converter: Stall test should be 2000-2400 rpm.

WARNING! Support transmission properly during removal. Use correct fluid types.

Cooling System

Radiator, thermostat, and cooling system maintenance.

Radiator capacity: 8.7 quarts with heater. Thermostat: Opens at 180°F. Cooling fan: Electric thermostatic control. Pressure cap: 13 psi rating.

Body & Interior

Body repair and interior component service.

Door adjustment: Loosen hinge bolts to align. Glass replacement: Remove interior trim panels. Seat repair: Track lubrication and mechanism service. Dashboard: Remove carefully to access instruments.

CAUTION! Use proper tools for trim removal to avoid damage.

Maintenance Schedule

Routine maintenance intervals for optimal performance.

Service	Interval	Details
Oil Change	3,000 miles	Use 10W-30, replace filter
Spark Plugs	30,000 miles	NGK BPR6ES, gap 0.030"
Timing Belt	60,000 miles	Replace belt and tensioner
Coolant	30,000 miles	50/50 ethylene glycol mix
Brake Fluid	2 years	DOT 3, complete system flush

Reset: Service reminder lights as required.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel pump, ignition	Check fuel pressure, spark, ECU codes.
Turbo lag	Wastegate, boost leaks	Inspect vacuum lines, wastegate operation.
Overheating	Thermostat, radiator	Test thermostat, flush cooling system.
Brake vibration	Warped rotors	Resurface or replace front rotors.
Transmission noise	Low fluid, bearings	Check fluid level, inspect for wear.

Technical Support: Mitsubishi Motors Service Department

Parts: Genuine Mitsubishi parts recommended for optimal performance