Mitsubishi Sigma 1990-1995 Workshop Service Repair Manual

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Type: Car

Vendor:

Sku: 61588

Tags: 1990 1991 1992 1993 1994 1995 Car Cars Mitsubishi Sigma

Product variants

Description

The Mitsubishi Sigma, produced for the model years 1990 through 1995, represents the second generation (ES/EC platform) of this mid-size sedan. Often recognized for its stylish design and commendable handling, particularly with the available V6 engine options, the Sigma offered a blend of performance and comfort, competing with established models of its era. Its engineering quality and reliability were hallmarks of Mitsubishi's automotive offerings during this period, with variants potentially featuring advanced systems like All-Wheel Control. This workshop service repair manual provides comprehensive guidance for the Mitsubishi Sigma. It covers all major vehicle systems, including engine mechanical and electrical components, manual and automatic transmissions, brake systems, suspension, steering, fuel, exhaust, cooling, and body electrical systems. The manual details routine maintenance, extensive repair procedures, component rebuilds, and electrical diagnostics, supported by hundreds of photos and illustrations. It is an essential resource for owners and technicians seeking to maintain, diagnose, and repair the vehicle effectively.

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Sigma

Generation:

Second Generation (ES/EC)

Codes

Platform Code:

ES/EC

👋 Introduction

Market Position

Segment:

Mid-size Sedan / Sports Sedan

Competitive Analysis

Key Competitors Era:

Toyota Camry, Honda Accord, Nissan Maxima, Ford Taurus, Chevrolet Lumina, Mazda 626.

Key Features

Distinctive Traits:

Often praised for its handling and performance, particularly with the V6 engine option and available AWD (Super All-Wheel Control) on some variants, though AWD was more common on the Diamante in some markets. Known for its stylish design for the era.

Manual Value Proposition

Benefits For Owner:

Empowers owners to perform maintenance and repairs, saving money and extending vehicle lifespan. Provides deep technical understanding for accurate diagnosis and repair.

📋 Manual Details

Coverage Areas

Model Years Covered:

1990, 1991, 1992, 1993, 1994, 1995

Trim Levels Covered:

All styles (implied to cover base, SE, ES, GSi, potentially GSR depending on market)

Page Count

Estimated Page Count:

Hundreds of pages (exact count not specified, typical for full factory manuals)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine overhaul, disassembly, assembly, cylinder head, block, pistons, crankshaft, camshaft, timing system, lubrication system, cooling system.

Engine Electrical:

Ignition system, fuel injection system, starting system, charging system, ECU diagnostics, sensors, actuators, wiring diagrams.

Transmission Manual:

Clutch, gearbox, driveline, overhaul, adjustments.

Transmission Automatic:

Automatic transmission overhaul, torque converter, valve body, internal components, adjustments, diagnostic codes.

Brake System:

Disc brakes, drum brakes, ABS (if applicable), hydraulic system, master cylinder, calipers, wheel cylinders, brake lines, bleeding procedures.

Suspension Steering:

Front suspension (MacPherson strut), rear suspension (independent multi-link), shock absorbers, springs, control arms, steering gear, power steering system, alignment specifications.

Fuel System:

Fuel tank, fuel pump, fuel lines, fuel injectors, fuel pressure regulation, evaporative emission control (EVAP).

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, pipes, emissions control components.

Cooling System:

Radiator, water pump, thermostat, coolant hoses, fan, heater core.

Electrical Body:

Lighting system, wipers, horn, power windows, power locks, mirrors, interior lights, exterior lights, fuses, relays, body control modules.

Climate Control:

Air conditioning system, heater, ventilation, blower motor, controls, refrigerant handling.

Body And Chassis:

Body panels, doors, hood, trunk, glass, interior trim, frame specifications, corrosion protection.

Procedures Included

Routine Maintenance:

Oil change, filter replacement, fluid checks and top-offs, spark plug replacement, air filter replacement, brake inspection, tire rotation.

Troubleshooting:

Diagnostic procedures for common starting, running, electrical, and mechanical issues, fault code interpretation.

Repair Procedures:

Step-by-step instructions for component removal, installation, and repair for all major vehicle systems.

Component Rebuild:

Detailed instructions for complete disassembly and reassembly of major components like engines, transmissions, and differentials.

Electrical Diagnostics:

Diagnosis of electrical circuits, using multimeters, oscilloscopes, and interpreting wiring diagrams.

Alignment Specifications:

Front and rear wheel alignment angles (camber, caster, toe) and adjustments.

Diagnostic Troubleshooting Charts:

Likely includes structured troubleshooting charts to help pinpoint the root cause of issues.

Technical Depth

Depth:

Comprehensive (factory level detail, suitable for professional mechanics and experienced DIYers)

Wiring Diagrams Coverage:

Includes detailed wiring diagrams for electrical systems, crucial for diagnosing faults.

Illustrations

Type Of Illustrations:

Hundreds of photos, detailed illustrations, drawings, and enlarged insets.

Manual Features

Notes Cautions Warnings:

Integrates notes, cautions, and warnings throughout each chapter to highlight critical information and safety precautions.

Instruction Format:

Numbered instructions and bold figure numbers for easy cross-referencing with illustrations.

Table Of Contents:

Features a numbered table of contents for quick information retrieval.

📊 Manual Specifications

File Format

Format:

Compatibility:

Works on all PC based Windows operating systems and Mac.

Print Quality

Printability:

Printable without any restriction (entire manual or selected pages).

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Format)

Searchability

Text Searchability:

Implied to be searchable due to PDF format, enhancing usability.

⚙️ Engine Specifications

Primary Engine

Engine Options:

Typically included a 2.5L V6 (6G73) and potentially a 3.0L V6 (6G72) depending on market and specific model year. Base models might have had a 4-cylinder, but the V6 was prominent.

Performance

Power Output V6 Approx:

Around 170-200 hp (Varies by specific engine and market tuning).

Torque V6 Approx:

Around 190-220 lb-ft (Varies by specific engine and market tuning).

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI).

Engine Codes

Common Engine Codes:

6G73 (2.5L V6), 6G72 (3.0L V6).

🔧 Transmission

Standard

Transmission Options:

Available with both a 5-speed manual transmission and a 4-speed automatic transmission.

Optional

Optional Features:

All-Wheel Drive (AWD) or All-Wheel Control (AWC) was an option on certain high-trim models or performance variants, particularly those related to the Diamante's platform sharing.

Features

Automatic Transmission Features:

Electronically controlled, potentially with a sport or comfort mode.

📐 Dimensions

Exterior

Body Styles:

Primarily a 4-door sedan.

Weights

Curb Weight Approx:

Approx. 3200-3600 lbs (depending on engine and trim).

🛡️ Safety Features

Ratings

NHTSA Ratings:

Specific ratings for this model year are not readily available, but typical safety features of the era would be present.

Active Features

Active Safety Features:

Anti-lock Braking System (ABS) was often optional or standard on higher trims.

Passive Features

Passive Safety Features:

Frontal airbags for driver and passenger, crumple zones, side-impact door beams.

💡 Technology Features

Infotainment

Audio System:

Factory-installed AM/FM stereo with cassette player, often with optional CD player and premium sound system (e.g., Mitsubishi's own brand or optional premium brands). Digital tuning, seeking, tone controls.

Driver Assistance

Driver Assistance Features:

Limited by era. Cruise control was common. ABS was an available safety feature. No advanced driver-assistance systems (ADAS) like lane keeping or adaptive cruise control.

Connectivity

Connectivity Features:

Basic by modern standards. May have power antenna. No Bluetooth or USB connectivity. Aftermarket head unit upgrades are common.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 3,000-5,000 miles or 3-6 months, depending on driving conditions and oil type used.

Timing Belt Replacement Interval:

Crucial for V6 engines with timing belts. Generally recommended every 60,000 to 90,000 miles or 5-7 years. This manual would specify the exact interval.

Fluid Specifications

Engine Oil Type:

API SG or higher, SAE 10W-30 or 5W-30 recommended (specific viscosity depends on climate). Consult manual for precise specification.

Coolant Type:

Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water. Manual will specify type and capacity.

Automatic Transmission Fluid Type:

Typically Mitsubishi Genuine ATF SP-II or equivalent. Manual will specify exact type and capacity.

Power Steering Fluid Type:

ATF or specific power steering fluid. Manual will provide specification.

Known Issues

Common Problems:

Potential issues include timing belt wear (critical for V6), valve stem seals leading to oil consumption, CV joint wear (especially on AWD models), and minor electrical gremlins common to vehicles of this era. Suspension wear and exhaust system corrosion can also occur.

Filters

Oil Filter Part Number Example:

Manual would list OEM or equivalent aftermarket part numbers (e.g., Mitsubishi MD068099 or equivalent from Mann, Wix, Bosch).

Air Filter Part Number Example:

Manual would list OEM or equivalent aftermarket part numbers (e.g., Mitsubishi MR188118 or equivalent).

📚 Vehicle History

Brand Heritage

Mitsubishi History Context:

Mitsubishi Motors, a division of the Mitsubishi Group, has a long history in automotive manufacturing, known for its engineering and performance-oriented vehicles, including rally success.

Model Evolution

Sigma Legacy:

The Sigma nameplate evolved from earlier Mitsubishi models like the Galant Sigma. In many markets, the Sigma was a version of the Mitsubishi Diamante, known for its luxury and performance focus.

Production

Manufacturing Locations:

Primarily Japan, with potential assembly in other global locations depending on market.

🏆 Awards & Recognition

Recognitions

Historical Awards:

While specific awards for the Sigma model itself from 1990-1995 are not widely publicized, Mitsubishi vehicles of this era, particularly the Diamante platform variants, were often recognized for their styling and performance within their segments.