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Mitsubushi SIGMA-DIAMANTE 1991-1995 Workshop Repair Manual

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The Sigma / Diamante, specifically the second generation sedan models produced between 1991 and 1995, represents a notable entry in the mid-size to full-size luxury sedan segment. Engineered by Mitsubishi...
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Mitsubushi SIGMA-DIAMANTE 1991-1995 Workshop Repair Manual
The Sigma / Diamante, specifically the second generation sedan models produced between 1991 and 1995, represents a notable entry in the mid-size to full-size luxury sedan segment. Engineered by Mitsubishi Motors Corporation, these vehicles were designed to offer a blend of comfort, performance, and advanced features for their era, often competing with established luxury marques. Key distinguishing features included the availability of All-Wheel Drive on select models, luxurious interior appointments, and advanced optional systems such as electronic suspension. The Diamante received industry recognition, notably being named Motor Trend's Import Car of the Year for 1992, underscoring its quality and appeal to consumers seeking a well-equipped and reliable sedan. This comprehensive workshop repair manual serves as an essential resource for maintaining and repairing your Sigma / Diamante. It covers a vast array of systems, including detailed procedures for the 6G72 V6 engine, both the F5M33 manual and F4A33 automatic transmissions, drivetrain, suspension, brakes, steering, body, chassis, electrical systems, and HVAC. The manual provides in-depth coverage of scheduled maintenance, diagnostic troubleshooting, repair and overhaul procedures, and the identification of special tools. With detailed step-by-step instructions, diagrams, and illustrations, this manual empowers owners, mechanics, and technicians to effectively service and preserve the longevity and performance of their vehicle.
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Sigma / Diamante
Model Variant:
Sedan
Generation:
Second Generation (Mitsubishi Sigma/Diamante Series JP:F11A/F12A, F13A/F14A, F15A/F16A; Mitsubishi Diamante Series US:J21A, J23A, J25A, J27A)
Codes
Chassis Codes Jp:
F11A, F12A, F13A, F14A, F15A, F16A
Chassis Codes Us:
J21A, J23A, J25A, J27A
Engine Code:
6G72
Transmission Codes:
F5M33 (Manual), F4A33 (Automatic)
👋 Introduction
Market Position
Segment:
Mid-size to Full-size Luxury Sedan
Target Audience:
Consumers seeking a comfortable, reliable, and well-equipped sedan, often with a focus on advanced features for its time.
Competitive Analysis
Key Competitors:
Toyota Avalon, Lexus ES, Nissan Maxima, Honda Accord (higher trims), Ford Taurus (higher trims)
Key Features
Distinguishing Features:
Available All-Wheel Drive (AWD) on some models, luxurious interior appointments, advanced (for its era) optional features like active suspension and climate control.
Manual Value Proposition:
Provides factory-level diagnostic and repair information, enabling cost-effective maintenance and troubleshooting for owners and independent workshops.
📋 Manual Details
Coverage Areas
Applicable Years:
1991, 1992, 1993, 1994, 1995
Covered Regions:
Global (specifications may vary slightly by market, but core procedures are universal)
Page Count
Estimated Pages:
Likely over 1000 pages (typical for comprehensive workshop manuals of this era)
Manual Type
Type:
Workshop Repair Manual
Language
Language:
English
Format
Format:
PDF (Digital Download)
📖 Manual Coverage
Systems Covered
Engine:
6G72 V6 (3.0L) - Overhaul, diagnostics, timing, fuel injection, ignition, cooling, lubrication, intake, exhaust, emission control
Transmission:
F5M33 5-Speed Manual Transmission (Clutch, gearbox overhaul, shift mechanisms, linkages, drive shafts), F4A33 4-Speed Automatic Transmission (Hydraulic control, valve body, torque converter, overhaul, diagnostics, fluid cooler)
Drivetrain:
Front Axle (CV joints, differential), Rear Axle (differential, drive components)
Suspension:
Front Suspension (MacPherson struts, control arms, ball joints, bushings, sway bar), Rear Suspension (Multi-link independent suspension, shock absorbers, springs, control arms, bushings)
Brakes:
Power Brake System (Master cylinder, booster, proportioning valve), Service Brakes (Front/Rear Disc Brakes, calipers, rotors, pads, hydraulic lines, parking brake)
Steering:
Power Steering System (Pump, rack and pinion, steering column, linkages)
Body And Chassis:
Body (frame, panels, doors, hinges, latches, glass), Exterior (trim, lighting, bumpers), Interior (seats, upholstery, trim panels, headliner), Body Mounts
Electrical:
Chassis Electrical (Wiring diagrams, lighting, instruments, power windows, locks, mirrors, horn, wipers), Engine Electrical (Starter, alternator, ignition system, sensors, ECU connectors), Supplemental Restraint System (SRS - Airbag system components, sensors, control module, pre-tensioners)
HVAC:
Heater, Air Conditioner, and Ventilation (Compressor, condenser, evaporator, blower motor, ducting, controls, refrigerant system)
Procedures Included
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, lubrication, tune-ups
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (where applicable), sensor testing
Repair And Overhaul:
Complete engine rebuild, transmission overhaul, brake system repair, suspension component replacement, steering system repair, electrical component repair, body panel repair
Special Tools:
Identification and usage of specialized tools required for specific repairs
Technical Depth
Depth:
Comprehensive (from basic maintenance to complete component overhauls and diagnostics)
Detail Level:
Detailed step-by-step instructions with exploded views, diagrams, and illustrations
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable if digitally created, image-based PDFs may have limited searchability
Print Quality
Printability:
Fully printable (selected pages or entire manual)
Binding Type
Binding:
Not applicable (Digital Download)
Paper Type
Paper Quality:
Not applicable (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
6G72
Engine Type:
SOHC V6 (Some models may have had DOHC variants, but the manual specifies the common 6G72 which is typically SOHC for this platform's core years)
Displacement:
3.0 Liters (2972 cc)
Performance
Horsepower Est:
140-150 HP (Varies slightly by market and specific engine tune)
Torque Est:
160-170 lb-ft (Varies slightly by market and specific engine tune)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI)
Fuel Type:
Unleaded Gasoline (87 Octane minimum)
Ignition System
Ignition Type:
Distributorless Ignition System (DIS) or Distributor-based system depending on specific market/year
🔧 Transmission
Standard
Transmission Type:
5-Speed Manual (F5M33)
Optional
Transmission Type:
4-Speed Automatic (F4A33)
Features
AWD Availability:
Available on select models with either transmission
Fluid Specs
Manual Transmission Fluid:
API GL-4, SAE 75W-90 gear oil (Consult manual for exact specification)
Automatic Transmission Fluid:
DIA QUEEN ATF SP-II (or equivalent like Dexron II/III compatible fluid - consult manual for exact specification)
📐 Dimensions
Exterior
Wheelbase Est:
Approx. 107.1 inches (2720 mm)
Length Est:
Approx. 191.7 inches (4870 mm)
Width Est:
Approx. 70.3 inches (1785 mm)
Height Est:
Approx. 55.1 inches (1400 mm)
Weights
Curb Weight Est:
Approx. 3300-3600 lbs (1497-1633 kg), varies with drivetrain and options
Wheels And Tires
Wheel Bolt Pattern:
5x114.3 mm (5x4.5 inches)
Standard Tire Size:
P205/60R15, P215/60R15, or P215/55R16 (depending on trim and year)
🛡️ Safety Features
Ratings
Crash Test Performance:
No specific standardized ratings like NHTSA/IIHS from the period are easily available for all markets, but generally considered a safe vehicle for its era. Consult specific regional automotive safety archives if available.
Active Features
ABS:
Anti-lock Braking System (ABS) - Standard on most models or widely available
Traction Control:
Traction Control System (TCS) - Optional on some models
Passive Features
Airbags:
Driver and front passenger airbags (SRS) - Standard on most models from 1993/1994 onwards, available or optional earlier.
Seat Belts:
3-point front and rear seat belts
💡 Technology Features
Infotainment
Audio System:
Factory premium audio systems with cassette player, optional CD player. Some models featured Rockford Fosgate branded audio.
Driver Assistance
Cruise Control:
Standard on most trims
Active Suspension:
Optional Electronic Controlled Suspension (ECS) on higher trim levels, offering adjustable ride stiffness.
Connectivity
Connectivity Features:
Limited by era; primarily focused on in-car entertainment and basic climate control. No Bluetooth or modern smartphone integration.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000-5,000 miles (4,800-8,000 km) or 3-6 months, whichever comes first (Consult manual for precise recommendation)
Timing Belt Replacement:
Typically every 60,000-90,000 miles (96,000-145,000 km) for the 6G72 engine. Crucial to replace as it's an interference engine.
Transmission Fluid Change:
Every 30,000-60,000 miles (48,000-96,000 km), depending on driving conditions. Automatic transmission fluid should be checked more frequently.
Fluid Specifications
Engine Oil Capacity:
Approx. 4.5 Liters (4.8 US Quarts) with filter (Consult manual for exact specification and oil type, e.g., 10W-30 or 5W-30)
Coolant Capacity:
Approx. 7.0 Liters (7.4 US Quarts) (50/50 mix of antifreeze and distilled water)
Power Steering Fluid:
Dexron II/III compatible ATF or specific Mitsubishi power steering fluid
Known Issues
Engine:
Timing belt failure if not replaced on schedule (interference engine), occasional head gasket issues, intake manifold gasket leaks.
Transmission:
Automatic transmission solenoid issues, occasional torque converter shudder, manual transmission clutch wear.
Suspension:
Worn bushings, strut mount failures, ball joint wear.
Electrical:
Power window regulators, HVAC blower motor resistor, aging wiring harnesses and sensor failures.
📚 Vehicle History
Brand Heritage
Manufacturer:
Mitsubishi Motors Corporation
Model Evolution
Platform Origin:
Developed from the Japanese market Mitsubishi Debonair, with the Diamante being a more globally oriented model.
Design Philosophy:
Aims to blend luxury, performance, and advanced technology for its time, often featuring sophisticated styling and a comfortable ride.
Production
Production Years:
1990-1996 (Globally for the second generation, with the covered range from 1991-1995)
Assembly Locations:
Primarily Japan (e.g., Mizushima Plant)
🏆 Awards & Recognition
Recognitions
Import Car Of The Year:
The Mitsubishi Diamante was named Motor Trend's Import Car of the Year for 1992, a significant industry recognition.
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