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DODGE STEALTH WORKSHIP Repair Manual 1991-1994

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🏷️ Basic Information Identification Make: Dodge Model: Stealth Years Covered: 1991, 1992, 1993, 1994 Codes Platform Code: MZ-2 / HM-2 (Shared with Mitsubishi 3000GT/GTO) 👋 Introduction Market Position Positioning: The...
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DODGE STEALTH WORKSHIP Repair Manual 1991-1994
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Stealth
Years Covered:
1991, 1992, 1993, 1994
Codes
Platform Code:
MZ-2 / HM-2 (Shared with Mitsubishi 3000GT/GTO)
👋 Introduction
Market Position
Positioning:
The Dodge Stealth was Chrysler's rebadged version of the Mitsubishi 3000GT (GTO), positioned as a sporty, technologically advanced coupe in the personal luxury/sports car segment.
Competitive Analysis
Competitors:
Primary competitors included the Chevrolet Corvette, Nissan 300ZX (Z32), Toyota Supra (Mk3/Mk4), Mazda RX-7 (FC/FD), and Porsche 944.
Key Features
Model Variants:
Available in base (non-turbo) and RT (twin-turbo) trims, with some models featuring all-wheel drive (AWD) and four-wheel steering (4WS).
Technological Innovations:
Twin-turbocharged V6, advanced AWD systems, active aerodynamics (deployable rear spoiler and front air dam), and optional four-wheel steering (4WS) were key technological highlights.
📋 Manual Details
Coverage Areas
Diagnostic Coverage:
Comprehensive engine diagnostics, ABS, SRS, HVAC, and chassis systems.
Repair Coverage:
Engine, transmission, drivetrain, suspension, steering, brakes, electrical, body, HVAC, fuel system, exhaust.
Maintenance Coverage:
Scheduled maintenance, fluid changes, filter replacements, tune-ups, lubrication.
Page Count
Estimated Page Count:
Thousands (specific count varies by sub-model and engine variant)
Manual Type
Type:
Professional Workshop Service & Repair Manual
Language
Language:
English
Format
File Format:
Acrobat PDF
Compatibility:
Windows & MAC compatible
📖 Manual Coverage
Systems Covered
Engine:
V6 (6G72), including naturally aspirated and Twin Turbo variants; timing belt replacement, cylinder head overhaul, piston and ring installation, valve train adjustments.
Transmission:
5-speed manual (F5M33) and 4-speed automatic (V4A51) with viscous coupling (VCU) and electronically controlled (ECS) differentials; clutch replacement, transmission overhaul, fluid specifications, shift linkage adjustment.
Drivetrain:
All-wheel drive (AWD) system, viscous coupling unit (VCU), active aerodynamic control systems (rear spoiler, front air dam), four-wheel steering (4WS) system on select models.
Suspension:
Independent front and rear suspension; strut replacement, shock absorber diagnosis, spring replacement, bushing service, wheel alignment specifications.
Steering:
Power assisted rack and pinion steering, 4-wheel steering system diagnosis and repair (if equipped).
Brakes:
Front and rear disc brakes (vented front on turbo models), ABS system diagnosis and repair, brake pad and rotor replacement, brake fluid specifications and bleeding procedures.
Electrical:
Complete wiring diagrams for all systems including engine control, lighting, instruments, power accessories, audio, and anti-theft systems.
Body:
Body panel repair, door mechanisms, glass replacement, interior trim removal and installation, active aerodynamics (spoiler, front dam) operation and repair.
HVAC:
Air conditioning system service, heater core replacement, blower motor diagnosis, refrigerant types and capacities, climate control system troubleshooting.
Fuel System:
Fuel pump replacement, fuel injector diagnosis and service, fuel filter replacement, fuel pressure specifications.
Exhaust System:
Exhaust manifold replacement, catalytic converter service, muffler replacement, exhaust system component diagnosis.
Procedures Included
Engine Rebuild:
Detailed procedures for complete engine disassembly, inspection, rebuilding, and reassembly, including torque specifications for critical fasteners.
Transmission Overhaul:
Step-by-step instructions for complete overhaul of both manual and automatic transmissions, including parts diagrams and assembly sequences.
Timing Belt Replacement:
Critical procedure with precise timing mark alignment instructions for V6 engines to prevent catastrophic damage.
Troubleshooting Charts:
Extensive diagnostic flowcharts and symptom-based troubleshooting guides for electrical, mechanical, and system issues.
Special Tools:
Identification and usage instructions for specialized tools required for specific repair procedures.
Electrical Component Testing:
Detailed procedures for testing sensors, actuators, relays, and other electrical components using multimeters and diagnostic equipment.
Body And Interior:
Procedures for removal and installation of exterior body panels, interior trim, seats, and dashboard components.
Restraint Systems:
SRS (Supplemental Restraint System) diagnosis, airbag component replacement, and related safety precautions.
Technical Depth
Depth:
Factory-level diagnostic and repair procedures, suitable for professional technicians and advanced DIY mechanics.
Diagnostic Capabilities:
In-depth diagnostic information for engine control units (ECUs), anti-lock braking systems (ABS), and other electronic modules.
Rebuild Instructions:
Complete rebuild instructions for major mechanical components like engines and transmissions.
📊 Manual Specifications
File Format
Quality:
High-resolution scans, clear text, and searchable content.
Print Quality
Printability:
Printable pages for convenient workshop use.
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Code:
6G72 (SOHC and DOHC variants)
Configuration:
3.0L V6 (2972cc)
Naturally Aspirated Performance:
Approx. 222 hp @ 6000 rpm, 200 lb-ft @ 4500 rpm (specifics vary slightly by year)
Twin Turbo Performance:
Approx. 300 hp @ 6000 rpm, 307 lb-ft @ 2500 rpm (specifics vary slightly by year)
Fuel System
Induction:
Multi-point fuel injection (MPI) for naturally aspirated; sequential multi-point fuel injection (MPI) with twin intercooled turbochargers for RT models.
Fuel Type:
Unleaded Premium Gasoline (91 octane or higher recommended)
Fuel Pump Type:
Electric, in-tank
Other Features
Valvetrain:
SOHC 12-valve (NA) or DOHC 24-valve (TT) with belt-driven camshafts.
Cooling System:
Pressurized liquid cooling system with fan and radiator.
🔧 Transmission
Standard
Manual Transmission:
5-speed manual (F5M33) typically found in base and some RT models.
Optional
Automatic Transmission:
4-speed automatic (V4A51) with overdrive, often coupled with advanced drivetrain features.
Features
Drivetrain Options:
Front-Wheel Drive (FWD) or All-Wheel Drive (AWD) with Viscous Coupling Unit (VCU) for torque distribution.
AWD System Details:
AWD system on RT TT models often incorporated a computerized electronically controlled suspension (ECS) and torque split.
📐 Dimensions
Exterior
Length:
Approximately 178.0 - 180.3 inches (varies by year/trim)
Width:
Approximately 70.2 - 70.4 inches
Height:
Approximately 47.4 - 48.0 inches
Wheelbase:
Approximately 97.2 inches
Weights
Curb Weight:
Approximately 3300 - 3600 lbs (varies significantly by trim and drivetrain)
🛡️ Safety Features
Ratings
NHTSA Ratings:
Specific NHTSA ratings for this era are not readily available in a standardized format as today; however, typical features were standard for the period.
Active Features
ABS:
Anti-lock Braking System (ABS) standard on most models, especially RT variants.
Aws:
Optional Four-Wheel Steering (4WS) on select models for improved low-speed maneuverability and high-speed stability.
Passive Features
Airbags:
Driver and passenger airbags became standard during this period, with the manual detailing their function and SRS system.
Seatbelts:
3-point inertia reel seatbelts with pre-tensioners.
💡 Technology Features
Infotainment
Audio System:
Factory premium audio systems with cassette player and AM/FM radio, often with amplifier and equalizer controls. CD players were optional on later models.
Driver Assistance
Cruise Control:
Standard electronic cruise control.
Connectivity
Diagnostics Port:
OBD-I diagnostic port, with specific breakout boxes or procedures detailed in the manual for accessing engine codes.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 3,000 - 7,500 miles, or 6-12 months, depending on oil type and driving conditions (refer to manual for specific recommendations).
Timing Belt Replacement Interval:
Recommended every 60,000 miles or 5 years for the 6G72 engine due to critical interference design.
Spark Plug Replacement:
Typically every 30,000 - 60,000 miles, depending on plug type (e.g., copper, platinum, iridium).
Fluid Specifications
Engine Oil Type:
API SG or higher, SAE 10W-30 or 10W-40 recommended (refer to manual for exact viscosity by temperature).
Engine Oil Capacity:
Approximately 4.5 - 5.0 quarts (with filter) for V6 engines.
Coolant Type:
Ethylene glycol-based antifreeze, typically a 50/50 mix with distilled water.
Transmission Fluid Manual:
API GL-4 or GL-5 gear oil, SAE 75W-90 recommended for manual transmissions.
Transmission Fluid Automatic:
Dexron II or equivalent automatic transmission fluid (ATF) for the 4-speed automatic.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Known Issues
Common Wear Items:
Suspension bushings, CV joints (especially on AWD models), front brake wear, and exhaust system corrosion.
Engine Specific:
Timing belt failure can cause catastrophic engine damage (due to interference design); regular replacement is critical. Oil leaks from valve covers and oil pan seals are common with age.
Turbo Specific:
Turbocharger seals and lines can degrade, leading to oil consumption or boost leaks. Intercooler efficiency can decrease over time.
Electrical Issues:
Corroded grounds, failing window motors, HVAC control module issues, and intermittent electrical gremlins can occur with age.
📚 Vehicle History
Brand Heritage
Dodge Heritage:
Dodge, a marque of Chrysler (now Stellantis), has a history of performance-oriented vehicles, including muscle cars and sports coupes.
Model Evolution
Stealth Introduction:
The Dodge Stealth was introduced for the 1991 model year as a joint venture with Mitsubishi, leveraging their sports car platform (3000GT/GTO).
Key Distinctions:
While mechanically identical to the Mitsubishi 3000GT, the Stealth featured distinct front and rear styling (headlights, grille, taillights) and interior trim differences.
Production
Production Years:
1991-1996 (North America)
Manufacturing Location:
Japan (by Mitsubishi Motors)
🏆 Awards & Recognition
Recognitions
Car And Driver:
Often featured on Car and Driver's '10Best' lists for its advanced technology and performance in its debut years.
Motortrend:
Received positive reviews from automotive publications for its handling and power, especially the twin-turbo variants.
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