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DODGE STEALTH Workshop Repair Manual All 1991-1994 ModelS COVERED

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🏷️ Basic Information Identification Make: Dodge Model: Stealth Generation: 1st Generation Production Years: 1991-1996 Codes Platform Code: Mitsubishi Z16A (platform shared with Mitsubishi 3000GT/GTO) 👋 Introduction Market Position Positioning: The...
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DODGE STEALTH Workshop Repair Manual All 1991-1994 ModelS COVERED
🏷️ Basic Information
Identification
Make:
Dodge
Model:
Stealth
Generation:
1st Generation
Production Years:
1991-1996
Codes
Platform Code:
Mitsubishi Z16A (platform shared with Mitsubishi 3000GT/GTO)
👋 Introduction
Market Position
Positioning:
The Dodge Stealth was a badge-engineered version of the Mitsubishi 3000GT/GTO, positioned as a sporty, performance-oriented coupe in the Dodge lineup. It offered advanced technology for its time, particularly the R/T Twin-Turbo models.
Competitive Analysis
Competitors:
Toyota Supra, Nissan 300ZX, Mazda RX-7, Chevrolet Corvette, and Ford Mustang.
Key Features
Distinguishing Features:
Unique styling, available All-Wheel Drive (AWD) and All-Wheel Steering (AWS), potent twin-turbocharged V6 engine (R/T Twin-Turbo), active aerodynamics (on some models), and advanced electronic systems.
Manual Value Proposition
Value For Owner:
Provides comprehensive, factory-level repair and maintenance information essential for owners and independent mechanics to keep the Dodge Stealth running optimally, covering complex systems unique to this model.
📋 Manual Details
Coverage Areas
Model Years:
1991, 1992, 1993, 1994
Trim Levels Covered:
All trims including Base, ES, R/T, R/T Twin-Turbo (AWD/AWS)
Page Count
Estimated Page Count:
Extensive, typically over 1500 pages for a complete workshop manual covering multiple years and variants.
Manual Type
Type:
Workshop Service and Repair Manual
Language
Language:
English
Format
Format:
PDF (Digital Download)
File Format:
PDF
Print Quality:
High resolution, suitable for printing. Contains clear diagrams and illustrations.
Binding Type:
N/A (Digital Download)
Paper Type:
N/A (Digital Download)
Software Compatibility:
Compatible with all modern operating systems (Windows, macOS, Linux) and devices capable of opening PDF files.
📖 Manual Coverage
Systems Covered
Engine:
6G72 SOHC & DOHC (Naturally Aspirated & Twin-Turbocharged V6), including diagnostics, repair, overhaul, tuning, and specifications.
Transmission:
5-Speed Manual, 4-Speed Automatic (F4A51, F5A51), including overhaul, adjustments, and electronic control diagnostics.
Drivetrain:
Front-Wheel Drive (FWD) and All-Wheel Drive (AWD) systems, including viscous coupling center differential, transfer cases, driveshafts, CV joints, and limited-slip differentials (for R/T Twin-Turbo).
Suspension:
Front McPherson strut with multi-link, Rear multi-link independent suspension, including geometry, adjustments, component replacement, and AWD Active Aerodynamics/Suspension (if applicable to specific trims/years covered).
Steering:
Power-assisted rack and pinion, All-Wheel Steering (AWS) system diagnostics and repair.
Brakes:
Front & Rear disc brakes (including 4-piston calipers for R/T Twin-Turbo), ABS system diagnostics, hydraulic components, parking brake.
Electrical System:
Complete automotive electrical system, including battery, charging system, starter, ignition system, lighting, horn, wipers, power windows/locks/seats, mirrors, and integrated diagnostic trouble codes (DTCs).
Climate Control:
HVAC system, A/C system, heater core, blower motor, refrigerant handling, diagnostic procedures.
Body And Interior:
Body panel removal/installation, interior trim, seats, dashboard, door mechanisms, glass, seals, convertible top (if applicable to later models not in this coverage).
Fuel System:
Fuel tank, fuel pump, fuel injectors, fuel pressure regulator, evaporative emission control (EVAP) system.
Exhaust System:
Exhaust manifolds, catalytic converters, mufflers, pipes, oxygen sensors.
Cooling System:
Radiator, water pump, thermostat, coolant hoses, cooling fans, pressure cap.
Exhaust Gas Recirculation:
EGR valve operation, diagnostics, and maintenance.
Turbocharger System:
For R/T Twin-Turbo models: turbocharger operation, intercooler, wastegate, boost control, diagnostics.
Procedures Included
Maintenance:
Scheduled maintenance (oil changes, filter replacements, fluid checks), spark plug replacement, belt inspection/replacement, brake pad/rotor replacement, coolant flush, tune-ups.
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting guides, fault code interpretation, wiring diagrams for electrical issues.
Repair:
Step-by-step instructions for component replacement, rebuilding, and repair for all major systems.
Disassembly Assembly:
Detailed exploded views and procedures for disassembling and reassembling engines, transmissions, suspension components, body panels, and interior parts.
Adjustments:
Engine timing, idle speed, clutch adjustment, parking brake adjustment, suspension alignment procedures.
Rebuilding Overhaul:
Complete engine and transmission rebuild procedures, including torque specifications, clearances, and component tolerances.
Torque Specifications:
Comprehensive list of torque values for all fasteners across all major systems.
Wiring Diagrams:
Detailed electrical wiring diagrams for all circuits, including component locations and connector pinouts.
Technical Depth
Depth:
Comprehensive workshop level, covering from basic maintenance and fluid changes to advanced engine and transmission overhauls, and complex diagnostic procedures.
Diagnostic Capability:
Includes diagnostic trouble codes (DTCs), electronic control unit (ECU) diagnostics, and sensor testing procedures.
⚙️ Engine Specifications
Primary Engine
Engine Code:
6G72
Engine Configuration:
3.0L (2972cc) SOHC V6 and DOHC V6
Valvetrain:
12 valves (SOHC) or 24 valves (DOHC), SOHC with 2 valves per cylinder, DOHC with 4 valves per cylinder.
Performance
Horsepower Naturally Aspirated:
Approximately 222 hp (166 kW) @ 6000 rpm (SOHC V6)
Torque Naturally Aspirated:
Approximately 200 lb-ft (271 Nm) @ 4500 rpm (SOHC V6)
Horsepower Twin Turbo:
Approximately 300 hp (224 kW) @ 6000 rpm (DOHC V6 Twin-Turbo)
Torque Twin Turbo:
Approximately 307 lb-ft (416 Nm) @ 2500 rpm (DOHC V6 Twin-Turbo)
Fuel System
Fuel Delivery:
Multi-point fuel injection (MPI)
Fuel Type:
Unleaded gasoline
Ignition System:
Electronic ignition with distributor (early models) or distributorless ignition system (DIS) with coil packs (later models).
Engine Maintenance
Spark Plug Type:
Refer to manual for specific part numbers based on engine variant and year (e.g., NGK Platinum or Iridium recommended).
Timing Belt Replacement Interval:
Typically 60,000 miles (96,000 km) or 5 years, whichever comes first. Critical for DOHC engines.
🔧 Transmission
Standard
Transmission Type:
5-speed manual transmission (Getrag 5-speed) for Base and R/T models.
Optional
Transmission Type:
4-speed automatic transmission (F4A51/F5A51) for Base, ES models. 4-speed automatic available for R/T Twin-Turbo (less common).
Features
AWD Transmission Features:
For R/T Twin-Turbo AWD models: Active all-wheel drive system with viscous coupling center differential.
Transmission Fluid
Manual Transmission Fluid Spec:
Refer to manual for specific GL-4 or GL-5 gear oil specifications. Typically 75W-90.
Automatic Transmission Fluid Spec:
Refer to manual for specific ATF specifications. Often Diamond SP-II or equivalent.
📐 Dimensions
Exterior
Length:
Approx. 180.7 inches (4590 mm)
Width:
Approx. 70.5 inches (1790 mm)
Height:
Approx. 49.4 inches (1255 mm)
Wheelbase:
Approx. 98.6 inches (2505 mm)
Weights
Curb Weight:
Approx. 3,400 - 3,800 lbs (1542 - 1724 kg) depending on trim and drivetrain.
Gross Vehicle Weight Rating:
Refer to vehicle VIN plate or manual for specific GVWR.
Cargo
Trunk Capacity:
Approx. 7.6 cu ft (0.21 m³)
🛡️ Safety Features
Ratings
NHTSA Ratings:
Varies by year and specific testing. Generally considered a safe vehicle for its era. Manual will detail specific safety system components.
Active Features
ABS:
Standard Anti-lock Braking System (ABS) on most models.
Aws:
Optional All-Wheel Steering (AWS) on some models for improved maneuverability.
Passive Features
Airbags:
Driver and passenger front airbags.
Seatbelts:
Three-point inertia-reel seatbelts with pretensioners.
Body Structure:
Reinforced safety cage construction.
💡 Technology Features
Infotainment
Audio System:
Factory AM/FM stereo with cassette player and CD player (optional). Premium sound systems available on some trims.
Driver Assistance
Cruise Control:
Standard electronic cruise control.
Active Aero:
Found on R/T Twin-Turbo models: retractable front air dam and rear wing that adjust with speed.
Connectivity
Factory Alarms:
Factory alarm system with immobilizer (features vary by year and region).
Gauge Cluster
Instrumentation:
Digital or analog instrument cluster depending on trim, including tachometer, speedometer, fuel gauge, engine temperature, and warning lights. Boost gauge on R/T Twin-Turbo.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first. Refer to manual for specific grade.
Transmission Fluid Change Interval:
Automatic: 30,000-50,000 miles (48,000-80,000 km). Manual: check and top up as needed, major service at higher mileage.
Coolant Flush Interval:
Every 2-3 years or 30,000-50,000 miles (48,000-80,000 km).
Fluid Specifications
Engine Oil Specification:
Refer to manual: typically 5W-30 or 10W-30, API SG/SH or higher, ILSAC GF-2.
Engine Oil Capacity:
Approx. 4.5 quarts (4.3 liters) with filter for V6 engines.
Coolant Specification:
Ethylene glycol-based coolant. Refer to manual for specific type and mixture ratio (usually 50/50).
Brake Fluid Specification:
DOT 3 or DOT 4 hydraulic brake fluid.
Known Issues
Common Problems:
ECS (Electronic Control Suspension) failure, ABS sensor issues, AWD system component wear, oil leaks from crank seals/gaskets, turbocharger issues on R/T Twin-Turbo models, potential electrical gremlins due to age, interior wear and tear.
Maintenance Schedule Importance:
Adhering to the timing belt replacement schedule is critical to prevent catastrophic engine damage. Regular fluid changes and inspection of aging rubber components are also important.
📚 Vehicle History
Brand Heritage
Dodge Legacy:
Dodge has a long history of performance vehicles, including the Charger, Challenger, and Viper. The Stealth was a departure into the sports coupe segment, leveraging Mitsubishi's engineering.
Model Evolution
Evolution 1991-1994:
While the Stealth was primarily a rebadged 3000GT, minor styling tweaks and feature changes occurred across the early production years. The most significant differentiation was between the naturally aspirated and twin-turbocharged models.
Production
Manufacturing Location:
Japan (manufactured by Mitsubishi Motors)
Production Volume:
Relatively low compared to mainstream models, making it a more niche vehicle. Exact figures vary by year.
🏆 Awards & Recognition
Recognitions
Automotive Press Reviews:
Received generally positive reviews for its performance, handling, and advanced technology, though some criticized its complexity and weight compared to more focused sports cars.
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