Mitsubishi Diamante / Magna / Verada 1990–2005 Repair Manual Set

Use the Ralliart supplement with the TJ Magna/KJ Verada base manual. The standalone component books cover wider Mitsubishi applications, so match the engine or transmission code before selecting procedures. Several component PDFs combine base pages and later revisions.

Coverage limits: The factory portion follows Australian-market series rather than one continuous 1990–2005 OEM manual. The Chilton guide excludes differential rebuilding and A/C component repair. The 1992 wiring extract includes menus that also reference diagram sheets outside the extract.

PDF Search, Linked Chapters and Wiring Detail

Search and diagram access: Factory and Chilton chapter text can be searched, but many schematic labels cannot. Six standalone PDFs lack usable body-text search: charging, starting, ignition, MPI, emissions and F4A33/W4A32/W4A33. Bookmarks are present in 356 files; retain the extracted folders for cross-file links. Small wiring labels require zooming, and some factory linework is faint. A black strip obscures part of PDF p. 4 in the 1992 extract.

The ZIP contains 375 printable PDFs totaling 5,769 pages, including title and contents pages, 34 notes pages, 10 intentionally blank pages and the two navigation/setup sheets listed above.

Engine Overhaul, Drivetrain Repair and Electrical Diagnosis

These are selected workshop topics, rather than a full contents list. Other chapters cover cruise control and windshield-wiper/washer circuits.

• Engine repair: Step-by-step procedures for engine removal, timing-belt work, cylinder-head and valve service, and internal inspection of the covered SOHC engines.

• Transmission overhaul: F5M51, F4A51, F5A51 and W5A51 service, including clutch work, internal disassembly, inspection, reassembly and drivetrain-specific repair sections.

• Fuel and cooling systems: MPI troubleshooting, fuel-supply service, emission-control checks, thermostat testing, water-pump work and cooling-system inspection.

• Fault diagnosis: MUT-II testing, warning-lamp code routines, symptom charts, fail-safe tables, data lists, actuator tests and Engine-A/T ECU terminal checks.

• Electrical documentation: Group 54A component locations, 54B harness configuration views and 54C wiring diagrams, supported by connector, fuse, relay and ground information.

• Brakes and chassis: Brake bleeding, pad replacement, disc-runout correction, steering tests, wheel alignment, suspension and axle service, with separate AWD sections.

• Body, HVAC and restraints: Exterior and interior repair, A/C charging and leak diagnosis, SRS post-collision inspection, and airbag and pretensioner service information.

The factory material suits mechanics equipped for scan-tool diagnosis and internal overhaul; the Chilton sections also support routine owner maintenance. Specialist work retains the qualifications and equipment requirements stated in the relevant manual.

Regional Fit, Updates and Ralliart Differences

VIN, compliance-plate and option-code tables distinguish specifications for Australia, New Zealand, Pacific markets and Brunei. ADR information, engine identification, dimensions and weights support those regional distinctions before wiring, control units or replacement components are selected.

The TJ/KJ files distinguish base chapters from August 2001 and March 2002 01M/Y updates and later AWD material. The TL/KL VIN table identifies 2003; use the series and regional tables to assess vehicle fit.

The Ralliart supplement adds 6G74 changes, F5M51-1-F5N and helical-LSD information, plus exhaust, brake, steering, wheel/tire and exterior differences. Its differential section describes the helical-LSD construction and warns against disassembling the differential case assembly.

Internal Engine and Transmission Work

Engine overhaul material reaches rocker gear and lash adjusters, oil pumps, pistons and connecting rods, crankshafts and seals. FIPG guidance, wear and rework limits, component torque tables and special-tool references accompany the procedures; MD998767 is identified for timing-belt tension-pulley work. The Chilton engine chapters also distinguish earlier Diamante SOHC and DOHC procedures.

Automatic-transmission coverage includes hydraulic circuits, oil pumps, clutch packs, planetary sets, valve bodies and differentials. Transfer components, propeller shafts and axles are treated in the applicable drivetrain sections. The separate transmission book adds assembly-specific F4A33/W4A32/W4A33 reference material.

MUT-II Tests and Circuit Tracing

Connector measurement points, intermittent-harness checks and ECU/BEM/immobilizer service requirements support fault isolation beyond code reading. Named equipment includes MB991502 MUT-II, MB991348 test harness, MB991529 diagnosis-code harness and MB991613 SRS check harness.

The general electrical chapter distinguishes a 12V test light for voltage and short-circuit checks from a self-powered light for continuity and ground checks. This distinction matters when selecting test equipment for the circuit being checked.

Representative schematics cover starting/charging, manual- and automatic-transmission MPI, ABS with and without TCL, SRS, full automatic A/C and central locking/keyless entry. Other electrical sections address power windows, lighting, instruments and theft alarm. Harness views trace connections through the engine compartment, dash, roof, floor, seats, doors, trunk, cargo area and tailgate.

Chassis Service and Component Precautions

Brake-disc correction procedures are supported by inspection limits and adjustment data. Steering and HVAC chapters add system-specific testing, while sectional views, fluid data, electrical test values, sealant references and the general bolt-head-mark tightening table support component work.

The SRS material warns that front-probing plated connector terminals can damage their plating and reduce circuit reliability. AWD towing guidance identifies viscous-coupling damage from one-end dolly towing and transfer-rear-bushing damage from rear-wheel lifting; incorrect lifting can also damage the bumper or body.

SRS service is reserved for authorized Mitsubishi service personnel. Refrigerant work requires suitable recovery equipment, and under-vehicle work requires the specified lifting and support arrangements.

Engine and Transmission Clearance Examples

The separate 6G72-SOHC engine book lists oil-pump tip clearance at 0.06–0.18 mm. Its crankshaft table gives 0.05–0.25 mm standard end play and a 0.3 mm limit.

For the TJ Ralliart F5M51-1-F5N manual transmission, the supplement specifies 0.05–0.17 mm input-shaft front-bearing end play.