1990–2005 Mitsubishi Diamante OEM Service Manual

• 5,769 pages across 375 PDF files — 4,878 pages of Mitsubishi Motors Australia workshop material, a 408-page Chilton guide for 1990–2000 Galant, Mirage, and Diamante models, and 483 pages of standalone Mitsubishi engine, transmission, fuel, emission, and electrical publications plus a 1992 Mitchell Diamante extract.
• Model coverage centers on TH/KH, TJ/KJ, and TL/KL Magna/Verada/Diamante, including sedan, wagon, Sports, AWD, and TJ Ralliart configurations. TJ/KJ base pages, August 2001 and March 2002 01M/Y updates, and the later AWD material are identified separately, with VIN, compliance-plate, option-code, and regional identification tables.
• Engine sections cover 6G72 and 6G74 SOHC repair and overhaul, with timing-system work, cylinder heads and valves, rocker gear and lash adjusters, oil pump, pistons and rods, crankshaft, seals, FIPG information, inspection limits, torque data, and Mitsubishi special tools. Separate engine books add 4G63, 4G64, 4G64 GDI, and 6G72 reference material.
• Drivetrain chapters identify F5M51, F4A51, F5A51, and W5A51 units, plus a separate F4A33/W4A32/W4A33 overhaul book. Coverage reaches from clutch and transmission removal to internal teardown, hydraulic circuits, oil pump, clutch packs, planetary sets, valve body, differential, transfer components, propeller shaft, and axles.
• Factory fault-finding covers MUT-II diagnostics, warning-lamp code routines, symptom charts, fail-safe tables, data lists, actuator tests, Engine-A/T ECU terminal checks, connector measurement points, fuse/relay and ground testing, intermittent harness faults, and ECU/BEM/immobilizer service requirements.
• Dedicated 54A, 54B, and 54C electrical sections provide component locations, harness configuration views, and circuit diagrams for power distribution, starting/charging, MPI, ABS/TCL, SRS, manual and full automatic A/C, central door locking/keyless entry, power windows, lighting, instruments, and theft alarm.
• Chassis and body sections cover brake bleeding, pad replacement and brake-disc runout correction, steering testing, suspension and axle variants, wheel alignment, exterior/interior repair, HVAC charging and leak diagnosis, SRS post-collision inspection, airbag and pretensioner service, and separate 2WD/AWD towing and hoisting guidance.

Coverage and Manual Structure

The factory portion is organized by Australian-market series rather than as one continuous 1990–2005 OEM manual. TH/KH and TJ/KJ cover sedan, wagon, and Sports configurations; TL/KL covers sedan and wagon models, with AWD-specific transmission, propeller-shaft, rear-axle, suspension, brake, and parking-brake sections. The 41-page TJ Ralliart volume is a supplement intended for use with the TJ Magna/KJ Verada base manual. It adds 6G74 changes, F5M51-1-F5N manual-transmission and helical-LSD material, plus Ralliart exhaust, brake, steering, wheel/tire, and exterior sections.

Model-year fit is determined by series code, VIN table, and update date. The factory identification pages decode the geographic area, manufacturer, Magna/Verada car line, H/J/L series, engine-transmission combination, price class, body code, year code, assembly plant, and build number. Compliance and data plate locations, ADR information, engine numbers, option codes, major dimensions, weights, and market variations are included for Australia, New Zealand, Pacific markets, and Brunei. The TL/KL VIN table explicitly identifies 2003. The broad 1990–2000 range belongs to the multi-model Chilton guide, which expressly omits some specialist rebuild work; it is not blanket factory coverage through 2005.

Electrical System Diagnostics and Vehicle Identification

The diagnostic chapters organize fault isolation around scan data, lamp sequences, symptom charts, connector checks, grounds, and control-unit terminals. MUT-II material covers code reading and erasing, data-list interpretation, actuator testing, and system-specific inspection charts. Where the scan tool is not used, warning-lamp methods are provided for systems such as MPI, TCL, ABS, and automatic transmission. Named factory tools include MB991502 MUT-II, MB991348 test harness, MB991529 diagnosis-code harness, MB991613 SRS check harness, and MD998767 timing-belt tension-pulley wrench.

Harness work is supported by terminal service points, connector and pin information, component locations, ground distribution, blown-fuse checks, and intermittent-fault guidance. The general electrical section distinguishes a 12V test light for voltage and short-circuit checks from a self-power test light for continuity and grounding checks. That level of identification matters before regional wiring, control units, or replacement immobilizer components are selected.

Circuitry and Specification Details

The wiring package is arranged in three layers. Group 54A locates relays, ECUs, sensors, solenoids, diodes, inspection terminals, fuses, and grounds. Group 54B traces harness routing through the engine compartment, dash, instrument panel, roof, floor, seats, doors, trunk, cargo area, and tailgate. Group 54C supplies the system schematics. Representative sheets include manual- and automatic-transmission MPI, ABS with and without TCL, SRS, full automatic air conditioning, central locking/keyless entry, and starting/charging networks.

Mechanical chapters document the larger repair jobs rather than stopping at maintenance. Engine removal and overhaul, automatic transmission disassembly and reassembly, clutch-pack and valve-body work, differential and transfer service, brake and steering repair, body work, and A/C component service are backed by sectional views, hydraulic circuits, torque tables, fluid data, wear and rework limits, adjustment charts, electrical test values, sealants, and special-tool numbers. A general tightening table by bolt head mark is also supplied.

The SRS material warns that front-probing plated connector terminals or using the wrong probe can damage the terminal and compromise the restraint circuit. AWD towing instructions identify one-end towing and incorrect lift points as risks to the viscous coupling, transfer rear bushing, bumper, and body. Those series-specific cautions are important before electrical testing or vehicle recovery begins.