Mitsubishi Sigma / Diamante 1991–1995 Chassis Service Manual (P/N PWGE9004-G)

This Mitsubishi Sigma chassis workshop manual (P/N PWGE9004-G) covers European-market F16A sedans with 6G72 SOHC or DOHC engines and left- or right-hand drive, incorporating revisions from the November 1990 base issue through May 1994. Match the listed model codes before choosing it for a Diamante-badged vehicle.

PDF Files, Bookmarks and Diagram Detail

Search and navigation: PDF text search is unavailable. The 28 chapter files have embedded bookmarks; the cover/revision file has none. Small connector numbers and wire codes require zooming in the denser diagrams.

The English-language ZIP download contains 29 printable PDFs totaling 1,441 pages, including 11 front-matter pages, 51 chapter Notes pages, and 48 older TCL pages marked “DELETED.”

V6 Service and Active Chassis Systems

The following selected coverage highlights outline the main repair areas rather than the complete contents. Other documented topics include parking-brake adjustment and power-seat motor checks.

• Engine service: Step-by-step procedures for timing belts, oil pans, camshaft/crankshaft seals, cylinder-head gaskets, and engine removal and installation.

• MPI and cruise control: Fault-code diagnosis, harness and sensor tests, injector checks, fuel-pressure testing, and throttle/idle-switch adjustment.

• Transmission and clutch: F4A33 hydraulic and electronic diagnosis, stall and actuator tests, F5M33 removal, shift-control service, and clutch hydraulic procedures.

• Active-ECS: Self-diagnosis, vehicle-height adjustment, pressure-switch and G-sensor checks, plus strut, compressor, reserve-tank, valve/dryer, and air-tube service.

• Brakes and steering: ABS tests, brake hydraulics and caliper repair, E.P.S. checks, and hydraulic 4WS bleeding, rear-pump and power-cylinder work.

• Electrical and HVAC: Charging and ignition tests, system circuit diagrams, SRS diagnostic charts, and separate R-12/R-134a charging and refrigerant-leak procedures.

• Body and suspension: Hub and drive-shaft service, alignment, conventional suspension, glass replacement, sunroof troubleshooting, lighting, and interior-component work.

Written for service mechanics, this manual assumes access to the specified test equipment and special tools.

Fitment and Repair Scope

The identification section explains the vehicle information plate, engine and transmission codes, trim level, steering position, European destination code, chassis numbering, and engine-number stamping.

Engine and transmission limits: The chassis publication covers on-vehicle inspection and adjustment, component replacement, and major-assembly removal and installation. Internal bench inspection, teardown, and rebuild require separate engine and transmission manuals.

Full vehicle wiring coverage requires the separate Electrical Wiring publications, although system-level circuits, connector checks, and diagnostic charts are included here. Configuration-specific test data and procedure scope help select the correct repair path before parts are removed.

Component illustrations and exploded views identify non-reusable parts, lubrication and sealant points, service sequences, and torque values in Nm, kgm, and ft-lb.

V6 Timing, Seals and Cooling

Separate SOHC/DOHC procedures cover drive-belt tension, ignition timing, idle-speed and mixture checks, manifold-vacuum testing, and hydraulic lash-adjuster inspection. DOHC ignition-timing tolerances distinguish vehicles built through November 1992 from those built from December 1992.

Special-tool tables identify MD998051 for cylinder-head bolts, MD998717 and MD998718 for crankshaft oil seals, and MD998754 for DOHC crankshaft-pulley support. Engine tables also provide bore/stroke and firing-order data.

Repair cautions: The DOHC timing-belt pages flag valve-to-piston and valve-to-valve interference from incorrect camshaft movement. For DOHC engines built from November 1992, the oil-pan procedure warns that remover MD998723 can damage the aluminum upper pan.

Cooling coverage adds leak and radiator-cap pressure tests, thermostat checks, and water-pump/radiator removal. Lubrication material includes oil/filter replacement and DOHC oil-cooler service.

MPI Fault Tracing and Test Equipment

Component procedures connect malfunction codes and symptom charts to ECU power/ground tests, sensor and harness checks, injector actuation, and fuel-pump operation. The Multi Point Injection System Diagram and Vacuum Hose Piping Diagram document the corresponding system connections and hose routing.

Diagnostic equipment includes the MB991341 Multi-use tester and MB991502 MUT-II, with ROM pack MB991419 for vehicles built through May 1992 and MB991481 from June 1992.

F4A33, F5M33 and Clutch Hydraulics

The F4A33 Automatic Transmission Sectional View, hydraulic circuit diagrams, and E.L.C. 4-Speed Automatic Transmission Control Components Layout support fault tracing. PWR/ECO shift charts identify transmission variants and distinguish left- and right-hand drive where applicable.

Adjustment procedures cover the kickdown servo, line and reducing pressure, and inhibitor-switch/control-cable setup. The F5M33 chapter adds oil-level/oil-change data and lever-assembly service; clutch material extends to pedal adjustment, bleeding, and master-cylinder disassembly and reassembly.

Active-ECS, ABS and Hydraulic Steering

Active-ECS charts link malfunction codes to circuit checks before compressor, valve, or height-sensor work. Component sections also address rolling diaphragms and front/rear reserve tanks.

ABS coverage includes wheel-speed-sensor output waveforms, hydraulic-unit checks, brake bleeding, and caliper disassembly. TCL revision note: The brake PDF retains older pages marked “DELETED”; revised TCL diagnosis and service checks appear in the Fuel group.

Power-steering procedures include hydraulic-pressure tests and E.P.S. solenoid/control-unit checks. The 4WS section adds rear-pump discharge-flow checks, power-cylinder service, and control-valve work.

Electrical, Body and Air Conditioning

Alternator diagnosis includes voltage-drop, output-current, and regulated-voltage tests, with primary/secondary ignition waveforms for engine-electrical checks. Body and chassis chapters add glass and door-regulator work, lighting diagnosis, and the Sunroof Circuit Diagram.

The SRS Construction Diagram and diagnostic charts distinguish vehicles with and without a front passenger airbag and include post-collision checks. Air-conditioning sections cover performance and leak diagnosis for R-12 and R-134a systems.

Service precautions: The manual restricts SRS work to authorized Mitsubishi dealer personnel and warns about retained deployment voltage and analog-ohmmeter risks. ABS, Active-ECS, fuel, and refrigerant procedures include the relevant isolation, pressure-release, and refrigerant-handling precautions.

Compression, Belt-Tension and ATF Data Preview

The warmed-engine compression tests specify minimum pressures of 1,050 kPa for SOHC and 980 kPa for DOHC, with a maximum cylinder-to-cylinder difference of 100 kPa. Both tests specify coolant at 80–95°C and fully open throttle.

For DOHC timing-belt verification after the specified rotation and settling checks, auto-tensioner rod projection is 3.8–4.5 mm.

The F4A33 line-pressure adjustment reference is 870–890 kPa. Its total fluid capacity is approximately 7.5 L of DIA QUEEN ATF-SP or equivalent; the fluid-change section distinguishes this from the smaller amount replaced during routine draining.