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Mitsubishi GTO Twin Turbo W5MG1 W6MG1 Manual Transmission Complete Workshop Service Repair Manual 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999

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🏷️ Basic Information Identification Make: Mitsubishi Model: GTO Twin Turbo Model Nickname: 3000GT (North American Market) Generation Generation Code: Z16A Codes Platform: Mitsubishi GTO platform 👋 Introduction Market Position Market Position: High-performance grand tourer, positioned as a flagship model for Mitsubishi, competing with contemporary Japanese and European sports cars. Competitive Analysis Key Competitors: Nissan 300ZX (Z32), Toyota Supra (Mk IV), Mazda RX-7 (FD), Porsche 968, Chevrolet Corvette C4/C5. Key Features Defining Features: Advanced AWD, twin-turbo V6 engine, groundbreaking technology (ECS, Active Aero), luxurious and driver-focused interior, sophisticated styling. Manual Value Proposition Value Proposition: Empowers owners to perform extensive maintenance and repairs, saving significant costs on specialized servicing, and enabling deep understanding of the vehicle's complex systems. 📋 Manual Details Coverage Areas Model Years Covered: 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999 Transmission Types Covered: W5MG1 (5-speed manual), W6MG1 (6-speed manual) Regions Covered: Primarily Japanese market (GTO) and global markets (3000GT), covering common specifications. Page Count Estimated Page Count: Likely over 1500 pages (typical for comprehensive workshop manuals of this era and complexity) Manual Type Manual Type: Complete Workshop Service Repair Manual Language Language: English (presumed, based on typical sales) Format Format: Digital Downloadable (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, cylinder head, cylinder block, pistons, crankshaft, camshafts, timing system, lubrication system, cooling system. Engine Electrical: Ignition system, fuel injection system (MPI/ECI), emission control systems (EVAP, EGR), engine sensors, ECU/ECM diagnostics, wiring diagrams. Transmission Manual: W5MG1 and W6MG1 gearbox disassembly, assembly, inspection, clutch system, transfer case (if applicable), driveshafts, differentials. Drivetrain: All-Wheel Drive (AWD) system, Active Electronically Controlled Suspension (ECS), Active Aerodynamics, Supercar Handling System (SHS). Suspension: Front suspension (multi-link), Rear suspension (multi-link), shock absorbers, springs, bushings, ECS components. Brakes: Front and rear disc brakes, ABS system, brake calipers, rotors, hydraulic lines, parking brake. Steering: Power steering system, steering rack, linkages, steering column. Electrical System: Battery, charging system (alternator), starting system (starter motor), lighting (headlights, taillights, interior), fuses, relays, power windows, mirrors, seats, climate control. Body And Chassis: Body panel removal/installation, interior trim, doors, hood, trunk, glass, structural components, Active Aerodynamics components (spoilers, vents). Heating Ventilation Air Conditioning: HVAC system components, refrigerant lines, compressor, condenser, evaporator, climate control unit. Diagnostics And Troubleshooting: On-board diagnostic (OBD-I) codes, symptom-based troubleshooting charts, electrical diagnostic procedures. Procedures Included General Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, battery maintenance. Engine Repair: Complete engine overhaul, cylinder head gasket replacement, timing belt replacement, turbocharger servicing, fuel injector replacement. Transmission Repair: Clutch replacement, transmission fluid change, gearbox rebuild, synchro ring inspection and replacement. Suspension And Steering Repair: Shock absorber/strut replacement, bushing replacement, wheel alignment specifications, steering rack repair. Brake System Repair: Brake pad and rotor replacement, brake caliper overhaul, brake fluid flush and bleed, ABS sensor replacement. Electrical System Repair: Alternator replacement, starter motor replacement, wiring harness repair, sensor diagnostics and replacement, ECU troubleshooting. Bodywork And Interior: Panel alignment, door mechanism repair, interior component replacement, weatherstrip sealing. Climate Control Repair: AC system recharge, heater core replacement, blower motor replacement. Troubleshooting Guides: Diagnostic flowcharts for common problems, fault code interpretation. Technical Depth Technical Depth: Comprehensive: Covers from basic maintenance to full engine and transmission rebuilds, including complex electronic systems and drivetrain components. 📊 Manual Specifications File Format File Format: PDF File Quality: High quality, printable, likely searchable text. Print Quality Print Quality: Designed for clear printing of text and diagrams. Binding Type Binding Type: N/A (Digital Downloadable) Paper Type Paper Type: N/A (Digital Downloadable) ⚙️ Engine Specifications Primary Engine Engine Code: 6G72 Engine Type: 60-degree SOHC V6 (later DOHC V6) Displacement: 3.0 Liters (2972 cc) Aspiration: Twin-Turbocharged Performance Horsepower Early Models: Approx. 276-296 hp (JDM/European variants may differ, North American NA/Turbo had lower figures) Horsepower Later Models: Approx. 300-320 hp (depending on market and DOHC update) Torque Early Models: Approx. 282-308 lb-ft Torque Later Models: Approx. 307-315 lb-ft Fuel System Fuel Delivery: Multi-Point Fuel Injection (MPI), Electronic Control Injection (ECI) Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) Engine Features Valve Train: SOHC or DOHC (Dual Overhead Camshafts), 24 valves Bore X Stroke: 85.0 mm x 88.0 mm Compression Ratio: 8.0:1 (approx.) Turbochargers: Sequential twin-turbo system with intercoolers 🔧 Transmission Standard Standard Transmission: W5MG1 5-speed manual transmission Optional Optional Transmission: W6MG1 6-speed manual transmission (available on specific models/years) Features Drivetrain Layout: All-Wheel Drive (AWD) with Active Transfer Case Clutch Type: Hydraulic actuated single-plate or dual-plate (depending on application/model year) Transmission Fluid Type: Dexron II/III or equivalent (Manual Transmission Fluid - consult specific manual for exact spec like DiaQueen Super Multi-Gear Oil) 📐 Dimensions Exterior Length: Approx. 4,650 mm (183.1 in) Width: Approx. 1,840 mm (72.4 in) Height: Approx. 1,295 mm (51.0 in) Wheelbase: Approx. 2,500 mm (98.4 in) Weights Curb Weight: Approx. 1,500 - 1,650 kg (3,300 - 3,640 lbs), varies by trim and options 🛡️ Safety...
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Mitsubishi GTO Twin Turbo W5MG1 W6MG1 Manual Transmission Complete Workshop Service Repair Manual 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
GTO Twin Turbo
Model Nickname:
3000GT (North American Market)
Generation
Generation Code:
Z16A
Codes
Platform:
Mitsubishi GTO platform
👋 Introduction
Market Position
Market Position:
High-performance grand tourer, positioned as a flagship model for Mitsubishi, competing with contemporary Japanese and European sports cars.
Competitive Analysis
Key Competitors:
Nissan 300ZX (Z32), Toyota Supra (Mk IV), Mazda RX-7 (FD), Porsche 968, Chevrolet Corvette C4/C5.
Key Features
Defining Features:
Advanced AWD, twin-turbo V6 engine, groundbreaking technology (ECS, Active Aero), luxurious and driver-focused interior, sophisticated styling.
Manual Value Proposition
Value Proposition:
Empowers owners to perform extensive maintenance and repairs, saving significant costs on specialized servicing, and enabling deep understanding of the vehicle's complex systems.
📋 Manual Details
Coverage Areas
Model Years Covered:
1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999
Transmission Types Covered:
W5MG1 (5-speed manual), W6MG1 (6-speed manual)
Regions Covered:
Primarily Japanese market (GTO) and global markets (3000GT), covering common specifications.
Page Count
Estimated Page Count:
Likely over 1500 pages (typical for comprehensive workshop manuals of this era and complexity)
Manual Type
Manual Type:
Complete Workshop Service Repair Manual
Language
Language:
English (presumed, based on typical sales)
Format
Format:
Digital Downloadable (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, cylinder head, cylinder block, pistons, crankshaft, camshafts, timing system, lubrication system, cooling system.
Engine Electrical:
Ignition system, fuel injection system (MPI/ECI), emission control systems (EVAP, EGR), engine sensors, ECU/ECM diagnostics, wiring diagrams.
Transmission Manual:
W5MG1 and W6MG1 gearbox disassembly, assembly, inspection, clutch system, transfer case (if applicable), driveshafts, differentials.
Drivetrain:
All-Wheel Drive (AWD) system, Active Electronically Controlled Suspension (ECS), Active Aerodynamics, Supercar Handling System (SHS).
Suspension:
Front suspension (multi-link), Rear suspension (multi-link), shock absorbers, springs, bushings, ECS components.
Brakes:
Front and rear disc brakes, ABS system, brake calipers, rotors, hydraulic lines, parking brake.
Steering:
Power steering system, steering rack, linkages, steering column.
Electrical System:
Battery, charging system (alternator), starting system (starter motor), lighting (headlights, taillights, interior), fuses, relays, power windows, mirrors, seats, climate control.
Body And Chassis:
Body panel removal/installation, interior trim, doors, hood, trunk, glass, structural components, Active Aerodynamics components (spoilers, vents).
Heating Ventilation Air Conditioning:
HVAC system components, refrigerant lines, compressor, condenser, evaporator, climate control unit.
Diagnostics And Troubleshooting:
On-board diagnostic (OBD-I) codes, symptom-based troubleshooting charts, electrical diagnostic procedures.
Procedures Included
General Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, battery maintenance.
Engine Repair:
Complete engine overhaul, cylinder head gasket replacement, timing belt replacement, turbocharger servicing, fuel injector replacement.
Transmission Repair:
Clutch replacement, transmission fluid change, gearbox rebuild, synchro ring inspection and replacement.
Suspension And Steering Repair:
Shock absorber/strut replacement, bushing replacement, wheel alignment specifications, steering rack repair.
Brake System Repair:
Brake pad and rotor replacement, brake caliper overhaul, brake fluid flush and bleed, ABS sensor replacement.
Electrical System Repair:
Alternator replacement, starter motor replacement, wiring harness repair, sensor diagnostics and replacement, ECU troubleshooting.
Bodywork And Interior:
Panel alignment, door mechanism repair, interior component replacement, weatherstrip sealing.
Climate Control Repair:
AC system recharge, heater core replacement, blower motor replacement.
Troubleshooting Guides:
Diagnostic flowcharts for common problems, fault code interpretation.
Technical Depth
Technical Depth:
Comprehensive: Covers from basic maintenance to full engine and transmission rebuilds, including complex electronic systems and drivetrain components.
📊 Manual Specifications
File Format
File Format:
PDF
File Quality:
High quality, printable, likely searchable text.
Print Quality
Print Quality:
Designed for clear printing of text and diagrams.
Binding Type
Binding Type:
N/A (Digital Downloadable)
Paper Type
Paper Type:
N/A (Digital Downloadable)
⚙️ Engine Specifications
Primary Engine
Engine Code:
6G72
Engine Type:
60-degree SOHC V6 (later DOHC V6)
Displacement:
3.0 Liters (2972 cc)
Aspiration:
Twin-Turbocharged
Performance
Horsepower Early Models:
Approx. 276-296 hp (JDM/European variants may differ, North American NA/Turbo had lower figures)
Horsepower Later Models:
Approx. 300-320 hp (depending on market and DOHC update)
Torque Early Models:
Approx. 282-308 lb-ft
Torque Later Models:
Approx. 307-315 lb-ft
Fuel System
Fuel Delivery:
Multi-Point Fuel Injection (MPI), Electronic Control Injection (ECI)
Fuel Type:
Premium Unleaded Gasoline (91 octane or higher recommended)
Engine Features
Valve Train:
SOHC or DOHC (Dual Overhead Camshafts), 24 valves
Bore X Stroke:
85.0 mm x 88.0 mm
Compression Ratio:
8.0:1 (approx.)
Turbochargers:
Sequential twin-turbo system with intercoolers
🔧 Transmission
Standard
Standard Transmission:
W5MG1 5-speed manual transmission
Optional
Optional Transmission:
W6MG1 6-speed manual transmission (available on specific models/years)
Features
Drivetrain Layout:
All-Wheel Drive (AWD) with Active Transfer Case
Clutch Type:
Hydraulic actuated single-plate or dual-plate (depending on application/model year)
Transmission Fluid Type:
Dexron II/III or equivalent (Manual Transmission Fluid - consult specific manual for exact spec like DiaQueen Super Multi-Gear Oil)
📐 Dimensions
Exterior
Length:
Approx. 4,650 mm (183.1 in)
Width:
Approx. 1,840 mm (72.4 in)
Height:
Approx. 1,295 mm (51.0 in)
Wheelbase:
Approx. 2,500 mm (98.4 in)
Weights
Curb Weight:
Approx. 1,500 - 1,650 kg (3,300 - 3,640 lbs), varies by trim and options
🛡️ Safety Features
Ratings
Safety Ratings:
Varies by market and testing agency; generally considered a safe vehicle for its era. Specific NHTSA/Euro NCAP ratings may not be readily available for all model years and markets.
Active Features
Active Safety Features:
Anti-lock Braking System (ABS), All-Wheel Drive (AWD), Active Aerodynamics (deployable spoiler and air ducts), optional Active Electronic Control Suspension (ECS).
Passive Features
Passive Safety Features:
Driver and passenger front airbags, three-point seat belts with pre-tensioners, energy-absorbing steering column, reinforced safety cell construction.
💡 Technology Features
Infotainment
Infotainment System:
Early models featured cassette players, optional CD players, basic radio systems. Later models saw upgrades to digital displays and improved audio components.
Driver Assistance
Driver Assistance Features:
Advanced traction control (TCL on some models), optional Active Electronically Controlled Suspension (ECS), Active Aerodynamics.
Connectivity
Connectivity:
Limited by era, primarily focused on internal vehicle systems rather than external connectivity.
Performance Tech
Performance Technology:
Sequential twin-turbocharging, advanced all-wheel-drive system, four-wheel steering (4WS) on some models, electronically controlled suspension (ECS), active aerodynamics.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 5,000-7,500 miles (8,000-12,000 km) or 6 months, whichever comes first (synthetic oil recommended).
Timing Belt Replacement:
Every 60,000-90,000 miles (96,000-145,000 km) or 5-7 years. Crucial for interference engine.
Transmission Fluid Change:
Every 30,000-50,000 miles (48,000-80,000 km) or 2-3 years.
Fluid Specifications
Engine Oil Specification:
API SG/SH or higher, SAE 10W-30 or 10W-40 (viscosity may vary based on climate). Synthetic is highly recommended.
Coolant Specification:
Mitsubishi DiaQueen SUPER LONG LIFE COOLANT (or equivalent HOAT type) - 50/50 mix with distilled water.
Brake Fluid Specification:
DOT 3 or DOT 4 (consult manual for exact specification)
Power Steering Fluid:
Automatic Transmission Fluid (ATF) Dexron II/III or equivalent.
Known Issues
Common Issues Engine:
Coil pack failure, fuel injector clogging, turbocharger oil starvation (if maintenance neglected), exhaust manifold cracking, oil leaks from valve covers and oil pan.
Common Issues Transmission:
Worn clutch components, shifter linkage issues, potential for synchro wear on high-mileage units.
Common Issues Electronics:
ECS component failure (sensors, actuators), intermittent electrical connections, aging wiring harnesses, climate control module issues.
Common Issues Drivetrain:
CV joint wear, transfer case issues (rare but possible).
📚 Vehicle History
Brand Heritage
Brand Heritage:
Mitsubishi has a long history of performance and rally-inspired vehicles, building on success with models like the Lancer Evolution and Starion.
Model Evolution
Generation 1 Evolution:
The Z16A generation (1990-1999) was a technological showcase for Mitsubishi, featuring advanced drivetrain and suspension systems. It received a facelift and powertrain updates in 1994, including a move to DOHC heads for the V6 and enhancements to AWD and Active Aerodynamics.
Production
Production Years:
1990-1999
Production Location:
Japan
🏆 Awards & Recognition
Recognitions
Automotive Journalism Awards:
Frequently cited in period automotive magazines for its performance, technology, and handling, though specific awards may vary by publication and region.
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