Mitsubishi TL KL TJ KJ TH KH Series Magna Verada Diamante Ralliart Magna Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Magna, Verada, Diamante, Ralliart Magna Internal Platform Codes: TL, KL, TJ, KJ, TH, KH Codes Engine Code Examples: 6G72, 6G74, 6G75 👋 Introduction Market Position Segment: Mid-size sedan/sports sedan (Magna/Verada), Luxury sedan (Diamante), Performance variant (Ralliart Magna). Competitive Analysis Competitors: Ford Falcon, Holden Commodore, Toyota Camry, Nissan Maxima, Mazda 626/Mazda Atenza. Key Features Vehicle Strengths: Spacious interiors, comfortable ride, powerful V6 engines, attractive styling, good value proposition, particularly in Australian market. Manual Value Proposition Benefit: Empowers owners and independent workshops with OEM-level technical data for accurate diagnosis, repair, and maintenance, saving time and money. 📋 Manual Details Coverage Areas Regions Covered: Australia, Japan, potentially other global markets where these models were sold Page Count Estimated Page Count: Likely over 1500 pages, typical for a comprehensive workshop manual covering multiple series and engine options. Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: DOWNLOAD (likely a digital format such as PDF) 📖 Manual Coverage Systems Covered Powertrain: Engine mechanical, fuel system, ignition system, cooling system, exhaust system, lubrication system, engine management (ECU, sensors, actuators). Transmission: Automatic Transmission (AT), Manual Transmission (MT) - including operation, diagnosis, overhaul, torque converter, valve body, shift control. Drivetrain: Front-wheel drive (FWD) systems, drive shafts, CV joints, differential. Suspension: Front and rear suspension systems (independent, MacPherson struts, multi-link), shock absorbers, springs, bushings, alignment specifications. Brakes: Hydraulic brake system, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), brake fluid specifications, disc and drum brake components, parking brake. Steering: Power steering system, steering rack, pump, fluid specifications, steering column. Electrical: Battery, charging system (alternator), starting system (starter motor), lighting systems (headlights, taillights, interior), fuses, relays, wiring diagrams, ECUs, body control modules (BCM). HVAC: Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant type, compressor, condenser, evaporator, climate control modules, diagnosis. Body: Body structure, exterior panels, doors, hood, trunk, bumpers, glass, interior trim, seats, safety restraint systems (airbags, seatbelts). Chassis: Frame and chassis components, mounting points, corrosion protection. Diagnostics: On-Board Diagnostics (OBD-II) system, diagnostic trouble codes (DTCs), scan tool procedures, troubleshooting flowcharts, diagnostic strategies. Procedures Included Routine Maintenance: Oil changes, filter replacements (oil, air, fuel, cabin), fluid checks and top-ups, spark plug replacement, belt inspections and replacement. Engine Repair: Engine overhaul, cylinder head removal and installation, piston and connecting rod service, crankshaft service, timing belt/chain replacement, component diagnostics. Transmission Repair: Transmission fluid and filter changes, overhaul procedures for AT and MT, torque converter replacement, clutch replacement (for MT), solenoid testing. Brake System Repair: Brake pad and rotor replacement, brake caliper service, brake line and hose replacement, bleeding the brake system, ABS component testing and replacement. Suspension And Steering Repair: Strut and shock absorber replacement, control arm bushing replacement, ball joint replacement, tie rod end replacement, power steering pump and rack replacement. Electrical Diagnostics: Troubleshooting electrical faults using wiring diagrams, component testing, sensor diagnostics, starting and charging system analysis, infotainment system troubleshooting. HVAC Service: Refrigerant recovery and recharging, AC system leak detection, compressor replacement, blower motor service, climate control panel troubleshooting. Body And Trim Repair: Body panel alignment and replacement, door mechanism repair, interior trim removal and installation, airbag system safety precautions and replacement. Troubleshooting Guides: Step-by-step diagnostic flowcharts for common drivability issues, electrical problems, and mechanical failures. Specifications And Tolerances: Torque specifications for all fasteners, engine clearances, bearing clearances, wheel alignment angles, tire pressures. Technical Depth Depth: Comprehensive, covering everything from basic preventative maintenance to complete engine and transmission overhauls, including detailed electrical diagnostics and bodywork. 📊 Manual Specifications File Format Format: Digital Download (likely PDF) Print Quality Quality: High-resolution, allowing for clear printing of diagrams and text. Binding Type Type: N/A (Digital Format) Paper Type Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Family: Mitsubishi 6G7 series V6 SOHC/DOHC. Engine Variants Displacements: 3.0L (6G72), 3.5L (6G74), 3.8L (6G75). Performance Horsepower Range: Approximately 140 kW to 230 kW (188 hp to 308 hp) depending on engine and model year. Torque Range: Approximately 260 Nm to 360 Nm (192 lb-ft to 266 lb-ft) depending on engine and model year. Fuel System Injection: Multi-point fuel injection (MPI) or direct injection (GDI) on later models. Fuel Type Type: Unleaded Petrol (Octane rating specified by region, typically 91 or 95 RON). Timing Mechanism Mechanism: Timing belt (most 6G72/6G74) or timing chain (some later 6G74/6G75). Emission Controls Controls: Catalytic converters, oxygen sensors, EVAP system. 🔧 Transmission Standard Transmission Type: Often a 4-speed or 5-speed automatic transmission (e.g., INVECS-II). Optional Transmission Type: 5-speed manual transmission (MT) available on some models. Features Automatic Features: Sequential shift mode (tiptronic on some models), adaptive shift control. Fluid Specifications Automatic Transmission Fluid: Mitsubishi DiaQueen ATF SP-II M, SP-III or equivalent. Manual Transmission Fluid: Gear oil conforming to API GL-4 or GL-5, viscosity grade as specified (e.g., 75W-90). 📐 Dimensions Exterior Body Styles: 4-door Sedan, Wagon (out of scope for...
Power steering system, steering rack, pump, fluid specifications, steering column.
Electrical:
Battery, charging system (alternator), starting system (starter motor), lighting systems (headlights, taillights, interior), fuses, relays, wiring diagrams, ECUs, body control modules (BCM).
HVAC:
Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant type, compressor, condenser, evaporator, climate control modules, diagnosis.
Body:
Body structure, exterior panels, doors, hood, trunk, bumpers, glass, interior trim, seats, safety restraint systems (airbags, seatbelts).
Chassis:
Frame and chassis components, mounting points, corrosion protection.
Oil changes, filter replacements (oil, air, fuel, cabin), fluid checks and top-ups, spark plug replacement, belt inspections and replacement.
Engine Repair:
Engine overhaul, cylinder head removal and installation, piston and connecting rod service, crankshaft service, timing belt/chain replacement, component diagnostics.
Transmission Repair:
Transmission fluid and filter changes, overhaul procedures for AT and MT, torque converter replacement, clutch replacement (for MT), solenoid testing.
Brake System Repair:
Brake pad and rotor replacement, brake caliper service, brake line and hose replacement, bleeding the brake system, ABS component testing and replacement.
Suspension And Steering Repair:
Strut and shock absorber replacement, control arm bushing replacement, ball joint replacement, tie rod end replacement, power steering pump and rack replacement.
Electrical Diagnostics:
Troubleshooting electrical faults using wiring diagrams, component testing, sensor diagnostics, starting and charging system analysis, infotainment system troubleshooting.
HVAC Service:
Refrigerant recovery and recharging, AC system leak detection, compressor replacement, blower motor service, climate control panel troubleshooting.
Body And Trim Repair:
Body panel alignment and replacement, door mechanism repair, interior trim removal and installation, airbag system safety precautions and replacement.
Troubleshooting Guides:
Step-by-step diagnostic flowcharts for common drivability issues, electrical problems, and mechanical failures.
Specifications And Tolerances:
Torque specifications for all fasteners, engine clearances, bearing clearances, wheel alignment angles, tire pressures.
Technical Depth
Depth:
Comprehensive, covering everything from basic preventative maintenance to complete engine and transmission overhauls, including detailed electrical diagnostics and bodywork.
📊 Manual Specifications
File Format
Format:
Digital Download (likely PDF)
Print Quality
Quality:
High-resolution, allowing for clear printing of diagrams and text.
Binding Type
Type:
N/A (Digital Format)
Paper Type
Type:
N/A (Digital Format)
⚙️ Engine Specifications
Primary Engine
Engine Family:
Mitsubishi 6G7 series V6 SOHC/DOHC.
Engine Variants
Displacements:
3.0L (6G72), 3.5L (6G74), 3.8L (6G75).
Performance
Horsepower Range:
Approximately 140 kW to 230 kW (188 hp to 308 hp) depending on engine and model year.
Torque Range:
Approximately 260 Nm to 360 Nm (192 lb-ft to 266 lb-ft) depending on engine and model year.
Fuel System
Injection:
Multi-point fuel injection (MPI) or direct injection (GDI) on later models.
Fuel Type
Type:
Unleaded Petrol (Octane rating specified by region, typically 91 or 95 RON).
Timing Mechanism
Mechanism:
Timing belt (most 6G72/6G74) or timing chain (some later 6G74/6G75).
Often a 4-speed or 5-speed automatic transmission (e.g., INVECS-II).
Optional
Transmission Type:
5-speed manual transmission (MT) available on some models.
Features
Automatic Features:
Sequential shift mode (tiptronic on some models), adaptive shift control.
Fluid Specifications
Automatic Transmission Fluid:
Mitsubishi DiaQueen ATF SP-II M, SP-III or equivalent.
Manual Transmission Fluid:
Gear oil conforming to API GL-4 or GL-5, viscosity grade as specified (e.g., 75W-90).
📐 Dimensions
Exterior
Body Styles:
4-door Sedan, Wagon (out of scope for manual title, but related models)
Wheelbase Approximate:
2700-2760 mm (106.3-108.7 inches) depending on series.
Weights
Curb Weight Range:
Approximately 1500-1700 kg (3300-3750 lbs).
🛡️ Safety Features
Ratings
Ancap Rating:
Varies by series and specific testing year; later models generally performed better.
Active Features
List:
ABS, EBD, Traction Control (TCS), Electronic Stability Control (ESC) on higher trims/later models.
Passive Features
List:
Front airbags, side airbags (optional/standard on higher trims), pre-tensioner seatbelts, crumple zones.
💡 Technology Features
Infotainment
Features:
Early models featured basic cassette/radio systems, evolving to CD players, and optional premium audio systems. Later models may have basic LCD displays for climate and audio.
Driver Assistance
Features:
Cruise control standard on most models. ABS and Traction Control became more common and sophisticated across generations.
Connectivity
Features:
Limited by era; typically basic radio and CD functions. No integrated Bluetooth or smartphone connectivity in early models.
🔧 Maintenance
Service Intervals
Oil Change:
Every 10,000-15,000 km (6,000-9,000 miles) or 12 months, whichever comes first, depending on driving conditions.
Timing Belt:
Recommended replacement every 90,000-100,000 km (56,000-62,000 miles) or 5-7 years for 6G72/6G74 engines due to risk of catastrophic failure if it breaks.
Spark Plugs:
Typically every 60,000-100,000 km, depending on plug type (e.g., iridium).
Fluid Specifications
Engine Oil:
SAE 10W-30 or 10W-40 API SJ/SL or higher, depending on ambient temperature. Check manual for specific grade.
Coolant:
Mitsubishi Genuine Long Life Coolant or equivalent (ethyle glycol based, typically a pink or red colour).
Known Issues
Engine Mounts:
Wear and tear leading to vibration, especially on V6 engines.
Transmission Issues:
Solenoid issues, torque converter shudder, fluid leaks in automatic transmissions.
Suspension Components:
Worn ball joints, control arm bushings, and sway bar links leading to knocking noises and poor handling.
Electrical Gremlins:
Wiring harness issues, sensor failures, particularly in older vehicles due to age and environmental factors.
Exhaust Manifold Cracks:
Cracking in exhaust manifolds, especially on V6 engines, leading to exhaust leaks and noise.
Heater Core:
Leaking heater cores, often a labour-intensive repair due to dashboard removal.
📚 Vehicle History
Brand Heritage
Affiliation:
Mitsubishi Motors, known for engineering and reliability.
Model Evolution
Generations:
The KH/TH/TJ/KJ/TL/KL series represent the third and fourth generations of the Mitsubishi Magna/Verada platform, evolving significantly in styling, technology, and performance.
Production
Location:
Primarily manufactured in Australia (Adelaide, South Australia) by Mitsubishi Motors Australia Limited (MMAL).
Production Years
Span:
The covered series (KH, TH, TJ, KJ, TL, KL) generally span from the late 1990s to the mid-2000s (e.g., 1996-2005).
🏆 Awards & Recognition
Recognitions
Australian Motoring Awards:
The Magna platform consistently received positive reviews and awards from Australian motoring publications for its value, performance, and comfort.
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