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Mitsubishi Sigma 1991-1996 Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Mitsubishi Model: Sigma Model Code: F1_Series (for applicable years and global markets) Platform: Mitsubishi Galant (shared platform for this generation) Generation Generation Designation: 8th Generation Mitsubishi Galant platform (Sigma being the badge-engineered version in some markets) Codes Engine Codes Likely Covered: 6A1x series V6 (e.g., 6A12, 6A13), 4G6x series inline-4 (e.g., 4G63, 4G64) - dependent on market and specific model variants 👋 Introduction Market Position Segment: Mid-size sedan (often positioned as a more premium or distinct offering compared to the base Galant in certain markets) Competitive Analysis Competitors: Ford Taurus, Chevrolet Lumina, Toyota Camry, Honda Accord, Nissan Maxima, Mazda 626, Hyundai Sonata (depending on market) Key Features Distinctive Attributes: Often featured Mitsubishi's advanced V6 engines (like the 6A12/6A13), stylish design, comfortable interiors, and sophisticated features for its era. The Sigma badge was used to differentiate it in markets where the Galant was also sold under its own name. 📋 Manual Details Coverage Areas Applicable Years: 1991, 1992, 1993, 1994, 1995, 1996 Page Count Total Pages: 1441 Manual Type Type: Workshop Service Repair Manual Language Primary Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Powertrain: Engine (mechanical, electrical, lubrication, cooling, fuel, emissions), Transmission (manual and automatic, internal components, hydraulics, electronic controls) Chassis: Suspension (front and rear, components, adjustments), Steering (system operation, components, power steering), Brakes (system hydraulics, components, ABS if equipped) Electrical: Wiring diagrams, lighting systems, starting and charging systems, ignition system, instrument cluster, accessories, power windows/locks, climate control electronics Body: Body panels, doors, windows, interior trim, seats, bumpers, exterior trim, paint and finish repair guidance Engine Mechanical: Cylinder head, block, pistons, crankshaft, camshafts, valves, timing system (belts/chains), oil pump, oil pan. Engine Fuel System: Fuel pump, fuel filter, fuel injectors, fuel rail, pressure regulator, evaporative emission control (EVAP) system. Engine Cooling System: Radiator, water pump, thermostat, coolant hoses, expansion tank, cooling fan(s). Engine Lubrication System: Oil filter, oil pump, oil pan, oil passages, oil pressure switch. Ignition System: Spark plugs, ignition coils, distributor (if applicable), ignition control module, sensors (crankshaft, camshaft). Exhaust System: Exhaust manifolds, catalytic converter, muffler, exhaust pipes, oxygen sensors. Transmission Manual: Clutch assembly, gearbox internal components, shift linkage, transmission fluid. Transmission Automatic: Torque converter, planetary gear sets, valve body, transmission control module (TCM), hydraulic circuits, transmission fluid. Suspension Front: MacPherson struts, control arms, ball joints, sway bar, springs, shock absorbers. Suspension Rear: Multi-link or independent rear suspension components, subframe, springs, shock absorbers. Steering System: Steering rack, power steering pump, steering column, tie rods, power steering fluid. Brake System: Brake pedal, master cylinder, brake booster, brake lines, calipers, brake pads, brake rotors, parking brake. ABS System: ABS control module, wheel speed sensors, hydraulic modulator (if equipped). Lighting Exterior: Headlights, taillights, turn signals, brake lights, fog lights, reverse lights. Lighting Interior: Dome light, map lights, vanity mirror lights, trunk light. Climate Control: HVAC unit, blower motor, evaporator, condenser, refrigerant lines, heater core, controls. Procedures Included Maintenance: Routine inspections, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, spark plug service, belt replacement, tire rotation Diagnostics: Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs) for applicable systems, component testing procedures Repair: Detailed step-by-step instructions for component removal, disassembly, repair, reassembly, and installation for all major systems Overhaul: Engine overhaul procedures, transmission rebuild steps, major component refurbishment Tune Ups: Detailed procedures for spark plug replacement, air filter inspection/replacement, fuel filter replacement, and ignition timing adjustment (if applicable). Removal Install: Comprehensive instructions for removing and reinstalling major components like engines, transmissions, radiators, suspension parts, and body panels. Assemblies Disassemblies: Step-by-step breakdown of component disassembly for inspection, repair, or replacement, including detailed diagrams. Technical Depth Depth: Comprehensive, covering from basic maintenance to in-depth engine and transmission disassembly/reassembly, and detailed electrical system diagnosis. Special Tools: Identifies and illustrates specific Mitsubishi special tools required for certain adjustments or repairs, with part numbers where available. Torque Specifications: Provides critical torque values for all fasteners to ensure correct assembly and prevent component damage or failure. Diagnostic Symbols: Explains the meaning and application of WARNING, CAUTION, and NOTE symbols used throughout the manual to highlight critical information. Manual Completeness Scope: A complete service manual covering all necessary instructions for any repair the vehicle may require, intended to equip technicians and owners with professional-level knowledge. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Printable: Yes Binding Type Digital Binding: N/A (Electronic delivery) Paper Type Digital Paper Type: N/A (Electronic delivery) ⚙️ Engine Specifications Primary Engine Engine Options: Likely included Mitsubishi's 6A1x V6 engines (e.g., 2.0L 6A12, 2.5L 6A13) and inline-4 engines (e.g., 2.0L 4G63, 2.4L 4G64) depending on the specific market and trim level. The V6 variants were often a hallmark of the Sigma nameplate. Performance Typical V6 Output: Outputs varied by displacement and market, but typically ranged from 150 hp to over 200...
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Mitsubishi Sigma 1991-1996 Workshop Service Repair Manual
🏷️ Basic Information
Identification
Make:
Mitsubishi
Model:
Sigma
Model Code:
F1_Series (for applicable years and global markets)
Platform:
Mitsubishi Galant (shared platform for this generation)
Generation
Generation Designation:
8th Generation Mitsubishi Galant platform (Sigma being the badge-engineered version in some markets)
Codes
Engine Codes Likely Covered:
6A1x series V6 (e.g., 6A12, 6A13), 4G6x series inline-4 (e.g., 4G63, 4G64) - dependent on market and specific model variants
👋 Introduction
Market Position
Segment:
Mid-size sedan (often positioned as a more premium or distinct offering compared to the base Galant in certain markets)
Competitive Analysis
Competitors:
Ford Taurus, Chevrolet Lumina, Toyota Camry, Honda Accord, Nissan Maxima, Mazda 626, Hyundai Sonata (depending on market)
Key Features
Distinctive Attributes:
Often featured Mitsubishi's advanced V6 engines (like the 6A12/6A13), stylish design, comfortable interiors, and sophisticated features for its era. The Sigma badge was used to differentiate it in markets where the Galant was also sold under its own name.
📋 Manual Details
Coverage Areas
Applicable Years:
1991, 1992, 1993, 1994, 1995, 1996
Page Count
Total Pages:
1441
Manual Type
Type:
Workshop Service Repair Manual
Language
Primary Language:
English
Format
File Format:
PDF
📖 Manual Coverage
Systems Covered
Powertrain:
Engine (mechanical, electrical, lubrication, cooling, fuel, emissions), Transmission (manual and automatic, internal components, hydraulics, electronic controls)
Chassis:
Suspension (front and rear, components, adjustments), Steering (system operation, components, power steering), Brakes (system hydraulics, components, ABS if equipped)
Electrical:
Wiring diagrams, lighting systems, starting and charging systems, ignition system, instrument cluster, accessories, power windows/locks, climate control electronics
Body:
Body panels, doors, windows, interior trim, seats, bumpers, exterior trim, paint and finish repair guidance
Engine Mechanical:
Cylinder head, block, pistons, crankshaft, camshafts, valves, timing system (belts/chains), oil pump, oil pan.
Engine Fuel System:
Fuel pump, fuel filter, fuel injectors, fuel rail, pressure regulator, evaporative emission control (EVAP) system.
Engine Cooling System:
Radiator, water pump, thermostat, coolant hoses, expansion tank, cooling fan(s).
Engine Lubrication System:
Oil filter, oil pump, oil pan, oil passages, oil pressure switch.
Ignition System:
Spark plugs, ignition coils, distributor (if applicable), ignition control module, sensors (crankshaft, camshaft).
Exhaust System:
Exhaust manifolds, catalytic converter, muffler, exhaust pipes, oxygen sensors.
Transmission Manual:
Clutch assembly, gearbox internal components, shift linkage, transmission fluid.
Transmission Automatic:
Torque converter, planetary gear sets, valve body, transmission control module (TCM), hydraulic circuits, transmission fluid.
Suspension Front:
MacPherson struts, control arms, ball joints, sway bar, springs, shock absorbers.
Suspension Rear:
Multi-link or independent rear suspension components, subframe, springs, shock absorbers.
Steering System:
Steering rack, power steering pump, steering column, tie rods, power steering fluid.
Brake System:
Brake pedal, master cylinder, brake booster, brake lines, calipers, brake pads, brake rotors, parking brake.
ABS System:
ABS control module, wheel speed sensors, hydraulic modulator (if equipped).
Lighting Exterior:
Headlights, taillights, turn signals, brake lights, fog lights, reverse lights.
Lighting Interior:
Dome light, map lights, vanity mirror lights, trunk light.
Climate Control:
HVAC unit, blower motor, evaporator, condenser, refrigerant lines, heater core, controls.
Procedures Included
Maintenance:
Routine inspections, fluid changes (oil, coolant, brake fluid, transmission fluid), filter replacements, spark plug service, belt replacement, tire rotation
Diagnostics:
Troubleshooting guides for common symptoms, diagnostic trouble codes (DTCs) for applicable systems, component testing procedures
Repair:
Detailed step-by-step instructions for component removal, disassembly, repair, reassembly, and installation for all major systems
Overhaul:
Engine overhaul procedures, transmission rebuild steps, major component refurbishment
Tune Ups:
Detailed procedures for spark plug replacement, air filter inspection/replacement, fuel filter replacement, and ignition timing adjustment (if applicable).
Removal Install:
Comprehensive instructions for removing and reinstalling major components like engines, transmissions, radiators, suspension parts, and body panels.
Assemblies Disassemblies:
Step-by-step breakdown of component disassembly for inspection, repair, or replacement, including detailed diagrams.
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to in-depth engine and transmission disassembly/reassembly, and detailed electrical system diagnosis.
Special Tools:
Identifies and illustrates specific Mitsubishi special tools required for certain adjustments or repairs, with part numbers where available.
Torque Specifications:
Provides critical torque values for all fasteners to ensure correct assembly and prevent component damage or failure.
Diagnostic Symbols:
Explains the meaning and application of WARNING, CAUTION, and NOTE symbols used throughout the manual to highlight critical information.
Manual Completeness
Scope:
A complete service manual covering all necessary instructions for any repair the vehicle may require, intended to equip technicians and owners with professional-level knowledge.
📊 Manual Specifications
File Format
Digital Format:
PDF (Portable Document Format)
Print Quality
Printable:
Yes
Binding Type
Digital Binding:
N/A (Electronic delivery)
Paper Type
Digital Paper Type:
N/A (Electronic delivery)
⚙️ Engine Specifications
Primary Engine
Engine Options:
Likely included Mitsubishi's 6A1x V6 engines (e.g., 2.0L 6A12, 2.5L 6A13) and inline-4 engines (e.g., 2.0L 4G63, 2.4L 4G64) depending on the specific market and trim level. The V6 variants were often a hallmark of the Sigma nameplate.
Performance
Typical V6 Output:
Outputs varied by displacement and market, but typically ranged from 150 hp to over 200 hp for V6 models.
Fuel System
Injection Type:
Electronic Fuel Injection (EFI) for all variants.
🔧 Transmission
Standard
Transmission Type:
Likely offered both 5-speed manual transmissions and 4-speed automatic transmissions as standard or optional, depending on the engine and trim level.
Optional
Automatic Transmission Features:
Optional automatic transmissions may have included electronically controlled units with different drive modes (e.g., sport, economy) depending on the market.
Features
All Wheel Drive:
All-Wheel Drive (AWD) variants, often featuring Mitsubishi's 'Viscous Coupling' or similar systems, were likely available on certain performance-oriented models.
📐 Dimensions
Exterior
Body Styles:
Primarily a 4-door sedan.
Weights
Curb Weight:
Typically ranged from approximately 3,000 lbs to 3,500 lbs (1360 kg to 1590 kg) depending on engine and equipment.
🛡️ Safety Features
Ratings
Safety Standard Era:
Reflects safety standards of the early to mid-1990s, likely featuring basic safety equipment of the time.
Active Features
Anti Lock Brakes:
Anti-lock Braking System (ABS) was likely available as an option or standard on higher trim levels.
Passive Features
Airbags:
Driver's side airbag was becoming more common and likely standard or optional on higher trims. Passenger airbags were less common in this era.
💡 Technology Features
Infotainment
Audio System:
Factory-installed cassette or CD players with AM/FM radio. Speaker configurations varied by trim level.
Driver Assistance
Cruise Control:
Electronic cruise control was a common feature on many models.
Connectivity
Power Accessories:
Power windows, power door locks, and power mirrors were available features, especially on higher trim levels.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-5,000 miles (5,000-8,000 km) or 6 months, using the appropriate viscosity oil. Consult manual for precise interval.
Timing Belt Replacement:
For V6 engines, timing belt replacement is a critical maintenance item, typically recommended every 60,000-90,000 miles (96,000-144,000 km) or 5-7 years. Critical to prevent catastrophic engine damage.
Fluid Specifications
Engine Oil Viscosity:
Commonly SAE 5W-30 or 10W-30, depending on ambient temperature. Refer to manual for specific API service classification.
Coolant Type:
Ethylene glycol-based antifreeze. Mixture of 50/50 antifreeze and distilled water is typical. Refer to manual for specific type and capacity.
Transmission Fluid Type Auto:
Likely requires Dexron II or equivalent automatic transmission fluid. Consult manual for exact specification and capacity.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid, depending on system requirements. Refer to manual for specific type.
Known Issues
Common Wear Items:
CV joints, wheel bearings, exhaust system components, engine mounts, and suspension bushings are common wear items in vehicles of this age.
Electrical Gremlins:
Older vehicles can develop minor electrical issues due to aging wiring, connectors, and components, such as intermittent power to accessories or warning lights.
Engine Performance:
Carbon buildup in intake manifolds and on valves, EGR system issues, and fuel injector clogging can affect engine performance and fuel economy.
📚 Vehicle History
Brand Heritage
Mitsubishi Motors:
Mitsubishi Motors is a Japanese automotive manufacturer with a long history of innovation and a diverse product range, known for its performance-oriented vehicles and advanced technologies.
Model Evolution
Sigma Lineage:
The Sigma was a badge-engineered version of the Mitsubishi Galant in many markets, offered to provide a distinct identity and potentially target different customer segments. This generation represented a significant styling and engineering update over its predecessors.
Production
Manufacturing Locations:
Primarily manufactured in Japan, with potential assembly in other global locations depending on market demand.
🏆 Awards & Recognition
Recognitions
Historical Accolades:
While specific 'awards' for the Sigma nameplate might be sparse as it was often tied to the Galant, the Mitsubishi Galant platform itself received positive reviews for its styling, performance (especially V6 models), and technology during its production run.
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