Mitsubishi Magna 1991-1996 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Magna Model Code: AW/AX Series Chassis Code: AW, AX Codes Product Sku: MITMGM199196 👋 Introduction Market Position Market Segment: Mid-size family sedan, popular in Australia Competitive Analysis Key Competitors Era: Holden Commodore, Ford Falcon Key Features Manual Purpose: To provide comprehensive repair, maintenance, and diagnostic information for DIY enthusiasts and professional mechanics. Download Method: Instant Download via Secure Payment Processor 📋 Manual Details Coverage Areas Model Years Covered: 1991, 1992, 1993, 1994, 1995, 1996 Page Count Total Pages: 1441 Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Full Engine Overhaul, Rebuild, Timing Belt/Chain, Seals, Gaskets, Pistons, Rings, Bearings, Valves, Camshafts, Cylinder Heads Engine Management: Fuel Injection System (MPI), Ignition System, Engine Control Unit (ECU), Sensors (MAP, TPS, O2, Crankshaft, Camshaft), Emission Controls Cooling System: Radiator, Water Pump, Thermostat, Hoses, Coolant Specifications, Fan Control Transmission Manual: Clutch System, Gearbox Removal/Installation, Gearbox Overhaul, Gear Ratios, Shifter Linkage Transmission Automatic: Automatic Transmission Operation, Removal/Installation, Overhaul, Fluid Specifications, Torque Converter, Valve Body Drivetrain: Front Wheel Drive (FWD), Driveshafts, CV Joints, Differential Suspension Front: MacPherson Strut, Control Arms, Bushings, Ball Joints, Springs, Shock Absorbers, Wheel Bearings Brakes Front: Disc Brakes, Caliper Replacement, Rotor Machining/Replacement, Brake Pads, Hydraulic Lines Steering: Power Steering System, Steering Rack, Tie Rods, Power Steering Pump, Fluid Specifications Fuel System Fuel System Components: Fuel Pump, Fuel Filter, Fuel Lines, Injectors, Fuel Tank, Evaporative Emission Control (EVAP) Suspension Rear Rear Suspension Components: Independent Rear Suspension (IRS), Control Arms, Bushings, Springs, Shock Absorbers, Wheel Bearings Brakes Rear Rear Brake Components: Disc Brakes, Caliper Replacement, Rotor Machining/Replacement, Brake Pads, Hydraulic Lines Electrical System Battery Charging: Alternator, Battery Testing and Replacement, Charging System Diagnostics Starter System: Starter Motor, Ignition Switch, Solenoid Lighting: Headlights, Taillights, Interior Lights, Bulb Types and Replacement Wiring Diagrams: Comprehensive Electrical Schematics for all Systems Body And Chassis Exterior: Body Panel Removal/Installation, Doors, Hood, Trunk, Bumpers, Trim Interior: Dashboard, Seats, Door Panels, Headliner, Carpets, Trim Removal HVAC: Heating, Ventilation, and Air Conditioning (HVAC) System, Compressor, Condenser, Evaporator, Controls, Refrigerant Procedures Included Maintenance Procedures: Oil Changes, Filter Replacements, Spark Plug Replacement, Fluid Level Checks, Brake Inspections Troubleshooting Diagnostics: Systematic Troubleshooting Guides, Fault Code Diagnosis, Diagnostic Connector Access Repair Procedures: Step-by-step instructions for component removal, disassembly, repair, and reassembly Installation Procedures: Installation guidelines for new or reconditioned components Adjustments: Alignment procedures, brake adjustments, throttle linkage adjustments Technical Depth Depth Of Coverage: Comprehensive Bumper-to-Bumper Coverage Pictorial Representation: Detailed Illustrations, Exploded Diagrams, Drawings, and Photos Service Data: Special Notes, Important Points, Service Data, Precautions, Tightening Torques, Wear Limits Special Tools: Identification and usage of required special service tools 📊 Manual Specifications File Format File Format: PDF Print Quality Printability: Yes, All Pages Printable Resolution: High Resolution for Clear Viewing and Printing Binding Type Binding: Digital Download (No Physical Binding) Paper Type Paper Type: N/A (Digital Format) Compatibility Operating Systems: Windows, Mac, Linux OS Requirements Software Requirement: Adobe Reader ⚙️ Engine Specifications Primary Engine Engine Family: 6G7x 'Cyclone' V6 Engine Variants Engine Displacements: 3.0L (6G72), 3.5L (6G74) Performance Horsepower Range: Approximately 145-165 hp (3.0L), 190-203 hp (3.5L) Torque Range: Approximately 240-260 Nm (3.0L), 300-330 Nm (3.5L) Fuel System Fuel Delivery: Electronic Multi-Point Fuel Injection (MPI) Ignition System Ignition Type: Distributorless Ignition System (DIS) or Distributor-based (depending on specific model year/variant) Maintenance Timing Belt Replacement Interval: Refer to manual for specific interval, typically 90,000-100,000 km or 5-6 years Fluid Specifications Engine Oil Type: Refer to manual for specific viscosity (e.g., 10W-30, 10W-40) and API service classification Coolant Type: Ethylene Glycol based, silicate-free coolant (e.g., Mitsubishi Diaqueen Super Long Life Coolant) 🔧 Transmission Standard Standard Transmission: 5-Speed Manual Optional Optional Transmission: 4-Speed Automatic (INVECS-II) Features Automatic Transmission Features: Electronically controlled, Adaptive shift logic (INVECS) Fluid Specifications Automatic Transmission Fluid: Refer to manual for specific ATF type (e.g., ATF SP-II or equivalent) Manual Transmission Fluid: Refer to manual for specific gear oil viscosity and API rating 📐 Dimensions Exterior Wheelbase: Approximately 2700 mm (2.7m) Length: Approximately 4700 mm (4.7m) Width: Approximately 1750 mm (1.75m) Height: Approximately 1400 mm (1.4m) Weights Curb Weight: Approximately 1400-1550 kg, depending on configuration Gross Vehicle Weight Rating: Refer to vehicle compliance plate Wheel Specifications Wheel Bolt Pattern: 5x114.3 mm (5x4.5 inches) Tire Sizes: Common sizes include 205/65R15, 215/60R15, 205/55R16 (refer to manual for specific fitments) 🛡️ Safety Features Ratings Crash Test Data: No specific ANCAP ratings for this era; refer to general safety standards of the time. Passive Features Airbags: Driver airbag standard on most models, passenger airbag optional or standard on higher trims/later years. Seatbelts: Front and rear seat belts, pre-tensioners may be present on front belts. Structural Reinforcement: Side impact protection beams, reinforced body structure. Active Features ABS: Anti-lock Braking System (ABS) optional or standard on higher trims. Traction Control: Traction Control System (TCS) optional...
Refer to manual for specific ATF type (e.g., ATF SP-II or equivalent)
Manual Transmission Fluid:
Refer to manual for specific gear oil viscosity and API rating
📐 Dimensions
Exterior
Wheelbase:
Approximately 2700 mm (2.7m)
Length:
Approximately 4700 mm (4.7m)
Width:
Approximately 1750 mm (1.75m)
Height:
Approximately 1400 mm (1.4m)
Weights
Curb Weight:
Approximately 1400-1550 kg, depending on configuration
Gross Vehicle Weight Rating:
Refer to vehicle compliance plate
Wheel Specifications
Wheel Bolt Pattern:
5x114.3 mm (5x4.5 inches)
Tire Sizes:
Common sizes include 205/65R15, 215/60R15, 205/55R16 (refer to manual for specific fitments)
🛡️ Safety Features
Ratings
Crash Test Data:
No specific ANCAP ratings for this era; refer to general safety standards of the time.
Passive Features
Airbags:
Driver airbag standard on most models, passenger airbag optional or standard on higher trims/later years.
Seatbelts:
Front and rear seat belts, pre-tensioners may be present on front belts.
Structural Reinforcement:
Side impact protection beams, reinforced body structure.
Active Features
ABS:
Anti-lock Braking System (ABS) optional or standard on higher trims.
Traction Control:
Traction Control System (TCS) optional or standard on higher trims/later years.
💡 Technology Features
Infotainment
Audio System:
Factory fitted radio/cassette player, with CD player becoming more common in later years. Speaker configurations varied by trim level.
Climate Control:
Manual air conditioning and heating standard, with automatic climate control available on higher trims.
Driver Assistance
Cruise Control:
Cruise control typically standard on higher trim levels.
Connectivity
Connectivity Features:
Limited by era; primarily focused on vehicle operation and basic comfort features. No integrated Bluetooth or advanced connectivity as understood today.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Refer to manual; typically 10,000-15,000 km or 6-12 months
Air Filter Replacement:
Refer to manual; typically 20,000-30,000 km
Spark Plug Replacement:
Refer to manual; platinum tipped plugs often have longer intervals (e.g., 60,000-100,000 km)
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (refer to manual for specific recommendation)
Power Steering Fluid Type:
Refer to manual for specific power steering fluid type (often ATF compatible)
Known Issues
Common Engine Issues:
Timing belt failure (if not replaced on schedule), oil leaks from valve cover gaskets or seals, occasional sensor failures (e.g., crankshaft position sensor).
Common Transmission Issues:
Automatic transmission 'flaring' (slipping between gears), worn transmission mounts.
Common Suspension Issues:
Worn control arm bushings leading to clunking noises, premature wear of ball joints and tie rod ends, shock absorber degradation.
Common Electrical Issues:
Faulty window regulators, aging wiring harnesses, minor electrical gremlins.
Common Body Issues:
Rust in common areas (wheel arches, sills), fading paintwork on plastic components.
📚 Vehicle History
Brand Heritage
Mitsubishi Legacy:
Mitsubishi has a long history of automotive manufacturing, known for durability and technological innovation.
Model Evolution
Magna Generation:
This manual covers the second generation (AW/AX) of the Mitsubishi Magna, which was a significant redesign from the previous model.
Australian Manufacturing:
The Mitsubishi Magna was largely designed and manufactured in Australia by Mitsubishi Motors Australia Limited (MMAL).
Production
Production Years Model:
1991-1996 (Second Generation)
🏆 Awards & Recognition
Recognitions
Model Reputation:
The Magna was generally well-regarded for its spaciousness, comfortable ride, and value for money in its segment.
Ratings
Reliability Perception:
Generally considered reliable with proper maintenance, though some specific components could be prone to wear.
Certifications
Manual Quality Assurance:
100% Complete and Intact, No Missing/Corrupt Pages/Sections
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