Mitsubishi Diamante 1991-1996 Workshop Repair Service Manual
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🏷️ Basic Information Identification Make: Mitsubishi Model: Diamante Generation: First Generation (JDM: Sigma, North America: Diamante) Model Years Covered: 1991, 1992, 1993, 1994, 1995, 1996 Chassis Codes Jdm: JS1A, JS2A (Sigma/Diamante Sedan) Model Designation North America: Diamante Model Designation Japan: Sigma (also associated with Debonair platform). Codes Chassis Codes: JS2 (sedan), JS3 (wagon - not covered by this manual, as it is primarily focused on sedan models based on typical workshop manual coverage for this era). 👋 Introduction Market Position Segment: Mid-size luxury sedan, competing with vehicles like the Toyota Camry, Honda Accord, Ford Taurus, and Chevrolet Lumina in its segment. Positioned as a more upscale offering from Mitsubishi. Target Audience: Aimed at buyers seeking a comfortable, stylish, and well-equipped sedan with a focus on smooth V6 performance and a refined driving experience. Competitive Analysis Strengths: Known for its distinctive styling (especially the early models), smooth V6 engines, and comfortable ride. Often offered a good value proposition compared to some established luxury marques. Key Features Features: Standard V6 engines, available all-wheel drive (AWD), premium interior materials (on higher trims), advanced (for its time) suspension systems, distinctive design cues. 📋 Manual Details Coverage Areas Manual Scope: Comprehensive workshop repair and service for the specified Mitsubishi Diamante model years. Specific Areas Covered: Engine Mechanical, Engine Electrical, Fuel System, Ignition System, Cooling System, Lubrication System, Intake & Exhaust, Clutch (if applicable), Automatic Transmission, Drivetrain, Suspension, Steering, Brakes, ABS System, Body Panels, Doors, Windows, Interior, HVAC, Electrical Distribution, Fuses & Relays, Wiring Diagrams. Page Count Estimated Page Count: 1000+ (typical for comprehensive workshop manuals of this era, though exact count not provided). Manual Type Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Delivery Method: Electronic delivery via email. 📖 Manual Coverage Systems Covered Engine: Complete overhaul, diagnostics, tune-ups, fuel system, ignition system, lubrication system, cooling system, emission control systems. Transmission: Repair and overhaul of automatic transmissions (likely INVECS-II or similar for V6 models), clutch system for manual transmissions (if applicable to specific markets/trims), drivetrain components (drive shafts, CV joints, differential). Brakes: Hydraulic system, ABS diagnostics and repair (if equipped), disc/drum brake component service, parking brake. Suspension Steering: Front and rear suspension components (struts, shocks, control arms, bushings), power steering system, steering gear/rack and pinion. Electrical: Complete wiring diagrams, charging system (alternator, battery), starting system, lighting, instrumentation, power accessories, fuse/relay identification and testing, basic diagnostic procedures. Body: Exterior body panels, doors, windows, locks, interior trim, HVAC system, body sealing, structural components. Fuel System: Fuel pump, fuel injectors, fuel pressure regulator, fuel filter replacement procedures, fuel tank service. Exhaust: Exhaust manifold, catalytic converter replacement, muffler and pipe service, emissions control components. Cooling System: Radiator, water pump, thermostat, hoses, fan clutch/electric fans, heater core diagnostics and replacement. Procedures Included Maintenance: Routine scheduled maintenance, fluid changes, filter replacements, lubrication, belt checks and replacement. Diagnostics: Troubleshooting guides, symptom-based diagnostics, electrical system testing, engine performance analysis. Repair: Component removal, installation, adjustment, and overhaul for all major vehicle systems. Special Tools: Identification and usage of specific Mitsubishi special tools required for certain procedures. Troubleshooting Charts: Comprehensive troubleshooting flowcharts and symptom guides for diagnosing common and complex issues. Torque Specifications: Detailed torque specifications for all critical fasteners, essential for proper assembly and safety. Technical Depth Depth: Advanced diagnostics and complete engine/transmission disassembly and reassembly, suitable for professional technicians and experienced DIYers. Diagrams Illustrations: Detailed exploded views, wiring diagrams, and step-by-step illustrations for major repair procedures. 📊 Manual Specifications File Format Format: PDF Print Quality Quality: Printable (high-resolution for clear text and diagrams). Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code Variants: 6G72 (3.0L SOHC V6), 6G73 (2.5L DOHC V6 - less common in North America, more prevalent in JDM Sigma variants). Performance 3.0L V6 Horsepower Torque: Approximately 170-180 hp and 195-200 lb-ft of torque, depending on year and specific tune. (Exact figures vary by market and year.) 2.5L V6 Horsepower Torque: Approximately 160-170 hp and 170-180 lb-ft of torque. (Less common for North American market). Fuel System Induction Type: Multi-port fuel injection (MPI) for all V6 engines. Engine Layout Layout: V6, 60-degree bank angle Bore X Stroke 3.0L: 81.0 mm x 95.0 mm (approximate). Cooling System Coolant Type Capacity: Typically uses a 50/50 mix of ethylene glycol coolant and distilled water. Capacity around 8-9 liters. Consult manual for precise specifications. Ignition System Ignition Type: Distributorless ignition system (DIS) with coil packs common on later models. Older models might have a distributor. 🔧 Transmission Standard Transmission Type: 4-speed automatic (e.g., INVECS-II). Optional Transmission Type Optional: 5-speed manual (less common, particularly in North American markets for the Diamante, more prevalent in JDM Sigma variants). Features Transmission Features: Electronically controlled, adaptive shift logic (INVECS-II) to optimize shift points based on driving style and conditions. Available All-Wheel Drive (AWD) system with viscous...
First Generation (JDM: Sigma, North America: Diamante)
Model Years Covered:
1991, 1992, 1993, 1994, 1995, 1996
Chassis Codes Jdm:
JS1A, JS2A (Sigma/Diamante Sedan)
Model Designation North America:
Diamante
Model Designation Japan:
Sigma (also associated with Debonair platform).
Codes
Chassis Codes:
JS2 (sedan), JS3 (wagon - not covered by this manual, as it is primarily focused on sedan models based on typical workshop manual coverage for this era).
👋 Introduction
Market Position
Segment:
Mid-size luxury sedan, competing with vehicles like the Toyota Camry, Honda Accord, Ford Taurus, and Chevrolet Lumina in its segment. Positioned as a more upscale offering from Mitsubishi.
Target Audience:
Aimed at buyers seeking a comfortable, stylish, and well-equipped sedan with a focus on smooth V6 performance and a refined driving experience.
Competitive Analysis
Strengths:
Known for its distinctive styling (especially the early models), smooth V6 engines, and comfortable ride. Often offered a good value proposition compared to some established luxury marques.
Key Features
Features:
Standard V6 engines, available all-wheel drive (AWD), premium interior materials (on higher trims), advanced (for its time) suspension systems, distinctive design cues.
📋 Manual Details
Coverage Areas
Manual Scope:
Comprehensive workshop repair and service for the specified Mitsubishi Diamante model years.
Repair and overhaul of automatic transmissions (likely INVECS-II or similar for V6 models), clutch system for manual transmissions (if applicable to specific markets/trims), drivetrain components (drive shafts, CV joints, differential).
Exhaust manifold, catalytic converter replacement, muffler and pipe service, emissions control components.
Cooling System:
Radiator, water pump, thermostat, hoses, fan clutch/electric fans, heater core diagnostics and replacement.
Procedures Included
Maintenance:
Routine scheduled maintenance, fluid changes, filter replacements, lubrication, belt checks and replacement.
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, electrical system testing, engine performance analysis.
Repair:
Component removal, installation, adjustment, and overhaul for all major vehicle systems.
Special Tools:
Identification and usage of specific Mitsubishi special tools required for certain procedures.
Troubleshooting Charts:
Comprehensive troubleshooting flowcharts and symptom guides for diagnosing common and complex issues.
Torque Specifications:
Detailed torque specifications for all critical fasteners, essential for proper assembly and safety.
Technical Depth
Depth:
Advanced diagnostics and complete engine/transmission disassembly and reassembly, suitable for professional technicians and experienced DIYers.
Diagrams Illustrations:
Detailed exploded views, wiring diagrams, and step-by-step illustrations for major repair procedures.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Quality:
Printable (high-resolution for clear text and diagrams).
Binding Type
Binding:
N/A (Digital PDF)
Paper Type
Paper:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Code Variants:
6G72 (3.0L SOHC V6), 6G73 (2.5L DOHC V6 - less common in North America, more prevalent in JDM Sigma variants).
Performance
3.0L V6 Horsepower Torque:
Approximately 170-180 hp and 195-200 lb-ft of torque, depending on year and specific tune. (Exact figures vary by market and year.)
2.5L V6 Horsepower Torque:
Approximately 160-170 hp and 170-180 lb-ft of torque. (Less common for North American market).
Fuel System
Induction Type:
Multi-port fuel injection (MPI) for all V6 engines.
Engine Layout
Layout:
V6, 60-degree bank angle
Bore X Stroke 3.0L:
81.0 mm x 95.0 mm (approximate).
Cooling System
Coolant Type Capacity:
Typically uses a 50/50 mix of ethylene glycol coolant and distilled water. Capacity around 8-9 liters. Consult manual for precise specifications.
Ignition System
Ignition Type:
Distributorless ignition system (DIS) with coil packs common on later models. Older models might have a distributor.
🔧 Transmission
Standard
Transmission Type:
4-speed automatic (e.g., INVECS-II).
Optional
Transmission Type Optional:
5-speed manual (less common, particularly in North American markets for the Diamante, more prevalent in JDM Sigma variants).
Features
Transmission Features:
Electronically controlled, adaptive shift logic (INVECS-II) to optimize shift points based on driving style and conditions. Available All-Wheel Drive (AWD) system with viscous coupling.
Fluid Specifications
Automatic Transmission Fluid:
Diamond ATF SP-II or equivalent. Capacity approximately 3.5-4.0 liters for a drain and fill. Full overhaul requires more. Always consult manual for precise type.
📐 Dimensions
Exterior
Length:
Approximately 193.5 inches (4915 mm).
Width:
Approximately 70.9 inches (1800 mm).
Height:
Approximately 55.1 inches (1400 mm).
Wheelbase:
Approximately 109.1 inches (2770 mm).
Weights
Curb Weight Range:
Approximately 3400-3700 lbs (1540-1680 kg), depending on drivetrain and options.
🛡️ Safety Features
Ratings
NHTSA Crash Test Rating:
Not readily available for this specific era and model through public databases, but generally considered a safe vehicle for its time. The manual will detail safety system components.
Active Features
ABS:
Anti-lock Braking System (ABS) available on most trims, especially those with AWD.
Passive Features
Airbags:
Driver airbag standard on most models from 1993/1994 onwards. Passenger airbag optional or standard on later models.
Seatbelts:
Three-point seatbelts with pretensioners for front occupants. Manual details proper adjustment and care.
💡 Technology Features
Infotainment
Audio System:
Factory-installed premium audio systems were available, often with cassette players and CD changers. Manual details controls and basic troubleshooting.
Driver Assistance
Cruise Control:
Electronic cruise control was standard or optional on most trims.
Connectivity
Early Tech:
Features like keyless entry (on later models) and power everything were common. This manual will help maintain these systems.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically every 3,000-5,000 miles (5,000-8,000 km) or 3-6 months, depending on driving conditions. Manual provides precise schedule.
Timing Belt Replacement:
Recommended every 60,000 miles (96,000 km) or 4-5 years for the 6G7x V6 engines. This is a critical maintenance item as failure can cause severe engine damage.
Transmission Fluid Change:
Recommended every 30,000-45,000 miles (48,000-72,000 km) for automatic transmissions. This is crucial for longevity.
Fluid Specifications
Engine Oil Viscosity:
SAE 5W-30 or 10W-30 recommended, depending on ambient temperature. Consult manual for specific temperature range charts and API service classification.
Coolant Type:
Ethylene glycol-based coolant, typically a 50/50 mix with distilled water. Avoid silicates in later formulations if possible, though early 90s often used conventional types. Manual is definitive.
Brake Fluid:
DOT 3 or DOT 4 brake fluid recommended. Always use fresh fluid and follow bleeding procedures carefully.
Power Steering Fluid:
Power steering fluid specific to Mitsubishi, or Dexron-II/III ATF on some models. Consult manual for precise specification to avoid damage.
Known Issues
Common Problems:
Suspension component wear (bushings, ball joints), aging electrical connectors (especially ground points), potential for radiator leaks or heater core issues, transmission control issues on high-mileage vehicles, catalytic converter efficiency decline.
Iac Valve:
Idle Air Control (IAC) valve can become dirty or fail, leading to rough idling or stalling.
ABS Sensors:
ABS wheel speed sensors can fail, triggering the ABS warning light.
Cv Axle Boots:
Torn CV axle boots can lead to grease loss and joint failure, requiring replacement.
📚 Vehicle History
Brand Heritage
Brand History Context:
Mitsubishi, a diversified Japanese conglomerate, established its automotive presence with vehicles known for durability and technological innovation, often leveraging partnerships.
Model Evolution
Diamante Development:
The Diamante was developed as Mitsubishi's flagship sedan, aiming to compete in the premium sedan market. It was based on a platform shared with Hyundai (Grandeur) and shared many components with the Mitsubishi Debonair (Japan).
Updates During Generation:
The first generation received minor styling updates and feature additions through its lifecycle, including revisions to safety equipment and minor interior tweaks.
Production
Production Location:
Primarily manufactured in Japan.
🏆 Awards & Recognition
Recognitions
Automotive Journalism Awards:
While specific 'awards' for the Diamante of this era are not as widely publicized as modern vehicles, it was generally well-received for its styling and comfort by automotive journalists upon release.