Mitsubishi Sigma Complete Workshop Service Repair Manual 1991 1992 1993 1994 1995 1996 1997

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🏷️ Basic Information Identification Make: Mitsubishi Model: Sigma Product Name: Mitsubishi Sigma Complete Workshop Service Repair Manual 1991 1992 1993 1994 1995 1996 1997 Codes Chassis Codes: EC5A (Sedan), E5#A, E6#A, E7#A, E8#A (Hatchback/Wagon - primarily Diamante/GTO in other markets, but Sigma nomenclature applies to these platforms in specific regions) 👋 Introduction Market Position Target Audience: DIY mechanics, home mechanics, independent repair shops, and owners seeking to understand their vehicle's service requirements. Competitive Analysis Value Proposition: Offers significant cost savings on repairs and maintenance compared to dealership or independent mechanic labor costs. Provides access to professional-level repair information. Key Features Feature Highlight: Comprehensive coverage 'A-Z' for all models and engine variants, easy-to-follow instructions, digital format for accessibility. 📋 Manual Details Coverage Areas Model Years Covered: 1991, 1992, 1993, 1994, 1995, 1996, 1997 Model Variants Covered: All models, engines, trim levels, and transmission types Manual Type Type: Complete Workshop Service Repair Manual Language Language: English Format Format: Downloadable Digital Format (PDF) Accessibility: Printable, Viewable on PC, MAC, Tablets, Smartphones Page Count Estimated Page Count: Extensive (exact count not specified, but described as 'Complete' and 'A-Z' covering all repair procedures) 📖 Manual Coverage Systems Covered Mechanical Systems: Engine (disassembly, assembly, diagnosis, repair), Fuel System (injection, delivery, emissions), Cooling System, Lubrication System, Exhaust System Drivetrain Systems: Transmission (manual and automatic), Clutch, Drive Axles, Differentials, Transfer Case (if applicable) Suspension Steering: Front Suspension, Rear Suspension, Steering System (power steering, rack and pinion) Braking System: Front Brakes, Rear Brakes, Parking Brake, ABS (Anti-lock Braking System) if equipped Electrical Systems: Ignition System, Charging System (alternator, battery), Starting System, Lighting System, Instrumentation, Wiring Diagrams, ECU (Engine Control Unit) functions Body Chassis: Body Panels, Doors, Windows, Bumpers, Chassis Lubrication, Corrosion Prevention HVAC System: Heating, Ventilation, and Air Conditioning (HVAC) system components and service Procedures Included Diagnostic Procedures: Troubleshooting guides, fault code interpretation (OBD-I), symptom-based diagnosis Maintenance Procedures: Fluid changes, filter replacements, lubrication, belt inspection/replacement, spark plug replacement, brake pad replacement Repair Procedures: Engine rebuilds, transmission overhauls, suspension component replacement, brake caliper repair, electrical component repair Overhaul Procedures: Detailed step-by-step instructions for complete disassembly and reassembly of major components Adjustment Procedures: Valve adjustments, idle speed adjustments, parking brake adjustments Technical Depth Depth: Comprehensive: from basic routine maintenance to in-depth engine and transmission overhauls, including detailed specifications and diagnostic procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF (common for modern digital manuals) Print Quality Quality: High Quality (as advertised) Images: Includes step-by-step instructions and pictures/illustrations Binding Type Binding: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Options: 6G72 3.0L V6 SOHC/DOHC, 6G74 3.5L V6 SOHC/DOHC, 4G63 2.0L I4 DOHC Turbo (less common, often in performance variants or other markets designated as 'GTO' or 'Galant VR-4' but sharing platform elements) Performance Displacement Range: 2.0L to 3.5L Power Output Range: Approx. 140 HP to 240 HP (naturally aspirated V6) and up to 280 HP (turbocharged variants), depending on engine and market. Torque Range: Approx. 175 Nm to 340 Nm (depending on engine and market). Fuel System Fuel Delivery: Multi-point Fuel Injection (MPI) or Direct Injection (GDI in later models/markets), Electronic Fuel Pump Fuel Type: Unleaded Gasoline (Octane rating specified in manual, typically 91+ RON) Ignition System Ignition Type: Electronic Ignition (Distributorless Ignition System - DIS or Distributor-based systems) Engine Management ECU: Engine Control Unit (ECU) managing fuel injection, ignition timing, and emissions. 🔧 Transmission Standard Transmission Type: 5-speed Manual Transmission (F5M33, F5M42 series) Optional Transmission Type: 4-speed Automatic Transmission (V4A51, W4A32 series) Features Drive Layout: Front-Wheel Drive (FWD) or All-Wheel Drive (AWD) depending on model variant and engine. AWD System: Full-time 4WD with viscous coupling center differential or Active Transfer Case (Active ALL-WHEEL CONTROL - ACT) Fluid Specifications Automatic Transmission Fluid: Mitsubishi DiaQueen SP-II M or equivalent DEXRON-III/MERCON specification fluid (specific type varies, refer to manual) Manual Transmission Fluid: API GL-4 or GL-5 rated gear oil, typically SAE 75W-90 or 80W-90 (specific viscosity depends on climate and transmission model) 📐 Dimensions Exterior Body Styles: 4-door Sedan, 5-door Hatchback/Wagon (depending on market designation, often related to the Mitsubishi Diamante or Mitsubishi Eterna) Length Range: Approx. 4700 mm - 4850 mm Width Range: Approx. 1750 mm - 1800 mm Height Range: Approx. 1380 mm - 1450 mm Weights Curb Weight Range: Approx. 1400 kg - 1650 kg Gross Vehicle Weight: Varies by model and configuration (specified in manual) 🛡️ Safety Features Ratings Crash Test Results: Not extensively rated by modern standards (e.g., NHTSA, IIHS) due to the era. Refer to specific market regulations for available data. Active Features Active Safety: Optional Anti-lock Braking System (ABS), Traction Control System (TCS) on select higher trims/models. Passive Features Passive Safety: Seatbelts (front and rear), optional driver-side airbag, reinforced chassis structure. 💡 Technology Features Infotainment Infotainment System: Basic analog gauges, radio/cassette player, optional...

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Type: Car

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Sku: 178120

Collections: ALL Mitsubishi

Availability: In stock

Tags: 1991 1992 1993 1994 1995 1996 1997 Car Cars Mitsubishi Sigma

Product variants

Description

🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

Sigma

Product Name:

Mitsubishi Sigma Complete Workshop Service Repair Manual 1991 1992 1993 1994 1995 1996 1997

Codes

Chassis Codes:

EC5A (Sedan), E5#A, E6#A, E7#A, E8#A (Hatchback/Wagon - primarily Diamante/GTO in other markets, but Sigma nomenclature applies to these platforms in specific regions)

👋 Introduction

Market Position

Target Audience:

DIY mechanics, home mechanics, independent repair shops, and owners seeking to understand their vehicle's service requirements.

Competitive Analysis

Value Proposition:

Offers significant cost savings on repairs and maintenance compared to dealership or independent mechanic labor costs. Provides access to professional-level repair information.

Key Features

Feature Highlight:

Comprehensive coverage 'A-Z' for all models and engine variants, easy-to-follow instructions, digital format for accessibility.

📋 Manual Details

Coverage Areas

Model Years Covered:

1991, 1992, 1993, 1994, 1995, 1996, 1997

Model Variants Covered:

All models, engines, trim levels, and transmission types

Manual Type

Type:

Complete Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Downloadable Digital Format (PDF)

Accessibility:

Printable, Viewable on PC, MAC, Tablets, Smartphones

Page Count

Estimated Page Count:

Extensive (exact count not specified, but described as 'Complete' and 'A-Z' covering all repair procedures)

📖 Manual Coverage

Systems Covered

Mechanical Systems:

Engine (disassembly, assembly, diagnosis, repair), Fuel System (injection, delivery, emissions), Cooling System, Lubrication System, Exhaust System

Drivetrain Systems:

Transmission (manual and automatic), Clutch, Drive Axles, Differentials, Transfer Case (if applicable)

Suspension Steering:

Front Suspension, Rear Suspension, Steering System (power steering, rack and pinion)

Braking System:

Front Brakes, Rear Brakes, Parking Brake, ABS (Anti-lock Braking System) if equipped

Electrical Systems:

Ignition System, Charging System (alternator, battery), Starting System, Lighting System, Instrumentation, Wiring Diagrams, ECU (Engine Control Unit) functions

Body Chassis:

Body Panels, Doors, Windows, Bumpers, Chassis Lubrication, Corrosion Prevention

HVAC System:

Heating, Ventilation, and Air Conditioning (HVAC) system components and service

Procedures Included

Diagnostic Procedures:

Troubleshooting guides, fault code interpretation (OBD-I), symptom-based diagnosis

Maintenance Procedures:

Fluid changes, filter replacements, lubrication, belt inspection/replacement, spark plug replacement, brake pad replacement

Repair Procedures:

Engine rebuilds, transmission overhauls, suspension component replacement, brake caliper repair, electrical component repair

Overhaul Procedures:

Detailed step-by-step instructions for complete disassembly and reassembly of major components

Adjustment Procedures:

Valve adjustments, idle speed adjustments, parking brake adjustments

Technical Depth

Depth:

Comprehensive: from basic routine maintenance to in-depth engine and transmission overhauls, including detailed specifications and diagnostic procedures.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable PDF (common for modern digital manuals)

Print Quality

Quality:

High Quality (as advertised)

Images:

Includes step-by-step instructions and pictures/illustrations

Binding Type

Binding:

Not Applicable (Digital Download)

Paper Type

Paper Type:

Not Applicable (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Options:

6G72 3.0L V6 SOHC/DOHC, 6G74 3.5L V6 SOHC/DOHC, 4G63 2.0L I4 DOHC Turbo (less common, often in performance variants or other markets designated as 'GTO' or 'Galant VR-4' but sharing platform elements)

Performance

Displacement Range:

2.0L to 3.5L

Power Output Range:

Approx. 140 HP to 240 HP (naturally aspirated V6) and up to 280 HP (turbocharged variants), depending on engine and market.

Torque Range:

Approx. 175 Nm to 340 Nm (depending on engine and market).

Fuel System

Fuel Delivery:

Multi-point Fuel Injection (MPI) or Direct Injection (GDI in later models/markets), Electronic Fuel Pump

Fuel Type:

Unleaded Gasoline (Octane rating specified in manual, typically 91+ RON)

Ignition System

Ignition Type:

Electronic Ignition (Distributorless Ignition System - DIS or Distributor-based systems)

Engine Management

Engine Control Unit (ECU) managing fuel injection, ignition timing, and emissions.

🔧 Transmission

Standard

Transmission Type:

5-speed Manual Transmission (F5M33, F5M42 series)

Optional

Transmission Type:

4-speed Automatic Transmission (V4A51, W4A32 series)

Features

Drive Layout:

Front-Wheel Drive (FWD) or All-Wheel Drive (AWD) depending on model variant and engine.

AWD System:

Full-time 4WD with viscous coupling center differential or Active Transfer Case (Active ALL-WHEEL CONTROL - ACT)

Fluid Specifications

Automatic Transmission Fluid:

Mitsubishi DiaQueen SP-II M or equivalent DEXRON-III/MERCON specification fluid (specific type varies, refer to manual)

Manual Transmission Fluid:

API GL-4 or GL-5 rated gear oil, typically SAE 75W-90 or 80W-90 (specific viscosity depends on climate and transmission model)

📐 Dimensions

Exterior

Body Styles:

4-door Sedan, 5-door Hatchback/Wagon (depending on market designation, often related to the Mitsubishi Diamante or Mitsubishi Eterna)

Length Range:

Approx. 4700 mm - 4850 mm

Width Range:

Approx. 1750 mm - 1800 mm

Height Range:

Approx. 1380 mm - 1450 mm

Weights

Curb Weight Range:

Approx. 1400 kg - 1650 kg

Gross Vehicle Weight:

Varies by model and configuration (specified in manual)

🛡️ Safety Features

Ratings

Crash Test Results:

Not extensively rated by modern standards (e.g., NHTSA, IIHS) due to the era. Refer to specific market regulations for available data.

Active Features

Active Safety:

Optional Anti-lock Braking System (ABS), Traction Control System (TCS) on select higher trims/models.

Passive Features

Passive Safety:

Seatbelts (front and rear), optional driver-side airbag, reinforced chassis structure.

💡 Technology Features

Infotainment

Infotainment System:

Basic analog gauges, radio/cassette player, optional CD player. Limited by era, focused on core functionality.

Driver Assistance

Driver Assistance Features:

Cruise Control, Optional ABS, Optional Traction Control.

Connectivity

Connectivity:

Minimal. Primarily for external devices via auxiliary inputs if available on aftermarket head units. No integrated Bluetooth or USB.

Other Tech Features

Climate Control:

Manual air conditioning and heating, optional automatic climate control on higher trims.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically 5,000 - 7,500 miles (8,000 - 12,000 km) or 6-12 months, depending on driving conditions (refer to manual for specific recommendation).

Spark Plug Replacement Interval:

Varies by spark plug type. Platinum or Iridium plugs can last 60,000 - 100,000 miles (96,000 - 160,000 km). Standard copper plugs typically 30,000 miles (48,000 km).

Timing Belt Replacement Interval:

For 6G7x V6 engines, typically 60,000 - 90,000 miles (96,000 - 144,000 km) or 5-7 years. Critical due to interference engine design.

Coolant Flush Interval:

Every 30,000 - 50,000 miles (48,000 - 80,000 km) or 2-3 years.

Fluid Specifications

Engine Oil Type:

API SH/SJ or newer, Viscosity SAE 5W-30 or 10W-30 (depending on climate, consult manual for exact specifications).

Engine Oil Capacity:

Approx. 4.0 - 4.5 liters for V6 engines, 3.5 - 4.0 liters for 4-cylinder engines (with filter change, refer to manual for exact capacity).

Coolant Type:

Ethylene Glycol based coolant, typically a green or blue color. Use Mitsubishi Super Long Life Coolant (SLLC) or equivalent silicate-free antifreeze.

Brake Fluid Type:

DOT 3 or DOT 4 brake fluid.

Known Issues

Common Wear Items:

Suspension bushings, CV joints, wheel bearings, exhaust components (rust), heater core leaks, automatic transmission torque converter issues (on some models).

Engine Specific Issues:

For 6G72/74 V6 engines: potential for oil leaks, intake manifold gasket leaks, and timing belt failure if not replaced at recommended intervals (interference engines).

Electrical Gremlins:

Age-related issues such as brittle wiring insulation, sensor failures (e.g., O2 sensors, crank position sensors), and power window/lock motor failures.

📚 Vehicle History

Brand Heritage

Brand History:

Mitsubishi Motors, a division of the Mitsubishi conglomerate, has a history of innovation in automotive engineering, particularly in performance and four-wheel-drive technology.

Model Evolution

Platform Sharing:

The Sigma nameplate was used in various markets, often overlapping with the Mitsubishi Diamante and Mitsubishi Galant platforms. This manual likely covers models based on the Mitsubishi J-platform or similar iterations.

Production

Manufacturing Location:

Primarily Japan, with potential assembly in other global locations.

Production Period:

Model years 1991-1997, representing a significant generation for Mitsubishi's executive and performance sedans/wagons.

🏆 Awards & Recognition

Recognitions

Awards:

Specific awards for the 'Mitsubishi Sigma' model itself during its production run are not widely documented as prominent as some other Mitsubishi vehicles of the era (e.g., Lancer Evolution). However, the platform shared with the Diamante received positive reviews for its ride quality and V6 engine performance in various automotive publications.