MITSUBISHI 3000GT 1991 Service Manual

ENGINE - Crankshaft. Flvwheel and Drive Plate11-51
id
PLASTIGAGE METHODMllUlAA
Plastigage may be used to measure the clearance.
(1) Remove oil and grease and any other dirt from bearings and
journals.(2) Cut plastigage to the same length as the width of the
bearing and place it in parallel with the journal, off oil holes.
(3) Install the crankshaft, bearings and caps and tighten them
to the specified torques. During this operation, do NOT turn
the crankshaft. Remove the caps. Measure the width-of the
plastigage at the widest part by using a scale printed on the
plastigage sleeve.
If the clearance exceeds the repair limit, the bearing should
be replaced.
Should the standard clearance not be obtained even after
bearing replacement, replace the crankshaft.
SERVICE POINTS OF INSTALLATIONMllUDAM
16. INSTALLATION OF CRANKSHAFT BEARING (UPPER) /
15.10. THRUST BEARING A / 14.11. THRUST BEARING
B
/ 12. CRANKSHAFT BEARING (LOWER)
(1) Classify the crankshaft bearings (upper and lower) by
whether there is an oil groove or not. Then, assemble asshown in the illustration.
(2) Assemble the thrust bearings (A and
B) on the No.3
journal area as shown in the illustration.
CautionInstall them with the groove side facing outward.Crankshaft bearing (upper)
Oil groove
Thrust bearing A
Front of engine(Tlmlng belt side)
EN269
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11-52ENGINE - Crankshaft, Flywheel and Drive Plate
9. INSTALLATION OF BEARING CAP
(1) Attach the bearing cap on the cylinder block as shown in
the illustration.
(2) Tighten the bearing cap bolts to the specified torque in‘I
the sequence shown in the illustration.
J ~
(3) Check that the crankshaft rotates smoothly.
Cral
Bearing cap
\Bearing cap bolt
Front of engine
(Timing belt side)
7EN270(4) Check the end plate. If it exceeds the limit value,
replace the thrust bearing.
Standard value: 0.05
- 0.25 mm (.0020 - .0098 in.)
Limit: 0.3 mm
(.012 in.)
-rent ofengineTimingIelt side)
8.
LLiN03,ij
1 TSB RevisionINSTALLATION OF BEARING CAP STAY
(1) Apply engine oil to the thread and bearing surface of
each bolt.
(2) Temporarily tighten the bolts on the cylinder block side.(3) Tighten the bolts on the bearing cap side to specified
torque.(4) Finally, tighten the bolts on the cylinder block side to
specified torque.
NOTEThe bearing cap stays A and B differ in shape. Install
correct ones on correct sides.d

ENGINE -Crankshaft, Flywheel and Drive Plate / Cylinder Block11-53
MB990938-01
CYLINDER BLOCK
REMOVAL AND INSTALLATION7. INSTALLATION OF CRANKSHAFT REAR OIL SEAL
Using the special tool, press-fit a new crankshaft rear oil
seal into the oil seal case.MllVA--
42 Nmftlbs.
1. Roll stopper bracket front2. Roll stopper bracket front (AWD only)3. Roll stopper bracket rear4. Detonation sensorI)* 5. Detonation sensor bracket
6. Cylinder block7EN0319
INSPECTION
CYLINDER BLOCK
MllVCAM(1) Using a straight edge and feeler gauge, measure the
flatness of the cylinder block upper surface.
Standard value: 0.05 mm
(-0020 in.)
Limit: 0.1 mm
(.004 in.)
Grinding limit: 0.2 mm
(.008 in.)
Caution
When the cylinder head is assembled, 0.2 mm (.008 in.)or less of grinding is permissible.
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11-54ENGINE - Cylinder Block
I
$jA A@/
,12 mm (.47 in.)
I
t+ ‘: ;I 2 Center -
Thrust
direction
-point7EN268
(2) Using a cylinder gauge, measure the inside diameter and
roundness of the cylinder. If excessively worn, repair (over~
size) the cylinder and replace the piston and piston rings.The measurement points are shown in the illustration.
)d
BORING THE CYLINDERMllVEEB
(1) Based on the largest cylinder bore, determine the over
sized piston to be used.
(2) Measure with the outside diameter of the piston as the
datum measurement points.
NOTE
There are four sizes of oversize piston -0.25 mm (.OlO in.),
0.50 mm
(.020 in.), 0.75 mm (.030 in.), 1.00 mm (.039 in.).
(3) Calculate the reground bore size based on the measured.value of the outside piston diameter.
NOTEBore size = outside piston diameter + 0.03 to 0.05 mm
(.0012 to .0020 in.) (gap between cylinder and piston) - 0.02mm (0008 in.) (honing amount)
(4) Hone each of the cylinders to the calculated measurement.
CautionTo prevent distortion resulting from the temperature‘drise during reboring, bore the cylinder holes in the
cylinder numbers sequence.
(5) Hone the cylinders, finishing them to the proper dimension(outside piston diameter + gap with cylinder).
(6) Check the gap between the piston and cylinder.
Standard value: 0.03
- 0.05 mm (.0012 - .0020 in.)
SERWCE POINT OF INSTALLATIONMllVDAL
5. INSTALLATION OF DETONATION SENSOR BRACKET
Check that the bracket is in intimate contact with the
cylinder block boss and tighten to specified torque in the
order shown.
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ENGINE - Engine Oil Cooler
ENGINE OIL COOLER
REMOVAL AND INSTALLATION
11-55
MllMA-.4Nm
2.9 ft.lbs.40-45
Nrh
29 - 33 ft.lbs.Removal steps
1.Front splash shield extensionl *2. Engine oil feed hose3.Engine oil return hose
4*4. Engine oil return tube5. Engine oil cooler
12Nm
9 ft.lbs.5
02FOOOi
SERVICE POINTS OF REMOVALMllMBAC
2.REMOVAL OF ENGINE .OIL FEED HOSE / 4. ENGINE OIL
RETURN TUBE
CautionBe sure to hold the weld nut of the oil cooler while
loosening the eye bolt.
INSPECTIONMllMCAC
l
Check the engine oil cooler fins for bends, breaks or plugs.l Check the engine oil cooler hoses for cracks, damage,
clogging or deterioration.l Check the gaskets for damage or deformation.
l Check the eye bolts for clogging or deformation.
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FUEL
SYSTEM
CONTENTSM13AA- _
CRUISE CONTROL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . .158SPECIFICATIONS. . . . . . . .._._....................................................155
CRUISE CONTROL SYSTEM*................................................185
SERVICE ADJUSTMENT PROCEDURES............................178
Cruise Control Cables Inspection and Adjustment........178Cruise Control SystemInspection....................................179individual Parts Inspection....................................................181
SPECIAL TOOLS........................................................................159
SPECIFICATIONS....................................................................158
General Specifications........................................................158Service Specifications........................................................158
TROUBLESHOOTING............................................................159
Check Chart............................................................................163Harness and Components Layout....................................176Preliminary Inspection........................................................159Self-diagnosis Checking........................................................172Troubleshooting Quick Reference Chart............................159
ENGINE CONTROL............................................155
ENGINE CONTROL................................................................157
SERVICE ADJUSTMENT PROCEDURES............................156
Accelerator Cable Inspection and Adjustment................156Accelerator Switch Inspection and Adjustment................156
Service Specifications........................................................
155
TROUBLESHOOTING............................................................
155
Accelerator Cable and Accelerator Pedal........................155
FUEL SYSTEM....................................................3
DETONATION SENSOR........................................................154
FUEL FILTER............................................................................
153
FUEL LINE AND VAPOR LINE................................................151
FUEL PUMP AND FUEL GAUGE UNIT ASSEMBLYAND OVERFILL LIMITER (TWO-WAY VALVE)................149
FUEL TANK.................................................................................146
GENERAL INFORMATION
....................................................
3
MPI System Diagram............................................................3
INJECTOR................................................................................141
ON-VEHICLE INSPECTION OF MPI COMPONENTS........36
Active Exhaust Control Unit <Turbo>............................130Air Conditioner Switch and Power Relay............................82Air Flow Sensor....................................................................54Anti-lock Brake Signal <Turbo>........................................133Barometric Pressure Sensor................................................60CONTINUED ON NEXT PAGE
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
(1)A Supplemental Restraint System (SRS), which uses a driver-side air bag, has been installed in the 3000GT.(2)The SRS includes the following components: impact sensors, SRS diagnosis unit: SRS warning light, air bagmodule, clock spring, interconnecting wiring. Other SRS-related components (that may have to be
removed/installed in connection with SRS service or maintenance) are indicated in the table of contents byan asterisk (*).
WARNING!(I)Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to
personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver (from
rendering the SRS inoperative).
(2) Service or maintenance of any SRS component or SRS-related component must be performed only at anauthorized MITSUBISHI dealer.
(3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP
528 -Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of theSRS or any SRS-related component.

13-2
Boost Meter <Turbo>........................................................128Components Inspection Procedure....................................40
Components Location........................................................36
Crank Angle Sensor
............................................................72Detonation Sensor................................................................84EGR Control Solenoid Valve
<California - Non Turbo, Turbo>........................................121
EGR Temperature Sensor <California>............................92ElectricalLoad Switch........................................................86Engine and Transaxle Total Control Signal <A/T>............135Engine Control Unit Power Ground....................................44Engine Coolant Temperature Sensor................................62Fuel Pressure Control Valve <Turbo>............................123Fuel Pressure Test................................................................138Fuel Pump <Non Turbo>....................................................45Fuel Pump <Turbo>............................................................48
Fuel Pump Operation Check................................................137Fuel Pump Relay No. 2........................................................53Fuel Pump Resistor............................................................53
Idle Position Switch............................................................68Idle Speed Control Servo (Stepper Motor Type)............1 IOIgnition Coil and Power Transistor....................................115Ignition Switch-ST and Inhibitor Switch <A/T>................76Ignition Switch-ST <M/T>................................................75Induction Control Valve Position Sensor
<Non Turbo>........................................................................90
Injectors<Non Turbo>........................................................101Injectors<Turbo>................................................................105Intake Air Temperature Sensor............................................57Muffler Mode Changeover Switch <Turbo>....................88Oxygen Sensor <Non Turbo>............................................
94
Oxygen Sensor <Turbo>....................................................98
Power Steering Oil Pressure Switch................................80Power Supply and Ignition Switch-IG................................41
Purge Control Solenord Valve............................................1 19Release of Residual Pressure from High
Pressure Fuel Hose............................................................137Throttle Position Sensor....................................................65Top Dead Center Sensor....................................................70Variable Induction Control Servo (DC Motor)
<Non Turbo>........................................................................131Vehicle Speed Sensor........................................................78Waste Gate Control Solenoid Valve <Turbo>................126
SERVICE ADJUSTMENT PROCEDURES............................31
Adjustment of Fixed SAS....................................................35Adjustment of Idle Position Switch and
Throttle Position Sensor (TPS)............................................33Basic Idle Speed Adjustment............................................31Throttle Body (Throttle Valve Area) Cleaning....................33
SPECIAL TOOLS........................................................................8
SPECIFICATIONS
....................................................................6
General Specifications........................................................6Sealant....................................................................................7Service Specifications........................................................7
THROlTLE BODY....................................................................143
TROUBLESHOOTING............................................................9
Check Chart Classified by Problem Symptoms................16Circuit Diagram....................................................................18Engine Warning Light (Malfunction Indicator Light)........11Explanation and Cautions about Harness Check............10Explanation of Troubleshooting Procedures....................9Fuel Tank and Fuel Line........................................................30
Problem Symptoms Table (For Your Information)............17Self-diagnosis........................................................................12)
I

FUEL SYSTEM - General Information
FUEL SYSTEM
L/ GENERAL INFORMATION
MPI SYSTEM DIAGRAM<Federal
-Non Turbo>4,xwo3 ,elOl alxesueJl/aulfiu~
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mJaS XI
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<California- Non Turbo>
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g 26;_I
P
5 ash
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13-4FUEL SYSTEM - General Information
-
tI
:‘iEI-2
Ln030-l03LLr?
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