drain bolt MITSUBISHI 3000GT 1991 Service Manual

00-40
GENERAL - Maintenance Service
(2) Check that the transaxle oil level is at the lower portion of
the filler plug hole. For AWD-vehicles, check that the
transfer oil level is at the portion shown in the illustration.
(3) Check to be sure that the transmission oil is not noticeably
‘ddirty, and that it has a suitable viscosity.
10. AUTOMATIC TRANSAXLE
(Inspect fluid level)
MOOSEDL
1.Drive until the fluid temperature reaches the usual tempera-
ture
[70 - 80°C (160 - 18O”F)I.2. Place vehicle on level floor.
3. Move selector lever sequentially to every position to fill
torque converter and hydraulic circuit with fluid, then place
lever in “N” Neutral position. This operation is necessary to
be sure that fluid level check is accurate.
4. Before removing dipstick, wipe all dirt from area around
dipstick. Then take out the dipstick and check the condition
of the fluid.
The transaxle should be overhauled under the following
conditions.
l If there is a “burning” odor.
l If the fluid color has become noticeably blacker.
lIf there is a noticeably great amount of metal particles in
the fluid.
5. Check to see if fluid level is in “HOT” range on dipstick. If
fluid level is low, add ATF until level reaches “HOT” range.
Low fluid level can cause a variety of conditions because it
allows pump to take in air along with fluid. Air trapped in
hydraulic circuit forms bubbles which make fluid spongy.
Therefore, pressures will be erratic.
Improper filling can also raise fluid level too high. When
transaxle has too much fluid, gears churn up foam and
cause same conditions which occur with low fluid level,
resulting in accelerated deterioration of ATF transmission
fluid.
In either case, air bubbles can cause overheating, fluid
oxidation, which can interfere with normal valve, clutch, and
servo operation. Foaming can also result in fluid escaping
from transaxle vent where it may be mistaken for a leak.
6. Be sure to examine fluid on dipstick closely.
L/(Change fluid)
Drain the fluid and check whether there is any evidence of
contamination.
Replenish with new fluid after the cause of any contamination
has been corrected.
(1) Remove drain plug at transaxle case bottom to let fluid
drain.(2) Place a drain container with large opening under the
transaxle oil pan.
(3) Loosen oil pan bolts and tap pan at one corner to break it
loose allowing fluid to drain, then remove oil pan.
d
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GENERAL - Maintenance Service00-41
Good
t-lVA0283
I04FOOOd(4) Check the oil filter for clogging and damage and replace if
necessary.
(5) Clean drain plug and tighten drain plug with gasket to 30
-35 Nm (22
- 25 ft.lbs.).
(6) Clean both gasket surfaces of transaxle case and oil pan.
(7) Install oil pan with new gasket and tighten oil pan bolts to
10 - 12 Nm (7.5 - 8.5 ft.lbs.).
(8) Pour 4.5 liters (4.8 qts.) of specified ATF into case through
dipstick hole. [Total quantity of ATF required is approx. 7.5
liters (7.9 qts.). Actually however, approx. 4.5 liters (4.8 qts.)
of fluid can be replaced because rest of fluid remains in
torque converter.]
Specified fluid: Dia ATF SP or MITSUBISHI PLUS ATF or
equivalent(9) Start engine and allow to idle for at least two minutes.
Then, with parking brake on, move selector lever momen-
tarily to each position, ending in “N” Neutral position.
(lO)Add sufficient ATF to bring fluid level to lower mark.
Recheck fluid level after transaxle is at normal operating
temperature. Fluid level should be between upper and
lower marks of “HOT” range. Insert dipstick fully to prevent
dirt from entering transaxle.
11. ENGINE COOLANT (Change)
MOOSBEHCheck the cooling system parts, such as radiator, heater, and
oil cooler hoses, thermostat and connections for leakage and
damage.
CHANGING COOLANT<Non-Turbo>
1.
2.
3.
4.
5.
6.
7.
8.Remove te heat protectors (front and rear) from the exhaust
manifold.
Loosen the radiator drain plug, remove two drain plugs from
the engine block (one for each bank) and remove the
radiator cap to discharge coolant.
Remove the reservoir tank and discharge coolant.
When coolant has been discharged, pour water through the
filler port to flush coolant passage.
Coat the threads of the engine drain plugs with the
specified sealant and tighten the plugs to specification.
Specified sealant: 3M Nut Locking Part No. 4171 or
equivalentTightening torque: 40 Nm (29
ftlbs.)Fit the radiator drain plug securely.
Mount the reserve tank.
Slowly pour coolant into the radiator to the brim and also
into the reserve tank up to the FULL line.
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ENGINE - Oil Pan and Oil Pump
Removal steps
1. Transaxle stay (front)
2. Transaxle stay (rear)
3. Oil pressure switch4.
Z:
;:9.10.l+11.l*12.** l * 13.
Oil pressure gauge unitOil filterOil cooler by-pass valve
Oil filter bracket stay
Oil filter bracket
Oil filter bracket gasket
Drain plugDrain plug gasket0; y; boltI<Turbo>
16. Relief plug17. Relief spring18. Relief plunger** 19. Crankshaft front oil seal
20. Oil pump case
21. Oil pump gasket
22. Oil pump cover
23. Oil pump outer rotor
24. Oil pump inner rotor
14. Oil screen
15. Oil screen gasket
Side
clearance
BodyclearanceSERVICE POINTS OF REMOVALMllRBBB
13. REMOVAL OF OIL PAN
(1) Knock the special tool in deeply between the oil pan and
cylinder block.
(2) Hitting the side of the special tool, slide and remove the
oil pan.
INSPECTION
OIL PUMPMllRKAB
Assemble the rotor on the oil pump and check the clearance
with a feeler gauge.
Standard value:
Body clearanceO.lOO- 0.181 mm (.0039 - .0071 in.)
Side clearance0.040 - 0.095 mm (.0016 - .0037 in.)
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/
iENGINE
- Oil Pan and Oil Pump11-43
Tlghtenlng sequence of flange bolts(bottom view)
iTiming beltside)7EN030f
7EN030
12. TIGHTENING SEQUENCE OF OIL PAN BOLTTighten the flange bolts in the sequence shown in the
illustration.illustration.
11. INSTALLATION OF DRAIN PLUG GASKETInstall the drain plug gasket in the direction shown in the
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INTAKE AND EXHAUST - Air Intake Plenum <Non Turbo>15-13
AIR INTAKE PLENUM <Non Turbo>
/REMOVAL AND INSTALLATIQNMlWA-B
L/
i
I Post-installation ODeration
Adjustment of Accelerator Cable
(Refer to GROUP 13 - Engine Control.)
Removal steps7-9ft.lbs.
I. Connection air intake hose2. Connection of accelerator cable_*I)3. Throttle body assemblyl *4. Throttle body gasket
5. Connection of brake booster vacuum hose
6. Harness connecters8 60Nm;6Nm05FOO32
43 ft.lbs.13 ft.lbs.
7. Connection of VIC servo motor
8. EGR pipe
9. EGR valve<Vehicles for10. EGR valve gasket
California>
11. EGR temperature sensor
12. Accelerator cable bracket
13. Connection of air intake plenum stay14. Air intake plenum installation bolts
15. Air intake plenum installation nuts
16. Air intake plenum
17. Air intake plenum gasket
Throttle body
SERVICE POINT OF REMOVALM15UBC23. REMOVAL OF THROTTLE BODY ASSEMBLY
Leaving the water hoses and vacuum hoses in their
installed positions, remove from the air intake plenum.
INSPECTIONM15UCAD2
Check the following points; replace the part if a problem is
found.
AIR INTAKE PLENUM
(1) Check air intake plenum for defect or cracks. Replace if
defective or cracked.
(2) Check load (negative pressure) of drain port. Clean if
required.
SERVICE POINT OF INSTALLATIONMl5UDAB2
4. INSTALLATION OF THROTTLE BODY GASKET
Install with the gasket protrusion positioned as shown.
CautionIf installed in an incorrect direction, idling failure or
other problems may occur.
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22-60MANUAL TRANSAXLE <dWD> - Transaxle Assembly
TRANSAXLE ASSEMBLY
The W5MGl transaxle cannot be disassembled.
If any parts other than describes below are defective, replace the transaxle assembly.
REPLACEABLE PART
1.l * 2.
3.
*a 4.l 4 5.6.
Transaxle to transfer connecting boltTransfer case oil seal
Transfer oil seal guide
Input shaft rear seal cap
Center shaft oil sealAir vents (breather caps) for transaxle and
transfer
Oil filler plugs for transaxle and transfer
Oil drain plugs for transaxle and transfer
TFM0157
SERVICE POINTS OF INSTALLATION6. INSTALLATION OF CENTER SHAFT OIL SEAL
Fabricate a tool having the following dimensions from a
pipe to install the oil seal.
Dimension :
I.D.. . . ..___........._...................... Approx. 27 mm (1.06 in.)
O.D.
. . . . . .._...........___............_.....Approx. 31 mm (1.22 in.)
Length . . . . . . . . . . . . . . . ..__......._____.Approx. 200 mm (7.87 in.)
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27-12REAR AXLE <AWD> - Troubleshooting
Symptom
Gear oil leakageProbable cause
Worn or damaged front oil seal, or an improperly
installed oil seal
Damaged gasketRemedyReplace
Loose companion flange self-locking nut
Loose filler or drain plugRetighten or replace
Retighten or apply adhesive
SeizureClogged or damaged vent plug
Insufficient final drive gear backlash
Excessive drive pinion preload
Excessive side bearing preloadClean or replace
Adjust
Insufficient differential gear backlash
Excessive clutch plate preload
NOTE
Inferior gear oil
Insufficient gear oil quantity
Replace
Replenish
In the event of seizure, disassemble and replace the parts involved, and also be sure to check all components forany irregularities and repair or replace as necessary.
Break downIncorrect final drive gear backlashInsufficient drive pinion preloadInsufficient side bearing preload
Adjust
Excessive differential gear backlash
NOTE
Loose drive gear clamping boltsRetighten
In addition to disassembling and replacing the failed parts, be sure to check all components for irregularities andrepair or replace as necessary.
The limited slipThe limited slip device is damagedDisassemble, check the functioning
differential does notand replace the damaged partsfunction (on snow,mud, ice, etc.)TSB Revision

27-24REAR AXLE <AWD>- Differential Carrier
DIFFERENTIAL CARRIER
REMOVAL AND INSTALLATION
M271A. -
Pre-removal and Post-installation Operationl Draining and Filling of Differential Gear Oil
(Refer to Group 00 - Maintenance Service.)l Removal and Installation of Main Muffler
(Refer to Group 15 - Exhaust Pipe and Muffler.)24Nm
17 ft.lbs.
90 Nm65 ft.lbs.4
/lIl8
c/
90 Nm65 ft.lbs.
63
i
i !f%
43 - 51ft.lbs.
90 Nm65 ftlbs.
,55-65Nm40 - 47 fklbs.
22 - 25 ft.lbs.
90 Nm65 ft.lbs.llFO034
Removal steps
a*1. Drive shaft
2. Circlipl * l a3. Propeller shaft connection
4. Differential support assembly
5. Differential support member assembly
6. Rear wheel oil pump installation bolt
l * l *7. Differential carrier
8. O-ring
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35-86SERVICE BRAKES - Hydraulic Unit (ABS)HYDRAULIC UNIT (ABS)
REMOVAL AND INSTALLATION
I
M350A.ARemoval steps
4*1. Brake tube connection
2. Harness connector connection
3.Bracketbolt4*4. Hydraulic unit (with bracket)
5. Hydraulic unit bolt
6. Grounding wire connection
1Flared brake line nuts
/15 Nmllftlbs. 14FO33
Pre-removal Operationl Removal of Splash Shieldl Draining of Brake Fluidl Removal of Relay Boxl Removal of Air DuctInstallation steps
l a6. Grounding wire connection
5. Hydraulic unit bolt initial tightening
4. Hydraulic unit (with bracket)
3. Bracket bolt
2. Harness connector connection
** 1. Brake tube connection19FO127
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STEERING - Service Adjustment Procedures37A-9
LL:13N002E
FluId f[uctuatlon
While
engineWhile engme
runningstopped13uo13:
Return ho
Vinyl hose13AO142
j
1.Press in V-belt at the illustrated position with about 100 N
(22 Ibs.) and measure deflection.
Standard value:
When belt tension is inspectedor readjusted
When new belt is installed
/ 9 - 11 mm (.35 - .43 in.)
I
’ 7 - 8.5 mm (.28 - .33 in.)
2.If the deflection is out of the standard values, adjust the belt
tension using the following procedure.
(1) Loosen the tension pulley’s securing bolts A and
B.(2) Mount the extension bar on the tension pulley.
(3) While increasing the tension of the V-belt with the
extension bar, retighten the tension pulley’s securing
bolts A and B in the order mentioned.
FLUID LEVEL CHECKM37FlAJ
1.Park the vehicle on a flat, level surface, start the engine, and
then turn the steering wheel several times to raise the
temperature of the fluid to approximately 50
- 60°C (122 -
140°F).
2.With the engine running, turn the wheel all the way to the
left and right several times.
3.Check the fluid in the oil reservoir for foaming or milkiness.
Check the difference of the fluid level when the engine is
stopped, and while it is running. If the fluid level changes
considerably, air bleeding should be done.
FLUID REPLACEMENTM37FJAL1. Raise the front wheels on a jack, and then support them
with rigid racks.
2. Disconnect the return hose connection.
3. Connect a vinyl hose to the return hose, and drain the oil
into a container.
4. Disconnect the high-tension cable, and then while operat-
ing the starting motor intermittently, turn the steering
wheel all the way to the left and right several times to drain
all of the fluid.
Caution
Be careful not to position the high-tension cable nearthe carburetor or the delivery pipe.
5.Connect the return hoses securely, and then secure it with
the clip.
6.Fill the oil reservoir with the specified fluid up to the lower
position of the filter, and then bleed the air.
Specified fluid:MITSUBISHI PLUS ATF/Automatic
transmission fluid “DEXRON” or
“DEXRON II”
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