light MITSUBISHI 3000GT 1991 Service Manual
[x] Cancel search | Manufacturer: MITSUBISHI, Model Year: 1991, Model line: 3000GT, Model: MITSUBISHI 3000GT 1991Pages: 1146, PDF Size: 76.68 MB
Page 782 of 1146
35-60SERVICE BRAKES - Service Adjustment Procedures
INSPECTION BY USING BRAKE FORCE TESTER
NOTE
(1) The brake force tester roller and tire must be dry during the
test.
(2) When testing the front brakes, apply the parking brake and
when testing the rear brakes, apply chocks to the front
wheels to lock them.
(I) Place the front or rear wheels on the brake force tester
roller.(2) Set the MUT through the adapter harness
(MB9913771 as
illustrated.
(3) After confirming that the shift lever or selector lever is in
the neutral position, start the engine.
(The ABS warning light lights up, it goes into the
-MUTmode. In the MUT mode, ABS does not function.)
(4) Operate the brake force tester roller.
(5) Depress the brake pedal until the brake force tester
indicates the following value and keep the brake force at
this level during the test.
Front wheels: 1,000 N (220
Ibs.)Rear wheels: 650 N (143
Ibs.)(6) Allow the brake tester indication to stabilize before operat-
ing the MUT to perform actuator test (Item No. 01,
02, 03).
Then, read change of tester indication.
Referring to the following “Judgement in Inspection by
Using Brake Force Tester” table, judge and take corrective
action if necessary.
NOTEWhile the ABS is in the fail safe mode, the MUT actuator
test cannot be made.
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Page 784 of 1146
When energized
Between terminals 4 and 5Continuity
When de-energized
Between terminals 4 and 5\i fl \\ 16FO264No continuity
Between terminals 1 and 3Continuity
16FO122L--J18FOCII
SERVICE BRAKES - Service Adjustment ProceduresI
INSPECTION OF POWER RELAYM35FOAP
7
1.Remove the relay box cover in the engine compartment and
remove the power relay.
2. Apply the battery voltage to the terminal @ and check for
‘L-J1
continuity between the following terminals when the
terminal @ is short-circuited to ground.
35-62
14FOOS14FOO8
l-TSB
1
REMEDY IN CASE OF DISCHARGED BATTERY
M35FOAQIf the engine is jump-started, because of a completely
discharged battery, the vehicle may suffer misfiring and fail to
start if an attempt is made to start without allowing the battery
to recover sufficiently. This is because the ABS consumes a
great deal of current for its self check. In such a case, allow the
battery to sufficiently charge or remove the ABS power relay in
the engine compartment to disable the ABS. Removing the
ABS causes the ABS warning light to light. After the battery is
charged sufficiently, install the power relay and restart the
engine to check that the ABS warning light goes out.
INSPECTION OF VALVE RELAY AND MOTOR
RELAY (ABS)M35FOAR1. Remove the splash shield
(FR) and remove the relay box
cover by inserting a screwdriver between the hydraulic unit
and cover to pry off the lock.
2.Remove the relays. The one closest to you (larger one) is
the motor relay and the one farthest from you (smaller one)
is the valve relay.
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wision
Page 786 of 1146
35-64SERVICE BRAKES - Brake Pedal
BRAKE PEDAL
REMOVAL AND INSTALLATIONM35GA-
-
Post-installation Operationl Installation of Steering Column
Assembly
(Refer to GROUP
37A-SteeringWheel and Shaft.)l Clutch Pedal Adjustment
(Refer to GROUP 21 -Clutch Pedal.)
l Brake Pedal Adjustment
(Refer to
P.3545.)
Stop light switch removal steps
I. Stop light switch connector
2. Stop light switch
Brake pedal removal steps
I)* 3. Return spring
4. Cotter pin
5. Washer
6. Clevis pin
9. Brake pedal assembly
(parts from step
10 to step 21)10. Brake pedal shaft bolt
13. Brake pedal
14. Bushing
15. Spacer
l * l * 20. Clutch pedal (Refer to Group 2
Pedal.)1 -Clutch
21. Brake pedal support member
30 Nmftlbs.
’ 12Nm9 ft.lbs.
c-iA.14
14FO10614
l?
14AO2564 5
%
,36il4”OOS,
. .
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I
I
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Page 787 of 1146
SERVICE BRAKES - Brake Pedal35-65
‘Ii14 Nm
i3Nmy9 ftlbs.
6
--2
-.113Nm14 Nm
9 ft.lbs.
10 klbs.
Stop light switch removal steps1. Stop light switch connector
2. Stop light switch
Brake pedal removal steps
l *3. Return spring
4. Cotter pin
5. Washer\12 Nlm9 ftllbs.6. Clevis pin
7. Cotter pin
8. Shift lock cable connection
9. Brake pedal assembly (parts from step
10 to
step 21)
/’/’10.
11.
12.13.
14.
15.
16.
17.
18.
19.
21.Brake pedal shaft bolt
Lever assembly installation nut
Lever assembly
Brake assembly
Bushing
Spacer
Cotter pin
Link assembly
Lever assemblyBushinq
Brake pedal support member
/
14FO107
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Page 788 of 1146
35-66SERVICE BRAKES - Brake Pedal
14LO142No continuity Continuity
4mm
(.I6 in.)14LO171
:Vehicles with cruise control>a
b14LO17C
Brake pedal
14FOO76
INSPECTIONM35GCANl Check the bushing for wear.
l Check the brake pedal for bend or twisting.
l Check the brake pedal return spring for damage.
‘LJ)STOP LIGHT SWITCH
(I) Connect a circuit tester to the stop light switch.
(2) The
stolj light
switch is in good condition if there is no
continuity when the plunger is pushed in to a depth of
within 4 mm
(.16 in.) from the outer case edge surface, and
if there is continuity when it is released.
For vehicles with the cruise control system, the check for
continuity should be made at connectors “a” and “b” of the
stop light switch.
SERVICE POINT OF INSTALLATIONM35GDBG3. INSTALLATION OF RETURN SPRING
Install the return spring with the shorter hook on the brake
pedal.
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Page 791 of 1146
SERVICE BRAKES - Master Cylinder and Brake Booster35-69light
scale14AO471
DISASSEMBLY AND REASSEMBLY
Brake fluid: Conforming to DOT3
Disassembly steps
1. Reservoir cap assembly
2. Diaphragm
3. Reservoir cap4. Filter
5. Brake fluid level sensor
6. Float7. Reservoir stopper bolt
8. Reservoir
9. Reservoir seal
*I)IO. Piston stopper bolt
11. Gasket
a*12. Piston stopper ring
13. Primary piston assembly
a*14. Secondary piston assembly
15. Master cylinder body(3) Measure the dimension
(D)der mounting surface on brake booster and the push
rod end.
NOTETo obtain
(D), first take measurement with a square
placed on the brake booster. Then, subtract the thick-
(D).
(3),push rod and primary piston.
Standard value: A (A
=- C - D)
7
+ 8 inch brake booster
0.55
- 0.75 mm (.022 - .030 in.)
8
+ 9 inch brake booster
0.65
- 0.85 mm (.026 - .033 in.)
(5) If the clearance is not within the standard value range,
adjust by changing the push rod length by turning the
adjustable end of the push rod.
Caution
Improper clearance may cause excessive brake
drag.M35HA-
-
14FOll3
Do not disassemble the primary ancH secondary
piston assembly.
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Page 817 of 1146
36-1
PARKING
BRAKES
CONTENTSM36AA-.
PARKINGBRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8SPECIAL TOOLS . .._.._.............................................
PARKING BRAKE LEVER AND PARKINGSPECIFICATIONS................................................
BRAKE CABLE*....................................................5General Specifications....................................
SERVICE ADJUSTMENT PROCEDURES4Lubricants....................................................................Parking Brake Lever Stroke Check4Sealants
andAdhesives....................................................Parking Brake Switch Check
............................4Service Specifications....................................
TROUBLESHOOTING........................................
i
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!(1)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 (fromrendering the SRS inoperative).(2) Service or maintenance of any SRS component or SRS-related component must be performed only at an
authorized MITSUBISHI dealer.(3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B
-Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of theSRS or any SRS-related component.
u
I
Page 820 of 1146
36-4PARKING BRAKES - Service Adiustment Procedures
-
\Adjusting nut14u015:
un' 14FOO3SERVICE ADJUSTMENT PROCEDURES
PARKING BRAKE LEVER STROKE CHECKM36FEAK
1. Pull the parking brake lever with a force of approx. 200 N d(45
Ibs.), and count the number of notches.
Caution
The 200 N
(45 Ibs.) force of the parking brake lever must
be strictly observed.Standard value: 3
- 5 notches
2.If the parking brake lever stroke is not the standard value,
adjust as described below.
(1) Remove the cup holder and plug and loosen the
adjustment nut to the cable end so that the cable
becomes free.
(2) Repeat depressing the brake pedal until the pedal
stroke becomes stable.
NOTEWhen the brake pedal is repeatedly depressed, shoe
clearance is adjusted properly.
(3) Disengage the drive shaft and companion flange.
(4) Remove the adjusting hole plug. Using a screwdriver,
turn the adjuster in the direction of the arrow (to expand
the shoe) until brake is lightly applied [where the disc
cannot be turned with both hands: approx. 2.7 Nm (23in.lbs.)]. Then, turn the adjuster five notches in the
direction opposite the arrow.
(Reference: Shoe clearance on one side 0.19 mm
‘d
I.0075 in.])
(6) After the parking brake lever stroke has been adjusted,
jack up the rear part of the vehicle. Loosen the parking
brake and turn the rear wheel to check that the parking
brake does not drag.
PARKING BRAKE SWITCH CHECKM36FDAG
1.Disconnect the connector of the parking brake switch, and
connect an ohmmeter to the parking brake switch and the
switch installation bolt.
2.The parking brake switch is good if there is continuity when
the parking brake lever is pulled and there is no continuity
when it is returned.
,(JTSB Revision
(51 Turn the adjusting nut to obtain specified parking brake
lever stroke. After the adjustment, check that there is
no play between the adjusting nut and pin.
CautionDo not adjust parking brake lever stroke too tight,
less than the standard value, or brake drag could
result.
Page 829 of 1146
37A-1
STEERING
CONTENTSM37AA-A
POWER STEERING GEAR BOX*....................17Steering Wheel Return to Center
Check................................................................8
POWER STEERING HOSES................................32Tie Rod End Ball Joint Startinq Torque
POWER STEERING OIL PUMP. .._....................28Check. . . . . . . . .._.............................. r . . . . . . . . ..I . . . . . .6Tie Rod End Ball Joint Variation Check
SERVICE ADJUSTMENT PROCEDURES5(Shaft direction)................................................5........
Bleeding............................................................10V-Belt Tension Check........................................8
Fluid Level Check............................................9SPECIAL TOOLS....................................................3Fluid Replacement
............................................9
/
bOil Pressure Switch Check
SPECIFICATIONS2............................12................................................Oil Pump Pressure Test
....................................1 1General Specifications....................................2Stationary Steering Effort Check
....................8Lubricants............................................................3Steering Angle Check
5Sealant and Adhesives....................................3........................................Steering Wheel Centering
6Service Specifications....................................2................................Steering Wheel Free Play Check
....................5STEERING WHEEL AND SHAFT*....................13
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 an
authorized MITSUBISHI dealer.(3) MITSUBISHI dealer personnel must thoroughly review this manual, and especially its GROUP 52B
-Supplemental Restraint System (SRS), before beginning any service or maintenance of any component of theSRS or any SRS-related component.
Page 833 of 1146
STEERING 2 Service Adjustment Procedures37A-5
13FOOOi13FOOO3SERVICE ADJUSTMENT PROCEDURES
STEERING WHEEL FREE PLAY CHECKM37FABI
1.With engine running (hydraulic operation), set front wheels
straight ahead.
2. Measure the play on steering wheel circumference before
wheels start to move when slightly moving steering wheel
in both directions.
Limit: 30 mm (1.2 in.)
3:When the play exceeds the limit, check for play on steering
shaft connection and steering linkage. Correct or replace.
4. If the free play still exceeds the limit value set steering
wheel straight ahead with engine stopped. Load 5 N
(1 lb.)
towards steering wheel circumference and check play.
Standard values (steering wheel play with engine
stopped): 11 mm
(.43 in.)
If the play exceeds the standard value, remove steering
gear box and check total pinion torque.
STEERING ANGLE CHECKM37FDBK1. Set front wheels on turning radius gauge and measure
steering angle.
Standard values:Inner wheel
33”45’ k 2”
Outer wheel
28”21’2. When not within the standard value, it is probably a toe
problem. Adjust toe (refer to GROUP 33A
- Service
Adjustment Procedures) and recheck.
TIE ROD END BALL JOINT VARIATION CHECK
(SHAFT DIRECTION)M37FPAF1. Hold the ball joint with pliers.
2.Set a caliper gauge as illustrated and measure the displace-
ment with the ball stud compressed.
Limit: 1.5 mm
(.059 in.)
3. If the measured displacement exceeds the limit, replace
the tie-rod end.
Caution
Even if the variation is within the limit, check ball jointstarting torque.
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