clock MITSUBISHI 3000GT 1991 User Guide

FUEL SYSTEM - Throttle Body13-145Orifice
Nipple (green)3EM05iGroundThrottle
positlonsensor output
Idle-position
switchTh>ottle position
sensor power7FUO535(5) Disconnect the hand vacuum pump and connect it to the
other nipple.
(6)Make sure that the negative pressure leaks out as soon as it
is applied.
CLEANING THROTTLE BODY PARTS
(1) Clean all throttle body parts.
Do not use solvent to clean the following parts:
l Throttle position sensor (Idle position switch)
l Idle speed control servo
If these parts are immersed in solvent, their insulation will
deteriorate.
Wipe them with cloth only.
(2) Check if the vacuum
pot-t or passage is clogged. usecompressed air to clean the vacuum passage.
SERVICE POINT OF REASSEMBLY
M13SGAN4. INSTALLATION OF THROTTLE POSITION SENSOR
(1) Set the throttle position sensor to the throttle body as
shown in the diagram.
(2) After turning the throttle position sensor 90” in the
clockwise direction to set it, tighten by turning the
screw.
(3) Connect the circuit tester between 1 (ground) and 3
(output), or between 3 (output) and 4 (power). Then,
make sure that the resistance changes smoothly when
the throttle valve is slowly moved to the fully open
position.
(4) Check for continuity across terminals 2 (Idle position
switch) and 1 (ground) with the throttle valve both fully
closed and fully open.
IThrottle valve positionIContinuityI
Fully closedConductive
Fully openINon-conductiveIIf there is not continuity with the throttle valve fully
closed, turn the counterclockwise direction, and then
check again.
(5) If the above specifications are not met, replace the idle
position switch.
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CRUISE CONTROL .SYSTEM - Troubleshooting13-177
DASH PANELJunction block
JUNCTION BLOCKFront side
36FOOO236FOOO3
i
10 Clutch pedal switch 11 Stop light switch
12 Clock spring
13 Accelerator pedal switch
LOCATION OF CONTROL UNIT
E%sQ/I.LIlll-I BCrutse
!tcontrol
unit
GROUND POINT14 Over drive switch
15 Cruise control unit16
l 7
1
Front wiring harness and junctionl 8 block combination
19 Adapter wiring harness and junction block
combination
Body wiring harness
(LH) and junction block
I-\ --*
I d
4tT
-G
1
q\ ($$ 16F02E
36FOO18
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13-182CRUISE CONTROL SYSTEM - Service Adjustment ProceduresI
CRUISE CONTROL SWITCH INSPECTION(1) Remove the air bag module using the following procedure.I07FOO12
07NOOl@ Remove the negative terminal of the battery and wait
for more than 30 seconds.
d
CautionThe capacitor in the SRS diagnosis unit retains
enough voltage to deploy the air bag for a given
period even after disconnection of the battery. If anoperation is performed during that given period,
unintended deployment of the air bag could result
and cause serious injury.@Remove the air bag module. To remove the clock spring
connector
(squib connector) from the air bag module,
force the lock outward and pry it with a plain screwdriv-
er as shown at left so that no undue force will be
exerted on the connector when it is removed.@ The removed air bag module should be stored in a
clean, dry, flat place with the pad side up.
(2) Disconnect the connector of the control switch and operate
the control switch to measure the resistance between the
individual terminals.
If the readings are as shown below, the control switch may
be considered good.
Switch operationResistance between-iJ
terminals
When switch is not operated
When switch is operated toward you
(CANCEL switch: ON)
When switch is operated upward
(RESUME switch: ON)
When switch is operated downward
(SET switch: ON)No continuity
Approx. 0
1RApprox. 820
1RApprox. 2,700
fi
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CRUISE CONTROL SYSTEM - Cruise Control Svstem13-187Vacuum hoseSERVICE POINT OF REMOVAL
Ml3lDBG20. REMOVAL OF AIR BAG MODULE
(1) Remove the negative terminal of the battery and wait
for more than 30 seconds.
CautionThe capacitor in the SRS diagnosis unit retains
enough voltage to deploy the air bag for a given
period even after disconnection of the battery. If anoperation is performed during that given period,
unintended deployment of the air bag could result
and cause serious injury.(2) Remove the air bag module. To remove the clock spring
connector (squib connector) from the air bag module,
force the lock outward and pry it with a plain screwdriv-
er as shown at left so that no undue force will be
exerted on the connector when it is removed.
(3) The removed air bag module should be stored in a
clean, dry, flat place with the pad side up.
INSPECTION
MlJTDCFl Check the inner and outer cable for damage.
l Check the cable for smooth movement.
l Check the link protector for damage.
INSPECTION OF INDIVIDUAL PARTSRefer to Service Adjustment Procedures
- Individual Parts
inspection (P.l3-181).
SERVICE POINT OF INSTALLATION
M13TDDF
6.CONNECTION OF VACUUM HOSE TO VACUUM PUMPRoute the vacuum hose over the throttle cable and connect
the hose to the vacuum pump so as to prevent the
slackened hose from interfering with other parts.
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22-1
iv,MANUAL ~
TRANSAXLE
~
I
CONTENTSM22AA. -
MANUAL TRANSAXLE . . . . . . . . . . . .._...48INPUT SHAFT ASSEMBLY_..________.............: . . . . . . . . . . . . . . . . . . . . . . . . . .30
GENERAL INFORMATION....................................................48
SERVICE ADJUSTMENT PROCEDURES
............................51
Drive Shaft OilSealsReplacement....................................
52Speedometer Cable Replacement....................................
53Transfer Oil Seal Replacement............................................53Transmission Oil Level Inspection....................................51Transmission Oil Replacement............................................51
SHIFT LEVER ASSEMBLY....................................................
53
SPECIAL TOOLS........................................................................50
SPECIFICATIONS
....................................................................49
General Specifications........................................................49Lubricants............................................................................49
TRANSAXLE ASSEMBLY....................................................56,60
TRANSAXLE CONTROL*........................................................54
TRANSFER ASSEMBLY
........................................................59
MANUAL TRANSAXLE ....................2
CLUTCH HOUSING ASSEMBLY............................................46
DIFFERENTIAL ASSEMBLY
....................................................43
5TH SPEED SYNCHRONIZER ASSEMBLY
........................28
GENERAL INFORMATION
....................................................2INTERMEDIATE GEAR ASSEMBLY
....................................
OUTPUT SHAFT ASSEMBLY................................................
SERVICE ADJUSTMENT PROCEDURES............................
Drive Shaft Oil Seals Replacement....................................Speedometer CableReplacement....................................Transmission Oil Level Inspection....................................Transmisston Oil Replacement............................................
SHIFT LEVER ASSEMBLY....................................................
SHIFT RAILS AND FORKS....................................................
SPECIAL TOOLS........................................................................
SPECIFICATIONS....................................................................
General Specifications........................................................
Lubricants............................................................................
Sealants and Adhesives........................................................Service Specifications........................................................
Snap Ring (for Adjustment) and Spacer............................
SPEEDOMETER DRIVEN GEAR ASSEMBLY....................
TRANSAXLE ASSEMBLY _____...._........__....................................
TRANSAXLE CONTROL*. . ..________.___.._ ..__._.__.__...............
36
41
9
10
9
9
9
13
42
6
3z
63
3
45
14
11TROUBLESHOOTING
___.._______._____.......,..................................8
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.

23-1
AUTOMATIC
TRANSAXLE
CONTENTSMZJAA- _
ANNULUS GEAR AND TRANSFER DRIVE GEARTransmission Fluid Level Inspection................................46SET................................................................................................
102Transmission Fluid Replacement........................................
46
DIFFERENTIAL........................................................................104SPECIAL TOOLS........................................................................
16
:......................................... 12IEND CLUTCH ASSEMBLY....................................................99SPECIFICATIONS..........................
FRONT CLUTCH ASSEMBLY................................................95
GENERAL INFORMATlON....................................................2
KICKDOWN SERVO................................................................
107
LOW-REVERSE BRAKE............................................................
107
OIL PUMP....................................................................................93
PLANETARY GEAR................................................................
100
REAR CLUTCH ASSEMBLY....................................................97
SELECTOR LEVER ASSEMBLY............................................58
SERVICE ADJUSTMENT PROCEDURES............................46
Accelerator Switch
Inspection and Adjustment................
50Drive Shaft Oil Seals Replacement....................................
52Inhibitor Switch and Control Cable Adjustment................
52Key Interlock Mechanism Check........................................50KickdownServo Adjustment................................................
47Line Pressure Adjustment....................................................
48Reducing Pressure Adjustment........................................
49Selector Lever Operation Check........................................
50Shift Lock Mechanism Check............................................51Speedometer Cable Replacement....................................53
General Specifications........................................................12Lubricants............................................................................15Service Specifications........................................................12Spacer and Snap Ring........................................................13Valve Body Spring Identification Chart............................13
SPEEDOMETER DRIVEN GEAR ASSEMBLY....................106
TRANSAXLE ASSEMBLY........................................................62
TRANSAXLE CONTROL*........................................................54
TRANSAXLE OIL COOLER, HOSES, TUBES
....................66
TRANSFER SHAFT....................................................................92
TROUBLESHOOTING............................................................
19
A/T Safety-lock System Troubleshooting........................44Converter Stall Test............................................................
43
Diagnosis and Test
................................................................
22
Element in Use at Each Position of Selector Lever........31Inspection
of ControlSystem............................................
28Inspection of Electronic Control System Components....32Oil Pressure Tests................................................................
39ShiftPatterns....................................................................
31,42Troubleshooting Guide........................................................
20
VALVE BODY. . . .._._.................................................................... 108
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
(1)A Supplemental Restraint System (SRS), which uses a driver-side air bag, has been installed in the 3668GT.(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 beremoved/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 topersonal 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) MlTSUBISHI 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 the
ISRS or any SRS-related component.

AUTOMATIC TRANSAXLE - Service Adjustment Procedures23-47
MD998916-3-01
KICKDOWN SERVO ADJUSTMENTM23FRAC(1) Remove dust, dirt, and other contaminants completely fromkickdown (K/D) servo cover and surrounding areas.
(2) Snap off the snap ring and remove K/D servo switch.
(3) Fit claw of special tool into cutout in piston to prevent
piston from turning and use adapter to fix the piston into
position.
Caution
1. Do not push piston with the special tool.
2.Secure adapter only hand-tight to L/R brake press-
ure take-up port and do not apply
excessiwe torque.
(4) Loosen lock nut to immediately before V-groove in adjust
rod (see illustration on left) and tighten special tool (Inner
Wrench) until it contacts lock nut.
(5) Fit special tool (Outer Wrench) over the lock nut. Turn Outer
Wrench counterclockwise and turn inner cylinder clockwise
to lock the lock nut and special tool (Inner Wrench).
(6) Fit torque wrench to special tool (Inner Wrench) and repeat
tightening and loosening cycle two times with a torque of
10 Nm (7.2 ft.lbs.). Then, torque to 5 Nm (3.6 ftlbs.).Next, back off special tool (Inner Wrench) 2 to
2’/4 turns.
(7) Fit special tool (Outer Wrench) to lock nut.
Turn Outer Wrench clockwise and Inner Wrench counter-
clockwise to unlock the lock nut from special tool (Inner
Wrench).
Caution
Be sure to apply even torque to the two special tools
when unlocking.
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AUTOMATIC TRANSAXLE - Service Adjustment Procedures23-49
1(9) Install valve body and oil temperature sensor.
Bolt A
= Length 18 mm (.709 in.)
Bolt B
= Length 25 mm (.984 in.)
Bolt C
= Length 40 mm (1.575 in.)
CautionSecure solenoid valve and oil temperature sensor
harness at locations shown.
(1O)lnstall oil filter.(1l)lnstall new oil pan gasket and oil pan.
(12)Add the specified amount of ATF.
(13)Carry out hydraulic test.
Readjust as necessary.
REDUCING PRESSURE ADJUSTMENTh323FfADWhen multi-use tester is not used
(1) Following the same steps as those in line pressure
adjustment, remove parts up to oil filter.
There is no need to remove valve body.
(2) Turn adjusting screw of lower valve body to obtain the
specified reducing pressure. Turn it counterclockwise to
increase the pressure.
Standard value:425 f 10 kPa (60 f 1 psi)
Oil pressure change for
each turn of adjusting screw:45 kPa (6 psi)(3) In the same way as in line pressure adjustment,
/nstall oil
filter and oil pan.
(4) Perform hydraulic test.
Adjust as necessary.
When multi-use tester is used
(1) Adjust to obtain the specified K/D brake pressure when PC
solenoid is energized at duty 50% with the multi-use tester.
Standard value:275 kPa (39 psi)
Oil pressure change for
each turn of adjusting screw:50 kPa (7 psi)(2) After adjustment has been made, check that the recuding
pressure is in the range 360
- 480 kPa (51 - 68 psi).
Caution
This adjustment should be made with oil temperature70
- 80°C (160 - 180°F).
The adjustment made with high oil temperature couldresult in improper adjustment due to a line pressure
drop at idle.
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23-56AUTOMATIC TRANSAXLE - Transaxle ControlOQPOOQQ
09FOO5
INSPECTIONM231CAMl Check the control cable for function and for damage.
lCheck the outer cable (key interlock cable, shift lock cable)
’for damage and spring for breakage and tension.~J
lCheck the inner cable (key interlock cable, shift lock cable)
for extension.
REVERSE
(R) POSITION ALARM BUZZER
Check that the buzzer sounds when battery voltage is applied
across terminals.
SERVICE POINTS OF INSTALLATIONM231DAW
19. CONNECTION OF SHIFT LOCK CABLE (BRAKE PEDAL
SIDE)Connect the shift lock cable so that its threads measure
about 4 mm
(.16 in.).
CautionDo not change the routing of shift lock cable to the
selector lever assembly.
16. INSTALLATION OF SLIDE LEVER / 15. KEY INTERLOCK
CABLE (STEERING LOCK ASSEMBLY SIDE) / 14. CAM
LEVER(1) Place the ignition key at the “LOCK” position or keep it
removed.
(2) Install the slide lever, key interlock cable, and cam lever
to the steering lock assembly as shown.
Caution
Do not change the routing of key interlock cable tothe selector lever assembly.
5. CONNECTION OF TRANSAXLE CONTROL CABLE
(SELECTOR LEVER ASSEMBLY SIDE)Connect the transaxle control cable, then make the follow-
ing adjustment.
(1) Place the selector lever in “N” position.
(2) Loosen the nut and slightly pull the transaxle control
cable in the direction of the arrow; then, tighten the nut.
4.CONNECTION OF SHIFT LOCK CABLE (SELECTOR LEV-
ER ASSEMBLY SIDE)(1) Place the selector lever in “P” position.
(2) Disconnect the key interlock cable from the selector
lever assembly side.
(3) Turn the lock cam B counterclockwise (arrow
0) to
move the set lever upward (arrow
0)._.-(4) Frt the cutout in set lever to the jock pm ot lock cam B. u
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REAR AXLE - Service Adjustment Procedures2743
,,rmr
SERVICE ADJUSTMENT PROCEDURES
REAR AXLE TOTAL BACKLASH CHECKM27FAAG
If the vehicle vibrates and produces a booming sound due to an
imbalance of the driving system, measure the rear axle total
backlash by the following procedures to see if the differential
carrier assembly required removal.
(1) Place the gearshift lever in the neutral position, apply the
parking brake and jack up the vehicle.
(2) Manually turn the propeller shaft clockwise as far as it will
go and make mating marks on the companion flange dustshield and the differential carrier.
(3) Manually turn the propeller shaft counterclockwise as far as
it will go and measure the movement of the mating marks.Limit: 5 mm
(.2 in.)
(4) If the backlash exceeds the limit, remove the differential
carrier assembly and adjust the backlash. (Refer to P.27-26.)
GEAR OIL LEVEL CHECKM27FCAG1. Remove the filler plug, and check the oil level.
2. The oil level is sufficient if it reaches the filler plug hole.
Specified
gear oil:
Hypoid Gear Oil API classification GL-5 or higher
[l.l liter (1.2 q&J]
NOTEAbove -23°C (-10°F): SAE 90,
85W-90, 8OW-90From -34°C (-30°F) to -23°C (-10°F): SAE
8OW, 8OW-90Below -34°C (-30°F): SAE 75W
REAR WHEEL BEARING END PLAY CHECKM27FBAF1. Support the vehicle on axle stands positioned at the
specified locations and remove the rear wheel.
2. Separate the parking brake cable from the rear brake.
3. Remove the caliper assembly and brake disc.
4. Place a dial gauge as shown in the illustration, and then
measure the play when the axle shaft is moved in the axial
direction.Limit: 0.8 mm
(.031 in.)
5.If the play exceeds the limit, check the tightening torque ofthe companion flange of the axle shaft; if it is correct,
replace the wheel bearing.
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