torque MITSUBISHI 3000GT 1991 Owner's Guide

EMISSION CONTROL - Exhaust Gas Recirculation IEGR) Svstem17-13
GM159
QQQQQQ7FMnn4EGR VALVE - Non Turbo, Turbo>
M17lCKJ
INSPECTION(1) Remove the EGR valve and check it for sticking, deposit of
carbon, etc.
If such condition exists, clean with adequate solvent to
ensure tight valve seat contact.
(2) Connect a hand vacuum pump to the EGR valve.
(3) Apply a vacuum of 500 mmHg (19.8 in.Hg.) and check
airtightness.
(4) Blow in air from one passage of the EGR to check condition
as follows.
INSTALLATIONInstall a new gasket and EGR valve, tighten bolts to specified
torque.
Specified tightening torque: 19
.Nm (13 ft.lbs.)
EGR TEMPERATURE SENSOR M17lCYC
INSPECTION(1) Remove the EGR temperature sensor.
(2) Place the EGR temperature sensor in water, and then
measure the resistance value between terminals 1 and 2
while increasing the water’s temperature.
Replace the EGR temperature sensor if there is a significant
deviation from the standard value.
INSTALLATIONInstall the EGR temperature sensor tighten to specified torque.
Specified tightening torque: 11 Nm (8
ftlbs.)
EGR CONTROL SOLENOID VALVE Non Turbo, Turbo>MlllCRE
INSPECTION
NOTEWhen disconnecting the vacuum hose, make an identification
mark on it so that it can be reconnected to the original position.
(1) Disconnect the vacuum hose (yellow and green stripe) from
the solenoid valve.
(2) Disconnect the harness connector.
(3) Connect a hand vacuum pump to the nipple to which the
green-striped vacuum hose was connected.
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CLUTCH - Service Adjustment Procedures21-5
Clutch pedal height
08YO41
auto-cruise control
L-l
\ \ 0Cl;tchswitch
\ \08F0010
Clutch pedal stroke
Lock nut
08F005414110052
SERVICE ADJUSTMENT PROCEDURES
CLUTCH PEDAL INSPECTION AND ADJUSTMENTMZlFAAP
1.Measure the clutch pedal height (from the face of the pedal
pad to the firewall).
Standard value: 177
- 182 mm (6.97 - 7.17 in.)
If the clutch pedal height is not within the standard value
range, adjust as follows:
For vehicles without auto-cruise control system, turn and
adjust the bolt so that the pedal height is the standard
value, and then secure by tightening the lock nut to the
specified torque.
Vehicles with auto-cruise control system, disconnect the
clutch switch connector and turn the switch for standard
clutch pedal height. Tighten the lock nut to the specified
torque.
Specified torque: 13 Nm (9
ft.lbs.)
NOTEWhen the pedal height is lower than the standard value,
loosen the bolt or clutch switch, and then turn the push rod
to make the adjustment. After making the adjustment,
tighten the bolt or clutch switch to reach the pedal stopper,
and then lock with the lock nut.
2. Measure the clutch pedal stroke.
Standard value: 160 mm (6.29 in.) or more
If the clutch pedal stroke deviates from the standard value,
turn the push rod to adjust the stroke.
3. Return the clutch pedal gradually from its full-stroke
position to measure amount of the return made by the
pedal
u,ntil the interlock switch makes an operating sound.
Standard value: 10
- 15 mm (.394 - .591 in.)
If the amount of pedal return deviates from the standard
value, adjust it by loosening the lock nut and turning the
interlock switch.
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21-22CLUTCH - Clutch Cover and Disc
APPLYgrease
6CLOlE
lir#LClutch disc
Clutch cover
assembly
v-l6CL02EITSB Revision
SERVICE POINTS OF INSTALLATIONMZIGDAU5. APPLICATION OF GREASE TO RELEASE FORK
(1) Apply a coating of the specified grease to the point of
contact with the fulcrum and the point of contact
withthe release bearing.
Specified grease: MITSUBISHI genuine grease
Part No. 0101011 or equivalent
CautionWhen installing the clutch, apply grease to each
part, but be careful not to apply excessive grease;excessive grease will cause clutch slippage and
shudder.(2) Apply a coating of the specified grease to the end of the
release cylinder’s push rod and to the push rod hole in
the release fork.
Specified grease: MITSUBISHI genuine grease
Part No. 0101011 or equivalent
4.APPLICATION OF GREASE TO CLUTCH RELEASE BEAR-ING (FWD)
Pack the inner surface of the clutch release bearing and the
groove with the specified grease.
Specified grease: MITSUBISHI genuine grease
Part No. 0101011 or equivalent
2. APPLICATION OF GREASE TO CLUTCH DISC
/ 1.
CLUTCH COVER ASSEMBLY
(1) Apply a coating of the specified grease to the clutch
disc spline, and then use a brush to rub it in.
Specified grease: MITSUBISHI genuine grease
Part No. 0101011 or equivalent
(2) Using the universal clutch disc aligner, position the
clutch disc to the flywheel.
(3) Install the clutch cover assembly. Tighten the bolts a
little at a time, working in a diagonal sequence, finally
tightening them to the specified torque.I

MANUAL TRANSAXLE - Transaxle Assembly
22-25
L
Slit
#Jl
Spring pin
/
II-+Shift rail1 I I201034
er
2150008
MD998325-01
(2) When installing, make sure that the slit of the spring pinis aligned with the shift rail center line.
46. INSTALLATION OF REVERSE IDLER GEAR SHAFTInstall in the direction illustrated.
35.37. 40. 42. INSTALLATION OF SPACERS
(1) Place two pieces of solder measuring about 10 mm (.4in.) in length and 1.6 mm
(.06 in.) in diameter as
illustrated and install the outer races.
(2) Install the transaxle case and tighten the bolts to
specified torque.
(3) Remove the transaxle case.
(4) Remove the outer races and remove the solder.
(5) If solder is not crushed, perform steps (1) to (4) with a
solder with a larger diameter.
(6) Measure the thickness of the crushed solder with a
micrometer and select and install a spacer of thicknessthat gives standard preload and end play.
Standard value:Input shaft end play
0
- 0.05 mm (0 - .002 in.)
Intermediate gear preload
0.05
- 0.10 mm (.002 - .004 in.)
Output shaft preload
0.05
- 0.10 mm (.002 - .004 in.)
Differential case preload0.05
- 0.10 mm (.002 - .004 in.)
33. INSTALLATION OF OIL SEALInstall the drive shaft oil seal using the special tool.
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22-26MANUAL TRANSAXLE . - Transaxle Assembly
Amountl-2 mm
27. INSTALLATION OF OIL GUIDEInstall the oil guide to the transaxle case as illustrated.
26. INSTALLATION OF TRANSAXLE CASE(1) Place the selected spacers on the intermediate gear
and differential’s bearing outer race. Also insert the
selected spacer between the output shaft bearing outer
race and the transaxle case.
(2) Set so that the threaded hole of the reverse idler gearshaft’s head is facing in the direction indicated in the
illustration.
NOTE
If there is a great deviation in the direction in which the
threaded hole is facing, it will be impossible to align thethreaded hole and the hole in the case after the
transaxle case is installed.
(3) Apply specified sealant to the clutch housing side of the
transaxle case.
Specified’ sealant: MITSUBISHI genuinePart No. MD997740 or equiva-
lentLJ
Caution
Squeeze out sealant from the tube uniformly with-
out excess or discontinuity.(4) Install the transaxle case onto the clutch housing.
(5) Insert a Phillips screwdriver
[8 mm (.32 in.) shaft
diameter] into the bolt hole in the case, as shown in thefigure, and use it to align the threaded hole of the
reverse idler gear shaft with the bolt hole in the
transaxle case.
(6) Install the reverse idler gear shaft bolt and tighten thebolt by fingers.
(7) Tighten the all transaxle tightening bolts to specified
torque.(8) Tighten the reverse idler gear shaft bolt to specified
torque.16.15. INSTALLATION OF LOCK NUTS
(1) Install the special tool to the splined end of input shaft.(2) Screw a bolt
[lo mm (.40 in.)] into the hole on the
periphery of clutch housing and attach a spinner handleto the special tool.
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MANUAL TRANSAXLE - Transaxle Assembly22-27
(3) Shift the transaxle in reverse using control lever and
select lever.
(4) Tighten the lock nut to specified torque, while using thebolt attached in the above step as a spinner handle
stopper.(5) Loosen the lock nuts.
(6) Retighten the lock nuts to the specified torque.
(7) Stake the lock nut.
IMD998245-01Spring pir
Shift rail
14. INSTALLATION OF SPRING PIN(1)
rr;‘tl.the spring pin using the special tool or a pin
CautionDo not reuse the spring pins.
(2) When installing, make sure that the slit of the spring pinis aligned with the shift rail center line.
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MANUAL TRANSAXLE Differential Assembly / Speed-
- ometer Driven Gear Assembly22-45
TFYOO4Q
The numerals @to @ indicate
the tightening sequence.
9
SPEEDOMETER DRIVEN GEAR ASSEMBLY
DISASSEMBLY AND REASSEMBLY
3. INSTALLATION OF TAPER ROLLER BEARINGInstall the taper roller bearings on both sides of the
differential case.
CautionWhen press-fitting the bearings, push the inner race
only.
1.INSTALLATION OF BOLTS
Apply specified adhesive to the entire threads of the bolts
and quickly tighten in the order shown to specified torque.
Specified adhesive: 3M Stud Locking Part No. 4170 or
equivalent
CautionIf a bolt is reused, remove traces of oil adhesive
completely from the threads.MZ2MNAE
Disassembly steps
I. O-ringl *2. Spring pin
l *3. Speedometer driven gear4. Oil seal
5. Sleeve201078
201075
SERVICE POINTS OF REASSEMBLY3. INSTALLATION OF SPEEDOMETER DRIVEN GEAR
Apply gear oil sparingly to the speedometer driven gear
shaft and insert the shaft.
2. INSTALLATION OF SPRING PIN
Install the spring pin in such a way that its slit does not facethe gear shaft.
J
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MANUAL TRANSAXLE - Service Adjustment Procedures22-51SERVICE ADJUSTMENT PROCEDURES
TRANSMISSION OIL LEVEL INSPECTIONM22FBAE2
Refer to GROUP 00
- Maintenance Service.
TRANSMISSION OIL REPLACEiVlENTMUFCAJ
(I) Position vehicle on a flat level and remove filler and drainplugs to drain transmission oil.
(2) Pour in fresh transmission oil through filler port.
Transmission oil: Hypoid gear oil, SAE 75W-85W con-
forming to API classification GL-4 or
higherTransaxle: 2.4 liters (2.5 qts.)
Transfer: 0.27 liters
(.29 qts.)
(3) After checking to be sure that the oil level is the specifiedlevel, tighten the filler plug at the specified torque.
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AUTOMATIC TRANSAXLE - General Information23-3HYDRAULIC CONTROL SYSTEM

i
Low-reversehr3b.3\t3ear clutch “IYhFI\\\\\\1
,/I // L1 ji‘erhaustvalve7 ;// j/ .j/,
Damper cluGcontrol solenoidvalve
To lubncatlon(front) cTo lubncatlon ,-=(rear)
Torquel-2 shift
valvek&!&!&I h TransaxldI e 1 11
---- il.valve
I 1 Shik control I!:;?A+;ilEjJJBi,
IIsolenoid
valve “6”S3ivcontroI
I/
i %
\sl
valve
Ex[ 011 filter J
011 pan
m Line pressure
-Tyue converter and lubricationsure
-_ucing pressureOil pump suction pressure
a Modulated line pressure
I”‘rl Damper clutch pressure
mDamper clutch control solenoid
valve pressure
IPressure control solenoidvalve pressureTFA0070
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23-4AUTOMATIC TRANSAXLE - General information

Tort-
CCvJ
Kickdown servo--
Low-reversebrake
Rear clutch Front clutch
F12/
!P
End clutchii
/
Ii”
t
OFF
z7szzz
10-IF=?
OFF
snort controlvalve
1'7 H I-------i II/
IIjamper clutcontrol solerwualveTo lubrrcatron c(front)To lubrrcatton c(rear)ReducingL valve
IIsolenoidvalve “B”
Pressure control
N-R control
valve
Pressurecontrol
OFFsolenord
m Oil pump suction pressure
0 Modulated line pressure
0 Damper clutch pressure
@gjJDamper clutch control solenoid
valve pressure
IPressure control solenoid
valve pressure
m Lrne pressure
0Torque converter and lubricationpressure
Reducing pressureTFA0071
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