ESP MITSUBISHI 3000GT 1991 Service Manual

SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
dir J
bag module, clock spring, interconnecting wiring. Other SRS-related comp\
onents (that may have to be
(*).
The Supplemental Restraint System (SRSI-related components are shown in the following MASTER TABLE
OF CONTENTS. Be sure to carefully read and understand the WARNING below \
before proceeding.
Group number
22.23
32
36
42
52A
Group nameSRS-related components
FUELCRUISE CONTROL SYSTEM/ P.13-185
MANUALTRANSAXLE.TRANSAXLE CONTROLAUTOMATIC TRANSAXLE
POWER PLANT MOUNTRIGHT MEMBER, LEFT MEMBER AND CROSSMEMBERP.32-6
ELECTRONIC CONTROLSUSPENSION’STEERING ANGULAR VELOCITY SENSORP.33B-19
PARKING BRAKESPARKING BRAKE LEVER AND PARKiNG BRAKE CABLE/ P.36~5I
STEERING/POWER STEERING GEAR BOX/ P.37A-17
/STEERING WHEEL AND SHAFTj P.37A-13
BODY
INTERIOR
FENDER
FLOOR CONSOLE/ P.52A-11
FRONT SEAT
INSTRUMENT PANEL
P52A-18
P.52A-8
CHASSIS ELECTRICAL
SEAT BELT
COLUMN SWITCH
HORN SWITCH
IGNITION SWITCH
P.52A-25
P.54-73
P.54-78
1 P.54-6
RADIO REMOTE-CONTROL/ P.54.110
HEATER, AIR CONDITIONERAIR-CONDITIONER CONTROL PANELAND VENTILATIONAIR-CONDITIONER CONTROL UNITP.55-56
/DAMPER CONTROL MOTOR ASSEMBLYI
/HEATER CONTROL ASSEMBLY1 P.55-18I
HEATER UNIT.1 P.55-22
WARNING!
VENTILATORS (INSTRUMENT PANEL)P.55-36
(1) Improper service or maintenance of any component of the SRS, or an\
y SRSrelated component,
can lead to personal injury or death to service personnel (from inadver\
tent firing of the air bag) or
to the driver (from rendering the SRS inoperative).
(260°F) in baking or in
drying after painting, remove the SRS components (air bag module, SRS d\
iagnosis unit, front
perfarmed
only at an authorized MITSUBISHI dealer.
52B
- Supplemental Restraint System (SRS), before beginning any service or m\
aintenance of any
component of the SRS or any SRS-related component.
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GENERAL - How to Use This Manual
EXPLANATION OF MANUAL CONTENTS
Indicates procedures to be per-formed before the work in thatsection is started, and procedures tobe performed after the work in thatsection is finished.
Maintenance and Servicing Procedures0 Removal steps:
(1) A diagram of the component parts is providedThe part designation number corresponds to the
near the front of each section in order to give thenumber in the illustration to indicate removal
reader a better understanding of the installedsteps.
condition of component parts.l Disassembly steps:
(2)The numbers provided within the diagram indicateThe part designation number corresponds to the
the sequence for maintenance and servicingnumber in the illustration to indicate disassembly
procedures; the symbol m indicates a non- . ln~~~~iion steps:reusable part; the tightening torque is providedwhere applicable.Specified in case installation is impossible inreverse order of removal steps.Omitted if installation is,possible in reverse orderof removal steps.l Reassembly steps:Specified in case reassembly is impossible inreverse order of disassembly steps. Omitted ifreassembly is possible in reverse order of dis-assembly steps.
Classifications of Major Maintenance/Service Points
When there’are major points relative to maintenance andservicing procedures (such as essential maintenance andservice points, maintenance and service standard values,informatton regarding the use of special toois, etc.), these arearranged together as major maintenance and service points andexplained in detail.
**:lndicates that there are essential points for removal ordisassembly.*+: Indicates that there are essential points for installation orreassembly.Symbols for Lubrication, Sealants and Adhesives
Information concerning the locations for lubricationand for application of sealants and adhesives isG&:
provided, by using symbols, in the diagram of compo-nent parts or on the page following the componentparts page, and explained.4:
Indicates (by symbols) where lubri-cation is necessary. In this example,
Grease(Multipurpose grease unless there is a brandor type specified)
Sealant or adhesive
Brake fluid, automatic transmission fluid or aconditioner compressor oil
Engine oil or gear oil
Adhesive tape or butyl rubber tape
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GENERAL - How to Use This Manual00-5
Indicates thepage number.
\
-.37A-28STEERING - Power Steering Gear Box
POWER STEERING GEAR BOX
REMOVAL AND INSTAUATION1!3-20 Plm
-7-Renloval steps
1 .Jrnyt assembly and gear box connecting2. Connection for
return tube3.Connection for press.ure hose
4. cotter pm
5.T1erod end and knuckle connecting
3.
maI,% ,v*, ,tu&w.,. *.-._10. Center member rear mourha WR11, Front exhaust pipe‘0 w 12. Gear box assembly” 13. Mountmg rubber
Denotes tightenrng
Denotes non-reus-able part.
SERVICE POINTS OF REMOVALJ-Y-6. Ol6CONN6CTtON OF TIE-ROD END* Using the special tool, disconnect the tie rod from the
Operating procedures, cau-tions, etc. on removal, installa-tion, disassembly and reassem-bly are described.
\
37A-24
1.60sumtotie6lec?rdofthaspecialwJdtotheneflrbY2.
~thsmItbutdonDt-vsit.
12. REMOVAL OF GEAR 60X ASSEMBLY
STEERING - Manual Steering Gwr Box
This number corresponds to thenumber appearing in “Removalsteps”,“Disassembly steps”,“installation steps” or “Reas-sembly steps”
\
The title of the page (followingthe page on which the diagramof component parts is pre-sented) indicating the locationsof lubrication and sealing proce-dures.
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00-6
GENERAL - How to Use This Manual
EXPLANATION OF THE TROUBLESHOOTING GUIDE
lndrcatesconnec-tor’s terminal num-ber.t
3. Cheddng the psssenger compartment-tempwsturs sensor, o&de-sir sensor, sir-thwtmctat CMSO~ and refrigerant-tempcmture sensor circuits
1.IProvides the neces-sary description ofcircuit operation forbasic understanding.I
Provides hints (in- -eluding standards forjudgement)whentroubleshooting pro-ceduresarefol-lowed.
- Opsrstion dnctiptionA negatkcharactensw fhemwor IS employed for each sensor nn order 10 convert the smbnen,temperature of rhe SB”SOf pan to ,es,s,ance.The sensor power-supply l2.W) of the air-condaioner control unit 1s applied to each sensor. and the
voltages of terminals 1161. 1151. I171 and 15) are divtded by the rwstance values of each sensor. andresislance R.
Indicates the checkto be made.t
-
I
Indicates the circuitdiagram for checking(including the inter-face of the air con-ditioner control unit).
Indicates the con-nector number.Numbers are used inthe operation de-scriptions only asnecessary, and thesenumbers correspondto the numbers usedin harness and com-ponent layout dia-grams.
- Tmublnkooting hff
NO 1, The DilFW+““P, P”m”il”m~“l.l~m~~=,,,,~ concnr ,w,p”t s,g”a, ,s ,,e,d ,o_ -____ .=_ __ .~_. .._... ._...r_._._._ ” -..--. ..,25°C 17rF).No 12: The outside-w sensor mput srgnal is he.----la to ,,“C IWFI.
-Air conditiuw ccnlml unit ta-.--* -.. No 13: The
awthwmos,a, sensor ~npu, signal isheld 10 4% IWF)l?mlMI “obuge
^I_I1Terminal) SWAW”IIWO”SNO
Dtagnosls
OUlYdedlr semorye pan ,emperatwe 25’C l77Wl.c-1.6v
sensor wwsr
SUPPI”Al as ,mlles2 45-2.55vRelngeran,.,emwrature *ensorSensor WR temperawe 25-Z 17PFI015”
when aar condwmer 1s OFF Bo nPassenger Compa*me”,-tempera.:“gol pm mnperat”re 25°C i77’FI1 a.1 6”lyre sensor
1 17 j Air-thermostat sensor1Sensor pan ,empelat”re 25°C ,777,I
’ Indicates the specification to be usedfor judgement of the check results.If there is no particular mention ofconditions in the “Conditions” column,the column shows the specificationunder normal conditions.
I
I
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00-18
GENERAL - Towing and Hoisting
Frame contact support location:
1,070 mm (42.0 in.): 1,130 mm (44.0 in.) OOFOO3'
Front OOFO046HOISTING
POST TYPESpecial care should be taken when raising the vehicle on a
\frame contact type hoist. The hoist must be equipped with theL)proper adapters in order to support the vehicle at the proper
locations.
Caution
When service procedures require removing rear suspen-sion, fuel tank, spare tire and liftgate, place additional
weight on rear end of vehicle or anchor vehicle to hoist toprevent tipping of center of gravity changes.
FLOOR JACKThe usual type of floor jack is used at the following locations.
Front: Under the mid point of No. 1 crossmember
NOTEOn vehicles with active-aero system, the front jacking point
can be accessed by removing the center cover panel from
the under cover. Be sure to reinstall the center cover panel
after jack-up operation.
Rear:
Under the jack up bracket of crossmember
Under the rear differential
Caution1. When lifting the No. 1 crossmember, do not allow jack
lifting plate to contact under cover.
2. In order to prevent scarring the crossmember, place a
piece of cloth on the jack’s contact surface (to prevent‘corrosion caused by damage to the coating).
d3. A floor jack must never be used on any part of the
underbody.
4.Do not attempt to raise one entire side of the vehicle by
placing a jack midway between front and rear wheels.This practice may result in permanent damage to the
body.
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00-30GENERAL - Master Troubleshooting
WHEEL BEARING TROUBLESHOOTING
1
Trouble
PittingSymptom
Pitting occurs because of uneven rotation of race
and bearing surfacesProbable causeExcessive bearing preloadExcessive load
FlakingThe surface peels because of uneven rotation ofthe race and bearing surfacesEnd of bearing life
Improper bearing assembly
Cracking
Chipping or cracking of cage or roller edges
Impact when bearing was
installed (such as being hit witha hammer)
Flat spottingWhen large load is applied, race and rollercontact surfaces compress, forming
indentationsExcessive bearing preload
Excessive load
Vibration when bearings are not
used, such as during shipment
on freight cars, transport trucks,
etc.
NicksInstead of rolling along race surface, rollers
slide, thus damaging surfaceInsufficient greaseExcessive bearing preload
Excessive load
Faulty oil seal
Smearing
Damage or wear caused by minute particles
adhering to surfaces results in rough movement
and such high temperatures that parts of surface
melt
Excessive variation of loads onbearingsUse of grease other than that
specified
Insufficient grease
Rust, corrosionAppears on various areas of the bearingUse of grease other than that
specified
Faulty oil sealPresence of water or moisture
WearWear of surface areas caused by frictionInsufficient grease
Foreign matter
Rust or corrosion due to
moisture
Use of grease other than thatspecifiedFaulty oil seal
Discoloration
Grease discoloration results from grease
deterioration which causes particles of pigment
contained in grease to adhere to surfaces
Heat discoloration will appear as a deep brown or
purple
Use of grease other than that
specified
Faulty oil seal
Excessive bearing preload
Excessive load
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GENERAL - Lubrication and Maintenance00-31LUBRICATION AND MAINTE-
NANCEMOOPA- -
iiMaintenance and lubrication service recommenda-
tions have been compiled to provide maximum
protection for the vehicle owner’s investment
against all reasonable types of driving conditions.
Since these conditions vary with the individual
vehicle owner’s driving habits, the area in which the
vehicle is operated and the type of driving to which
the vehicle is subjected, it is necessary to prescribe
lubrication and maintenance service on a time
frequency as well as mileage interval basis.
Oils, lubricants and greases are classified and
graded according to standards recommended by the
Society of Automotive Engineers
(SAE), the Amer-
ican Petroleum Institute (API) and the National
Lubricating Grease Institute
(NLGI).MAINTENANCE SCHEDULES
Information for service maintenance is provided
under “SCHEDULED MAINTENANCE TABLE”.
Three schedules are provided; one for “Required
Maintenance”, one for “General Maintenance” and
one for “Severe Usage Service”.
Item numbers in the “SCHEDULED MAINTE-
NANCE TABLE” correspond to the item numbers in
the “MAINTENANCE SERVICE” section.
LSEVERE SERVICE
Vehicles operating under severe service conditions
will require more frequent service.
Component service information is included in
appropriate units for vehicles operating under one or
more of the following conditions:
1. Police, taxi, or commercial type operation
2. Operation of Vehicle
(1) Short-trip operation at freezing temperature
(engine not thoroughly warmed up)
(2) More than 50% operation in heavy city
traffic during hot weather above 32°C
(90°F)(3) Extensive idling
(4) Driving in sandy areas
(5) Driving in salty areas
(6) Driving in dusty conditions
ENGINE OIL
The SAE grade number indicates the viscosity of
engine oils, for example, SAE 30, which is a single
grade oil. Engine oils are also identified by a dual
number, for example, SAE 1 OW-30, which indicates
a multigrade oil.
The API classification system defines oil perform-
ance in terms of engine usage. Only engine oil
idesigned “For Service SG” or “For Service
SGXD”,when available, should be used. These oils contain
sufficient chemical additives to provide maximumengine protection. Both the SAE grade and the API
designation can be found on the container.
Caution
Test results submitted to EPA have shown thatlaboratory animals develop skin cancer after
prolonged contact with used engine oil. Accor-dingly, the potential exists for humans to de-
velop a number of skin disorders, including
cancer, from such exposure to used engine oil.
Care should be taken, therefore, when changing
engine oil, to minimize the amount and length ofexposure time to used engine oil on your skin.
Protective clothing and gloves, that cannot be
penetrated by oil, should be worn. The skin
should be thoroughly washed with soap and
water, or use waterless hand cleaner, to removeany used engine oil. Do not use gasoline,
thinners, or solvents.GEAR
LUEiRlCANTSThe SAE grade number also indicates the viscosity
of Multi-Purpose Gear Lubricants.
The API classification system defines gear lubri-
cants in terms of usage. Typically gear lubricants
conforming to API GL-4 or GL-5 with a viscosity of
SAE
75W-85W are recommended for manual trans-
axle.
LUBRICANTS
- GREASES
Semi-solid lubricants, bear the
NLGI designation and
are further classified as grades 0, 1, 2, 3 etc.
Whenever “Chassis Lubricant” is specified,
Multi-Purpose Grease,
NLGI grade 2, should be used.
FUEL USAGE STATEMENT
Use premium unleaded gasoline having a minimum
octane rating of 91,
(R + M)/2. However, it is also
possible to use unleaded gasoline with an octane
rating of at least 87.
Unleaded gasolines only must be used in vehicles
equipped with catalyst emission control systems.
All vehicles, so equipped, have labels located on the
instrument panel and on the back of fuel filler lid that
state, “UNLEADED GASOLINE ONLY”. These vehi-
cles also have fuel filler tubes especially designed to
accept the smaller diameter unleaded gasoline
dispensing nozzles only.
MATERIALS ADDED TO FUEL
Indiscriminate use of fuel system cleaning agents
should be avoided. Many of these materials in-
tended for gum and varnish removal may contain
highly active solvents or similar ingredients that can
be harmful to gasket and diaphragm materials used
in fuel system component parts.
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11-28ENGINE - Timing Belt
Tlmlng mark01 N009E
A : :y,y;i;,$yi *&:;.~:;>
Exhaust valveside
*
/’*
120"* -1"
(*
6
7.^^^J‘c;Y
1zv w**
Intake valveside
Front bank
* : Approx. 35” o1 N0, og
Rockercoverslde
Exhaust valveside
Front bank
t~mng markOlNOlO
12. INSTALLATION OF TIMING BELT
(1) Align the timing marks on the respective sprockets.
In case of the camshaft sprockets in the front bank,
I~
proceed as follows:@ Install the crankshaft pulley. Shift the timing mark
on the crankshaft sprocket by three teeth to lower
the piston in No. 1 cylinder slightly from the top
dead center on compression stroke.
CautionTurning the camshaft sprocket with the piston
in No. 1 cylinder located at TDC on compression
stroke may cause the valves to interfere with the
piston.@ Make sure that the timing marks on the camshaft
sprockets for intake and exhaust valves are not
within the range A in the illustration at left.
If the timing mark is within range A, turn the
camshaft sprocket to move the timing mark to the
area closest to the range A.
CautionIn range A, the cam lobe on the camshaft lifts
the valve through the rocker arm and the
camshaft sprocket is apt to rotate by reaction
force of the valve spring. Therefore, be careful
not to have the finger pinched between the
sprockets.@ Turn the camshaft sprocket for either the intake or
exhaust valve to locate the timing mark as shown in
\the illustration at left. Then turn the other crankshaft
to locate the timing mark-as shown in the illustration
at left.
CautionIf the intake and exhaust valves of the same
cylinder lift simultaneously, interference with
each other may result. Therefore, turn the intake
valve camshaft sprocket and the exhaust valve
camshaft alternately.@ Turn the camshaft sprocket clockwise to align the
timing marks.
If the camshaft sprocket has been turned excessive-
ly, turn it counterclockwise to align the timing
marks.
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.@ Align the timing mark of the crankshaft sprocket.
NOTEShift the timing mark of the crankshaft sprocket one
teeth in counterclockwise direction to facilitate belt
installation.

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 ............................130Air Conditioner Switch and Power Relay............................82Air Flow Sensor....................................................................54Anti-lock Brake Signal ........................................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.

FUEL SYSTEM - Troubleshootina13-17
PROBLEM SYMPTOMS TABLE (FOR YOUR INFORMATION)
I;
L
/
L/
Items
Won’t start(no initial combustion)-g Starting problem
2(i;il;i combustion, then
Symptom
The starter is used to crank the engine, but there is no combustion within the
cylinders, and the engine won’t start.
There is combustion within the cylinders, but then the engine soon stalls.(Starting takes a long
time.)Engine won’t start quickly.
Idling instability
(Rough idling)Engine speed doesn’t remain constant; changes during idling.Usually, a judgement can be based upon the movement of the tachometer
>.rpointer, and the vibration transmitted to the steering wheel, shift lever, body, etc.
EThis is called rough idling.
s0
Incorrect idling speedThe engine doesn’t idle at the usual correct speed.
F.-=e-ImpDr;p;ertidling continuityThis non-continuity of idling includes the following elements.(1) Die outPass out. . . . . The engine stalls when the foot is taken from the accelerator pedal,regardless of whether the vehicle is moving or not.(2) Pass out . . The engine stalls when the accelerator pedal is depressed or while
it is being used.
Hesitation
Sag
“Hesitation” is the delay in responseHesitation
of the vehicle speed (engine rpm) thatLNormaloccurs when the accelerator pedal is
depressed in order to accelerate from---
the speed at which the vehicle is nowx\a,r- ,
traveling, or a temporary drop in vehi-g Initialv) accelerator**’ ,8’ /cle speed (engine rpm) during such+ pedal/,’ /
’
acceleration.2 depression
Serious hesitation is called “sag”.2
1“*’.’
/’ ,’I&L-e**’Ii Sag
Poor acceleration
Time1 FU022:
Poor acceleration is inability to obtain an acceleration corresponding to thedegree of throttle opening, even though acceleration is smooth, or the inability toreach maximum speed.
0, Stumble.F
‘iIn
Engine rpm response is delayed when
the accelerator pedal is initially.
depressed for acceleration from thestopped condition.
$Normal
x
:Initial
3acceleratorI//
c
-7
pedal2 depression,#’,
4,/Idling *--’Stumble
Shock
cTime1 FUO22L
The feeling of a comparatively large impact or vibration when the engine isaccelerated or decelerated.
SurgeThis is repeated surging ahead during constant speed travel or during variable
speed travel.
Knocking
A sharp sound like a hammer striking the cylinder walls during driving and which
adversely affects driving.TSB Revision