boot MITSUBISHI 3000GT 1991 Service Manual

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00-I
GENERALCONTENTS
MOOOA- .
GENERAL DATA AND SPECIFICATIONS . . . . . .21
HOW TO USE THIS MANUAL. . . . . . . . . . . . . . . . . . . . . . . . . . . .3Definition of Terms
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Explanation of Circuit Diagrams
. . . . . .._...........7Explanation of Manual Contents
. . . . . . . . . . . . . . . . . . . .4
Explanation of the Troubleshooting Guide . .
6ModelIndications
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Scope of Maintenance, Repair and
ServicingExplanations
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3Troubleshooting
. . . . . . .._.......................................3
LUBRICATION AND MAINTENANCE. . . . . .._....31SCHEDULED MAINTENANCE TABLE. . . . . . .._.
MAIN SEALANT AND ADHESIVE TABLE. . .44
MAINTENANCE SERVICE
. . . . . . . . . . . . . . . .._......_.....__Air Cleaner Element
. . . . . . .._......._......_................Automatic Transaxle
. . . . . . . . . . . . . . . . . . . . . . . . .._......._.....Ball Joint and Steering Linkage Seals
. . . . . . . . . . . .
BrakeHoses. . . . . . . . . . . . . . . . . . . . . . . . . . . .._......._.._...._......._..
Disc Brake Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Drive Belt (For Alternator)
. . . . . . . . .._.........._..........Drive Shaft Boots
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine Coolant
. . . . . . . . . . . . ..__.._.............................Engine Oil
.._....__._.................................................Engine Oil Filter
. . . . .._._.......__.................. . . . . . . . . . . .Exhaust System
_....._......._.....__._............,...........Fuel Hoses
..__......__............................................36
3740
42
42
42
38
43
41
38
39
43
36
FuelSystem. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Manual Transaxle
. . . . . . . . . .._........................_.......Rear Axle
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .._..._.._..____.._.......
SparkPlugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .._...............TimingBelt
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MASTER TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . .
PRECAUTIONS BEFORE SERVICE. . . . . . . . . . . . . . . .
RECOMMENDED LUBRICANTS AND
LUBRICANT CAPACITIES TABLE. . . . . . .._........
SPECIAL HANDLING INSTRUCTIONS
FOR AWD MODELS. . . . . . . . . . . . .._...._........................
TIGHTENING TORQUE. . . . . . . . . . . . . . . ..__.....................
TOWING AND HOISTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VEHICLE IDENTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . .._.....Chassis Number .
.._............................................Engine Model Stamping
.._..........................._...._Theft Protection
. . . . .._.........................................Vehicle Identification Code Chart Plate
.._.....Vehicle Identification Number List
.._._....._..._.Vehicle Identification Number Location
. . . .._
Vehicle Information Code Plate . . . . .._._......_.......Vehicle Safety Certification Label
. . . ..I . . . . .._..._...
36
3943
37
3724
1532
35
20
23
16
8
10
11
11
8
9
8
10
10

00-42GENERAL - Maintenance Service
14UOO729. Install the radiator cap securely.
10.
Start’the engine and warm up until the thermostat opens.
11. Race the engine up to around 3,000 rpm several times, then
stop the engine.,12. When the enkine has cooled down, remove the radiator cap
L/and add coolant up to the brim. Add coolant to the reserve
tank up to the FULL line.

1. Lift up the vehicle.
2.Loosen the radiator drain plug, remove the drain plug from
the rear bank of the engine and remove the radiator cap to
discharge coolant.
3. Follow the same steps 3 to 12 above.
12.DISC BRAKE PADS (Inspect for wear)MOOSBFDCheck for fluid contamination and wear. Replace complete set
of pads if defective.
Caution
The pads for the right and left wheels should be replaced atIIthe same time. Never “split” or intermix brake pad sets. AllUfour pads must be replaced as a complete set.
Thickness of lining (A):
Limit2.0 mm (.08 in.)
13. BRAKE HOSES (Check for deterioration or
leaks)
MOOSBHBInspection of brake hoses and tubing should be included in all
brake service operations.
The hoses should be checked for:
1.Correct length, severe surface cracking, pulling, scuffing or
worn spots. (If the fabric casing of the hoses is exposed by
cracks or abrasion in the rubber hose cover, the hoses
should be replaced. Eventual deterioration of the hose may
occur with possible bursting failure.)
2. Faulty installation, casing twisting or interference with
wheel, tire or chassis.
14. BALL JOINT AND STEERING LINKAGE SEALS
(Inspect for grease leaks and damage)
MOOSglC1. These components, which are permanently lubricated at
the factory, do not require periodic lubrication. Damaged
seals and boots should be replaced to prevent leakage or
contamination of the grease.
2.Inspect the dust cover and boots for proper sealing, leakageIdand damage. Replace them if defective.
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GENERAL - Maintenance Service00-43
15. DRIVE SHAFT BOOTS (Inspect for grease
leaks and damage)
MOOSBJD1. These components, which are permanently lubricated at
the factory, do not require periodic lubrication. Damaged
boots should be replaced to prevent leakage or contamina-
tion of the, grease.
2.Inspect the boots for proper sealing, leakage and damage.
Replace it if defective.
16. REAR AXLE (CONVENTIONAL DIFFEREN-
TIAL) (Inspect oil level)
- AWDMOOSBPDRemove the filler plug and inspect the oil level at bottom of filler
hole. If the oil level is slightly below the filler hole, it is in
satisfactory condition.
16. REAR AXLE (LIMITED-SLIP DIFFERENTIAL)
(Oil change)
- AWDMOOSBQEBefore changing the rear axle oil, check to make sure that there
is no oil leakage from the rear axle housing.
Remove the drain plug and drain out of the oil.
Put the oil plug
,back in place, and then pour new oil in through
the filler hole.
17. EXHAUST SYSTEM (CONNECTION PORTION
OF MUFFLER, PIPINGS AND CONVERTER
HEAT SHIELDS) (Check and service as re-
quired)
MOOSBLB1. Check for holes and gas leaks due to damage, corrosion,
etc.
2. Check the joints and connections for looseness and gas
leaks.3. Check the hanger rubber and brackets for damage.
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21-14CLUTCH i Clutch Master Cylinder
CLUTCH MASTER CYLINDER
DISASSEMBLY AND REASSEMBLY
M21NA. -Disassembly steps
1. Piston stop bolt 2. Gasket a*3. Piston stop ring *I)4. Snap ring 5. Push rod
6. Boot
c*7. Piston assembly
8. Reservoir cap
9. Reservoir band
10. Reservoir11. Master cylinder body
Master cvlinder kit..--_-.-I------- --.-
6.0 Nm4.0 ft.lbs
08FOO40
13 Nm9.0 ftlbs.
---&08FOO39
r
08FOO41
8
6.0 Nm4.0 ft.lbs:Master
cvlinder kit1
109FOl3414LO193
SERVICE POINTS OF DISASSEMBLYM21NSAE3. DISASSEMBLY OF PISTON STOP RING
/ 4.
SNAP RING
Remove the piston stop ring or snap ring, while depressing
the piston.
7. REMOVAL OF PISTON ASSEMBLY
Caution
1.Do not damage the master cylinder body and piston
assembly.2. Do not disassemble piston assembly.
INSPECTIONMZlNCAD
l Check the inside cylinder body for rust or scars.
l Check the piston cup for wear or deformation.
Idl Check the piston for rust or scars.
l Check the clutch tube connection part for clogging.
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CLUTCH - Clutch Release Cylinder21-15
CLUTCH RELEASE CYLINDER
DISASSEMBLY AND REASSEMBLY
L.4/
/
iJ
Lubricant: Conforming to DOT3Disassembly steps
1.Valve plate2.Spring3.Push rod4.Boots*I) l *5. Piston and cup6.Conical spring
7.Cap
8.Bleeder plug9.Release cylinder7CLOOOl
6CLO3!
SERVICE POINTS OF DISASSEMBLYM2lLBAF5. DISASSEMBLY OF PISTON AND CUP
(1) Remove the corrosion from the piston-removal port of
the release cylinder.
(2) Remove the piston from the release cylinder using
compressed air.
Caution1. Cover with rags to prevent the piston from
popping out.
2. Apply compressed air slowly to prevent brake
fluid from splashing.
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CLUTCH - Clutch Cover and Disc
CLUTCH COVER AND DISC
REMOVAL AND INSTALLATION
21-19
M21GA-.
I
)Il Removal of the Transaxle Assembly
30-42Nm
\\115-21 Nm11 - 15 klbs.2Removal steps
M w1. Clutch cover assembly+e W+ 2. Clutch disc3. Return clipI)* 4. Clutch release bearingW+ 5. Release fork6. Fulcrum
7. Release fork bootTSB Revision

22-12MANUAL TRANSAXLE - Transaxle Control
INSPECTIONM22JCAFl
lCheck the transaxle control cable assembly for function and
for damage.
l Check the boot for damage.
IlJ 1
lCheck each bushing for wear or abrasion, sticking, impeded
action, and damage.
0910023Lever B09FOO71
End of select cable
er B
Neutral position
OSFOOo8
SERVlCE POINTS OF INSTALLATIONMUJDAL
3. CONNECTION OF TRANSAXLE CONTROL CABLE
ASSEMBLY (SHIFT LEVER ASSEMBLY SIDE)
(I) Move the transaxle shift lever to the neutral position.
NOTEThe select lever will be set to the neutral position when
the transaxle shift lever is moved to the neutral position.
(2) With the shift lever on the passenger compartment side
in the neutral position, turn adjuster on select cable so
that select cable end is positioned as shown with
reference to lever B of shift lever.
(3) Install the select cable so that the flange side of the
\plastic bushing at the end of select cable is on the end
face side of lever B.
d(4) Turn adjuster on shift cable so that shift cable end is
positioned as shown with reference to shift lever on the
passenger compartment side.
(5) Install the shift cable so that the flange side of the
plastic bushing at the end of shift cable is on the split
pin side.
(6) Connect the shift cable, then turn adjuster on shift cable
so that dimension A equals dimension B.
(7) Move the shift lever to each position and check that the
shifting is smooth.
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22-46MANUAL TRANSAXLE - Clutch Housing Assembly
CLUTCH HOUSING ASSEMBLYM22MPAM
DISASSEMBLY AND REASSEMELY
iJ15-22Nm
II- 15 ft.lbs.
/
1443q 15-
m16----@20-27Nm
15- 19ft.lbs.
2100019
Disassembly steps
1.Bolt
2. Select lever assembly
3. Select lever shoe
4. Interlock plate bolt
5.Gasket
4~ l a6. Lock pin+* I)* 7. Spring pin8. Neutral return spring
9.Stopper body10.Control finger11.Interlock plate12. Neutral return spring assembly13.Control shaft14. Control shaft boot
l * 15. Oil seal
l *16.Needle
bearingI)+ 17. Needle bearing
; 98: F:;tch housing
20.Return
spring21. Stopper plate
22. Spring pin
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MANUAL TRANSAXLE - Transaxle Control22-55
03FOO
Air‘mtakehose A Air intake
hose C
Air intake hose B05FOO2:
Air hose A
05FOOZE
8
INSPECTIONM22JCAFZ
lCheck the transaxle control cable assembly for function and
for damage.l Check the boot for damage.
lCheck each bushing for wear or abrasion, sticking, impeded
action, and damage.
SERVICE POINTS OF INSTALLATIONM22JDAM5.
CdNNECTlON OF TRANSAXLE CONTROL CABLE
ASSEMBLY (SHIFT LEVER ASSEMBLY SIDE)Refer to
P.22-12.3. INSTALLATION OF VACUUM PIPE
If the vacuum pipe has a stepped part, connect the vacuum
hose to the pipe securely, up to the stepped part, as shownin the figure.
2. CONNECTION OF AIR CLEANER COVER, AIR INTAKE
HOSE A
Align slots indicated by arrows in air intake hose A with n
markings on air intake hoses B and C; then, insert hoses Band C all the way into air intake hose A.
1. CONNECTION OF AIR HOSE A
Connect the hoses ensuring that paint marks are alignedwith projections.
Insert air hoses B and C into air hose A all the way, or up tothe step in hose A.
Caution‘Be careful not to allow any foreign matter to get into
the hoses, pipes, or the intercooler itself.
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25-4PROPELLER SHAFT - ProDeller ShaftPropeller
LGbro joint
shaftL6bro Jointbootassembly
SERVICE POINTS OF REMOVALM25GEAI
3. REMOVAL OF PROPELLER SHAFT
(1) Make mating marks on the differential companion
flange and flange yoke.
CautionRemove the propeller shaft in a straight and level
manner so as to ensure that the boot is
notdamaged through pinching.
NOTEDamage to the boot can be avoided, and the work will
be easier, if a piece of cloth or similar material is
inserted in the boot.
(2) Use the special tool provided as a cover to prevent the
entry of foreign objects into the transfer.
4. REMOVAL OF SPACER
The number of spacers necessary may differ from one
location to another (front, rear, right, left). Record the
number of spacers used to ensure correct installation.
INSPECTIONM25GCAIl Check the sleeve yoke, center yoke and flange yoke for
wear, damage or cracks.
l Check the propeller shaft yokes for wear, damage or
cracks.
lCheck the propeller shaft for bends, twisting or damage.
l Measure the propeller shaft runout with a dial indicator.
Limit:
Front propeller shaft0.6 mm (.024 in.) or less
Center propeller shaft0.6 mm (.024 in.) or less
Rear propeller shaft0.6 mm (.024 in.) or less
NOTESet the V-blocks as much as possible to the end of the
shaft. Measure deflection at the center of the shaft.
d
Lj
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