brake fluid MITSUBISHI 3000GT 1991 Service Manual

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 - Maintenance Service00-41
Good
t-lVA0283
I04FOOOd(4) Check the oil filter for clogging and damage and replace if
necessary.
(5) Clean drain plug and tighten drain plug with gasket to 30
-35 Nm (22
- 25 ft.lbs.).
(6) Clean both gasket surfaces of transaxle case and oil pan.
(7) Install oil pan with new gasket and tighten oil pan bolts to
10 - 12 Nm (7.5 - 8.5 ft.lbs.).
(8) Pour 4.5 liters (4.8 qts.) of specified ATF into case through
dipstick hole. [Total quantity of ATF required is approx. 7.5
liters (7.9 qts.). Actually however, approx. 4.5 liters (4.8 qts.)
of fluid can be replaced because rest of fluid remains in
torque converter.]
Specified fluid: Dia ATF SP or MITSUBISHI PLUS ATF or
equivalent(9) Start engine and allow to idle for at least two minutes.
Then, with parking brake on, move selector lever momen-
tarily to each position, ending in “N” Neutral position.
(lO)Add sufficient ATF to bring fluid level to lower mark.
Recheck fluid level after transaxle is at normal operating
temperature. Fluid level should be between upper and
lower marks of “HOT” range. Insert dipstick fully to prevent
dirt from entering transaxle.
11. ENGINE COOLANT (Change)
MOOSBEHCheck the cooling system parts, such as radiator, heater, and
oil cooler hoses, thermostat and connections for leakage and
damage.
CHANGING COOLANT
1.
2.
3.
4.
5.
6.
7.
8.Remove te heat protectors (front and rear) from the exhaust
manifold.
Loosen the radiator drain plug, remove two drain plugs from
the engine block (one for each bank) and remove the
radiator cap to discharge coolant.
Remove the reservoir tank and discharge coolant.
When coolant has been discharged, pour water through the
filler port to flush coolant passage.
Coat the threads of the engine drain plugs with the
specified sealant and tighten the plugs to specification.
Specified sealant: 3M Nut Locking Part No. 4171 or
equivalentTightening torque: 40 Nm (29
ftlbs.)Fit the radiator drain plug securely.
Mount the reserve tank.
Slowly pour coolant into the radiator to the brim and also
into the reserve tank up to the FULL line.
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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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11-26ENGINE - Timing Belt
TIMING BELT
REMOVAL AND INSTALLATION
MllKA-BI
Pre-removal Operationl Removal of the Under Cover (Front L.H.,side L.H.)l Removal of Front Under Cover Panel(Refer to GROUP 51 -Aero Parts,)l Removal of Cruise Control Pump andLink Assembly(Refer to GROUP 13 -Cruise Control.)l Removal of Alternator Assembly(Referto GROUP 16-Alternator.)
l Raise and Suspend the Engine to the ExtentForce is not Applied to the Engine Mounti LIOO-
120 Nm72 - 87 ft.lbs.
35 Nm25 ft.l$.
TurbochargerOSFOO03
lo-12Nm7 - 9 ft.lbs.
Removal steps
1. Air hose
11 31 ftlbs.
‘5IO-12Nm
B;p 49ftJbs.
\
180- 190 Nm130 - 137 ft.lbs.
2. Air pipe
3. Tensioner assembly
4. Drive belt (power steering)
(RefertoP.ll-11.)4** I)* 5. Crankshaft pulley’6. Brake fluid level sensor
7. Timing belt upper cover
8. Engine mount bracket
9. Idler pulley (alternator
/ air conditioner)+* l * 10. Engine support bracketl * 11. Timing belt lower coverl * lAdjustment of timing belt tensionl * l a 12. Timing beltl * 13. Auto tensionerNm
[email protected].
Post-installation Operation
l Installation of Alternator Assembly(Refer to GROUP 16 -Alternator.)
l Installation of the Under Cover(Front L.H., Side L.H.)l Installation of Front Under Cover Panel
l Installation of Cruise Control Actuator(Refer to GROUP 13 - Cruise Control.)l Adjustment of theEngine (Refer to P.l l-1 1.)n7 m-m
M D998754nSERVICE POINTS OF REMOVAL
5. REMOVAL OF CRANKSHAFT PULLEYMllKBEF
,Using special tools, remove the crankshaft pulley from the
crankshaft.
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CautionUse only the specified special tools, or a damaged
pulley damper could result.
,
LJ

a-10CLUTCH - Clutch Control
CLUTCH CONTROL
REMOVAL AND INSTALLATIONMZlJA-
-
03% J 2’ti
m
I.“0050I
Pre-removal Operationl Draining of the Clutch Fluid
l Bleeding of the Clutch Line (Refer to P.21-7.)l Adjustment of Clutch Pedal (Refer to P.21-5.)Clutch master cylinder removalstep
1. Brake booster(Refer to GROUP 35 - Brake Booster.)2. Clevis pin 3. Clutch master cylinderl *Adjustment of piston to push rod clearance
4. Sealer3

9
Cluch tube
1.
**5.
6.
l +7.**8.9.IO.11.
a* l * 12.
\Gk
6
removal steps
Brake booster15Nm
-11 ft.lbs.
(Refer to GROUP 35
- Brake Booster.)Air hose A Air cleaner cover, air intake hose cFWD>.Air cleaner cover, air intake hose A Vacuum pipe Battery
Battery seat, washer tank
Steering column assembly
(Refer to GROUP 37A- Steering Wheel and
Shaft.)
Clutch tube15 Nm
11
ft.lbs.
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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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21-16CLUTCH - Clutch Release Cylinder
6CLOOO3
DCLOOE,
INSPECTIONM21LCAF
(1) Check the inner surface of the release cylinder for scratch-
es or irregular wear.
(2) Replace if the piston cup outer circumference is scratched
LIor shows signs of fatigue, or if there is excessive wear of
the lip where indicated in the figure.
SERVICE POINTS OF REASSEMBLYMZlLDAH
5. APPLICATION OF FLUID TO PISTON AND CUP
Apply specified brake fluid to the release cylinder inside and
outer surface of the piston and piston cup and push the
piston cup assembly in the cylinder.
Specified brake fluid: Conforming to DOT3
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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 - Troubleshootincl23-19Based upon use of the troubleshooting
Checks should be made of fluid levels and
the condition of the ATF, as well as the
condition of the manual control cables;
adjustments should then be made if found
to be necessary.
If a presumption has been made that there
is an abnormal condition somewhere in
the electronic-control system, check the
fault code, in order to determine the
probable location of the problem, by using
a multi-use tester or voltmeter.
I
When the abnormal system is discovered,
check each element (sensors, etc.) one by
one, and make repairs as necessary.
IWhen the abnormal condition is presumed
to be in the oil-pressure-control system
When the result of the oil-pressure test
does not satisfy the specified pressure,
check each system at places related to the
valve body, check the oil-pressure pas-
sages for leakage, etc.
I
If the problem isunusually dirty ATF,
abnormal noises, oil leakage, or slippage of
the clutch or brakes, or an abnormal
condition of the transaxle itself, disassem-
ble and repair the transaxle.
TROUBLESHOOTINGM23EEAYFunctional malfunctions of the ELC4A/T can lead to other
problems, such as those described below:(I
) Improper maintenance and/or adjustments
(2) Malfunctions of the electronic control functions
(3) Malfunctions of mechanical functions
(4) Malfunctions of hydraulic control functions
(5) Malfunctions of engine performance
etc.
In order to properly determine (“Troubleshoot”) the source of
these malfunctions, it is first essential to methodically question
the user concerning the details of the problem, such as the
condition of the problem, the situation at the time the problem
occurred, and any other relevant information, all in as much
detail as possible. The user should also be asked whether or
not the problem has occurred more than once, and under what
conditions.
Subsequently, certain tests should be conducted in a certain
order, as described at the left.
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23-22AUTOMATIC TRANSAXLE - Troubleshooting
0”
TM362
DIAGNOSIS AND TEST
FLUID LEVEL AND CONDITION
1.Drive until the fluid temperature reaches the usual tempera-
ture
[70 - 80°C (160 - 18O”F)].2. Place vehicle on level floor.
3. Move selector lever sequentially to every position to fill
torque converter and hydraulic circuit with fluid, then place
lever in “N” Neutral position. This operation is necessary to
be sure that fluid level check is accurate.
4. Before removing dipstick, wipe all dirt from area around
dipstick. Then take out the dipstick and check the condition
of the fluid.
The transaxle should be overhauled under the following
conditions.
l If there is a “burning” odor.
l If the fluid color has become noticeably blacker.
lIf there is a noticeably great amount of metal particles in
the fluid.
5.Check to see if fluid level is in “HOT” range on dipstick. If
fluid level is low, add automatic transaxle fluid until level
reaches “HOT” range.
Low fluid level can cause a variety of conditions because it
allows pump to take in air along with fluid. Air trapped in
hydraulic circuit forms bubbles which make fluid spongy.
Therefore, pressures will be erratic.
Improper filling can also raise fluid level too high. When
transaxle has too much fluid, gears churn up foam and
cause same conditions which occur with low fluid level,
resulting in accelerated deterioration of automatic transaxle
fluid.
dIn either case, air bubbles can cause overheating, fluid
oxidation, which can interfere with normal valve, clutch, and
servo operation. Foaming can also result in fluid escaping
from transaxle vent where it may be mistaken for a leak.
6. Be sure to examine fluid on dipstick closely.
,CONTROL CABLEWhether control cable is properly adjusted can be confirmed by
checking whether inhibitor switch is performing well.
1. Apply parking brakes and service brakes securely.
2. Place selector lever to “R” range.
3. Set ignition key to “ST” position.
4. Slowly move the selector lever upward until it clicks as it
fits in notch of “P” range. If starter motor operates when
lever makes a click, “P” position is correct.
5.Then slowly move selector lever to “N” range by the same
procedure as in foregoing paragraph. If starter motor
operates when selector lever fits in
“N”, “N” position is
correct.
6. Also check to be sure the vehicle doesn’t begin to move
and the lever doesn’t stop between P-R-N-D.
7. The control cable is properly adjusted if, as described
above, the starter motor starts at both the “P” range and
the “N” range.
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