engine MITSUBISHI 3000GT 1991 Service Manual

Volume lm
I ‘k,‘6III
Engine, Chassis & Bodyf

,
b
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

GENERAL - How to Use This Manual00-3HOW TO USE THIS MANUAL
MOOBAAF
c;SCOPE OF MAINTENANCE, REPAIR AND
DEFINITION OF TERMS
SERVICING EXPLANATIONSSTANDARD VALUE
bThis manual provides explanations, etc. concerning
procedures for the inspection, maintenance, repair
and servicing of the subject model. Unless other-
wise specified, each service procedure covers all
models. Procedures covering specific models are
identified by the model codes, or similar designation
(engine type, transaxle type, etc.). A description of
these designations is covered in this unit under
“VEHICLE IDENTIFICATION”.
SERVICE ADJUSTMENT PROCEDURES“Service Adjustment Procedures” are procedures
for performing inspections and adjustments of
particularly important locations with regard to the
construction and for maintenance and servicing, but
other inspections (for looseness, play, cracking,
damage, etc.) must also be performed.
SERVICE PROCEDURESThe service steps are arranged in numerical order
and attentions to be paid in performing vehicle
service are described in detail in SERVICE POINTS.
TROUBLESHOOTING
Troubleshootings are classified into master trouble-
shooting and group troubleshooting and located as
follows:
The master troubleshooting is prepared when the
trouble symptom relates to two or more groups and
given in MASTER TROUBLESHOOTING.
The group troubleshooting guide is prepared for
causes of problems related to that individual groupIndicates the value used as the standard for judging
the quality of a part or assembly on inspection or the
value to which the part or assembly is corrected and
adjusted. It is given by tolerance.
LIMITShows the standard for judging the quality of a part
or assembly on inspection and means the maximum
or minimum value within which the part or assembly
must be kept functionally or in strength. It is a value
established outside the range of standard value.
REFERENCE VALUEIndicates the adjustment value prior to starting the
work (presented in order to facilitate assembly and
adjustment procedures, and so they can be com-
pleted in a shorter time).
CAUTIONIndicates the presentation of information particularly
vital to the worker during the performance of
maintenance’ and servicing procedures in order to
avoid the possibility of injury to the worker; or
damage to component
.parts, or a reduction of
component or vehicle function or performance, etc.
INDICATION OF TIGHTENING TORQUEThe tightening torque shown in this manual is a
basic value with a tolerance of
+lO% except the
following cases when the upper and lower limits of
tightening torque are given.
(1) The tolerance for the basic value is within
+ I no/-
only; a troubleshooting guide is prepared for eachI iv,“.appropriate group.(2) Special bolts or the like are in use.
(3) Special tighteningmethods are used.
MODEL INDICATIONS
The following abbreviations are used in this manual for classification of model types.M/T:Indicates the manual transaxle, or models equipped with the manual transaxle.
A/T:Indicates the automatic transaxle, or models equipped with the automatic transaxle.
MPI: Indicates the multi-point injection, or engines equipped with the multi-point injection.
Turbo: Indicates an engine with turbocharger, or a model equipped with such an engine.
Non-Turbo: Indicates an engine without turbocharger, or a model equipped with such an engine.
FWD: Indicates the front wheel drive vehicles.
AWD; Indicates the all wheel drive vehicles.
ABS:Indicates the anti-lock braking system or models equipped with the anti-lock braking system.
ECS: Indicates the electronic control suspension or models equipped with the electronic control
suspension.
4WS:Indicates the 4-wheel steering system or models .equipped with the 4-wheel steering system.
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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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cGENERAL
- Vehicle Identificationdo-9VEHICLE IDENTIFICATION NUMBER LIST
MOOCC- .
VEHICLES FOR FEDERAL
1 V.I.N. (except sequence number)1 Brand/ Engine displacement1 Models code
JA3XD54BOMY
Mitsubishi 3000GT
JA3XD64BOMY
I
3.0 liters (181.4 cu.in.)[DOHC-MPI]
JA3XE74COMY
Mitsubishi 3000GT3.0 liters (181.4 cu.in.)Z15AMNGFL2M[DOHC-MPI-Turbo]ZlGAMNGFL2M
VEHICLES FOR CALIFORNIA
( V.I.N. (except sequence number)1 Brand
JA3XD54BClMYMitsubishi 3000GT
1 JA3XD64BlJMYI
Engine displacementModels codeI
tJA3XE74CClMY”Mitsubishi 3000GT
NOTEAWD marked with * can also be sold in Federal States. *
1
3.0 liters (181.4 cu.in.1Zl lAMNXML7M[DOHC-MPI]Zl lAMRXML7MZl lAMNPML7MZl lAMRPML7M
3.0 liters (181.4 cu.in.1Z15AMNGFL7M[DOHC-MPI-Turbo]ZIGAMNGFUMI
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00-10GENERAL - Vehicle Identification
0060046
.:@I*
@+!jg.., ,”
0
<1
~~~ k
,.‘.r, SS?b‘,,.‘$ .’‘S,‘,,:’
t
I
nf/OOFDO&VEHICLE INFORMATION CODE PLATE
MOOCD- .IVehicle information code plate is riveted onto the bulkhead in
the engine compartment.
:
i3' 'The place shows model code, engine model, transaxle model,
and body color code.
1. MODEL
ZllAMNXMLZM
L2iie ‘zze[2. ENGINE
6672/Engine model
3. EXTCA6
Y Exterior code
4. TRANSAXLE
F5M33
-Transaxle model
5. COLOR, INT
R2587VQ3V
OPT-p=~izgTj+Ly~deCHASSIS NUMBER
MOOCE- -
STAMPING. LOCATIONThe chassis number is stamped on the top center of thefirewall located in the engine compartment.
CHASSIS NUMBER CODE CHART
ZlOA MY[7000~10
Y cd:at!s t:beOGT-series. Refer to 10th thru 17th digits
VEHICLE SAFETY CERTIFICATION LABEL
MOOCF- -
1.The vehicle safety certification label is attached to the face
of left door pillar.
2. This label indicates the month and year of manufacture,
Gross Vehicle Weight Rating
(G.V.W.R.), Gross Axle Weight
Rating
(G.A.W.R.) front and rear, and Vehicle Identification
Number
(V.I.N.).
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GENERAL - Vehicle Identification00-I 1
c
Theft protection label
For original parts
OOK619
For replacement parts
[i]
001621ENGINE MODEL STAMPING
MOOCG- .
I, The engine model number is stamped at the front side on
the top edge of the cylinder block as shown in the
following:
Engine modelEngine displacement
6672
3.0 liters (181.4 cu.in.12. The engine serial number is stamped near the engine
model number, and the serial number cycles, as shown
below
Engine serial number
AA0201 to YY9999Number cyclingAA0201--- - -+ AA9999
L ABOOOI-- - - ---f AY9999
L BAOOOI - - - - + YY9999
THEFT PROTECTION.MOOCIACIn order to protect against theft, a Vehicle Identification
Number
(VIN) is stamped in, or attached as a label to, the
following major parts of the engine and transaxle, as well as
main outer panels:
Engine cylinder block, Transaxle housing, Fender, Door, Quar-
ter panel, Hood, Liftgate, Bumpers
In addition, a theft-protection label is attached
to‘ replacement
parts for the body outer panel main components, and the same
data are stamped into replacement parts for the engine and the
transaxle.
Cautions regarding panel repairs
1. When repainting original parts, do so after first mask-
ing the theft-protection label, and, after painting, be
sure to peel off the masking tape.
2. The theft-protection label for replacement parts is
covered by masking tape, so such parts can be paintedas is. The masking tape should be removed after
painting is finished.
3.The theft-protection label should not be removed fromoriginal parts or replacement parts.
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GENERAL - Precautions before Service0045
c
mm (in.)so005
PRECAUTIONS BEFORE SERWCEMOOOAAOSERVICING ELECTRICAL SYSTEM
1. Note the following before proceeding with work on the
electrical system.
Note that the following must never be done:
Unauthorized modifications of any electrical device or
wiring, because such modifications might lead to a vehicle
malfunction, over-capacity or short-circuit that could result
in a fire in the vehicle.
2. When servicing the electrical system, disconnect the
negative cable terminal from the battery.
Caution1. Before connecting or disconnecting the negative
cable, be sure to turn off the ignition switch and the
lighting switch.(If this is not done, there is the possibility of
semiconductor parts being damaged.)
2. After completion of the work steps [when the
battery’s negative (-) terminal is connected], warm
up the engine and allow it to idle for approximately
five minutes under the conditions described below,in order to stabilize the engine control conditions,
and then check to be sure that the idling is
satisfactory.
Engine coolant temperature: 80 - 95°C (176 - 203°F)
Lights, electric fans, accessories: OFF
Transaxle: neutral position(A/T models: “N” or “P”)
Steering wheel: neutral (center) position
VEHICLE WASHING
If high-pressure car-washing equipment or steam car-washing
equipment is used to wash the vehicle, be sure to maintain the
spray nozzle at a distance of at least 300 mm (12 in.) from any
plastic parts and all opening parts (doors, luggage compart-
ment, etc.).
c
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00-20GENERAL - Special Handling Instructions for AWD Models
14A019fOOPOO38
BalancingmachineOOA0046
Pick-up stand
OOA0024
I
FRONT WHEEL MEASUREMENTS1. Place the front wheels on the brake tester.
2. Perform the brake test.
CautionThe rear wheels should remain on the ground.
3.If the brake dragging force exceeds the specified value, jack
up the vehicle and manually rotate each wheel to check the
rotation condition of each wheel.
NOTEIf the brake dragging force exceeds the specified value, the
cause may be the effect of the viscous coupling’s dragging
force, so jack up the front wheels and check the rotation
condition of the wheels in this state for no effect by the
viscous coupling’s dragging force.
REAR WHEEL MEASUREMENTSAfter placing the rear wheels on the brake tester, follow the
same procedures as for the front wheel measurements.
WHEEL BALANCE
FRONT WHEEL MEASUREMENTS‘d
1. Jack up the rear wheels, and place an axle stand at the
designated part of the side sill.
2. Jack up the front wheels and set a pick-up stand and
balancing machine in place.
Caution
1.Set so that the front and rear of the vehicle are at
the same height.
2. Release the parking brake.
3. Rotate each wheel manually and check to be sure
that there is no dragging.
3. Use the engine to drive the tires, and then make the
measurements.
Caution
1.If an error is indicated in the state of engine drive,
motor drive can be used concurrently.
2. Do not operate the clutch suddenly, or increase or
reduce speed suddenly during the work.
REAR WHEEL MEASUREMENTS1. Jack up the front wheels, and place an axle stand at the
designated part of the side sill.
2. Jack up the rear wheels, and then, after setting a pick-up
stand and balancing machine in place; follow the same
procedure as for front wheel measurements.
\
\L)
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FOR AWD MODELSMOOUAACBRAKE TEST
‘dIn order to stabilize the viscous coupling’s dragging force, the
brake test should always be conducted after the speedometer
test.

GENERAL - General Data and Specifications
GENERAL DATA AND SPECIFICATIONS
00-21
MOOHA- -
c-i----J---i!--8GENERALSPECIFICATIONS
Vehicle dimensionsmm (in.)
Overall length
1
Overall width2
Overall height3
Wheelbase4
Tread
Front5
Rear6
OverhangFront7
Rear8
Minimum running groundclearance9
Angle of approachdegrees10
Angle of departuredegrees11
Vehicle weightkg (tbs.)
Curb weights
MIT
AI-T
Gross vehicle weight rating
Gross axle weight rating
Front
Rear
Seating capacity
Engine
Model No.
Piston displacementcm” (cu.in.)
3000GT
(Non-Turbo)
4,545(178.9)
1,840(72.4)
1,285(50.6)
2,470(97.2)
1,560(61.4)
1,580(62.2)
1,025(40.4)
1,050(41.3)
145(5.7)
12.2”
16.9”
1,455 (3,208)
1,495 (3,296)
1,925 (4,244)
1,100 (2,425)
850 (1.874)
4
6G72-(DOHC)
2,972 (181.4)3000GT SL
(Non-Turbo)
4,545(178.9)
1,840(72.4)
1,285
(50.6)
2,470(97.2)
1,560(61.4)
1,580(62.2)
1,025(40.4)
1,050(41.3)
145(5.7)
12.2”
16.9”
1,520 (3,351)
1,560 (3,439)
1,925 (4.244)
1,100 (2,425)
850 (1,874)
4
6G72-(DOHC) -
2,972 (181.4)
+64
OOFO015
3000GT VR-4
(Turbo)
4,545(I 78.9)
1,840
(72.4)
1,285(50.6)
2,470(97.2)
1,560(61.4)
1,580(62.2)
1,025(40.4)
1,050(41.3)
145 (5.7)
12.2”
16.9”
1,710 (3.770)1,720 (3,792)“’
-
2,050 (4.519)
1,110 (2,447)940
(2,072)
4
6G72-(DOHC)
2,972 (181.4)
NOTE“I : <4ws>
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