power steering 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.
1 TSB RevisionI

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.
TSB Revision

GENERAL - Master Troubleshootina00-27HARD STEERING
L
L
Symptom
Hard steeringProbable causeLoose power steering oil pump belt
Reference page or remedy37A-8
1POOR RETURN OF STEERING WHEEL TO CENTER
Symptom
Poor return of steering wheelto center
Probable cause
Improper front wheel alignment
Improper tire pressure
Excessive tightened rack support cover
Damaged front wheel bearing
Reference page33A-4
31-3
37A-1926-10
Low fluid levelReplenish
Air in power steering system37A-10
Low tire pressure
313
Excessive turning resistance of lower arm ball33A-9joint
Excessively tightened steering gear box
rack support cover
37A-19
Improper front wheel alignment
Excessive turning resistance of tie-rod ball
joint
Sticky flow control valve
Bent rack in steering gear box33A-437A-6
37A-30
37A-19
TSB Revision1

00-32 GENERAL - Recommended Lubricants and Lubricant Capacities Table
RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE
MOORA- -RECOMMENDED LUBRICANTS
\L/
DIA-QUEEN LONG-LIFE COOLANT (Part No. 0103044) orLUBRICANT CAPACITIES TABLE
Description
Engine oil
Crankcase
(excluding oil filter and oil cooler)
Oil filter
Oil cooler (Turbo)
Cooling system (including heater and coolant
reserve system)
Manual transaxle


Transfer
Automatic transaxle
Rear axle
Power steering
<2ws>
<4ws>
Fuel tank
Metric measureU.S. measure
4.0 liters4.2 qts.
0.3 liter1/2qt. s
0.21 liter112 qt.
8.0 liters8.5 qts.
2.3 liters2.4 qts.
2.4 liters
2.5 qts.
0.27 liter.29 qt.
7.5 liters
7.9 qts.
1
.I liters1.16qts.
0.9 liter
.95 qt.
1.5 liters1.59 qts.
75 liters
19.8 gals.
TSB Revision1
d

ENGINE - Specifications
/
L
L/
Items
Connecting rod bearing
Oil clearancemm (in.)
Crankshaft main bearing
Oil clearancemm (in.)
Crankshaft
Pin O.D.
mm (in.)
Journal O.D.mm (in.)
Out-of-roundness of journal and pin
mm (in.)
Taper of journal and pin
mm (in.)
End playmm (in.)
Oil pressure at curb idle speed
kPa (psi)
[Conditions: oil temperature is 75 to 90°C
(167 to
194”F)l
Standard value
0.016- 0.046 (.0006- .0018)
0.019 - 0.044 (.0007 - .0017)
49.9 (I ,965)
59.9 (2.358)
Less than 0.003 (.00012)
Less than 0.005 (0002)
0.05 - 0.25 (0020 - .0098)
80 (I 1.4) or more
Limit
0.1
(.004)
0.1 (.004)
0.3 (.012)
Oil pump
Side clearancemm (in.)
Body clearance0.100-0.181 (.0039-.0071)
Side clearance0.040 - 0.095 (.0016 - .0037)
Relief spring
Free lengthmm (in.)43.8 (1.724)
Load
137 N (8.3 Ibs.)]mm (in.)40.1 (1.579)
Drive belt
For alternator (Vehicle without air
conditioner)
Deflectionmm (in.)
Inspection
4.0-5.5(.157-,216)
New belt3.5-4.0(.138-,157)
Used belt4.0-5.0 (.157- ,197)
TensionN (Ibs.)
Inspection350 - 600 (77 - 132)
New belt650
- 850 (143 - 187)
Used belt450
- 600 (99 - 132)
For alternator and air conditioner
compressor
Deflectionmm (in.)
Inspection
4.0-5.5(.157-,216)
New belt3.5-4.0 (1388.157)
Used belt4.0-5.0(.157-,197)
For power steering pump
Deflection
mm (in.)9.0
- 11 .o (354 - ,433)
Timing belt
Amount of projection of auto tensioner3.8-4.5(.149-,177)rodmm (in.)(distance between the tensioner arm andauto tensioner body)
1 TSB Revision

II-12ENGINE - Service Adjustment Procedures-
r
AdJl
bolt
Alternator wllev
haft
Fixing nutOlFOOO8
Alternator pulley
Adjusting bolt
/Crankshaftpulley
Air contionercompressorpulleyw Tension pulleyFlxtng nutOlN007.
Crankshaft pulleyOlN007TENSION ADJUSTMENT OF THE ALTERNATOR DRIVE
BELT
I(1) Remove front under cover panel ’
aero> (Refer to GROUP 51 - Aero Parts.).\\
3 ’
(2) Remove under covers (front L.H., side L.H.).
(3) Loosen tension pulley fixing nut.
(4) Adjust belt deflection with adjusting bolt.
(5) Tighten fixing bolt.
(6) Run the engine one time or more.
(7) Check the belt tension. Readjust, if necessary.
(8) Install under covers.
DEFLECTION ADJUSTMENT OF THE ALTERNATOR AND
AIR CONDITIONER COMPRESSOR DRIVE BELT with air conditioner>
(1) Use straight handle box wrench to loosen tension pulley
fixing nut.
(2) Adjust belt deflection with adjusting bolt.
(3) Use straight handle box wrench to tighten fixing nut.
(4) Run the engine one time or more.
(5) Check the belt deflection. Readjust, if necessary.
DEFLECTION ADJUSTMENT OF POWER STEERING PUMP
DRIVE BELT(1) Insert an extension bar (insertion depth 12.7 mm), etc. into
the opening at the end of the tension pulley bracket.
(2) Loosen the tension pulley fixing bolts in the order of B and
(3)
iove the extension bar installed to the tension pulley in the‘LJdirection of arrow to adjust the belt tension.
(4) Tighten the tension pulley fixing bolts in the order of A and
8.Tightening torque: 35
- 50 Nm (25 - 36 ftlbs,)(5) Give the crankshaft two turns in normal direction (clock-
wise) to run in the belt.
(6) Check the belt deflection. Readjust, if necessary.
1 TSB Revision

ENGINE - Engine AssemblyII-17
ENGINE ASSEMBLY
/REMOVAL AND INSTALLATION
I
Pre-removal Operationl Release of Residual Pressure from HighPressure Fuel Hose(Refer to GROUP 13 -Service AdjustmentProcedures,)l Removal of Cruise Control Pump andLink Assembly(Refer to GROUP 13 - Cruise Control.)l Removal of Hood(RefertoGROUP42A-Hood.)
l
Removal of Air Hose and Air Pipe (Refer to GROUP 15 - Inter Cooler.)l Removal of Front Exhaust Pipe(Refer to GROUP 15 - Exhaust Pipe and Main Muffler.l Removal of Transaxle Assembly(Refer to GROUP 22, 23 -Transaxle Assembly.)l Removal of Radiator(Refer to GROUP 14-Radiator.)
Post-installation Operationl Installation of Radiator(Refer to GROUP 14 - Radiator.)l Installation of Cruise Control Pump andLink Assembly(Refer to GROUP 13 -Cruise Control.)l Installation of Transaxle Assembly(Refer to GROUP 22,23 -Transaxle Assembly.)l lnstallatron of Front Exhaust Pipe(Refer to GROUP 15 - Exhaust Pipe and Main Muffler.)l Installation of Air Hose and Air Pipe (Refer to GROUP 14 - Inter Cooler.)l Installation of Hood(Refer to GROUP 42A- Hood.)l Supplying of Engine Oil(Refer to GROUP 00 - Maintenance Service.)l Adjustment of the Accelerator Cable(Refer to GROUP 13 - Engine Control.)
MllSA-B
4 ft.lbs.
6
40-45 Nm
29 - 33 fklbs.
Removal steps
1. Connection of accelerator cable11. Drive belt (Alternator and air conditioner)
2. Connection of brake booster vacuum hose(Refer to P.l l-l 1.)
3. Connection of booster vacuum12. Drive belt (Power steering)
hose
(Referto P.l l-l I.)4. Connection of fuel return hose13. Connection of alternator harness
5. Connection of fuel high pressure hose14. Oxygen sensor connector
6. Connection of ground cablel *15. Air conditioner compressor
7. Solenoid valve assembly4w
16. Power steering oil pump
8. Connection of vapor hose17. Oil pressure switch connector (Power steer-9. Connection of heater hoseing)10. EGR temperature sensor connector18. Connection of oil cooler pipes

OlFOO43
TSB Revision1

ENGINE - Enaine AssemblvII-19
Engine mount bracketSERVICE POINTS OF REMOVALMllSBEH
15. DISCONNECTION OF Ail? CONDITIONER COMPRES-SOR
/ 16. POWER STEERING OIL PUMP
Disconnect air conditioner compressor and power steering
oil pump (with the hose).
NOTEThe removed air conditioner compressor and power steer-
ing oil pump should be fastened (by using rope, etc.) in
.aposition that will not interfere with the removal/installation
of the engine assembly.
34. REMOVAL OF ENGINE MOUNT BRACKETBefore removing the engine mount bracket installation bolt,
use a chain block or similar arrangement to suspend the
engine assembly (to the extent that there is no looseness of
the chain).
37. REMOVAL OF ENGINE ASSEMBLYAfter checking that the cables, hoses, harness connectors,
etc. are all removed, slowly raise the chain block to lift the
engine assembly upward out of the engine compartment.
SERVICE POINTS OF INSTALLATIONMl
1SDBC
37. INSTALLATION OF ENGINE ASSEMBLYWhen mounting the engine, check to be sure that the
cables, hoses, harness connectors, etc. are all in the correct
position.
34. INSTALLATION OF ENGINE MOUNT BRACKETAttach the engine mounting bracket so that the arrow mark
on the mounting stopper is in the direction as shown in the
illustration.
TSB Revision

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.
TSB RevisionII
CautionUse only the specified special tools, or a damaged
pulley damper could result.
,
LJ

13-2
Boost Meter ........................................................128Components Inspection Procedure....................................40
Components Location........................................................36
Crank Angle Sensor
............................................................72Detonation Sensor................................................................84EGR Control Solenoid Valve
........................................121
EGR Temperature Sensor ............................92ElectricalLoad Switch........................................................86Engine and Transaxle Total Control Signal ............135Engine Control Unit Power Ground....................................44Engine Coolant Temperature Sensor................................62Fuel Pressure Control Valve ............................123Fuel Pressure Test................................................................138Fuel Pump ....................................................45Fuel Pump ............................................................48
Fuel Pump Operation Check................................................137Fuel Pump Relay No. 2........................................................53Fuel Pump Resistor............................................................53
Idle Position Switch............................................................68Idle Speed Control Servo (Stepper Motor Type)............1 IOIgnition Coil and Power Transistor....................................115Ignition Switch-ST and Inhibitor Switch ................76Ignition Switch-ST ................................................75Induction Control Valve Position Sensor
........................................................................90
Injectors........................................................101Injectors................................................................105Intake Air Temperature Sensor............................................57Muffler Mode Changeover Switch ....................88Oxygen Sensor ............................................
94
Oxygen Sensor ....................................................98
Power Steering Oil Pressure Switch................................80Power Supply and Ignition Switch-IG................................41
Purge Control Solenord Valve............................................1 19Release of Residual Pressure from High
Pressure Fuel Hose............................................................137Throttle Position Sensor....................................................65Top Dead Center Sensor....................................................70Variable Induction Control Servo (DC Motor)
........................................................................131Vehicle Speed Sensor........................................................78Waste Gate Control Solenoid Valve ................126
SERVICE ADJUSTMENT PROCEDURES............................31
Adjustment of Fixed SAS....................................................35Adjustment of Idle Position Switch and
Throttle Position Sensor (TPS)............................................33Basic Idle Speed Adjustment............................................31Throttle Body (Throttle Valve Area) Cleaning....................33
SPECIAL TOOLS........................................................................8
SPECIFICATIONS
....................................................................6
General Specifications........................................................6Sealant....................................................................................7Service Specifications........................................................7
THROlTLE BODY....................................................................143
TROUBLESHOOTING............................................................9
Check Chart Classified by Problem Symptoms................16Circuit Diagram....................................................................18Engine Warning Light (Malfunction Indicator Light)........11Explanation and Cautions about Harness Check............10Explanation of Troubleshooting Procedures....................9Fuel Tank and Fuel Line........................................................30
Problem Symptoms Table (For Your Information)............17Self-diagnosis........................................................................12)
I