service MITSUBISHI 3000GT 1991 Service Manual

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L’ BackupServiceManual
3OOOG-r
1991: Volume 1
L
This Service Manual has been prepared with the
/
WE SUPPORT
I/National ,nwtute ‘or IIAUTOMOTIV E
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MITSUBISHI
li@ 1990 Mitsubishi Motors CorporationRqwinted in USA
I
General
..*............*......*.......................
Su;$emental Restraint System ....
*......*...........
I
NOTE:I
I I

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

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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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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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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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00-16GENERAL - Towina and Hoistina
Sling type
Wheel lift type
Flat bed type
Sling type
Wheel lift type
Flat bed typeTOWING AND HOISTING
MOOGAACWRECKER TOWING RECOMMENDATION

FRONT TOWING PICKUP
Caution
\‘i
d
This vehicle cannot be towed by a wrecker using sling-typeequipment to prevent the bumper from deformation.
If this vehicle is towed, use wheel lift or flat bed equip-
ment.The vehicle may be towed on its rear wheels for extended
distances provided the parking brake is released. It is recom-
mended that vehicles be towed using the front pickup
whenever possible.
REAR TOWING PICKUP
Caution
This vehicle cannot be towed by a wrecker using sling-typeequipment to prevent the bumper from deformation.
If this vehicle is towed, use wheel lift or flat bed equip-
\
ment.‘L*3Manual transaxle vehicles may be towed on the front wheels,
provided the transaxle is in neutral and the drive-line has not
been damaged. The steering wheel must be clamped in the
straight-ahead position with a steering wheel clamping device
designed for towing service use.
CautionDo not use steering column lock to secure front wheel
position for towing.
Automatic transaxle vehicle may be towed on the front wheels
at speeds not to exceed 50 km/h (30 mph) for a distances not to
exceed 30 km (18 miles).
CautionIf these limits cannot be met, the front wheels must be
placed on a tow dolly.
TOWING WHEN KEYS ARE NOT AVAILABLE
When a locked vehicle must be towed and keys are not
available, the vehicle may be lifted and towed from the front,
provided the parking brake is released. If not released, the rear
wheels should be placed on a tow dolly.
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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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GENERAL - Towing and Hoisting
LIFTING, JACKING SUPPORT LOCATION00-19


OOFOO20OOFO019
@ Floor lack locations$Approximate center of gravrty
@Frame contact hoist. twin post‘hoist or scissors lack (emergency) locatlons
EMERGENCY JACKINGJack receptacles are located at the body sills to accept the
scissors jack supplied with the vehicle for emergency road
service. Always block opposite wheels and jack on level
surface.
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