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Volume lm I ‘k

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Engine, Chassis & Body

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GROUP INDEX

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General ............................................. Engine .............................................. BackupServiceManual L’ Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3OOOG-r

Cooling ............................................. Intake and Exhaust ..........................

1991: Volume 1

Emission Control ............................. Clutch ................................................ Manual Transaxle ............................ Automatic Transaxle .......................

FOREWORD

L

Propeller Shaft .................................

This Service Manual has been prepared with the latest service information available at the time of publication. It is subdivided into various group categories and each section contains diagnosis, disassembly, repair, and installation procedures along with complete specifications and tightening references. Use of this manual will aid in properly performing any servicing necessary to maintain or restore the high levels of performance and reliability designed into these outstanding vehicles.

Front Axle ......................................... Rear Axle .......................................... Wheel and Tire ................................. Power Plant Mount .......................... Front Suspension ............................ Electronic Control Suspension ....... Rear Suspension .............................. Service Brakes ................................. Parking Brakes .................................

WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION THROUGH National ,nwtute ‘or

AUTOMOTIVE SERVICE EXCELLSNCE

Steering ............................................

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4-Wheel Steering System (4WS) /I

Body . . . . . . . . . . . . . . . . . ..*.............................

MITSUBISHI

MOTOR SALES OF AMERICA. Inc.

Exterior . . . . . . . . . . . . . . . . . ..*..........**............. Interior ..*............*......*....................... Su;$emental Restraint System ....

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Mitsubishi Motors Corporation reserves the right to make changes in design or to make addltlons to or tmprovements in Its products without Imposing any obligations upon Itself to install them on its products previously manufactured. @ 1990 Mitsubishi Motors Corporation

Rqwinted in USA

Heater, Air Conditioner *......*........... and Ventilation

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NOTE: For Electrical, refer to Volume-2 “Electrical” I I

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SUPPLEMENTAL RESTRAINT SYSTEM (SRS) (1) A Supplemental Restraint System (SRS), which uses a driver-side air bag, has been installed in the 3000GT. (2) The SRS includes the following components: impact sensors, SRS diagnosis unit; SRS warning light, dir J bag module, clock spring, interconnecting wiring. Other SRS-related components (that may have to be removed/installed in connection with SRS service or maintenance) are indicated in the table of contents by an asterisk (*). 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

Group name FUEL

CRUISE CONTROL SYSTEM

MANUALTRANSAXLE. AUTOMATIC TRANSAXLE

TRANSAXLE CONTROL

POWER PLANT MOUNT

RIGHT MEMBER, LEFT MEMBER AND CROSSMEMBER

ELECTRONIC CONTROL SUSPENSION 36

SRS-related components

PARKING BRAKES STEERING

’ STEERING ANGULAR VELOCITY SENSOR PARKING BRAKE LEVER AND PARKiNG BRAKE CABLE

P.33B-19 / P.36~5 / P.37A-17

/ STEERING WHEEL AND SHAFT

j P.37A-13

BODY

FENDER

52A

INTERIOR

FLOOR CONSOLE

HEATER, AIR CONDITIONER AND VENTILATION

P.32-6

/ POWER STEERING GEAR BOX

42

CHASSIS ELECTRICAL

/ P.13-185

/ P.52A-11

FRONT SEAT

P52A-18

INSTRUMENT PANEL

P.52A-8

SEAT BELT

P.52A-25

COLUMN SWITCH

P.54-73

HORN SWITCH

P.54-78

IGNITION SWITCH

1 P.54-6

RADIO REMOTE-CONTROL

/ P.54.110

AIR-CONDITIONER CONTROL PANEL AIR-CONDITIONER CONTROL UNIT

P.55-56

/ DAMPER CONTROL MOTOR ASSEMBLY

I 1 P.55-18

/ HEATER CONTROL ASSEMBLY

1 P.55-22

HEATER UNIT.

P.55-36

VENTILATORS (INSTRUMENT PANEL)

WARNING! (1) Improper service or maintenance of any component of the SRS, or any SRSrelated component, can lead to personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver (from rendering the SRS inoperative). (2) If it is possible that the SRS components are subjected to heat over 93°C (260°F) in baking or in drying after painting, remove the SRS components (air bag module, SRS diagnosis unit, front impact sensors) beforehand. (3) Service or maintenance of any SRS component or SRS-related component must be perfarmed only at an authorized MITSUBISHI dealer. (4) MITSUBISHI 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 SRS or any SRS-related component.

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GENERAL CONTENTS GENERAL DATA AND SPECIFICATIONS . . . . . . 21 HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Explanation of Circuit Diagrams

. . . . . .._...........

7

Explanation of Manual Contents . . . . . . . . . . . . . . . . . . . . Explanation of the Troubleshooting Guide . .

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Model Indications

............................................

3

Scope of Maintenance, Repair and Servicing Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Troubleshooting

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Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36

Manual Transaxle

. . . . . . . . . .._........................_.......

39

Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .._..._.._..____.._.......

43

Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .._............... 37 ........................................................ 37

Timing Belt

MASTER TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . .

24

PRECAUTIONS BEFORE SERVICE

................

15

3

RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE . . . . . . .._........

32

31

SCHEDULED MAINTENANCE TABLE . . . . . . . _.

35

. . . 44

SPECIAL HANDLING INSTRUCTIONS FOR AWD MODELS . . . . . . . . . . . . .._...._........................

20

TIGHTENING TORQUE . . . . . . . . . . . . . . . ..__.....................

23

Automatic Transaxle . . . . . . . . . . . . . . . . . . . . . . . ..._......._..... 40 Ball Joint and Steering Linkage Seals . . . . . . . . . . . . 42

TOWING AND HOISTING

................................

16

Brake Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . .._......._.._...._......._..

42

VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . _. . .

8

Disc Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42

. . . . . . .._.......................................

LUBRICATION AND MAINTENANCE

. . . . . . _. .

MAIN SEALANT AND ADHESIVE TABLE MAINTENANCE SERVICE Air Cleaner Element

6

. . . . . . . . . . . . . . . . _. . . _. . .__

36

. . . . . . .._......._......_................

37

Drive Belt (For Alternator) . . . . . . . . .._.........._.......... 38

Chassis Number . .._............................................ 10 Engine Model Stamping .._..........................._...._ 11

Drive Shaft Boots

Theft Protection . . . . .._.........................................

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

11

. . . . . . . . . . . . ..__.._............................. 41 Engine Oil .._....__._................................................. 38

Vehicle Identification Code Chart Plate

Engine Oil Filter

39

Vehicle Identification Number Location

. . . .._

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43

Vehicle Information Code Plate . . . . .._._......_.......

10

Fuel Hoses ..__......__............................................ 36

Vehicle Safety Certification Label . . . ..I . . . . .._..._...

10

Engine Coolant

. . . . .._._.......__.................. . . . . . . . . . . .

Exhaust System _....._......._.....__._............,...........

Vehicle Identification Number List

.._.....

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.._._....._..._.

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GENERAL - How to Use This Manual

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HOW TO USE THIS MANUAL

MOOBAAF

SCOPE OF MAINTENANCE, REPAIR AND SERVICING EXPLANATIONS This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair and servicing of the subject model. Unless otherwise 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

STANDARD VALUE Indicates 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.

LIMIT Shows 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.

“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.

Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly and adjustment procedures, and so they can be completed in a shorter time).

SERVICE PROCEDURES

CAUTION

The service steps are arranged in numerical order and attentions to be paid in performing vehicle service are described in detail in SERVICE POINTS.

Indicates 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.

TROUBLESHOOTING

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DEFINITION OF TERMS

Troubleshootings are classified into master troubleshooting 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 group only; a troubleshooting guide is prepared for each appropriate group.

REFERENCE VALUE

INDICATION OF TIGHTENING TORQUE The 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 +Ino/I iv,“. (2) Special bolts or the like are in use. (3) Special tightening methods 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 performed before the work in that section is started, and procedures to be performed after the work in that section is finished.

Maintenance and Servicing Procedures

0 Removal steps: The part designation number corresponds to the (1) A diagram of the component parts is provided number in the illustration to indicate removal near the front of each section in order to give the steps. reader a better understanding of the installed l Disassembly steps: condition of component parts. The part designation number corresponds to the (2) The numbers provided within the diagram indicate number in the illustration to indicate disassembly the sequence for maintenance and servicing procedures; the symbol m indicates a non- . ln~~~~iion steps: reusable part; the tightening torque is provided Specified in case installation is impossible in where applicable. reverse order of removal steps. Omitted if installation is,possible in reverse order of removal steps. l Reassembly steps: Specified in case reassembly is impossible in reverse order of disassembly steps. Omitted if reassembly is possible in reverse order of disassembly steps.

Classifications of Major Maintenance/Service Points When there’are major points relative to maintenance and servicing procedures (such as essential maintenance and service points, maintenance and service standard values, informatton regarding the use of special toois, etc.), these are arranged together as major maintenance and service points and explained in detail. **:lndicates that there are essential points for removal or disassembly. *+: Indicates that there are essential points for installation or reassembly.

Indicates (by symbols) where lubrication is necessary. In this example,

Symbols for Lubrication, Sealants and Adhesives Information concerning the locations for lubrication and for application of sealants and adhesives is provided, by using symbols, in the diagram of component parts or on the page following the component parts page, and explained.

G&: Grease (Multipurpose grease unless there is a brand or type specified) 4: Sealant or adhesive Brake fluid, automatic transmission fluid or a conditioner compressor oil Engine oil or gear oil Adhesive tape or butyl rubber tape

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GENERAL - How to Use This Manual Indicates the page number. \ -.37A-28

Denotes tightenrng

STEERING - Power Steering Gear Box

POWER STEERING GEAR BOX REMOVAL AND INSTAUATION

1!3-20

Plm

Denotes non-reusable part.

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-Renloval steps 1 .Jrnyt assembly and gear box connecting 2. Connection for return tube 3.Connection for press.ure hose 4. cotter pm 5.T1erod end and knuckle connecting

3. maI,% ,v*, ,tu&w.,. *.-._ 10. Center member rear mourha WR 11, Front exhaust pipe ‘0 w 12. Gear box assembly ” 13. Mountmg rubber

SERVICE POINTS OF REMOVALJ6. Ol6CONN6CTtON OF TIE-ROD END

Operating procedures, cautions, etc. on removal, installation, disassembly and reassembly are described.

Y-

* Using the special tool, disconnect the tie rod from the

\

1.60sumtotie6lec?rdofthaspecialwJdtotheneflrbY

This number corresponds to the number appearing in “Removal steps”, “Disassembly steps”, “installation steps” or “Reassembly steps”

2 . ~thsmItbutdonDt-vsit. 12.

37A-24

REMOVAL OF GEAR 60X ASSEMBLY

STEERING - Manual

Steering Gwr Box

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The title of the page (following the page on which the diagram of component parts is presented) indicating the locations of lubrication and sealing procedures.

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GENERAL - How to Use This Manual

EXPLANATION OF THE TROUBLESHOOTING GUIDE

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3. Cheddng the psssenger compartment-tempwsturs sensor, o&de-sir sensor, sirthwtmctat CMSO~ and refrigerant-tempcmture sensor circuits

lndrcates connector’s terminal number. t

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I . Provides the necessary description of circuit operation for - Opsrstion dnctiption A negatkcharactensw fhemwor IS employed basic understanding. I temperature of rhe SB”SOf pan to ,es,s,ance.

for each sensor nn order 10 convert the smbnen,

The sensor power-supply l2.W) of the air-condaioner control unit 1s applied to each sensor. and the voltages of terminals 1161. 1151. I171 and 15) are divtded by the rwstance values of each sensor. and resislance R.

Provides hints (ineluding standards for judgement) when troubleshooting proare folcedures lowed.

- - Tmublnkooting

Indicates the connector number. Numbers are used in the operation descriptions only as necessary, and these numbers correspond to the numbers used in harness and component layout diagrams.

hff

Dtagnosls

,w,p”t

NO 1, The _ DilFW+““P, s,g”a, ,s ,,e,d ,o -____ .=_ P”m”il”m~“l.l~m~~=,,,,~ __ .~_. .._... ._...r_._._._ ”concnr -..--. .., 25°C 17rF). No 12: The outside-w sensor mput srgnal is he. la to ---,,“C IWFI. No 13: The awthwmos,a, sensor ~npu, signal is held 10 4% IWF)

-Air conditiuw ccnlml unit ta-.--* -.. l?mlMI “obuge 1 Terminal NO

^ W”IIWO”S

) SWA OUlYdedlr semor

Indicates the check to be made. t

Indicates the circuit diagram for checking (including the interface of the air conditioner control unit).

sensor wwsr SUPPI” Relngeran,.,emwrature

*ensor

Passenger Compa*me”,-tempera. lyre sensor 1 17 j Air-thermostat

sensor

I_

ye pan ,emperatwe 25’C l77W

l.c-1.6v

Al as ,mlles

2 45-2.55v

Sensor WR temperawe 25-Z 17PFI when aar condwmer 1s OFF Bo n

015”

:“gol pm mnperat”re 25°C i77’FI

1 a.1 6”

1 Sensor pan ,empelat”re 25°C ,777,

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’ Indicates the specification to be used for judgement of the check results. If there is no particular mention of conditions in the “Conditions” column, the column shows the specification under normal conditions.

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GENERAL - How to Use This Manual

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EXPLANATION OF CIRCUIT DIAGRAMS / t

The symbols used in circuit diagrams are used as described below.

NOTE For detailed information concerning the reading of circuit diagrams, refer to Volume 2 - Circuit Diagrams.

The input/output (direction of current flow) relative to the electronic control unit is indicated by symbols (A. 0). The (A) symbol indicates that current flows in the upward direction. output Input \ Input/output

indicates a connector. A : female T : male

The broken (----I line indicates the same connector.

The connector symbol indicates the device side connector (for an intermediate connector, the male side connector) as seen from the terminal front (the connector’s connection face).

mc

lea\43 05B -.

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GENERAL - Vehicle Identification

VEHICLE IDENTIFICATION

MOOCA-

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VEHICLE IDENTIFICATION NUMBER LOCATION The vehicle identification number (V.I.N.) is located on a plate 1J attached to the left top s3e of the instrument panel.

VEHICLE IDENTIFICATION CODE CHART PLATE MOOCB- .

All vehicle identification numbers contain 17 digits. The vehicle number is a code which tells country, make, vehicle type, etc.

JJapan

AMitsubishi

3Passenger Car

XDriver Air Bag, F’a;;;;ger Seat Belt

D3000GT FWD E3000GT AWD

sPremium 6 Special 7Ultimate

43-door Hatchback

B3.0 liters (181.4 win.)

1 z

L:oHC-MP’l 3.0 liters 1 (181.4 cu.in.1 [DOHC-MPITurbo]

NOTE l “Check digit” means a srigle number or letter X used to verify the accuracy of transcription of vehicle identification number,

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M1991 Year

Yl%ya

000001 99iJF389


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GENERAL - Vehicle Identification VEHICLE IDENTIFICATION NUMBER LIST

MOOCC-

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VEHICLES FOR FEDERAL 1 V.I.N. (except sequence number)

1 Brand

JA3XD54BOMY

/ Engine displacement

1 Models code

Mitsubishi 3000GT <FWD>

3.0 liters (181.4 cu.in.) [DOHC-MPI]

Mitsubishi 3000GT <AWD>

3.0 liters (181.4 cu.in.) [DOHC-MPI-Turbo]

Z15AMNGFL2M ZlGAMNGFL2M

Engine displacement

Models code

3.0 liters (181.4 cu.in.1 [DOHC-MPI]

Zl lAMNXML7M Zl lAMRXML7M

JA3XD64BOMY I JA3XE74COMY

VEHICLES FOR CALIFORNIA ( V.I.N. (except sequence number)

1 Brand

JA3XD54BClMY 1 JA3XD64BlJMY JA3XE74CClMY”

Mitsubishi 3000GT <FWD>

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Zl lAMNPML7M Zl lAMRPML7M

I Mitsubishi 3000GT <AWD>

NOTE AWD marked with * can also be sold in Federal States. *

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3.0 liters (181.4 cu.in.1 [DOHC-MPI-Turbo]

Z15AMNGFL7M ZIGAMNGFUM

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1991 Mitsubishi 3000GT Service Repair Manual  
1991 Mitsubishi 3000GT Service Repair Manual  
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