1991 MITSUBISHI 3000GT oil

INTAKE AND EXHAUST - Exhaust Manifold 15-27
EXHAUST MANIFOLD
iREMOVAL AND INSTALLATION
Pre-removal and Post-installation Operationl Removal and Installation of Front Exhaust Pipe
l Removal and Installation of Condenser Fan Motor
Assembly
(Refer to GROUP 14 - Radiator.)
12-15Nm
P9 - 11 ft.lbs.
45 Nm33 ft.lbs.\24Nm
17ft.lbs.1
Li2
l-
45 Nm33 ft.lbs.
MSNA-8Removal steps of exhaust manifold (front)
1. Drive belt (Alternator)(Refer to GROUP 11 -Service Adjustment procedures)
2. Alternator assembly
3. Oil level gauge guide
4. Heat protector
5. Exhaust manifold (front)
6. Gasket
60 Nm,43 ft.lbs.
33 ftlbs.1 05F00337
8Removal steps of exhaust manifold (rear)
7. Stud
8. Heat protector
9. EGR pipe
IO. Exhaust manifold (rear)11. Gasket
INSPECTIONhllSNCAU2
Check the following points; replace the part if a problem is
found.
l Check for damage of cracking of any part.
TSB Revision
I

17-2EMISSION CONTROL - Specifications / Troubleshooting
SPECIFICATIONS
GENERAL SPECIFICATIONSMl’ICA- -\
Items
Crankcase emission control systemSpecifications
Closed type with positive crankcase ventilationvalve
Evaporative emission control systemCanister storage type
Canister
Charcoal type
Purge control solenoid valve
ON/OFF solenoid valve
Exhaust emission control system
Exhaust gas recirculation system
EGR valveVacuum-activated diaphragm type
EGR temperature sensor Thermistor type
EGR control solenoid valve - Non Turbo, Turbo>Duty cycle solenoid valve
Catalytic converter
Monolith type
Location
Under floor
Turbocharger outlet (front bank and rear bank,)
and under floor
SERVICE SPECIFICATIONSMl7CB-.
ItemsSpecifications
Purge control solenoid valve coil resistance
036 - 44 [at 20°C (68”F)I\
EGR temperature sensor resistancekfl60 - 83 [at 50°C (I 22”F)]
11 - 14 [at 100°C (212”F)l
EGR control solenoid valve coil resistance1236 - 44 [at 20°C (68”F)lI
TROUBLESHOOTING
Symptom
Engine will not start
or hard to start
Rough idle or engine
stalls
Probable cause
Vacuum hose disconnected or damaged
The EGR valve is not closed
Malfunction of the purge control solenoid valve
The EGR valve is not closed
Vacuum hose disconnected or damaged
Malfunction of the positive crankcase ventilationvalveRemedy
Repair or replace
Repair or replace
Repair or replace
Repair or replace
Repair or replace
Replace
Malfunction of the purge control systemCheck the system; if there is a
problem, check its component parts
Engine hesitates or3oor acceleration
Zxcessive oil:onsumptron
Malfunction of the exhaust gas recirculation
system
Positive crankcase ventilation line cloggedCheck the system; if there is a
problem, check its component parts
Check positive crankcase
ventila-tion system
Ioor fuel mileageMalfunction of the exhaust gas recirculation
systemTSB RevisionCheck the system; if there is a
problem, check its component parts
d

CLUTCH - Specifications / Troubleshooting21-3
LUBRICANTS
Items
Contact surface of release bearing and fulcrum of
clutch release forkSpecified lubricants
MITSUBISHI genuine grease
Part No.0101 011 or equivalent
Inner surface of clutch release bearing
Inner surface of clutch disc spline
Contact portion of release fork to release cylinder push rod
Clutch fluid
Inner surface of clutch release cylinder and outer
circumference of piston and cup
Inner surface of clutch master cylinder and outer
circumference of piston assembly
Conforming to DOT3
SEALANTM21CE. -
Items
Thread part fittingSpecified sealant
3M ADT Part No. 8660 or equivalent
TROUBLESHOOTINGtvl21EAAM
Symptom
Clutch slips
Gear shifting
failureProbable cause
Clutch pedal play too small
Excessive wear of clutch disc facing
Hardened clutch disc facing or oil on facing
Clutch release fork not operating smoothly
Settled or damaged diaphragm spring
Clogged hydraulic system
Poorly adjusted clutch booster push rod
Clutch pedal play too large
Large clutch disc distortion or runout
Worn clutch cover assembly
Worn or corroded clutch disc splines
Separated clutch disc facing
Worn clutch release bearing
Damaged pressure plate or flywheel
Leaky or clogged hydraulic system or air
trapped in hydraulic system
Poorly adjusted clutch booster push rod
Remedy
Adjust
Replace
Replace
Repair or replace
Replace
Repair or replace
Adjust
Adjust
Replace
Replace
Replace
Replace
Replace
Replace
Repair or replace
AdjustTSB Revision

CLUTCH - Clutch Cover and Disc21-21
Sleeve
Bearing
TFM0131
INSPECTIONMZlGCAG
CLUTCH COVER ASSEMBLYl Check the diaphragm spring end for wear and uneven
height.
lReplace if wear is evident or height difference exceeds the
limit.
Limit
: 0.5 mm (02 in.)
lCheck the pressure plate surface for wear, cracks and color
change.
lCheck the strap plate rivets for looseness and replace the
clutch cover assembly if loose.
CLUTCH DISC
lCheck the facing for loose rivets, uneven contact, deteriora-
tion due to seizure, adhesion of oil or grease and replace the
clutch disc if defective.
lMeasure the rivet sink and replace the clutch disc if it is out
of specification.
Limit
: 0.3 mm (.012 in.)
lCheck for torsion spring play and damage and if defective,
replace the clutch disc.
l Combine the clutch disc with the input shaft and check
sliding condition and check for play in the rotating direction.
If it does not slide smoothly, check after cleaning and
reassembling. If the play is excessive, replace the clutch
disc and/or the input shaft.
CLUTCH RELEASE BEARING
Caution
1.The release bearing is packed with grease, so don’t usecleaning oil, etc. to clean it.
2.Do not disassemble the bearing and sleeve of the clutch
release bearing. If disassembled, replace. (AWD only)l Check for bearing heat damage, other damage, abnormal
noise and/or improper rotation. Also check whether or not
there is wear at the point of contact with the diaphragm
spring.
lIf there is abnormal wear at the point of contact with the
release fork, replace the bearing.
RELEASE FORKIf there is abnormal wear at the point of contact with the
bearing, replace the release fork.
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22-1
iv,MANUAL ~
TRANSAXLE
~
I
CONTENTSM22AA. -
MANUAL TRANSAXLE . . . . . . . . . . . .._...48INPUT SHAFT ASSEMBLY_..________.............: . . . . . . . . . . . . . . . . . . . . . . . . . .30
GENERAL INFORMATION....................................................48
SERVICE ADJUSTMENT PROCEDURES
............................51
Drive Shaft OilSealsReplacement....................................
52Speedometer Cable Replacement....................................
53Transfer Oil Seal Replacement............................................53Transmission Oil Level Inspection....................................51Transmission Oil Replacement............................................51
SHIFT LEVER ASSEMBLY....................................................
53
SPECIAL TOOLS........................................................................50
SPECIFICATIONS
....................................................................49
General Specifications........................................................49Lubricants............................................................................49
TRANSAXLE ASSEMBLY....................................................56,60
TRANSAXLE CONTROL*........................................................54
TRANSFER ASSEMBLY
........................................................59
MANUAL TRANSAXLE ....................2
CLUTCH HOUSING ASSEMBLY............................................46
DIFFERENTIAL ASSEMBLY
....................................................43
5TH SPEED SYNCHRONIZER ASSEMBLY
........................28
GENERAL INFORMATION
....................................................2INTERMEDIATE GEAR ASSEMBLY
....................................
OUTPUT SHAFT ASSEMBLY................................................
SERVICE ADJUSTMENT PROCEDURES............................
Drive Shaft Oil Seals Replacement....................................Speedometer CableReplacement....................................Transmission Oil Level Inspection....................................Transmisston Oil Replacement............................................
SHIFT LEVER ASSEMBLY....................................................
SHIFT RAILS AND FORKS....................................................
SPECIAL TOOLS........................................................................
SPECIFICATIONS....................................................................
General Specifications........................................................
Lubricants............................................................................
Sealants and Adhesives........................................................Service Specifications........................................................
Snap Ring (for Adjustment) and Spacer............................
SPEEDOMETER DRIVEN GEAR ASSEMBLY....................
TRANSAXLE ASSEMBLY _____...._........__....................................
TRANSAXLE CONTROL*. . ..________.___.._ ..__._.__.__...............
36
41
9
10
9
9
9
13
42
6
3z
63
3
45
14
11TROUBLESHOOTING
___.._______._____.......,..................................8
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, air bagmodule, 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 byan asterisk (*).
WARNING!(1)Improper service or maintenance of any component of the SRS, or any SRS-related component, can lead to
personal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver (fromrendering 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) 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 theSRS or any SRS-related component.

MANUAL TRANSAXLE - Specifications22-3
SPECIFICATIONS
L
GENERAL SPECIFICATIONSM22CA.A
items
Model
Applicable engine
Type
Gear ratio
1 st
2nd
3rd
4th
5th
Reverse
Final reduction ratio
Speedometer gear ratio (driven/drive)
Oil quantityliters (qts.)
Specifications
F5M33-2-SNZR
6G72-DOHC MPI
5-speed transaxle floor shift
3.090
1.833
1.217
0.888
0.741
3.166
4.153
28136
2.3 (2.4)
SERVICE SPECIFICATIONSM22CB-A
mm (in.)
L.J
Items
Standard value
Transaxle
Input shaft end play
Input shaft rear bearing end play
Intermediate gear bearing end play
Intermediate gear preload
Output shaft preload
Differential
Differential case preload
Differential pinion backlash
Limit
Specifications
0 - 0.05 (0 - ,002)
0.01 - 0.09 i.0004 - ,004)0.01 -0.14 (.0004-
,006)
0.05 - 0.10 (.002 - ,004)
0.05 - 0.10 (.002 - ,004)
0.05 - 0.10 (.002 - .004)
0.025 - 0.150 (.OOl - ,006)
Synchronizer ring and clutch gear clearance0.5 (.02)
SNAP RING (FOR ADJUSTMENT) AND SPACERM22CF.A
Part name
Spacer
(For adjustment of input shaft end play)Thickness mm (in.)
0.80
i.0315)
0.83 (.0327)
0.86(.0338)
0.89t.0350)
0.92
(.0362)
Identificationsymbol
80
83
86
89
92
Part No.
MD727661
MD720937
M D720938
MD720939
MD720940TSB Revision

22-6MANUAL TRANSAXLE - Specifications / Special Tools
LUBRICANTS
M22CD-A
Items
Manual transmission oil
Drive shaft oil seal lip
Specified lubricant
Hypoid gear oil, SAE
75W-90 or75W-85W conforming to APIclassification GL-4 or higherQuantity lit.
(qts)
2.3 (2.4)
As required
SEALANTS AND ADHESIVES
Items
Transaxle case - clutch housing mating surfaces
Transaxle case
- rear cover mating surfaces
Differential drive gear bolts
Bearing retainer screw (flush head screw)
Reverse brake cone mounting screw bolts
MUCE- _
Specified sealants and adhesives
Mitsubishi genuine part No. 997740 or equivalent
3M Stud Locking part No. 4170 or equivalent
Air breather
3M ATD part No. 8001 or equivalent
SPECIAL TOOLSM22DA-A.
nstallation of spring pin and lock
MD998323-01TSB Revision

22-8MANUAL TRANSAXLE - Troubleshooting
TROUBLESHOOTING
Symptom
Vibration, noise
3il leakage
t-lard shiftProbable cause
a. Loose or damaged transaxle and
engine mounts
b. Inadequate shaft end play
c. Worn of damaged gears
d. Use of inadequate grade of oil
e. Low oil level
f. Inadequate engine idle speed
a. Broken or damaged, oil seal or O-ring
a. Faulty control cable
b. Poor contact or wear of synchronizer ringand gear cone
c. Weakened synchronizer spring
d. Use of inadequate grade of oil
a. Worn gear shift fork or broken poppet
spring
b. Synchronizer hub to sleeve spline
clearance too largeRemedy
a. Tighten or replace mounts
b. Correct end play
c. Replace gears
d. Replace with specified oil
e. Replenish
f. Adjust idle speed
a. Replace oil seal or O-ring
a. Replace control cable
-
Jumps out of gear
b. Correct or replace
c. Replace synchronizer spring
d. Replace with specified oil
a. Replace shift fork or poppet spring
b. Replace synchronizer hub and sleew
1 TSB RevisionI