1991 MITSUBISHI 3000GT service

CLUTCH- Service Adiustment Procedures
Intakemanifold sideValve
08FOO3
2.Check the operation of the check valve by using a vacuum
w-w.
Vacuum pump connectionAccept/reject criteria~
Connection at the clutchbooster side @
A negative pressure (vacuum) is
created and held.
rConnection at the intakemanifold side @
A negative pressure (vacuum) is not
created.
Caution
If the check valve is defective, replace it as an assemblyunit together with the vacuum hose.
BLEEDINGMZlFBAGWhenever the clutch tube, the clutch hose, and/or the clutch
master cylinder have been removed, or if the clutch pedal is~
spongy, bleed the system.
Specified fluid: Conforming to DOT3
CautionUse the specified fluid. Avoid using a mixture of the
specified fluid and other fluid.
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21-8CLUTCH - Clutch Pedal
CLUTCH PEDAL
REMOVAL AND INSTALLATIONMZlPA-
.
0‘@- D.,
a
;
IGsdRemoval steps
1. Connection of brake boosterAdjustment of brake pedal
(Refer to GROUP 35 - ServiceAdjustment Procedures.)
2. Connection of clutch master cylinder
3. Clevis pin4. Clevis pin
5. Return spring
6. Pedal support bracket
;: EIe;i; pin
9. Turn over spring10. RodB
11. Bush
12. Clutch pedal shaft
30 Nm22 ftlbs.
9 ft.lbs.
13 Nm
9 ft.lbs.Gw+,
8 !!
79 I_a 9ft.lbs.
k1608FOO47
13. Clutch pedal14. Bushing15. Spacer
16. Clutch pedal pad
17. Brake pedal shaft
18. Brake pedal
19. Stop light switch
20. Bolt
21. Clutch switch
22. Interlock switch
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Release cylinder
push rod
txw51:
15 Nm
11 ftlbs.1308FOO45
Clutch release cylinder removal steps
l 45. Air hose A 6. Air cleaner cover, air intake hose l *7. Air cleaner cover, air intake hose A l *8. Vacuum pipe cAWD>9. Battery
10. Battery seat, washer tankClutch tube A, tube B, tube C, damper removal steps+* *+ 13. Clutch release cylinder
5. Air hose A
Clutch hose removal steps
6. Air cleaner, air intake hose l7. Air cleaner cover, air intake hose A
l 45. Air hose A +* 8. Vacuum pipe
6. Air cleaner cover, air intake hose 9. Batteryl *7. Air cleaner cover, air intake hose A 10. Battery seat, washer tank
** 8. Vacuum pipe *I) l I 15. Clutch tube A cFWD>
9. Battery+* l a 16. Clutch tube B cAWD>
10. Battery seat, washer tank17. Clutch tube C *I) I)* 14. Clutch hose18. Cluch damper CLUTCH
- Clutch Control21-11
13. REMOVAL OF CLUTCH RELEASE CYLINDEROn AWD-vehicles, use a flat type short box wrench to
remove the clutch release cylinder mounting bolts.
08FOO351TSB Revision
SERVICE POINTS OF REMOVALM2lJBAH
12. REMOVAL OF CLUTCH TUBE (CLUTCH HOSE SIDE)While holding the clutch hose side nut, loosen the clutch
tube flare nut.

21-12CLUTCH - Clutch ControlOBFOOBf
!J
03FOOE
- Air intake hose B05FOO23
Air Intake
hose C
aAir intake hose A
Air hose CAir hose AI
05FOOZE
14. REMOVAL OF CLUTCH HOSETo disconnect clutch hose from the clutch tube, proceed as
follows:
(I) Secure the nut on the clutch hose and loosen the flare
nut on the clutch tube.
(2) Remove the clip from the clutch hose to remove clutch
hose from bracket.
15.REMOVAL OF CLUTCH TUBE A (CLUTCH
HOSE SIDE) / 16. CLUTCH TUBE B (CLUTCH
HOSE SIDE)While holding the clutch hose side nut, loosen the clutch
tube flare nut.
INSPECTIONM21 JCAFl Check the clutch hose or tube for cracks or clogging.
SERVICE POINTS OF INSTALLATIONM2lHDAO
16. INSTALLATION OF CLUTCH TUBE B
/ 15.
CLUTCH TUBE A
/ 14. CLUTCH HOSE / 12.
CLUTCH TUBEBe careful that the clutch hose does not become twisted.
13. INSTALLATION OF CLUTCH RELEASE CYLINDEROn AWD-vehicles, use a flat type short box wrench to
tighten the clutch release cylinder mounting bolts.
8. INSTALLATION OF VACUUM PIPE
If the vacuum pipe has a stepped part, connect the vacuum
hose to the pipe securely, up to the stepped part, as shown
in the illustration.
7. INSTALLATION OF AIR CLEANER COVER, AIR INTAKE
HOSE AAlign slots indicated by arrows in air intake hose A with
nmarkings on air intake hoses B and C; then, insert hoses B
and C all the way into air intake hose A.
Insert air intake hoses B and C all the way up to the roots on
the turbocharger end.
5. INSTALLATION OF AIR HOSE A
Connect the air hoses ensuring that alignment marks are
aligned with projections.
Insert air hoses B and C into pipe all the way to its step.
CautionBe careful not to allow any foreign matter to get into
the hoses, pipes, or the intercooler itself.
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21-14CLUTCH i Clutch Master Cylinder
CLUTCH MASTER CYLINDER
DISASSEMBLY AND REASSEMBLY
M21NA. -Disassembly steps
1. Piston stop bolt 2. Gasket a*3. Piston stop ring *I)4. Snap ring 5. Push rod
6. Boot
c*7. Piston assembly
8. Reservoir cap
9. Reservoir band
10. Reservoir11. Master cylinder body
Master cvlinder kit..--_-.-I------- --.-
6.0 Nm4.0 ft.lbs
08FOO40
13 Nm9.0 ftlbs.
---&08FOO39
r
08FOO41
8
6.0 Nm4.0 ft.lbs:Master
cvlinder kit1
109FOl3414LO193
SERVICE POINTS OF DISASSEMBLYM21NSAE3. DISASSEMBLY OF PISTON STOP RING
/ 4.
SNAP RING
Remove the piston stop ring or snap ring, while depressing
the piston.
7. REMOVAL OF PISTON ASSEMBLY
Caution
1.Do not damage the master cylinder body and piston
assembly.2. Do not disassemble piston assembly.
INSPECTIONMZlNCAD
l Check the inside cylinder body for rust or scars.
l Check the piston cup for wear or deformation.
Idl Check the piston for rust or scars.
l Check the clutch tube connection part for clogging.
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CLUTCH - Clutch Release Cylinder21-15
CLUTCH RELEASE CYLINDER
DISASSEMBLY AND REASSEMBLY
L.4/
/
iJ
Lubricant: Conforming to DOT3Disassembly steps
1.Valve plate2.Spring3.Push rod4.Boots*I) l *5. Piston and cup6.Conical spring
7.Cap
8.Bleeder plug9.Release cylinder7CLOOOl
6CLO3!
SERVICE POINTS OF DISASSEMBLYM2lLBAF5. DISASSEMBLY OF PISTON AND CUP
(1) Remove the corrosion from the piston-removal port of
the release cylinder.
(2) Remove the piston from the release cylinder using
compressed air.
Caution1. Cover with rags to prevent the piston from
popping out.
2. Apply compressed air slowly to prevent brake
fluid from splashing.
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21-16CLUTCH - Clutch Release Cylinder
6CLOOO3
DCLOOE,
INSPECTIONM21LCAF
(1) Check the inner surface of the release cylinder for scratch-
es or irregular wear.
(2) Replace if the piston cup outer circumference is scratched
LIor shows signs of fatigue, or if there is excessive wear of
the lip where indicated in the figure.
SERVICE POINTS OF REASSEMBLYMZlLDAH
5. APPLICATION OF FLUID TO PISTON AND CUP
Apply specified brake fluid to the release cylinder inside and
outer surface of the piston and piston cup and push the
piston cup assembly in the cylinder.
Specified brake fluid: Conforming to DOT3
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21-18CLUTCH - Clutch Vacuum Line. Vacuum Tank
Check valve
OSFOOO
OSFOO7
- iA&ir$ke
Air intake hose A
Air intake hose B05FOO23
Air hose CAir hose AI
SERVICE POINTS OF REMOVALM2lVBAA3. REMOVAL OF VACUUM HOSE C WITH CHECK VALVE
NOTESince the check valve is fit to the vacuum hose C, replace
the check valve as an assembly unit together with the
vacuum hose C if the check valve is defective.
INSPECTIONM2lWcAAl Check the hose and pipes for cracks, bend, deformation
and clogging.
l Check the vacuum tank for deformation or crack.
SERVICE POINTS OF INSTALLATIONMZlVDAA13. INSTALLATION OF VACUUM HOSE E
/ 10. VACUUM
HOSE D / 3. VACUUM HOSE C WITH CHECK VALVE / 2.VACUUM HOSE B
/ 1. VACUUM HOSE A
If a hose is connected to a pipe with a stepped part, insert
the hose up to the stepped part.
aIf it is connected to a pipe without any stepped part, insert
the hose until the insertion amount reaches the standard
value.
Standard value: 20
- 25 mm (.8 - 1.0 in.)
6. INSTALLATION OF AIR CLEANER COVER, AIR INTAKEHOSE A
Align slots indicated by arrows in air intake hose A with
nmarkings on air intake hoses B and C; then, insert hoses B
and C all the way into air intake hose A.
Insert air intake hoses B and C all the way up to the roots on
the turbocharger end.
5. INSTALLATION OF AIR HOSE A
Connect tha air hoses ensuring that alignment marks are
aligned with projections.
Insert air hoses B and C into pipe all the way to its step.
CautionBe careful not to allow any foreign matter to get into
the hoses, pipes, or the intercooler itself.
;i
J
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