1991 MITSUBISHI 3000GT maintenance

15-16INTAKE AND EXHAUST - Intake Manifold
INTAKE MANIFOLD
REMOVAL AND INSTALLATION
Pre-removal Operationl Release of Residual Pressure fromHigh Pressure Fuel Hose(Refer to GROUP 13-ServiceAdjustment Procedures.)l Draining of Engine Coolant (Refer
to GROUP 00 -Maintenance Service,)
l Removal of Air Intake Plenum(Referto P.15-13, 14.)5Nm
lo-13Nm4 ft.lbs.8-9ftJbs. w2\I
Post-installation Operationl Installation of Air Intake Plenum
(Refer to P.1.5-13. 14.)l Filling of Engine Coolant
(Refer to GROUP 00 - Maintenance
Service.)
l Adjustment of Accelerator Cable(Referto GROUP 13-EngineControl.). Checkina for Fuel Leakage6
5
2 :‘;bs.)
gp,.qgs ~-zt!EJ8OSFOO24
Removal steps
I. Connection for high-pressure fuel hose
2. O-ring
3. Connection for fuel return hose
4. Connection for vacuum hoses
5. Connection for injector connector
6. Delivery pipe (with injectors)
7. Insulators
8. Timing belt upper cover
I)*9. Intake manifold mounting nut I)* 10. Intake manifold mounting nut II. Cone disc spring
12. Intake manifold-
** 13. Intake manifold gasket
TSB Revision

INTAKE AND EXHAUST - Turbocharger (Rear)15-21
TURBOCHARGER (REAR)
iREMOVAL AND INSTALLATION
/
id
Post-installation ODerationIl Installation of Front Exhaust Pipe(Referto P.15-31.)l Refilling of the Engine Coolant
(Refer to GROUP 00 - Maintenance
l Adjustment of Accelerator Cable1~~~~o~~ GROUP 13 - Engine
lo-13Nm7 - 9 ft.lbs.
6.
7 55-65Nmb
5 40 - 47 ft.lbs.i18Nm’
d13 ft.lbs.
MlSLA-B
0-nng
05FOOO3Removal steps
1. Battery2. Connection of accelerator cable
** 3, pg,t;eye)l * 4.
AirpipeA5. Heat protector F
6. Clutch booster vacuum hose
7. Connection of accelerator cable
(pedal side)
I)+8. Air intake hose AO+9. Air intake hose Cl * I)* 10. Oxygen sensor
11. Heat protector D12. EGR pipe
9Nmv 10 //--!
-7 ft.lbs.45 Nm33 ft.lbs.LIZ-15NmOSFOO419- 11 ft.lbs.
13.Eye boltl * 14. Oil pipe15.EGR valve16. Water pipe A
17. Water pipe B
18.Exhaust fitting
19. Heat protector E
20.Gasket21,. Turbocharger & return pipe assembly
22. Oil return pipe
l * 23. Turbocharger assembly24.Gasket25.Ring26. Exhaust fitting stayTSB Revision

17-14 EMISSION CONTROL -Exhaust Gas Recirculation (EGR) System / Catalytic Converter
6EM01871
6EM0181(4) Apply a vacuum and check for air-tightness when voltage
applied directly to the EGR control solenoid valve and when
the voltage is discontinued.
Battery voltageResult
When applied
When discontinued
Vacuum is maintained
Vacuum leaks
(5) Measure the resistance between the terminals of the
solenoid valve.
Standard value: 36
- 44 R [at 20°C (68”F)]
AIR-FUEL RATIO CONTROL (MPI) SYSTEMM17ICAJ
lTo inspect the air-fuel ratio control (MPI) system, refer to
GROUP1 3 - Service Adjustment Procedures.
lFor detailed information concerning the illumination pattern
of the malfunction-indicator light and other aspects of the
self-diagnosis function, refer to GROUP 13 -Self-diagnosis.
\.J
CATALYTIC CONVERTERMl7N& -
REMOVAL AND INSTALLATIONRefer to GROUP 15
- Exhaust Pipe, Main Muffler and Catalytic
Converter.
INSPECTIONMl7NCAA
Inspect for damage, cracking or deterioration. Replace if faulty.
Caution1. Operation of any type, including idling, should be
avoided if engine misfiring occurs. Under this conditionthe exhaust system will operate at abnormally high
temperature, which may cause damage to the catalystor underbody parts of the vehicle.
2.Alteration or deterioration of ignition or fuel system, or
any type of operating condition which results in enginemisfiring must be corrected to avoid overheating the
catalytic converters.
3.Proper maintenance and tune up according to manufac-turer’s specifications should be made to correct the
‘bi
conditions as soon as possible.TSB Revision

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 - Service Adiustment Procedures22-9
110*u011009FO12
SERVICE ADJUSTMENT PROCEDURES
MZZFBAEl
TRANSMISSION OIL LEVEL INSPECTIONRefer to GROUP 00
- Maintenance Service.
TRANSMISSION OIL REPLACEMENTM22FCAI(1) Position vehicle on a flat level.
(2) Remove filler and drain plugs and allow the transmission oil
to drain.
(3) Refill the transaxle to the proper level with specified
transmission oil. The oil level should be the bottom of the oil
filler hole.
Transmission oil: Hypoid gear oil, SAE 75W-85W con-
forming to API classification GL-4 or
higherC2.3 liters (2.4 pts.)]
SPEEDOMETER CABLE REPLACEMENTMUFEALl
1.Correctly insert the adapter into the instrument panel, and
fasten the new speedometer cable.
2.Install the grommet so that, as shown in the illustration, the
cable attachment part and the projecting part are horizontal.
CautionThe cable arrangement should be made so that the
radius of cable bends is 150 mm (5.9 in.) or more.
3.At the transaxle end of the speedometer cable, the key joint
should be inserted into the transaxle, and the nut should be
securely tightened.
Caution
If the cable is not correctly and securely connected, it
may cause incorrect indication. by the speedometer, orabnormal noise. Be sure to connect it correctly.
DSB RevisionI

MANUAL TRANSAXLE - Service Adjustment Procedures22-51SERVICE ADJUSTMENT PROCEDURES
TRANSMISSION OIL LEVEL INSPECTIONM22FBAE2
Refer to GROUP 00
- Maintenance Service.
TRANSMISSION OIL REPLACEiVlENTMUFCAJ
(I) Position vehicle on a flat level and remove filler and drainplugs to drain transmission oil.
(2) Pour in fresh transmission oil through filler port.
Transmission oil: Hypoid gear oil, SAE 75W-85W con-
forming to API classification GL-4 or
higherTransaxle: 2.4 liters (2.5 qts.)
Transfer: 0.27 liters
(.29 qts.)
(3) After checking to be sure that the oil level is the specifiedlevel, tighten the filler plug at the specified torque.
1 TSB Revision

23-1
AUTOMATIC
TRANSAXLE
CONTENTSMZJAA- _
ANNULUS GEAR AND TRANSFER DRIVE GEARTransmission Fluid Level Inspection................................46SET................................................................................................
102Transmission Fluid Replacement........................................
46
DIFFERENTIAL........................................................................104SPECIAL TOOLS........................................................................
16
:......................................... 12IEND CLUTCH ASSEMBLY....................................................99SPECIFICATIONS..........................
FRONT CLUTCH ASSEMBLY................................................95
GENERAL INFORMATlON....................................................2
KICKDOWN SERVO................................................................
107
LOW-REVERSE BRAKE............................................................
107
OIL PUMP....................................................................................93
PLANETARY GEAR................................................................
100
REAR CLUTCH ASSEMBLY....................................................97
SELECTOR LEVER ASSEMBLY............................................58
SERVICE ADJUSTMENT PROCEDURES............................46
Accelerator Switch
Inspection and Adjustment................
50Drive Shaft Oil Seals Replacement....................................
52Inhibitor Switch and Control Cable Adjustment................
52Key Interlock Mechanism Check........................................50KickdownServo Adjustment................................................
47Line Pressure Adjustment....................................................
48Reducing Pressure Adjustment........................................
49Selector Lever Operation Check........................................
50Shift Lock Mechanism Check............................................51Speedometer Cable Replacement....................................53
General Specifications........................................................12Lubricants............................................................................15Service Specifications........................................................12Spacer and Snap Ring........................................................13Valve Body Spring Identification Chart............................13
SPEEDOMETER DRIVEN GEAR ASSEMBLY....................106
TRANSAXLE ASSEMBLY........................................................62
TRANSAXLE CONTROL*........................................................54
TRANSAXLE OIL COOLER, HOSES, TUBES
....................66
TRANSFER SHAFT....................................................................92
TROUBLESHOOTING............................................................
19
A/T Safety-lock System Troubleshooting........................44Converter Stall Test............................................................
43
Diagnosis and Test
................................................................
22
Element in Use at Each Position of Selector Lever........31Inspection
of ControlSystem............................................
28Inspection of Electronic Control System Components....32Oil Pressure Tests................................................................
39ShiftPatterns....................................................................
31,42Troubleshooting Guide........................................................
20
VALVE BODY. . . .._._.................................................................... 108
SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
(1)A Supplemental Restraint System (SRS), which uses a driver-side air bag, has been installed in the 3668GT.(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 beremoved/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 topersonal injury or death to service personnel (from inadvertent firing of the air bag) or to the driver (from
rendering 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) MlTSUBISHI 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
ISRS or any SRS-related component.

AUTOMATIC TRANSAXLE - Troubleshootincl23-19Based upon use of the troubleshooting
Checks should be made of fluid levels and
the condition of the ATF, as well as the
condition of the manual control cables;
adjustments should then be made if found
to be necessary.
If a presumption has been made that there
is an abnormal condition somewhere in
the electronic-control system, check the
fault code, in order to determine the
probable location of the problem, by using
a multi-use tester or voltmeter.
I
When the abnormal system is discovered,
check each element (sensors, etc.) one by
one, and make repairs as necessary.
IWhen the abnormal condition is presumed
to be in the oil-pressure-control system
When the result of the oil-pressure test
does not satisfy the specified pressure,
check each system at places related to the
valve body, check the oil-pressure pas-
sages for leakage, etc.
I
If the problem isunusually dirty ATF,
abnormal noises, oil leakage, or slippage of
the clutch or brakes, or an abnormal
condition of the transaxle itself, disassem-
ble and repair the transaxle.
TROUBLESHOOTINGM23EEAYFunctional malfunctions of the ELC4A/T can lead to other
problems, such as those described below:(I
) Improper maintenance and/or adjustments
(2) Malfunctions of the electronic control functions
(3) Malfunctions of mechanical functions
(4) Malfunctions of hydraulic control functions
(5) Malfunctions of engine performance
etc.
In order to properly determine (“Troubleshoot”) the source of
these malfunctions, it is first essential to methodically question
the user concerning the details of the problem, such as the
condition of the problem, the situation at the time the problem
occurred, and any other relevant information, all in as much
detail as possible. The user should also be asked whether or
not the problem has occurred more than once, and under what
conditions.
Subsequently, certain tests should be conducted in a certain
order, as described at the left.
TSB Revision