1991 MITSUBISHI 3000GT Service Manual

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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CLUTCH - Clutch Control21-13
14UOO6514U006t14GOO50
08FOO27. ADJUSTMENT OF CLEARANCE BETWEEN CLUTCH
BOOSTER PUSH ROD AND PISTON
Adjust the clearance (A) between the clutch booster push
rod and piston as follows:
(1) Measure the dimension
(B) between the master cylin-
der end face and piston.
NOTETo obtain
(B), first take measurement with a square
placed on the master cylinder end’ face. Then, subtract
the thickness of the square to arrive at (B).
(2) Obtain the dimension
(C) between the clutch booster
mounting surface on the master cylinder and the end
face.(3) Measure the dimension
(D) between the master cylin-
der mounting surface on. clutch booster and the push
rod end.
NOTETo obtain
(D). first take measurement with a square
placed on the clutch booster. Then, subtract the
thickness of the square to arrive at
(D).
(4) Using the measured values obtained in (1) through (3).obtain the clearance (A) between the clutch booster
push rod and piston.
Standard value: [A (A = B
- C - D )]
0.2j - 0.46 mm (.0082 - .0181 in.)
[Atmospheric pressure][When the clutch booster negative pressure of 66.7
kPa(9.7 psi) is applied, the clearance (A) becomes 0.1 to 0.3
mm
(.0039 to .0118 in.).]
(5) If the clearance is not within the standard value range,
adjust by changing the push rod length by turning the
adjustable end of the push rod.
CautionImproper clearance may cause excessive brake
drag.JTSB Revision
I

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.
1 TSB Revision

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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CLUTCH - Clutch Vacuum Line, Vacuum Tank
CLUTCH VACUUM LINE, VACUUM TANK
REMOVAL AND INSTALLATION
21-17M21VA-
_
I
i6
Hose clamp
4.0 NmI2.9 ftlbs.
.lO15
\
;308FOO21
II
l +1. Vacuum hose AI)* 2. Vacuum hose B+I) W+3. Vacuum hose C with check,valve4. Fitting
Vacuum pipe A removal steps
l *5. Air hose AI)+6. Air cleaner cover, air intake hose A
7. Vacuum pipe AVacuum pipe B, vacuum hose D removal steps
8. Brake booster(Refer to GROUP 35 - Brake Booster.)9. Vacuum pipe B
l + 10. Vacuum hose DVacuum tank assembly, vacuum hose E,
vacuum pipe C removal steps
11. Right member(Refer to GROUP 32 - Right Member, Left
Member and Crossmember)
12. Vacuum tank assembly
l * 13. Vacuum hose E
14. Vacuum pipe CTSB Revision

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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