Mitsubishi GTO (3000GT) Service & Repair Manual 1991-1999

Volume lm I ‘k ,‘6 I I I Engine, Chassis & Body f

d L’ BackupServiceManual 3OOOG-r 1991: Volume 1 FOREWORD L 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. / WE SUPPORT VOLUNTARY TECHNICIAN CERTIFICATION THROUGH I/ National ,nwtute ‘or II AUTOMOTIVE SERVICE EXCELLSNCE /I MITSUBISHI MOTOR SALES OF AMERICA. Inc. 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. li @ 1990 Mitsubishi Motors Corporation Rqwinted in USA GROUP INDEX MOOAA- -A I General ............................................. Engine .............................................. Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling ............................................. Intake and Exhaust .......................... Emission Control ............................. Clutch ................................................ Manual Transaxle ............................ Automatic Transaxle ....................... Propeller Shaft ................................. Front Axle ......................................... Rear Axle .......................................... Wheel and Tire ................................. Power Plant Mount .......................... Front Suspension ............................ Electronic Control Suspension ....... Rear Suspension .............................. Service Brakes ................................. Parking Brakes ................................. Steering ............................................ 4-Wheel Steering System (4WS) - Body . . . . . . . . . . . . . . . . . ..*............................. Exterior . . . . . . . . . . . . . . . . . ..*..........**............. Interior ..*............*......*....................... Su;$emental Restraint System .... Heater, Air Conditioner and Ventilation *......*........... I NOTE: For Electrical, refer to Volume-2 “Electrical” I I I I

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 36 42 52A Group name SRS-related components FUEL CRUISE CONTROL SYSTEM / P.13-185 MANUALTRANSAXLE. TRANSAXLE CONTROL AUTOMATIC TRANSAXLE POWER PLANT MOUNT RIGHT MEMBER, LEFT MEMBER AND CROSSMEMBER P.32-6 ELECTRONIC CONTROL SUSPENSION ’ STEERING ANGULAR VELOCITY SENSOR P.33B-19 PARKING BRAKES PARKING BRAKE LEVER AND PARKiNG BRAKE CABLE / P.36~5 I STEERING / POWER STEERING GEAR BOX / P.37A-17 / STEERING WHEEL AND SHAFT j P.37A-13 BODY INTERIOR FENDER FLOOR CONSOLE / P.52A-11 FRONT SEAT INSTRUMENT PANEL P52A-18 P.52A-8 CHASSIS ELECTRICAL SEAT BELT COLUMN SWITCH HORN SWITCH IGNITION SWITCH P.52A-25 P.54-73 P.54-78 1 P.54-6 RADIO REMOTE-CONTROL / P.54.110 HEATER, AIR CONDITIONER AIR-CONDITIONER CONTROL PANEL AND VENTILATION AIR-CONDITIONER CONTROL UNIT P.55-56 / DAMPER CONTROL MOTOR ASSEMBLY I / HEATER CONTROL ASSEMBLY 1 P.55-18 I HEATER UNIT. 1 P.55-22 WARNING! VENTILATORS (INSTRUMENT PANEL) P.55-36 (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. 1 TSB Revision I

, b 00-I GENERAL CONTENTS MOOOA- . GENERAL DATA AND SPECIFICATIONS . . . . . . 21 HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Explanation of Circuit Diagrams . . . . . .._........... 7 Explanation of Manual Contents . . . . . . . . . . . . . . . . . . . . 4 Explanation of the Troubleshooting Guide . . 6 Model Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Scope of Maintenance, Repair and Servicing Explanations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Troubleshooting . . . . . . .._....................................... 3 LUBRICATION AND MAINTENANCE . . . . . .._.... 31 SCHEDULED MAINTENANCE TABLE . . . . . . .._. MAIN SEALANT AND ADHESIVE TABLE . . . 44 MAINTENANCE SERVICE . . . . . . . . . . . . . . . .._......_.....__ Air Cleaner Element . . . . . . .._......._......_................ Automatic Transaxle . . . . . . . . . . . . . . . . . . . . . . . . .._......._..... Ball Joint and Steering Linkage Seals . . . . . . . . . . . . Brake Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . .._......._.._...._......._.. Disc Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Belt (For Alternator) . . . . . . . . .._.........._.......... Drive Shaft Boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Coolant . . . . . . . . . . . . ..__.._............................. Engine Oil .._....__._................................................. Engine Oil Filter . . . . .._._.......__.................. . . . . . . . . . . . Exhaust System _....._......._.....__._............,........... Fuel Hoses ..__......__............................................ 36 37 40 42 42 42 38 43 41 38 39 43 36 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Transaxle . . . . . . . . . .._........................_....... Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .._..._.._..____.._....... Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .._............... Timing Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MASTER TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . PRECAUTIONS BEFORE SERVICE . . . . . . . . . . . . . . . . RECOMMENDED LUBRICANTS AND LUBRICANT CAPACITIES TABLE . . . . . . .._........ SPECIAL HANDLING INSTRUCTIONS FOR AWD MODELS . . . . . . . . . . . . .._...._........................ TIGHTENING TORQUE . . . . . . . . . . . . . . . ..__..................... TOWING AND HOISTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . .._..... Chassis Number . .._............................................ Engine Model Stamping .._..........................._...._ Theft Protection . . . . .._......................................... Vehicle Identification Code Chart Plate .._..... Vehicle Identification Number List .._._....._..._. Vehicle Identification Number Location . . . .._ Vehicle Information Code Plate . . . . .._._......_....... Vehicle Safety Certification Label . . . ..I . . . . .._..._... 36 39 43 37 37 24 15 32 35 20 23 16 8 10 11 11 8 9 8 10 10

GENERAL - How to Use This Manual 00-3 HOW TO USE THIS MANUAL MOOBAAF c; SCOPE OF MAINTENANCE, REPAIR AND DEFINITION OF TERMS SERVICING EXPLANATIONS STANDARD VALUE b This manual provides explanations, etc. concerning procedures for the inspection, maintenance, repair and servicing of the subject model. Unless other- wise 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 “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. SERVICE PROCEDURES The service steps are arranged in numerical order and attentions to be paid in performing vehicle service are described in detail in SERVICE POINTS. TROUBLESHOOTING 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 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. REFERENCE VALUE Indicates the adjustment value prior to starting the work (presented in order to facilitate assembly and adjustment procedures, and so they can be com- pleted in a shorter time). CAUTION 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. 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 + I no/- only; a troubleshooting guide is prepared for each I iv,“. appropriate group. (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. TSB Revision

Mitsubishi GTO (3000GT) Service & Repair Manual 1991-1999

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