Mitsubishi 3000GT / SL / VR-4 1991 Service Manual, Vol. 1 (P/N MSSP-001B-91 (1/2))

Mitsubishi’s 1991 factory service manual covers the 3000GT, 3000GT SL, and 3000GT VR-4, including FWD non-turbo and AWD turbo models. This is Volume 1, Engine, Chassis & Body (P/N MSSP-001B-91 (1/2)). For vehicle-wide wiring diagrams, Mitsubishi directs readers to the separate Volume 2, Electrical.

PDF Search, Bookmarks, and Diagram Detail

Finding sections and circuit details: The main chapters have searchable OCR text. Some terms and identifiers are misread, and some labels are part of the diagram images. Embedded bookmarks jump to the chapters. The “Back to Navigator” bookmark requires a separate file. Small connector and pin numbers often need zooming, and some Electronic Control Suspension (ECS) labels and circuit lines remain faint or broken at higher magnification.

The download is one 1,146-page printable PDF in English. The total includes the front and back covers, two introductory pages, and 25 blank or notes pages.

Engine, Driveline, and Chassis Service

These selected topics show the repair and diagnostic coverage. Other sections include clutch release-cylinder service and power window diagnosis.

• Engine repair: Engine removal, cylinder-head and crankshaft inspection, timing-belt installation, and camshaft oil-seal replacement.
• Fuel and turbo systems: Multipoint fuel injection (MPI) diagnosis, injector and fuel-pressure tests, turbocharger service, and Active Exhaust System troubleshooting.
• Transaxle service: FWD manual and automatic transaxle disassembly and reassembly, plus AWD transaxle and transfer assembly removal and installation.
• Axles and final drive: Propeller shaft and drive shaft service, limited-slip differential inspection, and rear differential setup.
• Steering, brakes, and suspension: Four-wheel steering (4WS) bleeding, ABS hydraulic-unit tests, and ECS self-diagnosis.
• Body and cabin systems: Active Aero checks, Supplemental Restraint System (SRS) diagnostics, and manual and full-auto air-conditioning service.

The manual is suited to technicians and experienced rebuilders who have the specified test equipment and special tools. Mitsubishi reserves SRS-related service for authorized dealer personnel.

Engine Inspection and Timing Belt Work

The general section covers vehicle identification, safety certification labels, and separate FWD and AWD hoisting and towing procedures. Engine repair includes piston and connecting-rod service, cylinder-block measurements, valve-seat reconditioning, and tightening specifications for the cylinder head and crankshaft pulley.

During timing-belt installation, incorrect camshaft positioning can let the valves contact the pistons or each other. The manual identifies the timing marks and shows how to check the auto tensioner.

Fuel Injection, Turbochargers, and Cooling

Separate turbo and non-turbo MPI circuit diagrams, harness layouts, and injector waveforms help trace a fault to the wiring or the component before parts are replaced. The Multi-use Tester procedures cover live service data and actuator checks. The manual also covers turbocharger disassembly, wastegate actuator testing, non-turbo variable induction, emissions controls, and cruise control.

Cooling procedures cover the radiator fans, thermostat, and water pump. A coolant chart relates concentration and specific gravity to freezing point.

FWD Rebuilds and AWD Transaxle Limits

F5M33 procedures cover shafts, synchronizers, and differential inspection. F4A33 procedures include clutch packs, the oil pump, the valve body, oil-pressure tests, and a torque converter stall test. The hydraulic overview contains range diagrams labeled F4A21. The 3000GT automatic transaxle specifications identify the F4A33.

For the AWD W5MG1, the manual covers removal, installation, and designated replacement parts such as the center-shaft oil seal. It directs replacement of the assembly for other internal defects. Rear differential procedures include backlash, pinion preload, and tooth-contact pattern checks.

Chassis Tests and Body Controls

The 4WS chapter pairs bleeding with rear-pump flow and system function checks. ABS diagnosis includes wheel-speed sensor waveforms, and ECS diagnosis includes damping actuator tests and fail-safe charts. The body and climate sections cover ETACS-controlled door locks and wipers, Active Aero motor checks, and blower and damper service.

A Preview of Engine Clearances and Spark Plug Data

For the covered 6G72 DOHC engines, standard crankshaft main-bearing oil clearance is 0.019–0.044 mm (0.0007–0.0017 in.). Standard intake valve stem-to-guide clearance for cylinder-head inspection is 0.02–0.05 mm (0.0008–0.0020 in.).

The maintenance section lists a gap of 1.0–1.1 mm (0.039–0.043 in.) for the specified platinum spark plugs.