1991 Mitsubishi 3000GT / SL / VR-4 Service Manual, Volume 1: Engine, Chassis & Body

This Mitsubishi factory service manual covers the 1991 3000GT, 3000GT SL, and 3000GT VR-4 in the Z10 series, including FWD Non-Turbo and AWD Turbo configurations. Volume 1 covers Engine, Chassis & Body. The separate Volume 2 Electrical manual is not included.

• Engine repair: Engine removal, internal inspection and repair, cylinder-head service, timing-belt installation, and camshaft oil-seal replacement.

• Fuel and turbo systems: MPI fault diagnosis, injector and fuel-pressure testing, turbocharger service, wastegate checks, and Active Exhaust System troubleshooting.

• Transaxle service: FWD manual and automatic transaxle disassembly, inspection, and reassembly; hydraulic control testing; AWD unit removal and designated seal replacement.

• Driveline repair: Propeller shaft, front axle, rear axle, and drive shaft service, plus limited-slip differential inspection and final-drive adjustment.

• Chassis diagnostics: 4-Wheel Steering System (4WS) bleeding, ABS hydraulic-unit inspection, and Electronic Control Suspension (ECS) self-diagnosis and actuator tests.

• Body and cabin systems: ETACS diagnosis, Active Aero System checks, SRS diagnostics, and heater, manual A/C, and full-auto A/C service.

This manual is suited to technicians comfortable with internal mechanical repair and electrical fault tracing, with access to the specified test equipment and special tools.

Engine Repair and Service Preparation

General service information explains vehicle identification and safety certification labels, with separate FWD/AWD towing and hoisting guidance.

Internal engine work extends to piston and connecting-rod service, crankshaft bearing inspection, valve-seat reconditioning, and cylinder-block measurements. Engine sectional views and lubrication diagrams accompany the procedures, with tightening-torque specifications in Nm and ft-lbs for cylinder-head bolts, the crankshaft pulley, and other assemblies.

The timing-belt section warns that incorrect camshaft positioning can cause valve-to-piston or valve-to-valve contact and damage.

MPI Diagnosis, Turbochargers, and Cooling

Separate Turbo and Non-Turbo MPI circuit diagrams, harness and component layouts, injector oscilloscope waveforms, and sensor tests help distinguish wiring faults from failed components before replacement. Multi-use Tester procedures cover service-data readings and actuator tests.

Turbo coverage includes front and rear turbocharger removal, disassembly and reassembly, and wastegate actuator testing. Non-Turbo variable-induction checks, emissions-control tests, and Cruise Control System diagnosis are also covered.

Cooling procedures address radiator fans, the thermostat, and water-pump service. Maintenance tables cover the timing belt, oil filter, and cooling system, with coolant charts relating freezing point, concentration, and specific gravity.

FWD Transaxle Repair and AWD Service Limits

F5M33 repair includes input and output shafts, synchronizers, and differential inspection. F4A33 procedures extend to clutch packs, the oil pump, valve body, oil-pressure tests, and converter stall testing.

AWD limitation: W5MG1 coverage is limited to removal and installation and designated replacement parts. For other internal defects, the manual directs replacement of the transaxle assembly; it does not provide an internal W5MG1 rebuild procedure.

Rear-differential work includes gear backlash, pinion preload, and standard tooth-contact pattern charts. An AWD transaxle sectional view identifies the center differential and viscous coupling.

Steering, ABS, and Electronic Suspension

The 4WS section adds rear-pump flow and system-function checks to its bleeding procedures. It warns that trapped air can shorten steering-pump life.

Anti-lock Braking System (ABS) tests cover wheel-speed-sensor waveforms and hydraulic-unit operation. ECS circuit diagrams and fail-safe charts accompany damping-force actuator tests and control-function simulations.

Chassis service also covers suspension alignment, steering gear repair, power plant mounts, and wheel and tire inspection.

Body Controls, SRS, and Climate Systems

ETACS circuit tests address power windows, central door locking, and wipers. Active Aero System checks cover the front air dam and rear spoiler motors. SRS schematics support fault-code diagnosis and post-collision inspection.

Heater and ventilation procedures include blower and damper work. Separate manual and full-auto air-conditioning sections cover compressor service and circuit diagnosis.

Before heavy powertrain work, verify load capacities and follow the manual's lifting and SRS precautions to avoid accidental air bag deployment. The manual reserves SRS-related service for authorized Mitsubishi dealer personnel.

A Preview of Engine Clearances and Spark Plug Data

These examples are a small selection of the engine inspection and maintenance specifications in this manual.

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 is 0.02-0.05 mm (0.0008-0.0020 in.), used in cylinder-head inspection.

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

Text Search, Bookmarks, and PDF Contents

Search and circuit detail: Embedded OCR supports searches across the main chapters, although recognition errors can miss terms and identifiers. Chapter bookmarks are present; the external "Back to Navigator" link requires a separate file. Small connector numbers require zooming, and some ECS labels and circuit lines remain faint or broken.

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