1991 Mitsubishi 3000GT Service Repair Workshop Manual Download PDF

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🏷️ Basic Information Identification Make: Mitsubishi Model: 3000GT Year: 1991 Codes Internal Model Code: Z16A (for Twin Turbo) 👋 Introduction Market Position Positioning: A premium, technologically advanced Japanese sports car...

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Stichworte: 1991 3000GT Car Cars Misc Mitsubishi

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🏷️ Basic Information

Identification

Make:

Mitsubishi

Model:

3000GT

Year:

Codes

Internal Model Code:

Z16A (for Twin Turbo)

👋 Introduction

Market Position

Positioning:

A premium, technologically advanced Japanese sports car of its era, aiming to compete with European exotics

Competitive Analysis

Competitors:

Dodge Stealth (rebadged 3000GT), Nissan 300ZX (Z32), Toyota Supra (Mk3 and early Mk4), Mazda RX-7 (FC and FD), Porsche 944, Chevrolet Corvette (C4)

Key Features

Aerodynamics:

Sophisticated active aerodynamics system including an active front spoiler and an active rear wing for improved high-speed stability and drag reduction

Drivetrain:

Available in front-wheel drive (FWD) and all-wheel drive (AWD) configurations, with the AWD models featuring a sophisticated viscous coupling center differential and optional active yaw control (later models)

Engine Layout:

Longitudinal engine placement in a compact V6 configuration

Technology:

Early adoption of advanced technologies like four-wheel steering (4WS) on some models, electronic controlled suspension (ECS), and sophisticated engine management

📋 Manual Details

Coverage Areas

Coverage Scope:

Comprehensive factory service and repair

Page Count

Estimated Page Count:

Over 2000 pages (typical for full factory service manuals)

Manual Type

Type:

Factory Service Manual / Workshop Manual

Language

Language:

English

Format

Format:

Downloadable PDF

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, cylinder head, crankshaft, pistons, connecting rods, timing system, lubrication system, cooling system, fuel injection, emissions control

Engine Performance:

Turbocharger system, intercooler system, boost control, ignition system, exhaust system

Transmission Manual:

Manual transmission (Getrag 5-speed F5M33) - assembly, disassembly, internal components, shift mechanism

Transmission Automatic:

Automatic transmission (INVECS-II 4-speed) - assembly, disassembly, hydraulic control, electronic control unit (ECU) interface, torque converter

Drivetrain:

Front-wheel drive (FWD) and All-wheel drive (AWD) systems, transfer case, propeller shaft, drive shafts, CV joints, differential (front and rear)

Suspension:

Front suspension (MacPherson strut), Rear suspension (Multi-link), dampers, springs, bushings, anti-roll bars, Active Aerodynamics (active front spoiler, active rear wing)

Brakes:

Front and rear disc brakes, ABS (Anti-lock Braking System) components and diagnostics, brake calipers, rotors, hydraulic lines, parking brake

Steering:

Power steering system, steering gear, steering column, wheel alignment specifications

Electrical System:

Battery, charging system (alternator), starting system (starter), lighting system (headlights, taillights, interior), fuse boxes, relays, wiring diagrams, multiplex communication system

Engine Control System:

ECU (Engine Control Unit) functions, sensors (MAP, TPS, O2, ECT, CKP, CMP), actuators (injectors, ignition coils), diagnostic trouble codes (DTCs), emission control systems (EGR, EVAP)

Body Exterior:

Body panel removal and installation, doors, hood, trunk lid, bumpers, glass, seals, Active Aerodynamics system components

Body Interior:

Dashboard, seats, interior trim panels, HVAC system (heating, ventilation, air conditioning), audio system, airbags (SRS system components and servicing - *caution advised*)

Climate Control:

AC compressor, refrigerant system, heater core, evaporator, controls, diagnosis

Procedures Included

Scheduled Maintenance:

Oil change intervals, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement

Routine Inspections:

Visual checks of suspension, brakes, exhaust, belts, hoses, and electrical components

Engine Repair:

Complete engine rebuild procedures, piston ring replacement, bearing replacement, valve seat grinding, camshaft installation

Transmission Repair:

Manual and automatic transmission overhaul and repair, clutch replacement (manual), torque converter replacement (automatic)

Suspension Component Replacement:

Strut and shock absorber replacement, control arm bushings, ball joint replacement, power steering pump and rack replacement

Brake Service:

Brake pad and rotor replacement, brake fluid flush and bleeding, ABS system troubleshooting and component replacement

Electrical Diagnostics:

Wiring harness testing, sensor diagnosis, actuator testing, use of diagnostic tools, troubleshooting electrical faults using diagrams

Troubleshooting:

Systematic diagnostic procedures for common drivability issues, starting problems, overheating, electrical faults, and performance anomalies

Fuel System Service:

Fuel injector cleaning and replacement, fuel pump testing, fuel filter replacement, fuel pressure testing

Cooling System Service:

Radiator replacement, water pump replacement, thermostat replacement, coolant flush and refill

Air Conditioning Service:

Refrigerant recharge, leak detection, component replacement (compressor, condenser, evaporator)

Wheel Alignment:

Front and rear wheel alignment specifications and procedures

Body Repair:

Panel replacement, dent repair, frame straightening (with relevant data)

Active Aerodynamics Servicing:

Inspection, adjustment, and potential repair of the active front spoiler and active rear wing systems

Technical Depth

Depth:

Factory-level diagnostic and repair information

Diagnostic Capabilities:

Includes diagnostic trouble codes (DTCs), sensor data interpretation, and component testing procedures

Repair Procedures:

Detailed step-by-step instructions for disassembly, assembly, and repair of all major systems

Specifications:

Torque specifications for all fasteners, tolerances, clearances, fluid capacities, pressure specifications, electrical resistances

Diagrams And Illustrations:

Abundant technical illustrations, exploded views, and wiring diagrams

📊 Manual Specifications

File Format

Format:

Searchability:

Likely text-searchable (depending on PDF conversion quality)

Print Quality

Quality:

High-resolution for clear reproduction of diagrams and text

Binding Type

Binding:

N/A (Downloadable PDF)

Paper Type

Paper Type:

N/A (Downloadable PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code:

Configuration:

60-degree V6, SOHC (non-turbo) / DOHC (twin-turbo)

Displacement:

3.0 Liters (2972 cc)

Performance

Horsepower Non Turbo:

220 hp @ 6000 rpm (approx.)

Torque Non Turbo:

200 lb-ft @ 4500 rpm (approx.)

Horsepower Twin Turbo:

300 hp @ 6000 rpm (approx.)

Torque Twin Turbo:

307 lb-ft @ 4500 rpm (approx.)

Fuel System

Induction:

Multi-point Fuel Injection (MPI), Twin Turbochargers with intercoolers (Twin Turbo models)

Fuel Type:

Unleaded Premium Unleaded Gasoline

Timing

Timing Belt Replacement Interval:

Every 60,000 - 90,000 miles or 5-7 years (refer to manual for exact interval based on condition)

Lubrication

Oil Capacity:

4.5 Liters (4.8 US Quarts) with filter (approx., refer to manual)

Recommended Oil Viscosity:

10W-30 or 10W-40 (refer to manual for specific climate/usage recommendations)

🔧 Transmission

Standard

Transmission Type:

Getrag 5-speed Manual Transmission (F5M33)

Optional

Transmission Type:

INVECS-II 4-speed Automatic Transmission

Features

All Wheel Drive:

Available on Twin Turbo models, featuring a viscous coupling center differential and front Torsen LSD (on some later AWD models)

All Wheel Steering:

Available on select models (AWS - Active Four Wheel Steering)

Fluid Capacity Manual

Fluid Type:

GL-4 or GL-5 Gear Oil (API rating, refer to manual for specific viscosity)

Capacity:

2.3 Liters (2.4 US Quarts) (approx., refer to manual)

Fluid Capacity Automatic

Fluid Type:

Mitsubishi Genuine ATF-SPII or equivalent

Capacity:

7.0 Liters (7.4 US Quarts) for full refill (approx., refer to manual)

📐 Dimensions

Exterior

Length:

4,605 mm (181.3 in)

Width:

1,839 mm (72.4 in)

Height:

1,250 mm (49.2 in) (Twin Turbo)

Wheelbase:

2,500 mm (98.4 in)

Weights

Curb Weight Non Turbo:

1,550 kg (3,417 lbs) (approx.)

Curb Weight Twin Turbo AWD:

1,720 kg (3,792 lbs) (approx.)

Wheels Tires

Wheel Size:

17 x 8.0 inches

Tire Size Non Turbo:

225/55R17

Tire Size Twin Turbo:

245/40R17

Bolt Pattern:

5 x 114.3 mm (5 x 4.5 inches)

Offset:

+46 (approx., refer to manual)

🛡️ Safety Features

Ratings

Crash Test Ratings:

Limited data available for 1991 models in official ratings; advanced for its time in passive safety design.

Active Features

Standard Anti-lock Braking System (ABS) on all models

Optional Active Four Wheel Steering (AWS) system on certain trims for improved agility and stability

Passive Features

Airbags:

Driver's side airbag standard. Passenger airbag not standard in 1991.

Body Structure:

Reinforced safety cell, crumple zones

Seat Belts:

Three-point front seat belts with pretensioners

💡 Technology Features

Infotainment

Audio System:

Factory radio with cassette player, optional CD player, multiple speaker configurations.

Driver Assistance

Active Aerodynamics:

Active front spoiler retracts at low speeds and extends at higher speeds for aerodynamic efficiency and downforce. Active rear wing adjusts angle for optimal downforce.

Active Four Wheel Steering:

AWS system steers the rear wheels in conjunction with the front wheels, improving low-speed maneuverability and high-speed stability. (AWS system details covered in manual).

Electronic Controlled Suspension:

ECS allowed driver selection between Comfort and Sport modes, adjusting damping rates of the shock absorbers. (System details and servicing covered).

Connectivity

Multiplex Communication:

Early adoption of multiplex wiring systems for certain functions, reducing wire harness complexity. (Diagrams and troubleshooting for this are crucial).

🔧 Maintenance

Service Intervals

Engine Oil And Filter:

Every 3,750 - 7,500 miles or 6-12 months (refer to manual for specific driving conditions)

Transmission Fluid Change Manual:

Every 30,000 - 60,000 miles (refer to manual)

Transmission Fluid Change Automatic:

Every 30,000 - 45,000 miles (refer to manual)

Coolant Flush:

Every 30,000 - 50,000 miles or 2-3 years

Brake Fluid Flush:

Every 24,000 - 36,000 miles or 2 years

Fluid Specifications

Power Steering Fluid:

Dexron II or equivalent ATF (refer to manual for exact type)

Brake Fluid:

DOT 3 or DOT 4 (refer to manual for specific recommendation)

Known Issues

Engine:

Potential for oil leaks (valve cover gaskets, oil pan gaskets), spark plug blowout on early DOHC non-turbo models, turbocharger wear on high-mileage twin-turbo models.

Transmission:

Synchro wear in manual transmissions, potential for automatic transmission solenoid failure or torque converter issues.

Suspension:

ECS system failure (leaking struts/shocks), worn control arm bushings, potential for CV joint wear.

Electrical:

Corroded grounds, failing fuel pump relays, aging wiring harness components, HVAC blower motor resistor failure.

Active Aerodynamics:

Failure of motors for the active spoiler and wing, potential for control module issues.

📚 Vehicle History

Brand Heritage

Mitsubishi Motors:

Mitsubishi has a long history in motorsport and performance vehicle development, with predecessors like the Starion and Galant VR-4 laying groundwork for advanced AWD and turbocharged technology.

Model Evolution

Generation Introduction:

First generation launched in 1991, known as the Mitsubishi GTO in Japan and Mitsubishi 3000GT/Dodge Stealth in North America.

1991 Model Year:

Introduction of the flagship sports coupe. Key features included the V6 engine, optional AWD and AWS, and the technologically advanced active aerodynamics system on higher trims.

Production

Manufacturing Location:

Japan

🏆 Awards & Recognition

Recognitions

Car And Driver Ten Best:

The 1991 3000GT VR-4 was named to Car and Driver's 10Best list for 1991.

Motor Trend Car Of The Year:

Competed for MotorTrend Car of the Year, showcasing its technological advancements.