Clutch MITSUBISHI 3000GT 1996 2.G Owner's Manual

Downloaded from www.Manualslib.com manuals search engine 16-26ENGINE ELECTRICAL - Starting System
DISASSEMBLY AND REASSEMBLY
I<EXCEPT FROM 1994 CALIFORNIA VERSION>
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Disassembly steps
1.Screw;. f$gnntic switch
4:Screw5.Rear bracket6.Brush holder7.Brush8.Rear bearing
4Ab9.Armature;;. paF assembly
4A, .
12.Packing A13.Packing B14.Plate=I:. ;an$ary gear
+B, .A+ 17: Snap ring4B, .A+ 18. Stop ring19.Overrunning clutch20.Internal gear21. Planetary gear holder22.Front bracket
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Downloaded from www.Manualslib.com manuals search engine ENGINE ELECTRICAL - Starting System16-27
<FROM 1994 CALIFORNIA VERSION>
27EN0628
1'0
Disassembly steps
1.Screw2.Magnetic switch3.Screw4.Starter cover5.Rear bracket6.Brush holder7.Brush8.Bush4A,9.Armature;y. Fap assembly
4A, .
12.Packing A13.Packing B
14.Plate
15.Planetary gear16.Lever4B, .A4 17. Snap ring4B, .A4 18. Stop ring19.Overrunning clutch20.Internal gear21. Planetary gear holder22.Front bracketDISASSEMBLY SERVICE POINTS
+A,ARMATURE / BALL REMOVAL
Caution
When removing the armature, be careful not to lose
the ball (which is used as a bearing) in the armature
end.
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Downloaded from www.Manualslib.com manuals search engine 16-28ENGINE ELECTRICAL - Starting System
Stop ringZ6EL0097
Z6ELOO96+B,SNAP
RING / STOP RING REMOVAL
(1) Press the stop ring, by using an appropriate socket,wrench, to the snap ring side.
(2)After removing the snap ring (by using snap-ring pliers),
remove the stop ring and the overrunning clutch.STARTER MOTOR PARTS CLEANING
1.Do not immerse parts in cleaning solvent. Immersing the
yoke and field coil assembly and/or armature will damage
insulation. Wipe these parts with a cloth only.
2.Do not immerse drive unit in cleaning solvent. Overrunning
clutch is pre-lubricated at the factory and solvent will wash
lubrication from clutch.3. The drive unit may be cleaned with a brush moistened
with cleaning solvent and wiped dry with a cloth.
REASSEMBLY SERVICE POINT
,A+TOP RING / SNAP RING INSTALLATION
Using a suitable pulling tool, pull overrunning clutch stop
ring over snap ring.INSPECTION
COMMUTATOR INSPECTION
(1) Place the armature on a pair of V-blocks, and check thedeflection by using a dial gauge.
Standard value: 0.05 mm (JO20 in.)
Limit: 0.1 mm
(.004 in.)
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Downloaded from www.Manualslib.com manuals search engine ENGINE ELECTRICAL - Starting System16-29
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UndercutI
(2) Check the outer diameter of the commutator.
Standard value: 29.4 mm (1.158 in.)
Limit: 28.4 mm (1.118 in.)(3) Check the depth of the undercut between segments.
Standard value: 0.5 mm (.020 in.)
BRUSH HOLDER
Check for continuity between brush holder plate and brush
holder.
The normal condition is non-continuity.
OVERRUNNING CLUTCH
1.While holding clutch housing, rotate the pinion. Drive pinionshould rotate smoothly in one direction, but should not
rotate in opposite direction. If clutch does not function
properly, replace overrunning clutch assembly.
2.Inspect pinion for wear or burrs. If pinion is worn or burred,
replace overrunning clutch assembly. If pinion is damaged,also inspect ring gear for wear or burrs.
FRONT AND REAR BRACKET BUSHING
Inspect bushing for wear or burrs. If bushing is worn or burred,
replace front bracket assembly or rear bracket assembly.
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Downloaded from www.Manualslib.com manuals search engine LJ
/
:i:CHASSIS ELECTRICAL
- Meters and Gauges54-23
IGNISWI?
2B-k
2B-k
2B-k
r
2B-Y
(A-67)
2B-Y
jTARTING
SUPPLEMENTALl@TE"#'NT
IONH(ST)
B-YI
z(c-31)17-1
4B-Y I1 /
f
/STARTER--------__;RELAYsPOFFINjm
CLUTCH
PEDAL
&j+$HON
1.25B-Y
IMFI SYSTEM
IGNITIONSWITCH(IG1)I
CHARGING
J/B
s(c-71)
0.85B-W
Y
s(D-44)
0.85B-W
lmDIODE
1.25B-Yu(Y-G)Y-G0
D-10Y-G
66
A COMBINATIONMETER90(D-04)
HRlOMOIAB
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Downloaded from www.Manualslib.com manuals search engine 54-26CHASSIS ELECTRICAL - Meters and Gauges
<Rear wheels on free rollers>
Free
r&Hers -
Sear wheels raised on jack>
?qi&%!g
Rigid rack oooo2297
Anchor plate
-w216AO864
bracket
/IZ16FO13300002298ON-VEHICLE
SERVICEINSPECTION
SPEEDOMETER CHECK
(1) Assure tire pressure at standard value. (Refer to GROUP
- Specifications.)
(2)Gt the vehicle on a speedometer tester.
(3)Set free rollers securely on the floor according to the wheel-base and rear tread of the vehicle (when rear wheels
are to be set on free rollers).
(4) Raise the rear wheels on a jack and place rigid racks
to support the specified positions of the side sills (whenrear wheels are to be raised on a jack).
(5) Make sure the parking brake has been set.
cPWD>
(6)Attach anchoring bars on the tie-down brackets and secure
their ends to the anchor plates.(7) Make sure the tension on the right and left bars is the
same. Also be sure there is enough tension on each bar.(8) Attach a chain or wire to the rear tie-down hole. Make
sure the end of the wire or chain is secured firmly.
(9) Take all other necessary precautions.
(1O)Use a speedometer tester to measure the speedometer’s
indication error.
Standard value:
Standard indication
mph
Allowable range mph
2019-22
4038-44
8057-66
1 801 76-88--I
1 100
Caution
1 94-110
Do not operate the clutch or accelerator abruptly or
decelerate during the operations.
d
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Downloaded from www.Manualslib.com manuals search engine 54-164CHASSIS ELECTRICAL - Radio and Tape Player
A-6There is noise when starting the engine.
Noise type
Sounds are in pa-
rentheses ( ).
AM, FM:
Ignition noise
(Popping, Snap-
ping,Cracking,
Buzzing)
Otherelectrical
components
Static electricity
(Cracking, Crin-
kling)
Conditions
0Increasing the engine speedcausing the popping sound tospeed up, and volume de-creases.0Disappears when the ignitionswitch is turned to ACC.
-
lDisappears when the vehicle is
completely stopped.Occurs when parts or wir-
Severe when the clutch is en-ing move for some reasonlgaged.and contact metal parts of
the body.
lVarious noises are produced de-pending on the body part of thevehicle.
Due to detachment from
the body of the front hood,
bumpers, exhaust pipe
and muffler, suspension,
etc.
Causel
Mainly due to the
spark plugs.l Due to the enginenoise.
Noise may appear as
electrical components be-
come older.
Parts to be Location of
inspectedparts
or remedy(next page)
Noise con- 1
denser
Ground
cable2, 3
Repair or replace electricalcomponents.
Return parts or wiring to
their proper position.
Caution
1.Connecting a high tension cable to the noise
filter may destroy the noise filter and shouldnever be done.
2.Check that there is no external noise. Since
failure to do this may result in misdiagnosis
due to inability to identify the noise source,
this operation must be performed.3. Noise prevention should be performed by
suppressing strong sources of noise step
by step.
NOTE
1. Condenser
The condenser does not pass D.C. current, butas the number of waves increases when it
passes A.C. current, impedance (resistanceagainst A.C.) decreases, and current flow is
facilitated. A noise suppressing condenser
which takes advantage of this property is in-
serted between the power line for the noise
source and the ground. This suppresses noiseby grounding the noise component (A.C. or
pulse signal) to the body of the vehicle.
2. Coil
The coil passes D.C. current, but impedance
rises as the number of waves increases relativeto the A.C. current. A noise suppressing coil
which takes advantage of this property is in-
serted into the power line for the noise source,
and works by preventing the noise componentfrom flowing or radiating out of the line.
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Ground parts by bonding.
Cases where the problem
is not eliminated by a single
response to one area are
common, due to several
bodypartsbeing
imperfectly grounded.

Downloaded from www.Manualslib.com manuals search engine 54-216CHASSIS ELECTRICAL - Theft-alarm System
CIRCUIT DIAGRAM (CONTINUED)
KEYLIGHTi#+#ERAUTOMATIC
SHUT-OFF UNIT
7vI A/T hM/T
1B-LI
7
IGNITIONSWITCHCST)
2%-Y0B-Y
Y-B
M/T ! A/T
i-B
t
;-B ;)LG-E
I
CLUTCH
PEDAL
POSITION
N SWITCH
I(c-64)
2B-Y
2B-Y
I ,
O.05B-Y
A/T i M/T
MFI SYSTEMMFI SYSTEM
BATTERYlm0.85B-R
20B-R
oF;;;fBil?&&R ii'k'AL ^i
-----J;B (c-66)ygYE
R-B%B-LB B
I@ /I
164 5 EA
o , ~ ,o~~~A A
A
DATA LINK CONNECTOR
00
I
(A-09X)(A-66)0 E-22)EiQ(c-02)(c-31)(c-56)cm
El q
(c-65)(c-66)OFRONT SIDE
HR15M02BA
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Downloaded from www.Manualslib.com manuals search engine CHASSIS ELECTRICAL - Theft-alarm System54-223
Trouble symptom
Cause
Check method
Remedy
There is no alarm when, as analarm test, the hood is openedDamaged or disconnected
wiring of hood switch input
If input checks
Repairthe harness or re-
from within the vehicle.circuit.
(P.54-220) indicate aplace the hood switch.
(The alarm is activated, however,malfunction, check by
I
by opening a door or the liftgate.)using check chartMalfunction of the hood p.54-225.
switch.
Malfunction of the ECU.
-Replace the ECU.
Engine would not start [EngineThere is a short-circuit of
starting is possible when the the starter relay activationCheck by using check
chart P.54-234.
Repair the harness.
starter relay is in the switched-off
circuit
(normally closed) condition, with
the clutch switch in the switch-off
and the ECU harness connector
disconnected.]
When, as a test of the alarm, aDamaged or disconnectedCheck by using check
door or the
liftgate is opened wiring of headlight power chart P.54-231, 232.
Repairthe harness or re-
without using the key, orthe hood
is opened from within the vehicle,supply circuit or headlightplace the diode Ds.
activation circuitReplace the headlight
the horn and the theft-alarm hornrelay or the headlight.sound but the headlights don’t
flash. (The headlights can, how-
ever, be switched. ON by usingMa
lfunction of the ECUReplace the ECU.
the passing switch.)The headlights flash during an
alarm test but the horn orthe theftDamaged or disconnectedCheck by using checkRepair the harness.
alarm horn does not sound.wiring of horn relay power
chart P.54-229,230,231.supply circuit or horn ac-Replace the horn.
tivation circuitReplace dedicated fuse
Damaged or disconnectedNo. (6) or the fusible linkwiring of the theft-alarmNo. (6).horn relay power supply
circuit or the theft-alarm
horn activation circuit.
Malfunction of the ECU.
Replace the ECU.The system is not deactivated
nhen, during an alarm test in
Damaged or disconnected
If input checks
which the alarm is intentionallywiring of door key cylinder
Repair the harness.activated, the door or
liftgate isand
liftgate unlock switch(P.54-220) indicate a
input circuitmalfunction, check byReplace the key cylinder
Jnlocked by using the key.
using check chartswitch or the
liftgate
switch.
:The system also cannot be dis-P.54-227,228.
armed.)
Malfunction of door keycyl-inder and liftgate unlock
switch.
Malfunction of the ECU
Replace the ECU.
ECU: Electronic Control Unit
NOTEIf the
lifigate unlock switch or door key cylinder unlock switch is operated roughly, or if these switches have
been installed incorrectly or switches themselves are defective the ECU may not accept the warning or alarmcancelling signal. In such case, the alarm operation will take place when the door is opened using a key.
[When the door key cylinder switch has been shorted, however, if the ignition switch is turned ON, the ECU
judges the detection-switch as faulty and thereafter, it will prevent setting of (warning) alarm until the shorting
is corrected.]
If the
liftgate is opened using a key and is left opened when the door key cylinder switch system has a trouble
(wiring harness damage, open circuit, etc.), the ECU judges it as the
liftgate holding mode and does not producealarm even when the door is opened.
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Downloaded from www.Manualslib.com manuals search engine 54-234CHASSIS ELECTRICAL - Theft-alarm System
15. STARTER RELAY ACTIVATION CIRCUIT
lgnlllonKey reminderBattery
switch (STIswtch
B-23l-
Starter motor
Lo03 52“:
&Y
. ..--N. OYa.’ ‘pa3
PI/l i M/T
Theft-
alarm
starter
relay
IC-56
A1
ECUm
PANWNEUTNLl. PONlTlON WITCH:1(prom 1993 NODEL)
:2cm2 N@nEL>216Fcas
Description of operationThe ECU transistor is turned ON if the vehicle door etc. are opened without use of the key. This turns
OFF the starter relay and power ceases to be supplied to the starter magnet switch.
Checking the starter relay activation circuit (Disconnect the connector of the ECU, depress fully the clutch
pedal and activate the starter relay)
SW
1
t
2Check object
Starter relay terminal voltage
(2-Ground)
Startermotor terminal
(1 -Ground)I
Normal
condition
12v
12v
:
Malfunc-
tion
ov
ov
Cause
Malfunction of the starter
relay
Harness damaged or dis-
connected:
Remedy
Check the starter relay
Repair the harness
(Starter motor connector B-24: Separation)
3Continuity between “B-24” 0
Q-clDamaged magnet switchReplace magnet switch
connector and ground
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