service MITSUBISHI 3000GT 1996 2.G Workshop Manual

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i Service Manual
3000~l-
1992-l 996
Volume
2
Electrical
FOREWORD
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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 diagnossis,
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.
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A
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WESUF’FORTVOLUNTARY TECHNICIAN
CERTiFiCATlON THROUGH
National lnaltute forAUTOMOTIV ESERVICEEXCELLENC E
Mitsubishi Motors Corporation reserves the right to make changesin design or to make additions to or improvements in its products withou\
timposing any obligations upon itself to install them on its productspreviously manufactured.
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GROUP / SECTION INDEX
General. . . . . . . . . . . . . . . . . . . . . . . .
Fusible Link, Fuse an d IOD or
Storage Connector Locatio n
. . . . . . . . . .w
Inspection Terminal Location . . . . . . . . .
Grounding Location . . . . . . . . . . . . . . . . . .w
m
Relay Location . . . . . . . . . . . . . . . . . . . . . -m
Sensor Locatio
n. . . . . . . . . . . . . -. . . . . . .w
Control Unit Location . . . . . . . . . . . . . . . . .m
Solenoid, Solenoid Valve Location . . . . .d
Diode Location . . . . . . . . . . . . . . -. . . . . . .w
Junction Block . . . . . . . . . . . . . . . . . . . . . . .II
Centralized Junction . . . . . . . . . #. . . . . . .w
Harness Connector Inspectio n. I . . . . . .w
How to Diagnose . . . . . . . . . . . . . -. . . . . . .
111
Configuration Diagrams . . . . . . . . . . . - . .m;
Circuit Diagrams . . . ..*.............
Engine Electrical ...............
ChassisElectrical
............ .
Alphabetical Index .............
NOTE:
For information concerning all compo-
nents other than the electrical system and
on-vehicle service procedures for engines
and transmissions, refer to Volume 1
“Chassis & Body” of this paired Service
Manual.
For overhaul procedures of engines or
transmission, refer to the separately is-
sued Engine Service Manual or Manual/
Automatic Transmission Service Manual.
@ 1995 Mitsubishi Motors CorporationReprinted in USA

Downloaded from www.Manualslib.com manuals search engine CIRCUIT DIAGRAMS - Supplemental Restraint System (SRS) Circuit375
IGNISWIT
28-I
@10A
(c-77)
0.85B-

0.85B-k
015A
.6(c-71)
0.85B-WV
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B-
5
0.858-
-W
1
W
1
CONNECTOR 'LOCK SWITCH----
1
COMBINATION
0. 85
8
(c-79)&I
DATA LINKCONNECTOR
.--- ---------_I2019
0.85BI
f----f, gzt
I
ICAUT I ONT
‘&y;;’6read and observe the SRS SERVCE PRECAUTIONSlRefer to GROUP 52B- qrecautions)Ofior to any service.
HR15M17AB
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ENGINE
ELECTRICALCONTENTS
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CHARGING SYSTEM . . . . . . . . . . . . . . .2
GENERATOR. . . . ..*.............-.......12
ON-VEHICLE SERVICE.....................
6
Generator Output Line Voltage Drop Test.......6
Output Current Test..........................7
Regulated Voltage Test.......................9
Wave-form Check Using An Analyzer.........10
SPECIFICATIONS.........................2
General Specifications........................2
Service Specifications........................2
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . .3
IGNITION SYSTEM . . . . . . . . . . . . . . . .31
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . .45
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . .36
Camshaft Position Sensor
Check. . . . . . . . . .Refer to GROUP 13A
(ON-VEHICLE INSPECTION
OF
MFI COMPONENTS)Crankshaft Position Sensor
Check. . _ . . . . . . .Refer to GROUP 13A
(ON-VEHICLE INSPECTION
OF MFI COMPONENTS)
Ignition Primary Voltage Wave-form
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Ignition Secondary Voltage Wave-form
Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .._.37
Ignition Timing Adjustment . . . Refer to GROUP 11
Spark Plug Cable Test . . . . . . . . . . . . . . . . . . . . .36
Spark Plug Test . . . . . . . . . . . . . . . . . . . . . . . . . . .36
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . .31
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . .31
General Specifications . . . . . . . . . . . . . . . . . . . *. .31
Service Specifications . . . . . . . . . . . . . . . . . . . . . .31
TROUBLESHOOTING.....................32STARTING SYSTEM...............
19
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . .19~
General Specifications . . . . . . . . . . . . . . . . . . . . . .19
Service Specifications . . . . . . . . . . . . . . . . . . . . . .19
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . 23~
TROUBLESHOOTING . . . . . .-a.. . . . . . . . . . . . .20
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Downloaded from www.Manualslib.com manuals search engine ENGINE ELECTRICAL - Charging Svstem
CHARGING SYSTEM
SPECIFICATIONSGENERAL SPECIFICATIONS
GENERATOR
ItemsUp to 1995 modelsFrom 1996 models
TypeBattery voltage sensingBattery voltage sensing
Rated output
VIA12fllO12l95
1 Voltage regulator1 Electronic type1 Electronic typeSERVICE SPECIFICATIONS
GENERATOR
IItems1 Standard value 1 LimitI
I Regulated voltage
Ambient temp. at voltage
rkgulator V
1 -2O’C (-4°F) ( 14.2-15.41 -I
20°C (68°F)13.9-l 4.9 -
60°C (140°F)13.4-14.6 -IIIII
1 80°C (176°F)1 13.1-14.5I-
1 Slip ring O.D.mm (in.)1 26.7 (1.05)/ 26.1 (1.03)I
IField coil resistanceQ1 Approx. 3-5
I-I
I Output currentI-/ 70% of nominal output currentI
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Downloaded from www.Manualslib.com manuals search engine 16-6ENGINE ELECTRICAL - Charging System
ON-VEHICLE SERVICEGENERATOR OUTPUT LINE VOLTAGE DROP TEST
+I I.=-@=
Voltmeter
This test determines whether the wiring from thegenerator
“B” terminal to the battery (+) terminal
(including the fusible link) is in a good condition
or not.(1) Always be sure to check the following before
the test.l Generator installation
l Generator drive belt tension (Refer to
GROUP 00 - Maintenance Service.)l Fusible link
l Abnormal noise from the generator while
the engine is running
(2) Turn the ignition switch to the OFF position.
(3) Disconnect the negative battery cable.
(4) Disconnect the generator output wire from the
generator
‘73” terminal and connect a DC testammeter with a range of 0
- 100 A in series
between the “B” terminal and the disconnected
output wire. (Connect the
(+) lead of the amme-ter to the
‘73” terminal, and then connect the
Battery
6EN0962(-) lead of the ammeter to the disconnected
output wire.)
NOTE
A clamp-type ammeter which enables measure-
ments to be taken without disconnecting thegenerator output wire is recommended. The
reason for this is if a vehicle in which the voltage
may have dropped due to an imperfect connec-tion at the generator
“B” terminal is being in-
spected, and the generator “B” terminal is loos-
ened when the test ammeter is connected, the
connection will be completed at this time andthe possibility of finding problems will be re-
duced.
(5) Connect a digital-type voltmeter between thegenerator
“B” terminal and the battery (+)
terminal. (Connect the (+) lead of the voltmeterto the “B” terminal, and then connect the
(-)
lead of the voltmeter to the battery (+) cable.)
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(6) Connect a tachometer. (For the procedure for
connecting the tachometer, refer to GROUP
- On-vehicle Service.)(7)
kkconnect the negative battery cable.
(8) Leave the hood open.
(9) Start the engine.
(lO)With the engine running at 2500 rpm, turn the
headlights and other lights on and off to adjust
the generator load so that the value displayed
on the ammeter is slightly above 30A.Limit value: Max. 0.3 V
NOTE
When the generator output is high and the value
displayed on the ammeter does not decreaseto
30A, set the value to 40A. Read the value
displayed on the voltmeter at this time.
In this case the limit value becomes max. 0.4V.
Adjust the engine speed by gradually decreas-
ing it until the value displayed on the ammeterOUTPUT CURRENT TEST
is 30A. Take a reading of the value displayed
on the voltmeter at this time.
(11) If the value displayed on the voltmeter is above
the limit value, there is probably a malfunction
in the generator output wire, so check the wiring
between the generator
“IS” terminal and the bat-tery
(+) terminal (including fusible link).
If a terminal is not sufficiently tight or if the har-
ness has become discolored due to overheating,
repair and then test again.(12)After the test, run the engine at idle.
(13)Turn off all lights and turn the ignition switch
to the OFF position.
(14)Disconnect the negative battery cable.
(15)Disconnect the ammeter, voltmeter and tachom-
eter.
(16)Connect the generator output wire to the genera-
tor “B” terminal.
(17)Connect the negative battery cable.
Charging indicatorGenerator
30A
Voltmeter
BatteryAmmeter
t
-Load
6EN0893
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Downloaded from www.Manualslib.com manuals search engine 16-8ENGINE ELECTRICAL - Charging System
This test determines whether the generator outputs
normal current.(1) Before the test, always be sure to check the
following.l Generator installation
l
Battery (Refer to GROUP 54 - Battery.)
NOTE
The battery to be used should be slightly dis-charged. The load in a fully-charged battery
will be insufficient and the test may not be able
to be carried out correctly.l Generator drive belt tension (Refer to
GROUP 11- On-vehicle Service.)l Fusible link
l Abnormal noise from the generator while
the engine is running(2) Turn the ignition switch to the OFF position.
(3) Disconnect the negative battery cable.
(4) Disconnect the generator output wire from the
generator
“B” terminal and connect a DC testammeter with a range of O-100 A in series
between the “B” terminal and the disconnected
output wire. (Connect the
(+) lead of the amme-ter to the
“B” terminal, and then connect the(-) lead of the ammeter to the disconnected
output wire.)
Caution
Never use clips but tighten bolts and nutsto connect the line.
Otherwise loose
connections (e.g. using clips) will lead to
a serious accident because of high current.
NOTE
A clamp-type ammeter which enables measure-
ments to be taken without disconnecting the
generator output wire is recommended.(5) Connect a voltmeter with a range of 0
- 20
V between the generator “B” terminal and the
ground. (Connect the
(+) lead of the voltmeterto the “B” terminal, and then connect the (-)
lead of the voltmeter to the ground.)
(6) Connect a tachometer. (For the procedure forconnecting the tachometer, refer to GROUP
11 - On-vehicle Service.)
(7) Connect the negative battery cable.
(8) Leave the hood open.(9) Check to be sure that the reading on the
voltmeter is equal to the battery voltage.
NOTE
If the voltage is 0 V, the cause is probably an
open circuit in the wire or fusible link between
the generator “B” terminal and the battery
(+)
terminal.
(1O)After turning the light switch on and turning on
the headlights, start the engine.
(1l)lmmediately after setting the headlights to high
beam and turning the heater blower switch to
the high revolution position, increase the enginespeed to 2,500
r/min and read the maximum
current output value displayed on the ammeter.
Limit value: 70% of nominal current output
NOTEl
For the nominal current output, refer to the
Generator Specifications.l
Because the current from the battery will
soon drop after the engine is started, the
above step should be carried out as quickly
as possible in order to obtain the maximum
current output value.l The current output value will depend on
the electrical load and the temperature of
the generator body.l
If the electrical load is small while testing,the specified level of current may not be
output even though the generator is normal.
In such cases, increase the electrical load
by leaving the headlights turned on for sometime to discharge the battery or by using
the lighting system in another vehicle, and
then test again.l
The specified level of current also may not
be output if the temperature of the generator
body or the ambient temperature is too high.
In such cases, cool the generator and then
test again.
(12)The reading on the ammeter should be above
the limit value. If the reading is below the limit
value and the generator output wire is normal,
remove the generator from the engine and check
the generator.(13)Run the engine at idle speed after the test.
(14)Turn the ignition switch to the OFF position.
(15)Disconnect the negative battery cable.
(16)Disconnect the ammeter, voltmeter and
tachometer.(17)Connect the generator output wire to the
generator “B” terminal.
(18)Connect the negative battery cable.
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Downloaded from www.Manualslib.com manuals search engine ENGINE ELECTRICAL - Charging Svstem16-9REGULATED VOLTAGE TEST
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Ignitionswitch (IGl)Generator
This test determines whether the voltage regulator
is correctly controlling the generator output voltage.
(1) Always be sure to check the following before
the test.l Generator installation
lCheck to be sure that the battery installedin the vehicle is fully charged. (Refer to
GROUP 54 - Battery.)l Generator drive belt tension (Refer to
GROUP 00 - Maintenance Service.)l Fusible link
l Abnormal noise from the generator while
the engine is running(2) Turn the ignition switch to the OFF position.
(3) Disconnect the negative battery cable.
(4) Connect a digital-type voltmeter between the
generator “S” terminal and the ground. (Connect
the
(+) lead of the voltmeter to the “s” terminal,
and then connect the (-) lead of the voltmeter
to a secure ground or to the battery (-) terminal.)
(5) Disconnect the generator output wire from the
generator
“B” terminal.(6) Connect a DC test ammeter with a range of
O-100A in series between the “B” terminal andthe disconnected output wire. (Connect the
(+) lead of the ammeter to the “B” terminal,
and then connect the (-) lead of the ammeter
to the disconnected output wire.)
(7) Connect a tachometer. (Refer to GROUP 11
- On-vehicle Service.)
(8) Reconnect the negative battery cable.
VOLTAGE REGULATION TABLE
Ammeter
- Load
6EN1029
(9) Turn the ignition switch to the ON position and
check that the reading on the voltmeter is equal
to the battery voltage.
NOTE
If the voltage is 0 V, the cause is probably an
open circuit in the wire or fusible link between
the generator
“S” terminal and the battery (+)
terminal.
(1O)Check to be sure that all lights and accessories
are off.
(11) Start the engine.(12)lncrease the engine speed to 2,500
r/min.
(13)Read the value displayed on the voltmeter when
the current output by the generator becomes
10A or less.
(14)lf the voltage reading conforms to the value
in the voltage regulation table, then the voltage
regulator is operating normally.If the voltage is outside the standard value,
there is a malfunction of the voltage regulator
or of the generator.
(15)After the test, lower the engine speed to the
idle speed.
(16)Turn the ignition switch to the “OFF” position.
(17)Disconnect the negative battery cable.
(18)Disconnect the ammeter, voltmeter and
tachometer.(19)Connect the generator output wire to the
generator “B” terminal.
(20)Connect the negative battery cable.
Inspection
terminal
Terminal “S”
Voltage regula-Standard value Inspection
torambient (V)terminal
temperature
(“C PI)-20 (-4)14.2-15.4
Terminal “S”
20 (68)13.9-14.9
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Voltage regula- Standard value
torambient (V)
temperature(“c
PI)
60 (140)13.4-14.5
80 (176)13.1-14.5
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Downloaded from www.Manualslib.com manuals search engine 16-12ENGINE ELECTRICAL - Charging System
GENERATORREMOVAL AND INSTALLATION
Pre-removal and Post-installation Operationl Removal and Installation of Right Bank Warm Up
Three-Way Catalytic Converter(Refer to GROUP 15-Exhaust Pipe, Main Mufflerand Catalytic Converter.)14-18ft.lbs.
l b
Removal steps
1. Air hose E 2. Air hose C
3. Suction hose clamo nuts
conditioning,4. Drive belt
(Refer to GROUP 11
-Engine Adjustment.)
216FO346
5. Generator connector
6. Heated oxygen sensor connector
7. Generator and generator bracket
assembly8. Generator bracket
9. Generator
lo-12 Nm7-9 ft.lbs.24 NmREMOVAL SERVICE POINT
dAbCLAMP NUT REMOVAL
On vehicles with an air conditioning, remove the clamp
nut, raise the suction hose and suspend it from the engine
hood using a cord.
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Downloaded from www.Manualslib.com manuals search engine 16-14ENGINE ELECTRICAL - Charging System
(From 1996 models)
Disassembly steps
+A,,A+ :: ~%? assembly3.Rear bearing4.Bearing retainer5.Front bearing6.Front bracket
45,7.Stator assembly
13
TEN0906
8. Plate9. Regulator and brush holder
10. Brush
11. Slinger
12. Rectifier assembly
13. Rear bracket
IDISASSEMBLY SERVICE POINT
dAbGENERATOR PULLEY REMOVAL
(1) Remove the bolts.
(2) Insert plain screwdriver between front bracket and
stator core and pry downward.
Caution
Do not insert screwdriver too deep, as there is
danger of damage to
stator coil.
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