16-1

ENGINE
ELECTRICAL
CONTENTS

CHARGING SYSTEM . . . . . . . . . . . . . . . . 2 IGNITION SYSTEM . . . . . . . . . . . . . . . . . 27

GENERAL INFORMATION . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . 27

SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 3 SERVICE SPECIFICATIONS . . . . . . . . . . . . . 28

SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . 28

ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 4 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . 29

Alternator Output Line Voltage Drop Test . . . . 4 Ignition Coil (With Built-in Power Transistor)
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Output Current Test . . . . . . . . . . . . . . . . . . . . . . . . 5
Spark Plug Check and Cleaning . . . . . . . . . 30
Regulated Voltage Test . . . . . . . . . . . . . . . . . . . . . 7
Camshaft Position Sensor Check . . . . . . . . . 30
Waveform Check Using An Analyzer . . . . . . . . 9
Crank Angle Sensor Check . . . . . . . . . . . . . . . 30
Alternator Relay Continuity Check . . . . . . . . . 10
Detonation Sensor Check . . . . . . . . . . . . . . . . 30
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 11
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . 31
STARTING SYSTEM . . . . . . . . . . . . . . . . 17
CRANK ANGLE SENSOR . . . . . . . . . . . . . . . 32
GENERAL INFORMATION . . . . . . . . . . . . . . . 17
CAMSHAFT POSITION SENSOR . . . . . . . . 32
SERVICE SPECIFICATIONS . . . . . . . . . . . . . 17
DETONATION SENSOR . . . . . . . . . . . . . . . . 33
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . 18
16-2 ENGINE ELECTRICAL – Charging System

CHARGING SYSTEM
GENERAL INFORMATION
The charging system uses the alternator output to
keep the battery charged at a constant level under
various electrical loads.

Voltage OPERATION
Rotation of the excited field coil generates AC voltage in the
stator.
This alternating current is rectified through diodes to DC voltage
having a waveform shown in the illustration at left. The average
Approx. 14.4 V output voltage fluctuates slightly with the alternator load
condition.

Time

When the ignition switch is turned on, current flows approx. 14.4 V, the field current is cut off. When
in the field coil and initial excitation of the field coil the battery voltage drops below the regulated
occurs. voltage, the voltage regulator regulates the output
When the stator coil begins to generate power after voltage to a constant level by controlling the field
the engine is started, the field coil is excited by current.
the output current of the stator coil. In addition, when the field current is constant, the
The alternator output voltage rises as the field alternator output voltage rises as the engine speed
current increases and it falls as the field current increases.
decreases. When the battery voltage (alternator S
terminal voltage) reaches a regulated voltage of

SYSTEM DIAGRAM

B
Stator coil

Engine-ECU

Field coil G
S
L +
Voltage
regulator FR Ignition
Charging switch Battery
warning lamp
–
 ENGINE ELECTRICAL – Charging System 16-3
ALTERNATOR SPECIFICATIONS
Items Specifications

Type Battery voltage sensing

Rated output V/A 12/100

Voltage regulator Electronic built-in type

SERVICE SPECIFICATIONS
Items Standard value Limit

Alternator output line voltage drop (at 30 A) V – Max. 0.3

Regulated voltage ambient – 20_C 14.2 – 15.4 –

temp at voltage regulator V
temp.
20_C 13.9 –14.9 –

60_C 13.4 – 14.6 –

80_C 13.1 – 14.5 –

Output current – 70% of normal output current

SPECIAL TOOL
Tool Number Name Use
MB991519 Alternator test Checking the alternator (S terminal voltage)
harness
16-4 ENGINE ELECTRICAL – Charging System

ON-VEHICLE SERVICE
ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST

+ –

Alternator Ammeter
Voltmeter

Battery
Terminal B + –

This test determines whether the wiring from the output wire. (Connect the (+) lead of the
alternator “B” terminal to the battery (+) terminal ammeter to the “B” terminal, and then connect
(including the fusible line) is in a good condition the (–) lead of the ammeter to the disconnected
or not. output wire.)
(1) Always be sure to check the following before NOTE
the test. An inductive-type ammeter which enables
D Alternator installation measurements to be taken without disconnect-
D Alternator drive belt tension ing the alternator output wire should be
D Fusible link recommended. Using this equipment will lessen
D Abnormal noise from the alternator while the possibility of a voltage drop caused by a
the engine is running loose “B” terminal connection.
(2) Turn the ignition switch to the LOCK (OFF)
position. (5) Connect a digital-type voltmeter between the
(3) Disconnect the negative battery cable. alternator “B” terminal and the battery (+)
(4) Disconnect the alternator output wire from the terminal. (Connect the (+) lead of the voltmeter
alternator “B” terminal and connect a DC test to the “B” terminal and the connect the (–) lead
ammeter with a range of 0–100 A in series of the voltmeter to the battery (+) cable.)
between the “B” terminal and the disconnected
 ENGINE ELECTRICAL – Charging System 16-5
(6) Reconnect the negative battery cable. (11)If the value displayed on the voltmeter is above
(7) Connect a tachometer or the MUT-II. the limit value, there is probably a malfunction
(8) Leave the hood open. in the alternator output wire, so check the wiring
(9) Start the engine. between the alternator “B” terminal and the
(10)With the engine running at 2,500 r/min, turn battery (+) terminal (including fusible link).
the headlamps and other lamps on and off to If a terminal is not sufficiently tight or if the
adjust the alternator load so that the value harness has become discolored due to
displayed on the ammeter is slightly above 30 overheating, repair and then test again.
A. (12)After the test, run the engine at idle.
Adjust the engine speed by gradually (13)Turn off all lamps and the ignition switch.
decreasing it until the value displayed on the (14)Remove the tachometer or the MUT-II.
ammeter is 30 A. Take a reading of the value (15)Disconnect the negative battery cable.
displayed on the voltmeter at this time. (16)Disconnect the ammeter and voltmeter.
Limit: max. 0.3 V (17)Connect the alternator output wire to the
alternator “B” terminal.
NOTE (18)Connect the negative battery cable.
When the alternator output is high and the value
displayed on the ammeter does not decrease
until 30 A, set the value to 40 A. Read the
value displayed on the voltmeter at this time.
When the value range is 40 A, the limit is max.
0.4 V.

OUTPUT CURRENT TEST

Load

Voltmeter
Ammeter
Charging warning lamp

Ignition switch

Alternator relay – + + –

B
FR
L
S
G
Battery
Alternator
Engine
-ECU
16-6 ENGINE ELECTRICAL – Charging System

This test determines whether the alternator output (10)Turn the light switch on to turn on headlamps
current is normal. and then start the engine.
(1) Before the test, always be sure to check the (11)Immediately after setting the headlamps to high
following. beam and turning the heater blower switch to
D Alternator installation the high revolution position, increase the engine
D Battery speed to 2,500 r/min and read the maximum
NOTE current output value displayed on the ammeter.
The battery should be slightly discharged. Limit: 70% of normal current output
The load needed by a fully-charged battery NOTE
is insufficient for an accurate test. D For the nominal current output, refer to the
D Alternator drive belt tension Alternator Specifications.
D Fusible link D Because the current from the battery will
D Abnormal noise from the alternator while soon drop after the engine is started, the
the engine is running. above step should be carried out as quickly
(2) Turn the ignition switch to the LOCK (OFF) as possible in order to obtain the maximum
position. current output value.
(3) Disconnect the negative battery cable. D The current output value will depend on
(4) Disconnect the alternator output wire from the the electrical load and the temperature of
alternator “B” terminal. Connect a DC test the alternator body.
ammeter with a range of 0–100 A in series D If the electrical load is small while testing,
between the “B” terminal and the disconnected the specified level of current may not be
output wire. (Connect the (+) lead of the output even though the alternator is normal.
ammeter to the “B” terminal. Connect the (–) In such cases, increase the electrical load
lead of the ammeter to the disconnected output by leaving the headlamps turned on for
wire.) some time to discharge the battery or by
Caution using the lighting system in another vehicle,
Never use clips but tighten bolts and nuts and then test again.
to connect the line. Otherwise loose D The specified level of current also may not
connections (e.g. using clips) will lead to be output if the temperature of the alternator
a serious accident because of high current. body or the ambient temperature is too high.
In such cases, cool the alternator and then
NOTE test again.
An inductive-type ammeter which enables (12)The reading on the ammeter should be above
measurements to be taken without disconnect- the limit value. If the reading is below the limit
ing the alternator output wire should be value and the alternator output wire is normal,
recommended. remove the alternator from the engine and check
(5) Connect a voltmeter with a range of 0–20 V the alternator.
between the alternator “B” terminal and the (13)Run the engine at idle after the test.
earth. (Connect the (+) lead of the voltmeter (14)Turn the ignition switch to the LOCK (OFF)
to the “B” terminal, and then connect the (–) position.
lead of the voltmeter to the earth.) (15)Remove the tachometer or the MUT-II.
(6) Connect the negative battery cable. (16)Disconnect the negative battery cable.
(7) Connect a tachometer or the MUT-II. (17)Disconnect the ammeter and voltmeter.
(8) Leave the hood open. (18)Connect the alternator output wire to the
(9) Check that the reading on the voltmeter is equal alternator “B” terminal.
to the battery voltage. (19)Connect the negative battery cable.
NOTE
If the voltage is 0 V, the cause is probably an
open circuit in the wire or fusible link between
the alternator “B” terminal and the battery (+)
terminal.
 ENGINE ELECTRICAL – Charging System 16-7
REGULATED VOLTAGE TEST

Load
Ignition Charging warning
switch lamp MB991519
Alternator

FR
Alternator relay L
S
G

Yellow
Engine-
ECU Ammeter

Voltmeter
Battery

– +
+ –
16-8 ENGINE ELECTRICAL – Charging System

This test determines whether the voltage regulator NOTE

is correctly controlling the alternator output voltage. If the voltage is 0 V, the cause is probably an
(1) Always be sure to check the following before open circuit in the wire or fusible link between
the test. the alternator “S” terminal and the battery (+)
D Alternator installation terminal.
D Check that the battery installed in the vehicle (10)Turn all lamps and accessories off.
is fully charged. (11)Start the engine.
D Alternator drive belt tension (12)Increase the engine speed to 2,500 r/min.
D Fusible link (13)Read the value displayed on the voltmeter when
D Abnormal noise from the alternator while the alternator output current alternator becomes
the engine is running 10 A or less.
(2) Turn the ignition switch to the LOCK (OFF) (14)If the voltage reading conforms to the value
position. in the voltage regulation, then the voltage
(3) Disconnect the negative battery cable. regulator is operating normally.
(4) Use the special tool (Alternator test harness: If the voltage is not within the standard value,
MB991519) to connect a digital voltmeter there is a malfunction of the voltage regulator
between the alternator S terminal and earth. or of the alternator.
(Connect the (+) lead of the voltmeter to the (15)After the test, lower the engine speed to the
“S” terminal, and then connect the (−) lead of idle speed.
the voltmeter to a secure earth or to the battery (16)Turn the ignition switch to the LOCK (OFF)
(−) terminal.) position.
(5) Disconnect the alternator output wire from the (17)Remove the tachometer or the MUT-II.
alternator “B” terminal. (18)Disconnect the negative battery cable.
(6) Connect a DC test ammeter with a range of (19)Disconnect the ammeter and voltmeter.
0–100 A in series between the “B” terminal (20)Connect the alternator output wire to the
and the disconnected output wire. (Connect the alternator “B” terminal.
(+) lead of the ammeter to the “B” terminal. (21)Remove the special tool, and return the
Connect the (–) lead of the ammeter to the connector to the original condition.
disconnected output wire.) (22)Connect the negative battery cable.
(7) Reconnect the negative battery cable.
(8) Connect a tachometer or the MUT-II.
(9) Turn the ignition switch to the ON position and
check that the reading on the voltmeter is equal
to the battery voltage.

Voltage Regulation Table

Standard value:
Inspection terminal Voltage regulator ambient temperature _C Voltage V

Terminal “S” – 20 14.2 – 15.4

20 13.9 – 14.9

60 13.4 – 14.6

80 13.1 – 14.5
 ENGINE ELECTRICAL – Charging System 16-9
Special WAVEFORM CHECK USING AN ANALYZER
patterns Analyzer
Alternator pickup
MEASUREMENT METHOD
Connect the analyzer special patterns pick-up to the alternator
B terminal.

B terminal

STANDARD WAVEFORM
Observation Conditions
FUNCTION SPECIAL PATTERNS

PATTERN HEIGHT VARIABLE

VARIABLE knob Adjust while viewing the wave-

form.

PATTERN SELECTOR RASTER

Engine speed Curb idle speed

0.4

0.2
Voltage at
alternator 0
B terminal
– 0.2

– 0.4

Time

NOTE
The voltage waveform of the alternator “B” terminal can
undulate as shown at left. This waveform is produced when
the regulator operates according to fluctuations in the alternator
load (current), and is normal for the alternator.
In addition, when the voltage waveform reaches an excessively
high value (approx. 2 V or higher at idle), it often indicates
an open circuit due to a brown fuse between alternator “B”
terminal and battery, but not a defective alternator.
16-10 ENGINE ELECTRICAL – Charging System

EXAMPLES OF ABNORMAL WAVEFORMS

NOTE
1. The size of the waveform patterns differs largely, depending on the adjustment of the variable knob
on the analyzer.
2. Identification of abnormal waveforms is easier when there is a large output current (regulator is not
operating). (Waveforms can be observed when the headlamps are illuminated.)
3. Check the conditions of the charging warning lamp (illuminated/not illuminated). Also, check the charging
system totally.
Abnormal waveforms Problem Abnormal waveforms Problem cause
cause
Example 1 Open diode Example 4 Short in stator
coil

Example 2 Short in diode Example 5 Open

supplementary
diode

Example 3 Broken wire

in stator coil

At this time, the charging warning lamp

is illuminated.

ALTERNATOR RELAY CONTINUITY CHECK

1. Remove the alternator relay from the relay box inside
the instrument panel.
2. Set the analogue-type circuit tester to the Ω range and
check that there is continuity when the (+) terminal of
the tester is connected to terminal 2 of the alternator relay
and the (–) terminal is connected to terminal 4.
Alternator
3. Next, check that there is no continuity when the (+) terminal
relay is connected to terminal 4 and the (–) terminal is connected
to terminal 2.
4. If the continuity checks in steps 2 and 3 show a defect,
replace the alternator relay.
2
1

4
3
 ENGINE ELECTRICAL – Charging System 16-11
ALTERNATOR
REMOVAL AND INSTALLATION
Pre-removal Operation Post-installation Operation
Under Cover Removal D Drive Belt Tension Adjustment
D Under Cover Installation

20 – 25 Nm 3

1
4
2

44 Nm
5

44 Nm

Disassembly steps
1. Drive belt (Power steering, A/C) 4. Alternator connector
2. Drive belt (Alternator) 5. Alternator
3. Alternator brace
16-12 ENGINE ELECTRICAL – Charging System

DISASSEMBLY AND REASSEMBLY

4
3

5
7 6

12
10
9

8
14

13

11

Disassembly steps
AA" 1. Front bracket assembly AC" 8. Stator
AB" 2. Alternator pulley 9. Plate
"BA 3. Rotor AC" "AA 10. Regulator assembly
4. Rear bearing 11. Brush
5. Bearing retainer 12. Slinger
6. Front bearing 13. Rectifier
7. Front bracket 14. Rear bracket
ENGINE ELECTRICAL – Charging System 16-13
DISASSEMBLY SERVICE POINTS
AA" FRONT BRACKET ASSEMBLY REMOVAL
Insert a flat tip screwdriver, etc., in the clearance between
the front bracket assembly and stator core, to pry open and
separate the stator and front bracket.
Caution
The stator coil could be damaged so do not insert the
screwdriver too far.

AB" ALTERNATOR PULLEY REMOVAL

Face the pulley side upward, fix the rotor with a work bench
and remove the pulley.
Caution
Use care so that the rotor is not damaged.

AC" STATOR/REGULATOR ASSEMBLY REMOVAL

Soldered
1. Use a soldering iron (180 to 250 W) to unsolder the stator.
This work should complete within approximately four
seconds to prevent heat from transferring to the diode.
2. When removing the rectifier from the regulator assembly,
remove the soldered sections of the rectifier.
Caution
(1) Use care to make sure that the heat of the soldering
iron is not transmitted to the diodes for a long
period.
(2) Use care that no undue force is exerted to the
lead wires of the diodes.
16-14 ENGINE ELECTRICAL – Charging System

REASSEMBLY SERVICE POINTS

Wire "AA REGULATOR ASSEMBLY INSTALLATION
After installing the regulator assembly, insert a wire into the
hole provided on the rear bracket while pressing in the brush
to fix the brush.
NOTE
The brush is fixed when a wire is inserted, making rotor
installation easier.

Rear bracket

Brush

Wire

"BA ROTOR INSTALLATION

Wire
After installing the rotor, remove the wire used to fix the brush.

INSPECTION
ROTOR CHECK
1. Check the continuity between the rotor coil slip rings, and
replace the rotor if the resistance value is not at the
standard value.
Standard value: 3 – 5 Ω

2. Check the continuity between the slip ring and core, and
if there is continuity, replace the rotor.
ENGINE ELECTRICAL – Charging System 16-15
STATOR CHECK
1. Check the continuity between the coil leads, and if there
is continuity, replace the stator.

2. Check the continuity between the coil and core, and if

there is continuity, replace the stator.

RECTIFIER CHECK
1. Inspect the (+) heat sink by checking the continuity between
the (+) heat sink and stator coil lead wire connection
terminal using a tester probe.
If there is a continuity at both, the diode is short circuited,
so replace the rectifier.

2. Inspect the (–) heat sink by checking the continuity between

the (–) heat sink and stator coil lead wire connection
terminal using a tester probe.
If there is a continuity at both, the diode is short circuited,
so replace the rectifier.

3. Check the diode trio by connecting an ohmmeter to both

ends of each diode and check the continuity of the three
diodes.
If there is a continuity at both ends, or if there is no
continuity, the diode is damaged so replace the rectifier.
16-16 ENGINE ELECTRICAL – Charging System

BRUSH CHECK
1. Measure the length of the brush protrusion shown in the
illustration, and replace the brush if the measured value
is below the limit value.
Protrusion Limit: 2 mm or less
length

Soldered 2. The brush can be removed if the solder of the brush lead
wire is removed.
3. When installing a new brush, insert the brush into the
holder as shown in the illustration, and then solder the
lead wires.
 ENGINE ELECTRICAL – Starting System 16-17

STARTING SYSTEM
GENERAL INFORMATION
If the ignition switch is turned to the “START” M-terminal to conduct. Thus, current flows to engage
position, current flows in the pull-in and holding coils the starter motor.
provided inside magnetic switch, attracting the When the ignition switch is returned to the “ON”
plunger. When the plunger is attracted, the lever position after starting the engine, the starter clutch
connected to the plunger is actuated to engage is disengaged from the ring gear.
the starter clutch. An overrunning clutch is provided between the pinion
On the other hand, attracting the plunger will turn and the armature shaft, to prevent damage to the
on the magnetic switch, allowing the B-terminal and starter.

SYSTEM DIAGRAM
Holding coil Plunger

Pull-in coil Lever

Over-running
clutch

Pinion shaft
Ignition
switch

Armature

Battery

Brush
Yoke

STARTER MOTOR SPECIFICATIONS

Items Specifications
Type Reduction drive with planetary gear
Rated output kW/V 1.2/12
No. of pinion teeth 8

SERVICE SPECIFICATIONS
Items Standard value Limit
Pinion gap mm 0.5 – 2.0 –
Commutator outer diameter mm 29.4 28.8
Commutator runout mm – 0.05
Commutator undercut mm 0.5 0.2
16-18 ENGINE ELECTRICAL – Starting System

STARTER MOTOR
Switch
S INSPECTION
B M PINION GAP ADJUSTMENT
1. Disconnect field coil wire from M-terminal of magnetic
Battery switch.
Field coil wire
2. Connect a 12-volt battery between S-terminal and
M-terminal.
3. Set switch to “ON”, and pinion will move out.
Caution
This test must be performed quickly (in less than 10
seconds) to prevent coil from burning.

4. Check pinion to stopper clearance (pinion gap) with a

thickness gauge.
Standard value: 0.5 – 2.0 mm

Stopper
Pinion gap

Pinion

5. If pinion gap is out of specification, adjust by adding or

removing gaskets between magnetic switch and front
bracket.
 ENGINE ELECTRICAL – Starting System 16-19
MAGNETIC SWITCH PULL-IN TEST
S 1. Disconnect field coil wire from M-terminal of magnetic
switch.
M 2. Connect a 12-volt battery between S-terminal and
Battery
M-terminal.
Caution
Field coil wire
This test must be performed quickly (in less than 10
seconds) to prevent coil from burning.
3. If pinion moves out, then pull-in coil is good. If it doesn’t,
replace magnetic switch.

MAGNETIC SWITCH HOLD-IN TEST

S 1. Disconnect field coil wire from M-terminal of magnetic
switch.
2. Connect a 12-volt battery between S-terminal and body.
Battery
Caution
This test must be performed quickly (in less than 10
Field coil wire seconds) to prevent coil from burning.
3. Manually pull out the pinion as far as the pinion stopper
position.
4. If pinion remains out, everything is in order. If pinion moves
in, hold-in circuit is open. Replace magnetic switch.

Carbon-pile rheostat FREE RUNNING TEST

1. Place starter motor in a vise equipped with soft jaws and
S connect a fully-charged 12-volt battery to starter motor
B M A as follows:
Ammeter 2. Connect a test ammeter (100-ampere scale) and carbon
Starter pile rheostat in series with battery positive post and starter
motor V
Battery motor terminal.
Voltmeter 3. Connect a voltmeter (15-volt scale) across starter motor.
4. Rotate carbon pile to full-resistance position.
5. Connect battery cable from battery negative post to starter
motor body.
6. Adjust the rheostat until the battery voltage shown by the
voltmeter is 11-volt.
7. Confirm that the maximum amperage is within the
specifications and that the starter motor turns smoothly
and freely.
Current: max. 90 A
16-20 ENGINE ELECTRICAL – Starting System

MAGNETIC SWITCH RETURN TEST

1. Disconnect field coil wire from M-terminal of magnetic
switch.
M 2. Connect a 12-volt battery between M-terminal and body.
Battery
Caution
This test must be performed quickly (in less than 10
Field coil wire
seconds) to prevent coil from burning.
3. Pull pinion out and release. If pinion quickly returns to
its original position, everything is in order. If it doesn’t,
replace magnetic switch.
Caution
Be careful not to get your fingers caught when pulling
out the pinion.
 ENGINE ELECTRICAL – Starting System 16-21
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Engine Cover and Under Cover Removal and
Installation
D Front Propeller Shaft Removal and Installation
(Refer to GROUP 25.)

1
26 – 33 Nm

5
11 10 – 12 Nm 8

7
28 Nm

34 Nm
10
4 10 – 12 Nm

6
34 Nm
9
26 – 33 Nm 10 – 12 Nm
3
26 – 33 Nm
5 Nm

2 5 Nm

Disassembly steps
1. Starter harness connection 7. Water pipe clamp
2. A/T oil pipe clamp 8. Injector harness connector
3. Earth cable connection connection
4. Intake manifold stay 9. Harness connector bracket
5. Oxygen sensor connector 10. Detonation sensor connector
connection connection
6. Front exhaust pipe connection AB" 11. Starter motor assembly
AA" "AA D Transmission mount crossmember
16-22 ENGINE ELECTRICAL – Starting System

REMOVAL SERVICE POINTS

AA" TRANSMISSION MOUNT CROSSMEMBER
REMOVAL
1. Remove the transmission mount crossmember. (Refer to
GROUP 32.)
2. Lower the jack holding the engine and transmission
assembly to create clearance enough to remove the starter
motor installation bolts.

AB" STARTER MOTOR ASSEMBLY REMOVAL

Pull the starter motor assembly out of space between the
intake manifold and cylinder block.

INSTALLATION SERVICE POINT

"AA TRANSMISSION MOUNT CROSSMEMBER
INSTALLATION
Refer to GROUP 32.
 ENGINE ELECTRICAL – Starting System 16-23
DISASSEMBLY AND REASSEMBLY

13
14
16

12 11
15

1 21
4

20
19
18
3
17
8 5
22 7

10

Disassembly steps
1. Screw 12. Packing A
AA" 2. Magnetic switch 13. Packing B
3. Screw 14. Plate
4. Through bolt 15. Planetary gear
5. Rear bracket 16. Lever
6. Brush holder AC" "AA 17. Snap ring
7. Brush AC" "AA 18. Stop ring
8. Rear bearing 19. Overrunning clutch
AB" 9. Armature 20. Internal gear
10. Yoke assembly 21. Planetary gear holder
AB" 11. Ball 22. Front bracket
16-24 ENGINE ELECTRICAL – Starting System

S-terminal
DISASSEMBLY SERVICE POINTS
Magnetic
switch AA" MAGNETIC SWITCH REMOVAL
M-terminal Disconnect the field coil wire from M-terminal of the magnetic
switch.
Field coil
wire

AB" ARMATURE AND BALL REMOVAL

When removing the armature, do not lose the ball placed
at the end as a bearing.

AC" SNAP RING/STOP RING REMOVAL

Socket 1. Using an appropriate wrench socket, push the stop ring
toward the overrunning clutch.
Stop ring
Pinion gear

Overrunning
clutch

2. Remove the snap ring with snap ring pliers and then remove
Snap ring pliers the stop ring and overrunning clutch.
Snap ring

Pinion gear

Over-
running
clutch

STARTER MOTOR PARTS CLEANING

1. Do not immerse the 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 the drive unit in cleaning solvent. The
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.
 ENGINE ELECTRICAL – Starting System 16-25
REASSEMBLY SERVICE POINTS
"AA STOP RING/SNAP RING INSTALLATION
Using an appropriate tool, pull the stop ring over the snap
ring.
Stop ring
Overrunning
Stop ring clutch

Snap ring

INSPECTION
COMMUTATOR
1. Place the armature in a pair of “V” blocks and check the
runout with a dial indicator.
Standard value: 0.05 mm
Limit: 0.1 mm

2. Measure the commutator outer diameter.

Standard value: 29.4 mm
Limit: 28.8 mm

3. Check the undercut depth between segments.

Undercut Standard value: 0.5 mm
Segment Limit: 0.2 mm
Mica

OVERRUNNING CLUTCH
1. Check that the pinion locks when it is turned anti-clockwise
and moves smoothly when it is turned clockwise.
2. Check the pinion for wear or damage.
Free

Lock
16-26 ENGINE ELECTRICAL – Starting System

BRUSH
1. Check the brush for roughness of the surface that contacts
the commutator and check the brush length.
Limit: Wear limit line
2. In case the contacting surface has been corrected or the
Wear limit line brush has been replaced, correct the contacting surface
by winding sandpaper around the commutator.

ARMATURE COIL SHORT-CIRCUIT TEST

Growler
1. Place armature in a growler.
2. Hold a thin steel blade parallel and just above while rotating
armature slowly in growler. A shorted armature will cause
blade to vibrate and be attracted to the core. Replace
shorted armature.
Caution
Clean the armature surface thoroughly before
checking.

3. Check the insulation between each commutator segment

and armature coil core.
If there is no continuity, the insulation is in order.

ARMATURE COIL OPEN-CIRCUIT INSPECTION

Check the continuity between segments. If there is continuity,
the coil is in order.
 ENGINE ELECTRICAL – Ignition System 16-27

IGNITION SYSTEM
GENERAL INFORMATION
This system is equipped with four ignition coils with The engine-ECU determines which ignition coil
built-in power transistors for each of the cylinders. should be controlled by means of the signals from
Interruption of the primary current flowing in the the camshaft position sensor and the crank angle
primary side of an ignition coil generates a high sensor. It also detects the crankshaft position, in
voltage in the secondary side of the ignition coil. order to provide ignition at the most appropriate
The high voltage thus generated is applied to the timing in response to the engine operation
spark plugs to generate sparks. conditions.
The engine-ECU turns the power transistors inside When the engine is cold or running at high altitudes,
the ignition coils alternately on and off. This causes the ignition timing is slightly advanced to provide
the primary currents in the ignition coils to be optimum performance. Furthermore, if knocking
alternately interrupted and allowed to flow to fire occurs, the ignition timing is gradually retarded until
the cylinders in the order 1 – 3 – 4 – 2. knocking ceases.

SYSTEM DIAGRAM

Ignition switch Battery

Air flow sensor
Barometric pressure sensor
Intake air temperature sensor
Engine coolant temperature
sensor
Accelerator pedal position
switch Engine-
Camshaft position sensor ECU
Crank angle sensor
Ignition switch-ST Ignition coil
Detonation sensor

Vehicle speed sensor

Inhibitor switch
Spark plug

A/T-ECU
Cylinder No. 1 2 3 4
To tachometer
16-28 ENGINE ELECTRICAL – Ignition System

IGNITION COIL SPECIFICATIONS

Items Specifications

Type Molded 4-coil

SPARK PLUG SPECIFICATIONS

Items Specifications

NGK IZFR6B

SERVICE SPECIFICATIONS
SPARK PLUG
Items Standard value Limit

Spark plug gap mm 0.5 – 0.6 0.75

Spark plug insulation resistance MΩ – 1

SPECIAL TOOL
Tool Number Name Use
MD998773 Detonation sensor Detonation sensor removal and installation
wrench
 ENGINE ELECTRICAL – Ignition System 16-29
ON-VEHICLE SERVICE
IGNITION COIL (WITH BUILT-IN POWER
TRANSISTOR) CHECK
Check by the following procedure, and replace if there is a
malfunction.

PRIMARY COIL AND POWER TRANSISTOR

CONTINUITY CHECK
1.5 V
+ – NOTE
1. An analogue-type circuit tester should be used.
2. Connect the negative (–) prove of the circuit tester to
– + terminal 1.
Caution
This test must be performed quickly (in less than 10
seconds) to prevent coil from burning and power transistor
from breakage.
Voltage:
g 1.5V Terminal No.
1 2 3
When current is
flowing

When current is
not flowing

SECONDARY COIL CHECK

NOTE
It is impossible to check the secondary coil through the
continuity check as a diode is integrated in the secondary
coil circuit of this ignition coil. So, check the secondary coil
in the following procedure.
1. Disconnect the ignition coil connector.
2. Remove the ignition coil and install a new spark plug to
the ignition coil.
3. Connect the ignition coil connector.
4. Earth the side electrode of the spark plug and crank the
engine.
5. Check that spark is produced between the electrodes of the
spark plug.
6. If no spark is produced, replace the ignition coil with a
new one and recheck.
7. If spark is produced with the new ignition coil, replace
the old one as it is faulty. If no spark is produced again,
the ignition circuit is suspected as faulty. Check the ignition
circuit.
16-30 ENGINE ELECTRICAL – Ignition System

SPARK PLUG CHECK AND CLEANING

CAUTION
1. Do not adjust the gap for iridium plugs.
2. The iridium tips may become damaged when iridium
plugs are cleaned. Accordingly, if the plugs are sooty
and need to be cleaned, use a plug cleaner in order
to protect the terminals, and do not clean for more
than 20 seconds. Tools such as wire brushes must
never be used.
3. The terminals of iridium plugs may become blackened,
even when the plugs are functioning normally.
However, the carbon which is deposited onto these
plugs burns off more easily than for conventional
spark plugs, so such blackening is not normally a
problem. Measure the insulation resistance of the
spark plug to judge if the plug is still usable or not.
(1) Check the plug gap, and replace the plug if the gap is
greater than the limit value.
Standard Valve : 0.5 – 0.6 mm
Limit : 0.75 mm

(2) Measure the insulation resistance of the spark plug, and

replace the plug if the resistance is below the limit value.
Limit : 1 MΩ

CAMSHAFT POSITION SENSOR CHECK

Refer to GROUP 13A – Troubleshooting.
CRANK ANGLE SENSOR CHECK
Refer to GROUP 13A – Troubleshooting.
DETONATION SENSOR CHECK
Check the detonation sensor circuit if self-diagnosis code,
No. 31 is shown.
NOTE
For information concerning the self-diagnosis codes, refer to
GROUP 13A – Troubleshooting .
 ENGINE ELECTRICAL – Ignition System 16-31
IGNITION COIL
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Engine Cover Removal and Installation
D Resonance Tank Removal and Installation
(Refer to GROUP 15.)
D Air Cleaner Assembly and Air Intake Hose Removal
and Installation

10 Nm
2

25 Nm

Disassembly steps
1. Ignition Coil Connector
2. Ignition Coil
3. Spark Plug
16-32 ENGINE ELECTRICAL – Ignition System

CRANK ANGLE SENSOR

REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Timing Belt Front Lower Cover Removal and Installation
(Refer to GROUP 11.)

Crank angle sensor

9 Nm

CAMSHAFT POSITION SENSOR

REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Engine Cover Removal and Installation

9 Nm

Camshaft
position
sensor
 ENGINE ELECTRICAL – Ignition System 16-33
DETONATION SENSOR
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Engine Cover Removal and Installation

10 – 12 Nm

20 – 25 Nm

10 – 12 Nm

Disassembly steps
1. Water pipe clamp
AA" "AA 2. Detonation sensor

REMOVAL SERVICE POINT

AA" DETONATION SENSOR REMOVAL

INSTALLATION SERVICE POINT

"AA DETONATION SENSOR INSTALLATION

MD998773
NOTES