16-1

GROUP 16

ENGINE
ELECTRICAL
CONTENTS

CHARGING SYSTEM . . . . . . . . 16-2 IGNITION SYSTEM . . . . . . . . . 16-32

GENERAL DESCRIPTION . . . . . . 16-2 GENERAL DESCRIPTION . . . . . . . 16-32

SPECIAL TOOL . . . . . . . . . . . . . . . 16-3 SPECIAL TOOL . . . . . . . . . . . . . . . 16-33

CHARGING SYSTEM DIAGNOSIS 16-4 ON-VEHICLE SERVICE . . . . . . . . . 16-33

IGNITION COIL CHECK . . . . . . . . . . . . 16-33
ON-VEHICLE SERVICE. . . . . . . . . 16-7 SPARK PLUG CABLE RESISTANCE
GENERATOR OUTPUT LINE VOLTAGE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 16-34
DROP TEST . . . . . . . . . . . . . . . . . . . . . 16-7 SPARK PLUG CHECK AND
OUTPUT CURRENT TEST . . . . . . . . . . 16-8 CLEANING . . . . . . . . . . . . . . . . . . . . . . 16-35
REGULATED VOLTAGE TEST . . . . . . . 16-10 CAMSHAFT POSITION SENSOR CHECK 16-35
WAVE PATTERN CHECK USING AN CRANK ANGLE SENSOR CHECK . . . . 16-35
OSCILLOSCOPE. . . . . . . . . . . . . . . . . . 16-11 IGNITION SECONDARY VOLTAGE
WAVE PATTERN CHECK USING AN
GENERATOR ASSEMBLY . . . . . . 16-14 OSCILLOSCOPE . . . . . . . . . . . . . . . . . . 16-35
REMOVAL AND INSTALLATION . . . . . 16-14
DISASSEMBLY AND ASSEMBLY. . . . . 16-16 IGNITION COIL. . . . . . . . . . . . . . . . 16-39
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-18 REMOVAL AND INSTALLATION. . . . . . 16-39
STARTING SYSTEM . . . . . . . . . 16-21 CAMSHAFT POSITION SENSOR . 16-39
REMOVAL AND INSTALLATION. . . . . . 16-39
GENERAL DESCRIPTION . . . . . . 16-21
CRANKSHAFT POSITION SENSOR 16-40
DIAGNOSIS . . . . . . . . . . . . . . . . . . 16-22 REMOVAL AND INSTALLATION. . . . . . 16-40

ON-VEHICLE SERVICE. . . . . . . . . 16-23 KNOCK SENSOR . . . . . . . . . . . . . . 16-41

STARTER RELAY CHECK . . . . . . . . . . 16-23 REMOVAL AND INSTALLATION. . . . . . 16-41

STARTER MOTOR ASSEMBLY . . 16-24 SPECIFICATIONS . . . . . . . . . . 16-42

REMOVAL AND INSTALLATION . . . . . 16-24
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-24 FASTENER TIGHTENING
DISASSEMBLY AND ASSEMBLY. . . . . 16-27 SPECIFICATIONS . . . . . . . . . . . . . 16-42
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-29
GENERAL SPECIFICATIONS . . . . 16-43

SERVICE SPECIFICATIONS . . . . . 16-43

16-2 ENGINE ELECTRICAL
CHARGING SYSTEM

CHARGING SYSTEM
GENERAL DESCRIPTION
M1161000100254
The charging system charges the battery with output
from the generator to keep the battery charged at a
constant level during varying electrical loads.
Operation
When the ignition switch is turned to the "ON" posi-
VOLTAGE tion, current flows in the field coil and initial excitation
of the field coil occurs.
When the stator coil begins to generate power after
APPROXIMATELY
the engine is started, the field coil is excited by the
14.4 V output current of the stator coil.
Generator output voltage rises as the field current
increases and falls as the field current decreases.
When the battery positive voltage (generator S termi-
TIME
AKX00183 AB
nal voltage) reaches a regulated voltage of approxi-
mately 14.4 V, the field current is cut off. When the
Rotation of the excited field coil generates AC volt- battery positive voltage drops below the regulated
age in the stator. voltage, the voltage regulator regulates the output
This alternating current is rectified through diodes to voltage to a constant level by controlling the field cur-
DC voltage having a waveform shown in the illustra- rent.
tion above. In addition, when the field current is constant, the
The average output voltage fluctuates slightly with generator output voltage rises as the engine speed
the generator load condition. increases.

GENERATOR

B
STATOR
COIL

ECM

FIELD COIL S
L
+

FR IGNITION
SWITCH BATTERY
VOLTAGE REGULATOR CHARGING
WARNING
LIGHT –

AK100054AE

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 ENGINE ELECTRICAL
CHARGING SYSTEM
16-3
SPECIAL TOOL
M1161000600204

TOOL TOOL NUMBER AND SUPERSESSION APPLICATION

NAME
MB991502 MB991496-OD Checking of engine idle
Scan tool (MUT-II) speed

B991502

MB991958 Checking of engine idle

A A: MB991824 speed
B: MB991827
C: MB991910
D: MB991911
MB991824
E: MB991914
F: MB991825
B G: MB991826
MUT-III sub assembly
A: Vehicle Communication
Interface (V.C.I.)
MB991827
B: MUT-III USB Cable
C C: MUT-III Main Harness
A (Vehicles with CAN
communication system)
D: MUT-III Main Harness
MB991910 B (Vehicles without CAN
D
communication system)
E: MUT-III Main Harness
C (for Chrysler models
only)
F: MUT-III Adapter
MB991911
Harness
E G: MUT-III Trigger
Harness

MB991914

MB991825

MB991826
MB991958

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16-4 ENGINE ELECTRICAL
CHARGING SYSTEM

TOOL TOOL NUMBER AND SUPERSESSION APPLICATION

NAME
MB991519 Tool not available Checking of generator (S
Generator harness terminal voltage)
connector

CHARGING SYSTEM DIAGNOSIS

M1161000700193

TROUBLESHOOTING HINTS
1. Charging warning light does not come on when the ignition
switch is turned to "ON" position, before the engine starts.
• Check the bulb.
2. Charging warning light does not switch off after the engine
starts.
• Check the IC voltage regulator inside the generator.
3. Discharged or overcharged battery.
• Check the IC voltage regulator inside the generator.
4. The charging warning light illuminates dimly.
• Check the diode (inside the combination meter or genera-
tor) for a short-circuit.

TROUBLESHOOTING GUIDE
The charging system troubleshooting guide is shown in the fol-
lowing chart.

STEP 1.
Q: Is the battery in good condition? (Refer to GROUP 54A,
Battery − On-vehicle Service − Battery Check P.54A-3.)
YES : Go to Step 2.
NO : Charge or replace the battery.

STEP 2.
Q: Is the generator drive belt in good condition? (Refer to
GROUP 00, Maintenance Service − Drive Belts P.00-37.)
YES : Go to Step 3.
NO : Adjust the belt tension or replace the belt.

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 ENGINE ELECTRICAL
CHARGING SYSTEM
16-5

STEP 3.
Q: Does the charging system warning light turn on brightly
when the ignition switch is turned to the "ON" position?
YES : Go to Step 4.
NO : • Check the ignition switch. (Refer to GROUP 54A,
Ignition switch − Inspection P.54A-53.)
• Check for burnt-out charging system warning light
bulb.
• Check the generator. (Refer to Generator −
Disassembly and assembly − Inspection P.16-18.)
• Check the charging system warning light-related
circuits.

STEP 4.
Q: Does the charging warning light go out after starting the
engine?
YES : Go to Step 5.
NO : Check the generator (Refer to Generator −
Disassembly and assembly − Inspection P.16-18.)

STEP 5.
Q: Is an oscilloscope available?
YES : Go to Step 6.
NO : Go to Step 7.

STEP 6.
Q: Does the oscilloscope show a normal wave pattern?
(Refer to Charging system − Wave pattern check using a
oscilloscope P.16-11.)
YES : Go to Step 7.
NO : Check the generator. (Refer to Generator −
Disassembly and assembly − Inspection P.16-18.)

STEP 7.
• Engine: 2,500 r/min
• Headlight: ON (high beam)
• Voltage between generator "B" terminal and the positive
battery terminal
OK: 0.5 V or less
• Voltage between the negative battery terminal and genera-
tor body
OK: 0.5 V or less
Q: Are the generator output line and ground line in good
condition?
YES : Go to Step 8.
NO : • Check the generator output line.
• Check the generator ground line.

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16-6 ENGINE ELECTRICAL
CHARGING SYSTEM

STEP 8.
Q: Is the output current normal? (Refer to Charging system
− On vehicle service − Output current test P.16-8.)
YES : Go to Step 9.
NO : Check the generator (Refer to Generator −
Disassembly and assembly − Inspection P.16-18.)

STEP 9.
Q: Is the regulated voltage normal? (Refer to Charging
system − On vehicle service − Regulated voltage test
P.16-10.)
YES : Go to Step 10.
NO : Check the generator (Refer to Generator −
Disassembly and assembly − Inspection P.16-18.)

STEP 10.
Q: Is the voltage drops in the generator output line
normal? (Refer to Charging system − On vehicle servise
− Generator output line voltage drop test P.16-7.)
YES : Generator is normal. Check other systems.
NO : Check the output line.

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 ENGINE ELECTRICAL
CHARGING SYSTEM
16-7
ON-VEHICLE SERVICE
GENERATOR OUTPUT LINE VOLTAGE DROP TEST
M1161000900227

AMMETER
GENERATOR (CLAMP-TYPE)

VOLTMETER
(DIGITAL-TYPE)

BATTERY
"B" TERMINAL

AK203361AC

Required Special Tools: NOTE: The way of disconnecting the generator

• MB991502: Scan Tool (MUT-II) output wire and of connecting the ammeter is pos-
• MB991958: Scan Tool (MUT-III Sub Assembly) sibly not found the problem that the output current
• MB991824: V.C.I. is dropping due to the insufficient connection
• MB991827: USB Cable between terminal "B" and the output wire.
• MB991911: Main Harness B 5. Connect a digital-type voltmeter between the
This test determines whether the wiring from the generator "B" terminal and the positive battery
generator "B" terminal to the positive battery terminal terminal. (Connect the positive lead of the
(including the fusible link) is in good condition or not: voltmeter to the "B" terminal, and then connect the
WARNING negative lead of the voltmeter to the positive
Battery posts, terminals and related acces- battery cable.)
sories contain lead and lead compounds. 6. Reconnect the negative battery cable.
WASH HANDS AFTER HANDLING. 7. Connect an engine tachometer, scan tool
1. Always be sure to check the following before the MB991502 or MB991958.
test. 8. Leave the hood open.
• Generator installation 9. Start the engine.
• Generator drive belt tension (Refer to GROUP
10.With the engine running at 2,500 r/min, turn the
00, Maintenance Service − Drive Belts P.00-37.)
headlights and other lights on and off to adjust the
• Fusible link
generator load so that the value displayed on the
• Abnormal noise from the generator while the
ammeter is slightly above 30 A.
engine is running.
2. Turn the ignition switch to the "LOCK" (OFF) Read the voltmeter. Voltage reading at or below
position. limit value means voltage drop between generator
and battery is OK.
3. Disconnect the negative battery cable.
Limit value: maximum 0.3 V
4. Connect a clamp-type DC test ammeter with a
range of 0 − 100 A to the generator "B" terminal NOTE: When the generator output is high and the
output wire. value displayed on the ammeter does not
decrease to 30 A, set the value to 40 A. Read the
value displayed on the voltmeter at this time.

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16-8 ENGINE ELECTRICAL
CHARGING SYSTEM

In this case the limit value becomes maximum 0.4 If a terminal is not sufficiently tight or if the
V. harness has become discolored due to
Adjust the engine speed by gradually decreasing overheating, repair and then test again.
it until the value displayed on the ammeter is 30 12.After the test, run the engine at idle.
A. Take a reading of the value displayed on the
13.Turn off all lights and turn the ignition switch to the
voltmeter at this time.
"LOCK" (OFF) position.
11.If the value displayed on the voltmeter is above
14.Disconnect the engine tachometer, scan tool
the limit value, there is probably a malfunction in
MB991502 or MB991958.
the generator output wire. Check the wiring
between the generator "B" terminal and the 15.Disconnect the negative battery cable.
positive battery terminal (including fusible link). 16.Disconnect the ammeter and voltmeter.
17.Connect the negative battery cable.
18.Run the engine for 10 minutes at an idle.
OUTPUT CURRENT TEST
M1161001000216

LOAD

AMMETER
VOLTMETER (CLAMP-TYPE)

– +

IGNITION CHARGING
SWITCH INDICATOR

B
FR

BRAKE WARNING LIGHT L

S
G

GENERATOR

ECM

BATTERY

AK203362 AF

Required Special Tools: WARNING

• MB991502: Scan Tool (MUT-II) Battery posts, terminals and related acces-
• MB991958: Scan Tool (MUT-III Sub Assembly) sories contain lead and lead compounds.
• MB991824: V.C.I.
WASH HANDS AFTER HANDLING.
• MB991827: USB Cable
• MB991911: Main Harness B 1. Before the test, always be sure to check the
This test determines whether the generator outputs following.
normal current. For best results, use a charging sys- • Generator installation
tem tester. If not available, follow the steps below. • Battery (Refer to GROUP 54A, Battery − On-
vehicle Service − Battery Check P.54A-3.)

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 ENGINE ELECTRICAL
CHARGING SYSTEM
16-9
NOTE: The battery to be used should be slightly 11.Immediately after setting the headlights to high
discharged. The load in a fully-charged battery beam and turning the heater blower switch to the
will be insufficient and the test may not be able to highest position, increase the engine speed to
be carried out correctly. 2,500 r/min and read the maximum current output
• Generator drive belt tension (Refer to GROUP value displayed on the ammeter.
00, Maintenance Service − Drive Belts P.00-37.) Limit value: 70 % of nominal current output
• Fusible link
NOTE: For the nominal current output, refer to the
• Abnormal noise from the generator while the
Generator Specifications.
engine is running.
2. Turn the ignition switch to the "LOCK" (OFF) NOTE: The current output value will depend on
position. the electrical load and the temperature of the gen-
erator body.
3. Disconnect the negative battery cable.
NOTE: If the electrical load is small while testing,
WARNING the specified level of current may not be output
Never use clips to connect the line. Loose even though the generator is normal. In such
connections (for example, using clips) will cases, increase the electrical load by leaving the
lead to a serious accident because of high headlights turned on for some time to discharge
current. the battery or by using the lighting system in
4. Connect a clamp-type DC test ammeter with a another vehicle, and then test again.
range of 0 − 100 A to the generator "B" terminal NOTE: The specified level of current also may not
output wire. be output if the temperature of the generator body
5. Connect a voltmeter with a range of 0 − 20 V or the ambient temperature is too high. In such
between the generator "B" terminal and ground. cases, cool the generator and then test again.
(Connect the positive lead of the voltmeter to the 12.The reading on the ammeter should be above the
"B" terminal, and then connect the negative lead limit value. If the reading is below the limit value
of the voltmeter to ground.) and the generator output wire is normal, remove
6. Connect the negative battery cable. the generator from the engine and check the
generator.
7. Connect an engine tachometer, scan tool
MB991502 or MB991958. 13.Run the engine at idle speed after the test.
8. Leave the hood open. 14.Turn the ignition switch to the "LOCK" (OFF)
position.
9. Check to be sure that the reading on the voltmeter
is equal to the battery positive voltage. 15.Disconnect the engine tachometer, scan tool
MB991502 or MB991958.
NOTE: If the voltage is 0 V, the cause is probably
an open circuit in the wire or fusible link between 16.Disconnect the negative battery cable.
the generator "B" terminal and the battery positive 17.Disconnect the ammeter and voltmeter .
terminal or malfunctioning voltmeter. 18.Connect the negative battery cable.
10.After turning on the headlights, start the engine. 19.Run the engine for 10 minutes at an idle.
NOTE: Because the current from the battery will
soon drop after the engine is started, step 11
should be carried out as quickly as possible in
order to obtain the maximum current output value.

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16-10 ENGINE ELECTRICAL
CHARGING SYSTEM

REGULATED VOLTAGE TEST

M1161001100224

LOAD
AMMETER (CLAMP-TYPE)

IGNITION MB991519
SWITCH
BLACK

B FR
L GENERATOR
S
G

ECM BLUE
BATTERY RED YELLOW

VOLTMETER (DIGITAL-TYPE)

AK202360AF

Required Special Tools: 4. Use the special tool (Generator harness

• MB991502: Scan Tool (MUT-II) connector: MB991519) to connect a digital-type
• MB991958: Scan Tool (MUT-III Sub Assembly) voltmeter between the generator "S" terminal and
• MB991824: V.C.I. ground. (Connect the positive lead of the
• MB991827: USB Cable voltmeter to the "S" terminal, and then connect the
• MB991911: Main Harness B negative lead of the voltmeter to a secure ground
• MB991519: Generator Harness Connector or to the negative battery terminal.)
This test determines whether the voltage regulator is 5. Connect a clamp-type DC test ammeter with a
correctly controlling the generator output voltage. range of 0 − 100 A to the generator "B" terminal
WARNING output wire.
Battery posts, terminals and related acces- 6. Reconnect the negative battery cable.
sories contain lead and lead compounds. 7. Connect an engine tachometer, scan tool
WASH HANDS AFTER HANDLING. MB991502 or MB991958.
1. Always be sure to check the following before the 8. Turn the ignition switch to the "ON" position and
test: check that the reading on the voltmeter is equal to
• Generator installation the battery positive voltage.
• Check to be sure that the battery installed in the
NOTE: If the voltage is 0 V, the cause is probably
vehicle is fully charged. (Refer to GROUP 54A,
an open circuit in the wire or fusible link between
Battery − On-vehicle Service − Battery Check
the generator "S" terminal and the battery positive
P.54A-3.) terminal or malfunctioning voltmeter.
• Generator drive belt tension (Refer to GROUP
9. Check to be sure that all lights and accessories
00, Maintenance Service − Drive Belts P.00-37.)
are off.
• Fusible link
• Abnormal noise from the generator while the 10.Start the engine.
engine is running. 11.Increase the engine speed to 2,500 r/min.
2. Turn the ignition switch to the "LOCK" (OFF) 12.Read the value displayed on the voltmeter when
position. the current output by the generator becomes 10 A
3. Disconnect the negative battery cable. or less.

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 ENGINE ELECTRICAL
CHARGING SYSTEM
16-11
13.If the voltage reading conforms to the value in the 15.Turn the ignition switch to the "LOCK" (OFF)
voltage regulation table, then the voltage regulator position.
is operating normally. 16.Disconnect the engine tachometer, scan tool
If the voltage is outside the standard value, there MB991502 or MB991958.
is a malfunction of the voltage regulator or the 17.Disconnect the negative battery cable.
generator (Refer to the following table). 18.Disconnect the ammeter and voltmeter.
14.After the test, lower the engine speed to idle. 19.Connect the negative battery cable.
20.Run the engine for 10 minutes at an idle.
VOLTAGE REGULATION TABLE
INSPECTION TERMINAL VOLTAGE REGULATOR STANDARD VALUE (V)
AMBIENT TEMPERATURE
[°C (°F)]
Terminal "S" −20 (−4) 14.2 − 15.4
20 (68) 13.9 − 14.9
60 (140) 13.4 − 14.5
80 (176) 13.1 − 14.2

WAVE PATTERN CHECK USING AN

OSCILLOSCOPE
M1161001200094

Measurement Method
OSCILLOSCOPE Connect the oscilloscope probe to the generator "B" terminal.
GENERATOR
PROBE

"B" TERMINAL
AKX00188AB

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16-12 ENGINE ELECTRICAL
CHARGING SYSTEM

Standard Waveform
OBSERVATION CONDITIONS
FUNCTION SPECIAL PATTERNS
Pattern height Variable
Variable knob Adjust while viewing the wave
pattern
Pattern selector Raster
Engine revolutions Curb idle speed

(V)

0.4
"NORMAL"
VOLTAGE AT 0.2
GENERATOR
"B" TERMINAL 0

–0.2

–0.4

TIME

AKX00189 AD

NOTE: The voltage waveform of the generator "B" terminal can

undulate as shown at left. This waveform is produced when the
regulator operates according to fluctuations in the generator
load (current), and is normal for the generator. If the ripple
height is abnormally high (approximately 2 V or more during
idling), the wires between the generator B terminal and the bat-
tery have broken due to fuse blowing, etc. The generator is
usually operating properly.

AKX00190

Abnormal Waveforms Examples

NOTE: The size of the waveform patterns can differ greatly, depending on the adjustment of the variable
knob on the oscilloscope.
NOTE: Identification of abnormal waveforms is easier when there is a large output current (regulator is not
operating). (Waveforms can be observed when the headlights are illuminated.)
NOTE: Check the conditions of the charging system warning light (illuminated/not illuminated) also, and carry
out a total check.

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 ENGINE ELECTRICAL
CHARGING SYSTEM
16-13

ABNORMAL WAVEFORMS PROBABLE CAUSE

Example 1 Open circuit in diode

AKX00191

Example 2 Short-circuit in diode

AKX00192

Example 3 Open circuit in stator coil

AKX00193

Example 4 Short-circuit in stator coil

AKX00194

Example 5 Open circuit in supplementary

diode

AKX00195

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16-14 ENGINE ELECTRICAL
CHARGING SYSTEM

GENERATOR ASSEMBLY
REMOVAL AND INSTALLATION
M1161001400429

CAUTION
If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact
the parts or tools to the caliper because the paint of caliper will be scratched.
Pre-removal Operation Post-installation Operation
• Under Cover Removal (Refer to GROUP 51, Front • Front Exhaust Pipe Assembly Installation (Refer to
Bumper P.51-2). GROUP 15, Exhaust Pipe and Main Muffler P.15-23).
• Strut Tower Bar Removal (Refer to GROUP 42, Strut • Crossmember Bar Installation (Refer to GROUP 32,
Tower Bar P.42-12). Engine Roll Stopper and Centermember P.32-6).
• Crossmember Bar Removal (Refer to GROUP 32, Engine • Strut Tower Bar Installation (Refer to GROUP 42, Strut
Roll Stopper and Centermember P.32-6). Tower Bar P.42-12).
• Front Exhaust Pipe Assembly Removal (Refer to GROUP • Drive Belt Tension Adjustment [Refer to GROUP 00,
15, Exhaust Pipe and Main Muffler P.15-23). Maintenance Service − Drive Belts (Check Condition)
P.00-37].
• Under Cover Installation (Refer to GROUP 51, Front
Bumper P.51-2).

10
5.0 ± 1.0 N·m
9 44 ± 9 in-lb

11 ± 1 N·m
1 98 ± 8 in-lb

4
7
6 3 11

N 12
18
5
13 ± 1 N·m
115 ± 9 in-lb 36 ± 6 N·m 19
27 ± 4 ft-lb
9.0 ± 1.0 N·m 14 ± 3 N·m
80 ± 9 in-lb 124 ± 26 in-lb
20 ± 2 N·m
(ENGINE OIL) 15 ± 1 ft-lb

N 2 14

22 ± 4 N·m 16
16 ± 3 ft-lb
17 44 ± 10 N·m
23 ± 3 N·m 33 ± 7 ft-lb
17 ± 2 ft-lb 15
8.8 ± 1.0 N·m
78 ± 9 in-lb

13

AC210295 AB

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 ENGINE ELECTRICAL
CHARGING SYSTEM
16-15
REMOVAL STEPS REMOVAL STEPS (Continued)
1. OIL LEVEL GAUGE AND GUIDE 11. INSULATORS
ASSEMBLY 12. INSULATORS
2. O-RING <<B>> 13. DRIVE BELT
3. FUEL PRESSURE SOLENOID 14. GENERATOR CONNECTOR AND
CONNECTOR TERMINAL
4. FUEL PRESSURE SOLENOID • ENGINE MOUNT (REFER TO
5. KNOCK SENSOR CONNECTOR GROUP 32, ENGINE MOUNT
6. EVAPORATIVE EMISSION P.32-3).
PURGE SOLENOID CONNECTOR <<C>> 15. GENERATOR
7. EVAPORATIVE EMISSION 16. WATER PUMP PULLEY
PURGE SOLENOID 17. GENERATOR BRACE
8. GROUND CABLE CONNECTION 18. CRANKSHAFT POSITION
9. FUEL INJECTOR CONNECTORS SENSOR CONNECTOR
<<A>> 10. FUEL INJECTOR, FUEL RAIL, 19. GENERATOR BRACE STAY
FUEL RETURN PIPE AND FUEL
PRESSURE REGULATOR
ASSEMBLY

REMOVAL SERVICE POINTS

.

<<A>> FUEL INJECTOR, FUEL RAIL, FUEL RETURN PIPE

AND FUEL PRESSURE REGULATOR ASSEMBLY
REMOVAL
After loosening the fuel rail mounting bolts, move the fuel injec-
tor, fuel rail, fuel return pipe and the fuel pressure regulator as
an assembly aside in order to make room for the generator
removal.
.

<<B>> DRIVE BELT REMOVAL

The following operations will be needed due to the serpentine
driveCAUTION
system with the drive belt auto-tensioner.
To reuse the drive belt, draw an arrow indicating the rotat-
AUTO-TENSIONER ing direction (to the right) on the back of the belt using
chalk, etc.
1. Securely insert the spindle handle or ratchet handle with a
12.7mm (1/2-inch) insertion angle into the jig hole of the
auto-tensioner, and turn the auto-tensioner
HOLE B counterclockwise until it hits the stopper.

HOLE A AC107640AC

2. Align hole A with hole B, insert an L-shaped hexagon

AUTO-TENSIONER wrench, etc. to fix and then remove the drive belt.

L-SHAPED
HEXAGON
WRENCH AC107641AB

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16-16 ENGINE ELECTRICAL
CHARGING SYSTEM

<<C>> GENERATOR REMOVAL

Push up the engine with a floor jack to the top and remove the
generator upward from engine room.
DISASSEMBLY AND ASSEMBLY
M1161001600144

1
4
3

5
7 6

12
10
9

8
14

13

11

AK202845 AC

DISASSEMBLY STEPS DISASSEMBLY STEPS (Continued)

<<A>> 1. FRONT BRACKET ASSEMBLY <<C>> 8. STATOR
<<B>> 2. ALTERNATOR PULLEY 9. PLATE
>>B<< 3. ROTOR <<C>> >>A<< 10. REGULATOR ASSEMBLY
4. REAR BEARING 11. BRUSH
5. BEARING RETAINER 12. RUBBER PACKING
6. FRONT BEARING 13. RECTIFIER
7. FRONT BRACKET 14. REAR BRACKET

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 ENGINE ELECTRICAL
CHARGING SYSTEM
16-17
DISASSEMBLY SERVICE POINTS
.

<<A>> FRONT BRACKET ASSEMBLY REMOVAL

CAUTION
Do not insert the screwdriver blades too deep. Doing so
could damage the stator coil.
Insert the blades of screwdrivers between the front bracket
assembly and stator core, and pry and separate them with the
screwdrivers.

AK202718

<<B>> ALTERNATOR PULLEY REMOVAL

CAUTION
Perform operation carefully not to damage the rotor.
Clamp the rotor in a vise with the pulley facing up to remove the
pulley.

AK202714

<<C>> STATOR / REGULATOR ASSEMBLY REMOVAL

CAUTION
RECTIFIER SOLDER • Use a 180 − 250 W soldering iron, and finish unsolder-
ASSEMBLY ing within four seconds. Diodes will be damaged by
heat if unsoldering time is too long.
• Avoid applying undue force to the diode leads.
1. Unsolder the stator leads from the main diode of the rectifier
assembly when the stator is removed.
2. When removing the rectifier assembly from the regulator
assembly, undo the soldered points on the rectifier
SOLDER
assembly.
AK202778 AC

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16-18 ENGINE ELECTRICAL
CHARGING SYSTEM

REASSEMBLY SERVICE POINTS

.

>>A<< REGULATOR ASSEMBLY INSTALLATION

After installing the regulator assembly, insert a piece of wire
through the hole in the rear bracket while pressing the brush to
keep the brush against movement.
WIRE
NOTE: Holding the brush with the wire facilities installation of
the rotor.

AK202779 AC

REAR BRACKET

BRUSH

WIRE

AK202830 AC

>>B<< ROTOR INSTALLATION

Remove the brush holding wire after the rotor has been
installed.

WIRE
INSPECTION (DISASSEMBLY AND ASSEMBLY)

AK202779 AC

M1161001700118
.

ROTOR
1. Measure the resistance between the two slip rings of the
rotor coil to check the continuity between them.
Replace the rotor if the resistance is not within the standard
value range.
Standard value: 3 − 5 Ω

AK202735

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 ENGINE ELECTRICAL
CHARGING SYSTEM
16-19
2. Check the continuity between the slip rings and core.
If continuity is present, replace the rotor.

AK202736

STATOR
1. Check the continuity between coil leads.
If there is no continuity, replace the stator.

AK202716

2. Check the continuity between coil and core.

If there is no continuity, replace the stator.

AK202717

RECTIFIER ASSEBMLY
1. Check the condition of the (+) heat sink by checking
continuity between the (+) heat sink and each of the stator
coil lead connecting terminals.
If continuity is present for both terminals, the diode is
shorted. Replace the rectifier assembly.

AK202803

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16-20 ENGINE ELECTRICAL
CHARGING SYSTEM

2. Check the condition of the (−) heat sink by checking

continuity between the (−) heat sink and each of the stator
coil lead connecting terminals.
If continuity is present in both directions, the diode is
shorted. Replace the rectifier assembly.

AK202802

3. Check the condition of the diode trio by testing continuity of

each of the three diodes using a circuit tester connected to
both sides of the diode. Connect in a polarity and then
reverse the polarity for each test.
If continuity exists or no continuity exists for both polarities,
the diode is defective. Replace the rectifier assembly if any
of the diodes is defective.

AK202804

BRUSH
1. Measure the length of the protrusion of the brush. Replace
the brush if the protrusion length is shorter than the limit.
Limit: 2 mm minimum

PROTRU-
2. Unsolder the lead of the brush. The brush will come out,
SION becoming ready for removal.
LENGTH

AK202808 AC

3. Install a new brush by pushing it into the holder as shown in

SOLDER
the drawing a nd soldering the lead.

AK202834 AC

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 ENGINE ELECTRICAL
STARTING SYSTEM
16-21
STARTING SYSTEM
GENERAL DESCRIPTION
M1162000100172
If the ignition switch is turned to the "START" posi- When the ignition switch is returned to the "ON" posi-
tion, current flows in the coil provided inside mag- tion after starting the engine, the overrunning clutch
netic switch, attracting the plunger. When the plunger is disengaged from the ring gear.
is attracted, the lever connected to the plunger is An overrunning clutch is provided between the pinion
actuated to engage the overrunning clutch with the and the armature shaft, to prevent damage to the
ring gear. starter.
At the same time, attracting the plunger will turn on
the magnetic switch, allowing the B terminal and M
terminal to conduct. Thus, current flows to engage
the starter motor.
HOLDING
COIL
PLUNGER
PULL-IN COIL
LEVER

OVERRUNNING
B CLUTCH
IGNITION
SWITCH M
PINION GEAR
S

+ ARMATURE

BATTERY

BRUSH
YOKE

AK202970 AC

OPERATION NOTE: If the ignition switch is switched to the

• The clutch pedal position switch contact is "ST" position without the clutch pedal being
switched OFF when the clutch pedal is depressed, electricity flows to the starter relay
depressed. When the ignition switch is then (coil), the clutch pedal position switch (contacts)
switched to the "ST" position, electricity flows to and to ground, with the result that the contacts of
the starter relay and the starter motor, the contact the starter relay are switched OFF, and because
(magnetic switch) of the starter is switched ON the power to the starter motor is thereby inter-
and the starter motor is activated. rupted, the starter motor in not activated.

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16-22 ENGINE ELECTRICAL
STARTING SYSTEM

DIAGNOSIS
M1162000700226

TROUBLESHOOTING HINTS
The starter motor does not operate at all.
• Check the starter (coil).
• Check for poor connection at the battery terminals and
starter.
• Check starter relay.
• Check the clutch pedal position switch.
The starter motor doesn't stop
• Check the starter (magnetic switch).

TROUBLESHOOTING GUIDE
The starting system troubleshooting guide is shown in the fol-
lowing chart.

STEP 1.
Q: Is the battery in good condition? (Refer to GROUP 54A,
Battery − On-vehicle Service − Battery Check P.54A-3.)
YES : Go to Step 2.
NO : Charge or replace the battery.

STEP 2.
• Disconnect the starter motor "S" (solenoid) terminal con-
nector.
• Using a jumper wire, apply battery positive voltage to the
starter motor "S" (solenoid) terminal.
• Check the engine condition.
OK: Turns normally
Q: Does the starter motor operate normally?
YES : • Check the ignition switch (Refer to GROUP 54A,
Ignition Switch − Inspection P.54A-53.)
• Check the starter relay and clutch pedal position
switch.
• Check the line between the battery and starter
motor "S" (solenoid) terminal.
NO : Go to Step 3.

STEP 3.
• Check the cable between starter "B" (battery) terminal and
battery positive terminal for connection and continuity.
Q: Is the starter cable in good condition?
YES : Go to Step 4.
NO : Repair or replace the cable.

STEP 4.
• Check the connection and the continuity of the cable
between the starter motor body and the negative battery
terminal.
Q: Is the ground cable in good condition?
YES : Go to Step 5.
NO : Repair or replace the cable.

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 ENGINE ELECTRICAL
STARTING SYSTEM
16-23

STEP 5.
Q: Is the starter motor in good condition? (Refer to Starting
system − Starter motor − Inspection P.16-24.)
YES : Starter motor is normal. Check the excessive
rotational resistance of the engine.
NO : Replace the starter motor.

ON-VEHICLE SERVICE

STARTER RELAY CHECK

M1162001400176
BATTERY
BATTERY TERMINAL CONTINUITY TEST
VOLTAGE NUMBER TO BE RESULTS
CONNECTED TO
TESTER
Not applied 2−5 Open circuit
• Connect 2−5 Less than 2 ohms
terminal 1 to the
positive battery
RELAY BOX AC208874
terminal
• Connect
terminal 3 to the
negative battery
terminal
1 2 3 2
5
4

5 3 1

AC210410 AB

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16-24 ENGINE ELECTRICAL
STARTING SYSTEM

STARTER MOTOR ASSEMBLY

REMOVAL AND INSTALLATION
M1162001000480

Pre-removal and Post-installation Operation

• Under Cover Removal and Installation (Refer to GROUP
51, Front Bumper P.51-2).
• Crossmember Bar Removal and Installation (Refer to
GROUP 32, Engine Roll Stopper and Centermember
P.32-6).
• Front Exhaust Pipe Assembly Removal and Installation
(Refer to GROUP 15, Exhaust Pipe and Main Muffler
P.15-23).

3
13 ± 2 N·m
111 ± 22 in-lb

30 ± 3 N·m
23 ± 2 ft-lb

4.9 ± 1.0 N·m 2

44 ± 8 in-lb

30 ± 3 N·m
23 ± 2 ft-lb
1

4.9 ± 1.0 N·m

44 ± 8 in-lb
AC210296 AB

REMOVAL STEPS REMOVAL STEPS (Continued)

1. STARTER COVER 2. STARTER CONNECTOR AND
TERMINAL
3. STARTER ASSEMBLY

INSPECTION
M1162001100153
.

PINION GAP ADJUSTMENT

1. Disconnect the field coil wire from the M-terminal of the
SWITCH
magnetic switch.
2. Connect a 12-volt battery between the S-terminal and M-
B
terminal.
S M CAUTION
This test must be performed quickly (in less than 10 sec-
BATTERY
onds) to prevent the coil from burning.
STARTER WIRE
MOTOR 3. Set the switch to "ON", and the pinion will move out.

AKX01239 AC

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 ENGINE ELECTRICAL
STARTING SYSTEM
16-25
4. Check the pinion-to-stopper clearance (pinion gap) with a
feeler gauge.
STOPPER
Standard value: 0.5 − 2.0 mm (0.02 − 0.07 inch)

PINION

PINION GAP AKX00198 AB

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

removing gasket(s) between the magnetic switch and front
bracket.

AKX00199

MAGNETIC SWITCH PULL-IN TEST

1. Disconnect the field coil wire from the M-terminal of the
magnetic switch.
CAUTION
B
This test must be performed quickly (in less than 10 sec-
S M onds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal and M-
BATTERY
terminal.
STARTER WIRE
MOTOR 3. If the pinion moves out, the pull-in coil is good. If it doesn't,
replace the magnetic switch.
AKX01243 AC

MAGNETIC SWITCH HOLD-IN TEST

1. Disconnect the field coil wire from the M-terminal of the
magnetic switch.
CAUTION
B
This test must be performed quickly (in less than 10 sec-
S M
onds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal and body.
BATTERY
STARTER 3. Manually pull out the pinion as far as the pinion stopper
MOTOR position.
WIRE
4. If the pinion remains out, everything is operating properly. If
AKX01245 AC
the pinion moves in, the hold-in circuit is open. Replace the
magnetic switch.
.

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16-26 ENGINE ELECTRICAL
STARTING SYSTEM

FREE RUNNING TEST

1. Place the starter motor in a vise equipped with soft jaws and
CARBON-PILE connect a fully-charged 12-volt battery to the starter motor
RHEOSTAT
B as follows:
AMMETER
S
2. Connect a test ammeter (100-ampere scale) and carbon pile
A
M rheostat in series between the positive battery terminal and
starter motor terminal.
BATTERY
STARTER V 3. Connect a voltmeter (15-volt scale) across the starter motor.
MOTOR VOLTMETER
4. Rotate carbon pile to full-resistance position.
5. Connect the battery cable from the negative battery terminal
AKX01247 AC to the starter motor body.
6. Adjust the rheostat until the battery positive voltage shown
by the voltmeter is 11 V.
7. Confirm that the maximum amperage is within the
specifications and that the starter motor turns smoothly and
freely.
Current: maximum 95 Amps
.

MAGNETIC SWITCH RETURN TEST

1. Disconnect the field coil wire from the M-terminal of the
magnetic switch.
CAUTION
B
This test must be performed quickly (in less than 10 sec-
S
M onds) to prevent the coil from burning.
2. Connect a 12-volt battery between the M-terminal and body.
BATTERY
STARTER WARNING
MOTOR Be careful not to get your fingers caught when pulling
WIRE
out the pinion.
AKX01249 AC
3. Pull the pinion out and release. If the pinion quickly returns
to its original position, everything is operating properly. If it
doesn't, replace the magnetic switch.

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 ENGINE ELECTRICAL
STARTING SYSTEM
16-27
DISASSEMBLY AND ASSEMBLY
M1162001200172

2
14
12 11

13
19

1 10
18
17
16
15
4

7
20 5

9
AK204335AB

DISASSEMBLY STEPS DISASSEMBLY STEPS (Continued)

1. SCREW 11. PACKING B
<<A>> 2. MAGNETIC SWITCH 12. PLATE
3. SCREW 13. PLANETARY GEAR
4. BOLT 14. LEVER
5. REAR BRACKET <<B>> >>A<< 15. SNAP RING
6. BRUSH HOLDER <<B>> >>A<< 16. STOP RING
7. REAR BEARING 17. OVERRUNNING CLUTCH
8. ARMATURE 18. INTERNAL GEAR
9. YOKE ASSEMBLY 19. PLANETARY GEAR SHAFT
10. PACKING A 20. FRONT BRACKET

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16-28 ENGINE ELECTRICAL
STARTING SYSTEM

DISASSEMBLY SERVICE POINTS

.

<<A>> MAGNETIC SWITCH REMOVAL

CAUTION
Do not clamp the yoke assembly with a vise.
B TERMINAL S TERMINAL Disconnect the lead from the M terminal of the magnetic switch.

FIELD COIL
M TERMINAL LEAD

AK202890 AC

<<B>> SNAP RING/STOP RING REMOVAL

1. Apply a long socket wrench of an appropriate size to the
SOCKET WRENCH stop ring and strike the wrench to drive out the stop ring
toward the pinion gear side.
STOP RING PINION GEAR

OVERRUNNING
CLUTCH

AK202790 AC

2. Remove the snap ring with snap ring pliers, then remove the
SNAP RING
SNAP RING stop ring and overrunning clutch.
PLIERS PINION GEAR

OVERRUNNING
CLUTCH

AK202791 AC

STARTER MOTOR PARTS CLEANING

.

1. Never clean in a solvent such starter motor parts as the

magnetic switch, brush holder, and armature. If they are
soaked in a solvent, their insulation could be impaired.
When these parts require cleaning, wipe off contamination
with cloth.
2. Never soak the drive unit in a solvent. If it is washed in a
solvent, the grease having been packed in the overrunning
clutch at the factory will be washed out. Wipe the drive unit
with cloth if it requires cleaning.

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 ENGINE ELECTRICAL
STARTING SYSTEM
16-29
REASSEMBLY SERVICE POINTS
.

>>A<< STOP RING/SNAP RING INSTALLATION

Use a suitable puller to pull the stop ring until it gets over the
snap ring.

INSPECTION (DISASSEMBLY AND ASSEMBLY)

OVERRUNNING STOP RING
CLUTCH
STOP RING

SNAP RING AK202911 AC

M1162001300124
.

COMMUTATOR
1. Support the armature with a pair of V block and turn it to
measure the runout of the surface not rubbed by the
brushes using a dial gauge.
Standard value: 0.05 mm or less
Limit: 0.1 mm

AK202712

2. Measure the diameter of the commutator.

Standard value: 29.4 mm
Limit: 28.8 mm

AK202715

3. Measure the depth of the undercut between segments.

Standard value: 0.5 mm
UNDERCUT
SEGMENT Limit: 0.2 mm
MICA

AK202711 AC

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16-30 ENGINE ELECTRICAL
STARTING SYSTEM

BRUSH HOLDER
Push the brush into the brush holder to make sure that the
spring is working on the brush.
If the spring is not working, replace the brush holder.

AK204343

OVERRUNNING CLUTCH
1. Make sure that the pinion cannot be turned
counterclockwise and can be turned clockwise freely.
2. Check the pinion for abnormal ware and damage.

FREE

LOCK

AK202710 AC

BRUSHES
1. Check the commutator contacting surface of each brush for
abnormal roughness. Also check the height of the brush.
Replace the brush holder if the height is lower than the limit.
Limit: 7.0 mm
BRUSH 2. When the contact surface of the brush is rectified or the
HEIGHT brush holder is replaced, recondition the contact surface
with sandpaper wrapped around the commutator.

AK202846 AC

ARMATURE COIL
1. Check the armature coil for short circuit as follows:
GROWLER
2. Set the armature in a growler.
CAUTION
Clean the surface of the armature thoroughly before per-
forming the test.
3. While holding a thin strip of iron against the armature in
parallel with its axis, turn the armature slowly. The armature
is normal if the iron strip is not attracted to the armature or it
does not vibrate.

AK202733 AB

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 ENGINE ELECTRICAL
STARTING SYSTEM
16-31
4. Check the insulation between commutator segments and
armature coils. The armature coils are properly insulated if
no continuity is present.

AK202734

5. Check continuity between a segment and another. There is

no open circuit in the tested coil if there is continuity.

AK202713

MAGNETIC SWITCH
1. Coil open circuit test
• Check that there is continuity between the M terminal and
A body A.
• If there is no continuity, replace the magnetic switch.

AK202891 AC

2. Contact fusion check

• Check that there is no continuity between the B terminal
B TERMINAL
and M terminal.
• If there is continuity, replace the magnetic switch.

M TERMINAL

AK202892 AC

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16-32 ENGINE ELECTRICAL
IGNITION SYSTEM

3. Switch contact check

• Push the indicated end of the magnetic switch with a strong
B TERMINAL force to close the internal contacts. Without releasing the
switch end, check that there is continuity between the B ter-
minal and M terminal.
• If there is no continuity, replace the magnetic switch.

M TERMINAL

AK202893 AC

IGNITION SYSTEM
GENERAL DESCRIPTION
M1163000100227
This system is provided with two ignition coils (A and The engine control module controls the two ignition
B) with built-in ignition power transistors for the num- power transistors to turn them alternately ON and
ber 1 and number 4 cylinders, and number 2 and OFF. This causes the primary currents in the ignition
number 3 cylinders respectively. coils to be alternately interrupted and allowed to flow
Interruption of the current flowing in the primary side to fire the cylinders in the order 1 − 3 − 4 − 2.
of ignition coil A generates a high voltage in the sec- The engine control module determines which ignition
ondary side of ignition coil A. coil should be controlled by means of the signals
The high voltage generated is applied to the spark from the camshaft position sensor and from the
plugs of number 1 and number 4 cylinders to gener- crankshaft position sensor.
ate sparks. At the time that the sparks are generated It also detects the crankshaft position in order to pro-
at both spark plugs, if one cylinder is at the compres- vide ignition at the most appropriate timing in
sion stroke, the other cylinder is at the exhaust response to the engine operation conditions.
stroke, so that ignition of the compressed air/fuel When the engine is cold or operated at high alti-
mixture occurs only for the cylinder which is on the tudes, the ignition timing is slightly advanced to pro-
compression stroke. vide optimum performance.
In the same way, when the primary current flowing in
ignition coil B is interrupted, the high voltage thus
generated is applied to the spark plugs of number 2
and number 3 cylinders.

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 ENGINE ELECTRICAL
IGNITION SYSTEM
16-33

TO TACHOMETER
VOLUME AIRFLOW SENSOR
INTAKE AIR TEMPERATURE SENSOR IGNITION COIL A
BAROMETRIC PRESSURE SENSOR
ENGINE COOLANT TEMPERATURE
SENSOR IGNITION
ECM SWITCH
CAMSHAFT POSITION SENSOR IGNITION COIL B
CRANKSHAFT POSITION SENSOR
VEHICLE SPEED SENSOR
IGNITION SWITCH-ST
BATTERY
KNOCK SENSOR

SPARK PLUGS

CYLINDER NO. 3 2 4 1

AK100055 AF

SPECIAL TOOL
M1163000600170

TOOL TOOL NUMBER AND SUPERSESSION APPLICATION

NAME
MD998773 MD998773-01 Knock sensor removal
Knock sensor wrench and installation

ON-VEHICLE SERVICE

IGNITION COIL CHECK

M1163001200302
Check by the following procedure, and replace the coil if there
is a malfunction.
.

SECONDARY COIL RESISTANCE CHECK

Measure the resistance between the high-voltage terminals of
the ignition coil.
Standard value: 8.5 − 11.5 kΩ

AKX01264

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16-34 ENGINE ELECTRICAL
IGNITION SYSTEM

PRIMARY COIL AND IGNITION POWER TRANSISTOR

CONTINUITY CHECK

1.5 V

– + 1 2 3

AKX01265AB

NOTE: An analog-type ohmmeter should be used.

NOTE: Connect the negative probe of the ohmmeter to termi-
nal No. 1.
CAUTION
This test must be performed quickly (in less than 10 sec-
onds) to prevent coil from burning and ignition power tran-
sistor from breaking.
1. Connect and disconnect 1.5 V battery between terminals
No. 2 and No. 3, and observe the ohmmeter whether there
is continuity or not.
2. If results do not agree with the table below, replace the
primary coil and ignition power transistor assembly.
1.5 V POWER SUPPLY CONTINUITY BETWEEN
BETWEEN 2 − 3 1−2
Current flowing Yes
Current not flowing No

SPARK PLUG CABLE RESISTANCE CHECK

M1163001400072
Measure the resistance of the all spark plug leads.
1. Check the cap and coating for cracks.
2. Measure the resistance.
Limit: 19 kΩ
3. If resistance is greater than 19 kΩ, replace the cable.

AKX00382

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 ENGINE ELECTRICAL
IGNITION SYSTEM
16-35
SPARK PLUG CHECK AND CLEANING
M1163004300278

CAUTION
• Do not attempt to adjust the gap of the iridium plug.
• Cleaning of the iridium plug may result in damage to
the iridium and platinum tips. Therefore, if carbon
deposits must be removed, use a plug cleaner and
complete cleaning within 20 seconds to protect the
electrode. Do not use a wire brush.
IRIDIUM
TIP Check the plug gap and replace if the limit is exceeded.
Standard value: 0.7 − 0.8 mm (0.028 − 0.031 inch)
PLATINUM Limit: 1.0 mm (0.039 inch)
TIP AKX01327AB

CAMSHAFT POSITION SENSOR CHECK

M1163004400101
Refer to GROUP 13A, Diagnostic Trouble Code Procedures −
DTC 0340: Camshaft Position Sensor Circuit P.13A-317.

CRANK ANGLE SENSOR CHECK

M1163004500120
Refer to GROUP 13A, Diagnostic Trouble Code Procedures −
DTC P335: Crankshaft Position Sensor Circuit P.13A-302.

IGNITION SECONDARY VOLTAGE WAVE

PATTERN CHECK USING AN OSCILLOSCOPE
M1163001700125
.

MEASUREMENT METHOD
1. Clamp the spark plug cable (Number 1 or 3) with the
secondary pickup.
NOTE: Because of the two-cylinder simultaneous ignition
system, the waves for two cylinders in each group appear
during wave observation. However, wave observation is car-
ried out for the cylinder (Number 1 or 3) with the spark plug
cable which has been clamped by the secondary pickup.
NOTE: Identification of which cylinder wave pattern is dis-
played can be difficult, but the wave pattern of the cylinder
which is clamped by the secondary pickup will be stable, so
this can be used as a reference.
2. Clamp the spark plug cable (Number 1 or 3) with the trigger
pickup.
NOTE: Clamp the same spark plug cable as the one which
has been clamped by the secondary pickup.
.

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16-36 ENGINE ELECTRICAL
IGNITION SYSTEM

STANDARD WAVE PATTERN

SETTINGS
FUNCTION SECONDARY
Pattern height High (or low)
Pattern selector Raster
Engine speed Curb idle speed

SPARK LINE (POINT A)

kV

IGNITION VOLTAGE
(POINT D)

SECONDARY
IGNITION
VOLTAGE
WAVE PATTERN WAVE DAMPING REDUCTION SECTION (POINT B)

DWELL SECTION

POINT C

TIME

AKX00278 AB

SETTINGS
Pattern selector Display
Pattern height High (or low)
Engine speed Curb idle speed

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 ENGINE ELECTRICAL
IGNITION SYSTEM
16-37

kV

NO. 2 CYLINDER
NO. 1 CYLINDER NO. 3 CYLINDER NO. 4 CYLINDER IGNITION NOISE
IGNITION NOISE

SECONDARY IGNITION
VOLTAGE TIME
WAVE 0
PATTERN
2 NEUTRAL SECTION

AKX01275AB
.

ABNORMAL WAVEFORMS EXAMPLES

Example 1
• Wave characteristics
Spark line is high and short.
• Cause of problem
Spark plug gap is too large.

AKX00280

Example 2
• Wave characteristics
Spark line is low and long, and is sloping. Also, the second
half of the spark line is distorted. This could be a result
of misfiring.
• Cause of problem
Spark plug gap is too small.

AKX00281

Example 3
• Wave characteristics
Spark line is low and long, and is sloping. However, there is
almost no spark line distortion.
• Cause of problem
Spark plug gap is fouled.

AKX00282

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16-38 ENGINE ELECTRICAL
IGNITION SYSTEM

Example 4
• Wave characteristics
Spark line is high and short. Difficult to distinguish between
this and abnormal wave pattern example 1.
• Cause of problem
Spark plug cable is not properly connected. (Causing a dual
ignition)

AKX00283

Example 5
• Wave characteristics
No waves in wave damping section
• Cause of problem
Short in ignition coil.

AKX00284

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 ENGINE ELECTRICAL
IGNITION SYSTEM
16-39
IGNITION COIL
REMOVAL AND INSTALLATION
M1163004000352

Pre-removal and Post-installation Operation

• Center Cover Removal and Installation (Refer to GROUP
11A, Camshaft and Valve Stem Seal P.11A-28).

10 ± 2 N·m
89 ± 17 in-lb

1
2
4
1

4 3

5
25 ± 4 N·m
18 ± 3 ft-lb

AC210297AB
REMOVAL STEPS REMOVAL STEPS (Continued)
1. IGNITION COIL CONNECTOR 4. IGNITION COIL
2. SPARK PLUG CABLE NUMBER 1 5. SPARK PLUG
3. SPARK PLUG CABLE NUMBER 3

CAMSHAFT POSITION SENSOR

REMOVAL AND INSTALLATION
M1163003400391

2
3N 1

10.5 ± 0.5 N·m

93 ± 4 in-lb
AC210298 AB
REMOVAL STEPS REMOVAL STEPS (Continued)
1. CAMSHAFT POSITION SENSOR 2. CAMSHAFT POSITION SENSOR
CONNECTOR 3. O-RING

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16-40 ENGINE ELECTRICAL
IGNITION SYSTEM

CRANKSHAFT POSITION SENSOR

REMOVAL AND INSTALLATION
M1163003500376

CAUTION
If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact
the parts or tools to the caliper because the paint of caliper will be scratched.
Pre-removal and Post-installation Operation
• Timing Belt Removal and Installation (Refer to GROUP
11A,Timing Belt P.11A-50).
• Radiator Reserve Tank Assembly Removal and Installa-
tion (Refer to GROUP 14, Radiator P.14-22).

12 ± 2 N·m
102 ± 2 in-lb
22 ± 4 N·m
16 ± 3 ft-lb
22 ± 4 N·m
16 ± 3 ft-lb 2
12 ± 2 N·m
102 ± 2 in-lb
5

1 22 ± 4 N·m
16 ± 3 ft-lb

6
8.8 ± 1.0 N·m
40 ± 5 N·m
78 ± 9 in-lb 3 30 ± 3 ft-lb
4 49 ± 9 N·m
36 ± 7 ft-lb
49 ± 9 N·m
36 ± 7 ft-lb

AC210409AB

REMOVAL STEPS REMOVAL STEPS (Continued)

1. POWER STEERING PRESSURE 4. POWER STEERING OIL PUMP
SWITCH CONNECTOR BRACKET
2. POWER STEERING OIL PUMP 5. CRANKSHAFT POSITION
HEAT PROTECTOR SENSOR CONNECTOR
<<A>> 3. POWER STEERING OIL PUMP, 6. CRANKSHAFT POSITION
BRACKET AND OIL RESERVOIR SENSOR
ASSEMBLY

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 ENGINE ELECTRICAL
IGNITION SYSTEM
16-41
REMOVAL SERVICE POINT
.

<<A>> POWER STEERING OIL PUMP, BRACKET AND OIL

RESERVOIR ASSEMBLY REMOVAL
NOTE: Tie the removed power steering oil pump, bracket and
oil reservoir assembly with a rope and set aside where they
cannot hinder the removal of the power steering oil pump
bracket.
Remove the power steering oil pump, bracket and oil reservoir
assembly with the hoses attached from the power steering oil
pump bracket.

KNOCK SENSOR
REMOVAL AND INSTALLATION
M1163002800426

Pre-removal and Post-installation Operation

• Intake Manifold Stay Removal and Installation (Refer to
GROUP 15,Intake Manifold P.15-13).

INTAKE MANIFOLD STAY 23 ± 2 N·m

17 ± 1 ft-lb

1
2

AC210411AB

REMOVAL
1. KNOCK SENSOR CONNECTOR
<<A>> >>A<< 2. KNOCK SENSOR
Required Special Tool:
• MD998773: Knock sensor wrench
REMOVAL SERVICE POINT
.

<<A>> KNOCK SENSOR REMOVAL

Use special tool MD998773 to remove the knock sensor.
KNOCK SENSOR

MD998773

AC100807AB

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16-42 ENGINE ELECTRICAL
SPECIFICATIONS

INSTALLATION SERVICE POINT

.

>>A<< KNOCK SENSOR INSTALLATION

Use special tool MD998773 to install the knock sensor.
KNOCK SENSOR

MD998773

AC100807AB

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1161002100487

ITEM SPECIFICATION
Charging system
Evaporative emission purge solenoid bolt 9.0 ± 1.0 N⋅m (80 ± 9 in-lb)
Fuel pressure solenoid bolt 9.0 ± 1.0 N⋅m (80 ± 9 in-lb)
Fuel rail bolt 11 ± 1 N⋅m (98 ± 8 in-lb)
Generator bolt 22 ± 4 N⋅m (16 ± 3 ft-lb)
Generator brace bolt (water pump bolt) 23 ± 3 N⋅m (17 ± 2 ft-lb)
Generator brace bolt 22 ± 4 N⋅m (16 ± 3 ft-lb)
Generator brace stay bolt (intake manifold bolt) 20 ± 2 N⋅m (15 ± 1 ft-lb)
Generator brace stay nut (intake manifold nut) 36 ± 6 N⋅m (27 ± 4 ft-lb)
Generator nut 44 ± 10 N⋅m (33 ± 7 ft-lb)
Generator terminal nut 14 ± 3 N⋅m (124 ± 26 in-lb)
Ground cable bolt 5.0 ± 1.0 N⋅m (44 ± 9 in-lb)
Oil level gauge guide bolt 13 ± 1 N⋅m (115 ± 9 in-lb)
Water pump pulley bolt 8.8 ± 1.0 N⋅m (78 ± 9 in-lb)
Starting system
Starter bolt 30 ± 3 N⋅m (23 ± 2 ft-lb)
Starter cover bolt 4.9 ± 1.0 N⋅m (44 ± 8 in-lb)
Starter cover nut 4.9 ± 1.0 N⋅m (44 ± 8 in-lb)
Starter terminal nut 13 ± 2 N⋅m (111 ± 22 in-lb)
Ignition system
Camshaft position sensor bolt 10.5 ± 0.5 N⋅m (93 ± 4 in-lb)
Crankshaft position sensor bolt 8.8 ± 1.0 N⋅m (78 ± 9 in-lb)
Ignition coil bolt 10 ± 2 N⋅m (89 ± 17 in-lb)
Knock sensor 23 ± 2 N⋅m (17 ± 1 ft-lb)
Power steering oil pressure hose bolt 12 ± 2 N⋅m (102 ± 2 in-lb)

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 ENGINE ELECTRICAL
SPECIFICATIONS
16-43
ITEM SPECIFICATION
Power steering oil pump bracket bolt (cylinder block side) 49 ± 9 N⋅m (36 ± 7 in-lb)
Power steering oil pump bracket bolt (power steering oil M8 22 ± 4 N⋅m (16 ± 3 ft-lb)
pump side) M10 40 ± 5 N⋅m (30 ± 3 ft-lb)
Power steering oil pump heat protector bolt 22 ± 4 N⋅m (16 ± 3 in-lb)
Power steering oil reservoir bolt 12 ± 2 N⋅m (102 ± 2 in-lb)
Spark plug 25 ± 4 N⋅m (18 ± 3 ft-lb)

GENERAL SPECIFICATIONS
M1161000200239

ITEMS SPECIFICATIONS
Generator
Type Positive battery positive voltage sensing
Identification number A3TB1791
Part No. MD366831
Rated output V/A 12/90
Voltage regulator Electronic built-in type
Starter motor
Type Reduction drive with planetary gear
Identification number M0T31171
Part No. MN128202
Rated output kW/V 1.2/12
Number of pinion teeth 8
Ignition coil
Type Molded 2-coil
Spark plugs
NGK IGR7A-G
DENSO −
CHAMPION −

SERVICE SPECIFICATIONS
M1161000300281

ITEMS STANDARD VALUE LIMIT

Generator
Regulated voltage −20°C (−4°F) 14.2 − 15.4 −
(Ambient temperature at voltage 20°C (68°F) 13.9 − 14.9 −
regulator)
60°C (140°F) 13.4 − 14.5 −
80°C (176°F) 13.1 − 14.5 −
Generator output line voltage drop (at 30A) V − Maximum 0.3
Output current − 70% of normal output
current
Field coil resistance Ω Approximately 2 − 5 −
Brush protrusion length mm (in) − Minimum 2 (0.08)

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16-44 ENGINE ELECTRICAL
SPECIFICATIONS

ITEMS STANDARD VALUE LIMIT

Starter motor
Free running characteristics Terminal voltage 11 −
V
Current A 95 −
Speed r/min 2,500 or more −
Pinion gap mm (in) 0.5 − 2.0 (0.02 − 0.07) −
Commutator run-out mm (in) 0.05 (0.002) Minimum 0.1 (0.004)
Commutator diameter mm (in) 29.4 (1.16) Minimum 28.8 (1.13)
Undercut depth mm (in) 0.5 (0.02) Minimum 0.2 (0.008)
Ignition parts
Ignition secondary coil resistance at 20°C (68°F) kΩ 8.5 − 11.5 −
Spark plug gap mm (in) 1.0 − 1.1 (0.039 − 0.043) −
Resistor wire resistance kΩ − Maximum 19

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