Engine Electrical

System(D4FA DSL1.5)
GENERAL
CHARGING SYSTEM
ALTERNATOR
BATTERY

STARTING SYSTEM
STARTER
STARTER RELAY

PREHEATING SYSTEM

EEA -2

ENGINE ELECTRICAL SYSTEM(D4FA - DSL1.5)

GENERAL
SPECIFICATION

E63F15E2

STARTING SYSTEM
Items

Specification

Rated voltage

12 V, 1.7 kW

No. of pinion teeth

No-load
characteristics
Starter
Commutator diameter

Under cut depth

Voltage

11 V

Ampere

90A, MAX

Speed

2,600 rpm, MIN

Standard

29.4 mm (1.1575in.)

Limit

28.8 mm (1.1339in.)

Standard

0.5 mm (0.0197in.)

Limit

0.2 mm (0.0079in.)

CHARGING SYSTEM
Items

Alternator

Battery

Specification
Type

Battery voltage sensing

Rate voltage

12 V, 120A

Speed in use

1,000 ~ 18,000 rpm

Voltage regulator

Electronic built-in type

Regulator setting voltage

14.55 0.2 V

Temperature compensation

-7 3 mV / C

Type

MF 68AH

Cold cranking amperage [at -18 C(-0.4 F)]

600 A

Reserve capacity

110 min

Specific gravity [at 20 C(68 F)]

1.280 0.01

NOTE
COLD CRANKING AMPERAGE is the amperage
a battery can deliver for 30 seconds and maintain
a terminal voltage of 7.2V or greater at a specified
temperature.
RESERVE CAPACITY RATING is amount of time
a battery can deliver 25A and maintain a minimum terminal voltage of 10.5V at 26.7 C(80.1 F).

GENERAL
TROUBLE SHOOTING

EEA -3
E81C5D80

STARTING SYSTEM
Symptom
Engine will not crank

Suspect area

Remedy

Battery charge low

Battery cables loose, corroded
or worn out
Transaxle range switch (Vehicle with
automatic transaxle only)
Fuse blown
Starter motor faulty
Ignition switch faulty

Charge or replace battery

Repair or replace cables

Battery charge low

Battery cables loose, corroded
or worn out
Starter motor faulty

Charge or replace battery

Repair or replace cables

Starter keeps running

Starter motor
Ignition switch

Replace
Replace

Starter spins but engine

will not crank

Short in wiring
Pinion gear teeth broken or starter motor
Ring gear teeth broken

Repair wiring
Replace
Replace fly wheel or torque converter

Engine cranks slowly

Refer to TR group-automatic transaxle

Replace fuse
Replace
Replace

Replace

CHARGING SYSTEM
Symptom

Suspect area

Remedy

Charging warning indicator

does not light with ignition
switch "ON" and engine off.

Fuse blown
Light burned out
Wiring connection loose
Electronic voltage regulator

Check fuses
Replace light
Tighten loose connection
Replace voltage regulator

Charging warning indicator

does not go out with engine
running. (Battery requires
frequent recharging)

Drive belt loose or worn

Battery cable loose, corroded or worn
Fuse blown
Electronic voltage regulator or alternator
Wiring

Adjust belt tension or replace belt

Inspect cable connection, repair or
replace cable
Check fuses
Replace voltage regulator or alternator
Repair or replace wiring

Overcharge

Electronic voltage regulator

Voltage sensing wire

Replace voltage regulator

Repair or replace wiring

Discharge

Drive belt loose or worn

Wiring connection loose or short circuit

Adjust belt tension or replace belt

Inspect wiring connection, repair or
replace wiring
Check fuses
Replace voltage regulator or alternator
Inspect ground or repair
Replace battery

Fuse blown
Electronic voltage regulator or alternator
Poor grounding
Worn battery

EEA -4

ENGINE ELECTRICAL SYSTEM(D4FA - DSL1.5)

CHARGING SYSTEM
DESCRIPTION

ON-VEHICLE INPECTION

E52DA296

CAUTION

ECD624A6

The charging system included a battery, an alternator with

a built-in regulator, and the charging indicator light and
wire.
The Alternator has eight built-in diodes, each rectifying AC
current to DC current.
Therefore, DC current appears at alternator "B" terminal.
In addition, the charging voltage of this alternator is regulated by the battery voltage detection system.
The alternator is regulated by the battery voltage detection system. The main components of the alternator are
the rotor, stator, rectifier, capacitor brushes, bearings and
V-ribbed belt pulley. The brush holder contains a built-in
electronic voltage regulator.

Brush

Check that the battery cables are connected

to the correct terminals.
Disconnect the battery cables when the battery is given a quick charge.
Never disconnect the battery while the engine
is running.
CHECK BATTERY VOLTAGE
1.

If 20 minutes have not passed since the engine was

stopped, turn the ignition switch ON and turn on the
electrical system (headlamp, blower motor, rear defogger etc.) for 60 seconds to remove the surface
charge.

2.

Turn the ignition switch OFF and turn off the electrical
systems.

3.

Measure the battery voltage between the negative (-)

and positive (+) terminals of the battery.

Drive belt pulley

Standard voltage : 12.5 ~ 12.9V at 20 C(68 F)

Rectifier
Stator

If the voltage is less than specification, charge the

battery.

Rotor

CHECK THE BATTERY TERMINALS AND FUSES

LBGF001A

1.

Check that the battery terminals are not loose or corroded.

2.

Check the fuses for continuity.

VISUALLY CHECK ALTERNATOR WIRING AND

LISTEN FOR ABNORMAL NOISES
1.

Check that the wiring is in good condition.

2.

Check that there is no abnormal noise from the alternator while the engine is running.

CHECK DISCHARGE WARNING LIGHT CIRCUIT

1.

Warm up the engine and then turn it off.

2.

Turn off all accessories.

3.

Turn the ignition switch "ON". Check that the discharge warning light is lit.

4.

Start the engine. Check that the light is lit.

If the light does not go off as specified, troubleshoot
the discharge light circuit.

CHARGING SYSTEM

EEA -5

INSPECT CHARGING SYSTEM

TEST

VOLTAGE DROP TEST OF ALTERNATOR OUTPUT

WIRE

1.

Start the engine.

2.

Turn on the headlamps and blower motor, and set the

engine speed until the ammeter indicates 20A.
And then, read the voltmeter at this time.

This test determines whether or not the wiring between the

alternator "B" terminal and the battery (+) terminal is good
by the voltage drop method.

RESULT

PREPARATION

1.

1.

Turn the ignition switch to "OFF".

2.

Disconnect the output wire from the alternator "B" terminal. Connect the (+) lead wire of ammeter to the
"B" terminal of alternator and the (-) lead wire of ammeter to the output wire. Connect the (+) lead wire of
voltmeter to the "B" terminal of alternator and the (-)
lead wire of voltmeter to the (+) terminal of battery.

Alternator

Ammeter

Voltmeter

Battery

BBGE002A

The voltmeter may indicate the standard value.

Standard value : 0.2V max

2.

If the value of the voltmeter is higher than expected

(above 0.2V max.), poor wiring is suspected. In this
case check the wiring from the alternator "B" terminal
to the battery (+) terminal. Check for loose connections, color change due to an over-heated harness,
etc. Correct them before testing again.

3.

Upon completion of the test, set the engine speed at

idle.
Turn off the headlamps, blower motor and the ignition
switch.

EEA -6

ENGINE ELECTRICAL SYSTEM(D4FA - DSL1.5)

OUTPUT CURRENT TEST

TEST

This test determines whether or not the alternator gives an

output current that is equivalent to the normal output.

1.

Check to see that the voltmeter reads as the same

value as the battery voltage. If the voltmeter reads 0V,
and the open circuit in the wire between alternator "B"
terminal and battery (-) terminal or poor grounding is
suspected.

2.

Start the engine and turn on the headlamps.

3.

Set the headlamps to high beam and the heater

blower switch to HIGH, quickly increase the engine
speed to 2,500 rpm and read the maximum output
current value indicated by the ammeter.

PREPARATION
1.

Prior to the test, check the following items and correct

as necessary.
Check the battery installed in the vehicle to ensure
that it is good condition. The battery checking method
is described in the section "Battery".
The battery that is used to test the output current
should be one that has been partially discharged.
With a fully charged battery, the test may not be conducted correctly due to an insufficient load.
Check the tension of the alternator drive belt. The
belt tension check method is described in the section
"Inspect drive belt".

2.

Turn off the ignition switch.

3.

Disconnect the battery ground cable.

4.

Disconnect the alternator output wire from the alternator "B" terminal.

5.

Connect a DC ammeter (0 to 150A) in series between

the "B" terminal and the disconnected output wire. Be
sure to connect the (-) lead wire of the ammeter to the
disconnected output wire.

NOTE
After the engine start up, the charging current quickly
drops. Therefore, the above operation must be done
quickly to read the maximum current value correctly.
RESULT
1.

The ammeter reading must be higher than the limit

value. If it is lower but the alternator output wire is in
good condition, remove the alternator from the vehicle
and test it.

Limit value (120A alternator) : 84A min.

NOTE

NOTE

The nominal output current value is shown on the

nameplate affixed to the alternator body.
The output current value changes with the electrical load and the temperature of the alternator
itself.
Therefore, the nominal output current may not be
obtained. If such is the case, keep the headlamps on the cause discharge of the battery, or
use the lights of another vehicle to increase the
electrical load.
The nominal output current may not be obtained if
the temperature of the alternator itself or ambient
temperature is too high. In such a case, reduce
the temperature before testing again.

Tighten each connection securely, as a heavy current

will flow. Do not rely on clips.
6.

Connect a voltmeter (0 to 20V) between the "B" terminal and ground. Connect the (+) lead wire to the alternator "B" terminal and (-) lead wire to a good ground.

7.

Attach an engine tachometer and connect the battery

ground cable.

8.

Leave the engine hood open.

Voltmeter Ammeter

Ioad

2.

Upon completion of the output current test, lower the

engine speed to idle and turn off the ignition switch.

3.

Disconnect the battery ground cable.

4.

Remove the ammeter and voltmeter and the engine

tachometer.

5.

Connect the alternator output wire to the alternator

"B" terminal.

6.

Connect the battery ground cable.

Check engine
L
S or DUMMY

LBGF002A

CHARGING SYSTEM

EEA -7

REGULATED VOLTAGE TEST

TEST

The purpose of this test is to check that the electronic voltage regulator controls voltage correctly.

1.

PREPARATION
1.

Turn on the ignition switch and check to see that the

voltmeter indicates the following value.

Voltage: Battery voltage

Prior to the test, check the following items and correct

if necessary.
Check that the battery installed on the vehicle is fully
charged. The battery checking method is described
in the section "Battery".
Check the alternator drive belt tension. The belt tension check method is described in the section "Inspect
drive belt".

If it reads 0V, there is an open circuit in the wire between the alternator "B" terminal and the battery and
the battery (-) terminal.
2.

Start the engine. Keep all lights and accessories off.

3.

Run the engine at a speed of about 2,500 rpm and

read the voltmeter when the alternator output current
drops to 10A or less

2.

Turn ignition switch to "OFF".

3.

Disconnect the battery ground cable.

RESULT

4.

Connect a digital voltmeter between the "B" terminal

of the alternator and ground. Connect the (+) lead
of the voltmeter to the "B" terminal of the alternator.
Connect the (-) lead to good ground or the battery (-)
terminal.

1.

5.

Disconnect the alternator output wire from the alternator "B" terminal.

6.

7.

REGULATING VOLTAGE TABLE

Voltage regulator
ambient temperature
C ( F)

Connect a DC ammeter (0 to 150A) in series between

the "B" terminal and the disconnected output wire.
Connect the (-) lead wire of the ammeter to the disconnected output wire.

-20 (-4)
20 (68)
60 (140)
80 (176)

Attach the engine tachometer and connect the battery

ground cable.

Voltmeter Ammeter

14.2
14.0
13.7
13.5

~
~
~
~

15.4
15.0
14.9
14.7

Upon completion of the test, reduce the engine speed

to idle, and turn off the ignition switch.

3.

Disconnect the battery ground cable.

4.

Remove the voltmeter and ammeter and the engine

tachometer.

5.

Connect the alternator output wire to the alternator

"B" terminal.

6.

Connect the battery ground cable.

Check engine

LBGF002A

Regulating voltage (V)

2.
Ioad

L
S or DUMMY

If the voltmeter reading agrees with the value listed in

the regulating voltage table below, the voltage regulator is functioning correctly. If the reading is other than
the standard value, the voltage regulator or the alternator is faulty.

EEA -8

ENGINE ELECTRICAL SYSTEM(D4FA - DSL1.5)

ALTERNATOR
REPLACEMENT

E32558EE

1.

Disconnect the battery negative terminal first, then the

positive terminal.

2.

Disconnect the alternator connector(A), and remove

the cable(B) from alternator "B" terminal.
B

LCGF119A

3.

Remove the alternator(A).

Tightening torque :
38.2 ~ 58.8N.m (3.9 ~ 6.0kgf.m, 28.2 ~ 43.4lbf.ft)

LCGF005A

4.

Installation is the reverse order of removal.

CHARGING SYSTEM
COMPONENT

EEA -9

EBE188A8

23
7
6
21

20
4

16

22
19
12
18
17

11
10
15

14
13
1.
2.
3.
4.
5.
6.
7.
8.

Nut
Pulley
Bushing
Front cover assembly
Stator coil
Front bearing
Front bearing cover
Front bearing cover bolt

9.
10.
11.
12.
13.
14.
15.
16.

Rotor coil
Rear bearing
Rear bearing cover
Damper
Packing
Rear cover
Through bolt
Seal

17.
18.
19.
20.
21.
22.
23.

Rectifier assembly
Brush holder assembly
Brush holder bolt
Stud bolt
Guard
Cover
Cover nut
LBGF037A

EEA -10

ENGINE ELECTRICAL SYSTEM(D4FA - DSL1.5)

DISASSEMBLY
1.

4.

EE5DAE6A

Remove the slip ring guide(A).

Remove the B terminal mounting nut(A) and rear

cover nut(B).

A
B

LBGF005A

5.

Remove the pulley(A) using the special tool.

LCGF120A

2.

Remove the alternator cover(A) using a screw

driver(B).
B
A

SST(09373-27000)
LBGF006A

6.

Unsolder the 3 stator leads(A).

LBGF003A

3.

Loosen the mounting bolts(A) and disconnect the

brush holder assembly(B).
A
A

B
A

LCGF121A

LBGF004A

CHARGING SYSTEM
7.

EEA -11
INSPECTION

Loosen the 4 through bolts(A).

E1D4E7FD

INSPECT ROTOR

1.

Check that there is continuity between the slip

rings(A).
A

A
LBGF007A

8.

Disconnect the rotor(A) and cover(B).

C
B

A
LBGF009A

2.

Check that there is no continuity between the slip rings

and the rotor(B) or rotor shaft(C).

3.

If the rotor fails either continuity check, replace the

alternator.

INSPECT STATOR
1.

Check that there is continuity between each pair of

leads(A).

B
A
LBGF008A

9.

Reassembly is the reverse order of disassembly.

LBGF010A

2.

Check that there is no continuity between each lead

and the coil core.

3.

If the coil fails either continuity check, replace the alternator.

EEA -12

ENGINE ELECTRICAL SYSTEM(D4FA - DSL1.5)

BATTERY
DESCRIPTION

EF8FBD2E

1.

The maintenance-free battery is, as the name implies,

totally maintenance free and has no removable battery cell caps.

2.

Water never needs to be added to the maintenancefree battery.

3.

The battery is completely sealed, except for small vent

holes in the cover.

EBJD008A

CHARGING SYSTEM
INSPECTION

EEA -13

EC7F1CDF

BATTERY DIAGNOSTIC TEST (1)

CHECKING FLOW

Step 1 : Visual inspection

Check for obvious damage such as a cracked or broken
terminal and case or cover that could permit leakage of
electrolyte.
Determine the cause of damage and correct as needed.
Clean any corrosion with as solution of baking soda and
water.

Terminal & case of

cover damage,
electrolyte leakage
Replace battery

OK

Step 2 : Measure battery voltage

Check the voltage after at least one day in case of
recharging the battery, and the recharging should be made
in accordance with the charging instructions.

Below 11.0V
Replace battery
Above 12.5V

Charging system inspection

OK (11.0 ~ 12.4V)

Charge battery

Step 3 : Load test

Perform an eletrical load using the appropriate load test
amperage specifications for the battery.

Refer to load test

Replace battery

OK

Battery is good

LBGF011A

EEA -14

ENGINE ELECTRICAL SYSTEM(D4FA - DSL1.5)

LOAD TEST

BATTERY DIAGNOSTIC TEST (2)

1.

Perform the following steps to complete the load test

procedure for maintenance free batteries.

1.

Make sure the ignition switch and all accessories are

in the OFF position.

2.

Connect the load tester clamps to the terminals and

proceed with the test as follow:

2.

Disconnect the battery cables (negative first).

1)

3.

Remove the battery from the vehicle.

If the battery has been on charge, remove the

surface charge by connect a 300ampere load for
15 seconds.

2)

Connect the voltmeter and apply the specified

load.

3)

Read the voltage after the load has been applied

for 15 seconds.

4)

Disconnect the load.

5)

Compare the voltage reading with the minimum

and replace the battery if battery test voltage is
below that shown in the voltage table.
Voltage

Temperature

9.6V

20 C (68.0 F) and above

9.5V

16 C (60.8 F)

9.4V

10 C (50.0 F)

9.3V

4 C (39.2 F)

9.1V

-1 C (30.2 F)

8.9V

-7 C (19.4 F)

8.7V

-12 C (10.4 F)

8.5V

-18 C (-0.4 F)

CAUTION
Care should be taken in the event the battery case
is cracked or leaking, to protect your skin from the
electrolyte.
Heavy rubber gloves (not the household type)
should be wore when removing the battery.

EBJD008B

4.

Inspect the battery tray for damage caused by the loss

of electrolyte. If acid damage is present, it will be
necessary to clean the area with a solution of clean
warm water and baking soda. Scrub the area with a
stiff brush and wipe off with a cloth moistened with
baking soda and water.

5.

Clean the top of the battery with the same solution as

described above.

6.

Inspect the battery case and cover for cracks.

cracks are present, the battery must be replaced.

7.

Clean the battery posts with a suitable battery post

tool.

8.

Clean the inside surface of the terminal clamps with

a suitable battery cleaning tool. Replace damaged or
frayed cables and broken terminal clamps.

9.

Install the battery in the vehicle.

NOTE
-

If the voltage is greater shown in the table, the

battery is good.
If the voltage is less than shown in the table, replace the battery.

If

10. Connect the cable terminals to the battery post, making sure tops of the terminals are flush with the tops
of the posts.

CHARGING SYSTEM

EEA -15

11. Tighten the terminal nuts securely.

12. Coat all connections with light mineral grease after
tightening.
CAUTION
When batteries are being charged, an explosive
gas forms beneath the cover of each cell. Do
not smoke near batteries being charged or which
have recently been charged. Do not break live circuit at the terminals of batteries being charged.
A spark will occur when the circuit is broken.
Keep open flames away from battery.

EBJD008A

EEA -16

ENGINE ELECTRICAL SYSTEM(D4FA - DSL1.5)

STARTING SYSTEM
DESCRIPTION

STARTER CIRCUIT
TROUBLESHOOTING

E9CCB56A

E6CD00C1

NOTE
The starting system includes the battery, starter, solenoid
switch, ignition switch, inhibitor switch (A/T), ignition lock
switch, connection wires and the battery cable.
When the ignition key is turned to the start position, current
flows and energizes the starter motors solenoid coil.
The solenoid plunger and clutch shift lever are activated,
and the clutch pinion engages the ring gear.
The contacts close and the starter motor cranks. In order
to prevent damage caused by excessive rotation of the
starter armature when the engine starts, the clutch pinion
gear overruns.

The battery must be in good condition and fully

charged.
1.

Remove the fuel pump relay from the fuse box.

Solenoid

ABGE002A

2.
Brush assembly
Armature

With the shift lever in N or P (A/T) or clutch pedal

pressed (M/T), turn the ignition switch to "START"
If the starter normally cranks the engine, starting system is OK. If the starter will not crank the engine at
all, go to next step.

Overrun clutch
LBGF012A

If it wont disengage from the ring gear when you release key, check for the following until you find the
cause.
Solenoid plunger and switch malfunction.
Dirty pinion gear or damaged overrunning clutch.
3.

Check the battery condition. Check electrical connections at the battery, battery negative cable connected
to the body, engine ground cables, and the starter for
looseness and corrosion. Then try starting the engine
again.
If the starter cranks normally the engine, repairing the
loose connection repaired the problem. The starting
system is now OK.
If the starter still does not crank the engine, go to next
step.

4.

Disconnect the connector from the S-terminal of solenoid. Connect a jumper wire from the B-terminal of
solenoid to the S-terminal of solenoid.
If the starter cranks the engine, go to next step.
If the starter still does not crank the engine, remove
the starter, and repair or replace as necessary.

STARTING SYSTEM
5.

Check the following items in the order listed until you

find the open circuit.
Check the wire and connectors between the
drivers under-dash fuse/relay box and the ignition switch, and between the drivers under-dash
fuse/relay box and the starter.
Check the ignition switch (Refer to BE group ignition system)
Check the transaxle range switch connector or
ignition lock switch connector.
Inspect the starter relay.

EEA -17
STATER SOLENOID TEST
1.

Disconnect the field coil wire from the M-terminal of

solenoid switch.

2.

Connect a 12V battery between S-terminal and the

starter body.

B
M

Starter
motor

12V

BBGE004A

3.

Connect the field coil wire to the M-terminal.

CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.

4.

If the pinion moves out, the pull-in coil of solenoid is

working properly.
If the pinion does not move, replace the solenoid.

5.

Diconnect the field coil wire from the M-terminal.

6.

If the pinion has moved out, the hold-in coil of the

solenoid is working properly.
If the pinion moves in, replace the solenoid.

EEA -18

ENGINE ELECTRICAL SYSTEM(D4FA - DSL1.5)

STARTER

FREE RUNNING TEST

1.

2.
3.

Place the starter motor in a vise equipped with soft

jaws and connect a fully-charged 12-volt battery to
starter motor as follows.
Connect a test ammeter (100-ampere scale) and carbon pile rheostats shown is the illustration.

REPLACEMENT
1.

Disconnect the battery negative cable.

2.

Disconnect the starter cable(A) from the B terminal on

the solenoid then disconnect the connector(B) from
the S terminal.

Connect a voltmeter (15-volt scale) across starter motor.

S
M

EFC90D5C

Corbon-pile rheostat
Ammeter
A

Starter
motor

V Voltmeter

Battery
12V
A
B
LCGF122A
BBGE005A

4.

Rotate carbon pile to the off position.

5.

Connect the battery cable from batterys negative post

to the starter motor body.

6.

Adjust until battery voltage shown on the voltmeter

reads 11volts.

7.

Confirm that the maximum amperage is within

the specifications and that the starter motor turns
smoothly and freely.

Current : 90A max

Speed : 2,600 rpm

3.

Remove the 2 bolts holding the starter, then remove

the starter.

4.

Installation is the reverse of removal.

5.

Connect the battery negative cable to the battery.

STARTING SYSTEM
COMPONENT

EEA -19

E9B18E5C

14
6
7
4

1
13
12
11
10
15
9

5
3
2
20
19
18

17
16

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Screw
Front bracket assembly
Stop ring
Stopper
Overrun clutch assembly
Lever
Plate
Lever packing
Internal gear assembly
Planet shaft assembly

11.
12.
13.
14.
15.
16.
17.
18.
19.
20.

Planetary gear assembly

Steel ball
Packing
Magnet switch assembly
Through bolt
Yoke assembly
Armature assembly
Brush holder assembly
Rear bracket
Screw
LBGF013A

EEA -20

ENGINE ELECTRICAL SYSTEM(D4FA - DSL1.5)

DISASSEMBLY
1.

4.

E3BDCF91

Remove the rear bracket(A) and brush holder assembly(B).

Disconnect the M-terminal(A) on the magnet switch

assembly(B).
A
B
A

LBGF017A

LBGF014A

2.

5.

Remove the yoke(A) and armature(B).

After loosening the 2 screws(A), detach the magnet

switch assembly(B).

A
B

A
B
LBGF018A

6.
LBGF015A

3.

Loosen the brush holder mounting screw(A) and

through bolts(B).

Remove the lever plate(A) and planet shaft packing(B).

A

LBGF019A

LBGF016A

STARTING SYSTEM
7.

EEA -21

Disconnect the planet gear(A).

10. After removing the stopper(A) using stopper pliers(B).

8.

LBGF020A

LBGF023A

Disconnect the planet shaft assembly(A) and lever(B).

11. Disconnect the stop ring(A), overrunning clutch(B), internal gear(C) and planet shaft(D).

B
D
B

A
A

LBGF021A
LBGF024A

9.

Press the stop ring(A) using a socket(B).

LBGF022A

EEA -22

ENGINE ELECTRICAL SYSTEM(D4FA - DSL1.5)

INSPECTION

12. Reassembly is the reverse of disassembly.

EB74B9B5

ARMATURE INSPECTION AND TEST

NOTE
Using a suitable pulling tool(A), pull the overrunning
clutch stop ring(B) over the stopper(C).

1.

Remove the starter.

2.

Disassemble the starter as shown at the beginning of

this procedure.

3.

Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or
damage, replace the armature.

LBGF025A

LBGF026A

4.

Check the commutator(A) surface. If the surface is

dirty or burnt, resurface with emery cloth or a lathe
within the following specifications, or recondition with
#500 or #600 sandpaper(B).

LBGF027A

STARTING SYSTEM
5.

EEA -23

Check the commutator diameter. If the diameter is

below the service limit, replace the armature.

7.

Commutator diameter
Standard (New) : 29.4 mm (1.1575 in)
Service limit : 28.8 mm (1.1339 in)

Check the mica depth(A). If the mica is too high(B),

undercut the mica with a hacksaw blade to the proper
depth. Cut away all the mica(C) between the commutator segments. The undercut should not be too
shallow, too narrow, or v-shaped(D).

Commutator mica depth

Standard (New) : 0.5 mm (0.0197 in.)
Limit : 0.2mm (0.0079 in.)

D
B

A
LBGF028A

6.

Measure the commutator(A) runout.

If the commutator runout is within the service
limit, check the commutator for carbon dust or
brass chips between the segments.
If the commutator run out is not within the service
limit, replace the armature.

LBGF030A

8.

Check for continuity between the segments of the

commutator. If an open circuit exists between any
segments, replace the armature.

Commutator runout
Standard (New) : 0.02mm (0.0008in.) max
Service limit : 0.05mm (0.0020in.)

LBGF031A

LBGF029A

EEA -24
9.

ENGINE ELECTRICAL SYSTEM(D4FA - DSL1.5)

Check with an ohmmeter that no continuity exists between the commutator(A) and armature coil core(B),
and between the commutator and armature shaft(C).
If continuity exists, replace the armature.

STARTER BRUSH HOLDER TEST

Check that there is no continuity between the (+) brush
holder(A) and (-) brush holder(B). If there is no continuity,
replace the brush holder assembly.

A
B

A
LBGF032A
EBBD330A

INSPECT STARTER BRUSH

INSPECT OVERRUNNING CLUTCH
Brushes that are worm out, or oil-soaked, should be replaced.

1.

Slide the overrunning clutch along the shaft.

Replace it if does not slide smoothly.

2.

Rotate the overrunning clutch both ways.

Does it lock in one direction and rotate smoothly in
reverse? If it does not lock in either direction of it locks
in both directions, replace it.

Limit line

LBGF033A

LBGF034A

3.

If the starter drive gear is worn or damaged, replace

the overrunning clutch assembly. (the gear is not
available separately)
Check the condition of the flywheel or torque converter ring gear if the starter drive gear teeth are damaged.

STARTING SYSTEM
CLEANING
1.

Do not immerse parts in cleaning solvent.

Immersing the yoke assembly and/or armature will
damage the insulation wipe these parts with a cloth
only.

2.

Do not immerse the drive unit in cleaning solvent.

The overrun clutch is pre-lubricated at the factory and
sol-vent will wash lubrication from the clutch.

3.

The drive unit may be cleaned with a brush moistened

with cleaning solvent and wiped dry with a cloth.

EEA -25

STARTER RELAY
INSPECTION

E4DA1682

1.

Remove the fuse box cover.

2.

Remove the starter relay(A).

ABGE018A

3.

4.

Using an ohmmeter, check that there is continuity between each terminal.

Terminal

Continuity

30 - 87

NO

85 - 86

YES

Apply 12V to terminal 85 and ground to terminal 86.

Check for continuity between terminals 30 and 87.

LDAD510B

5.

If there is no continuity, replace the starter relay.

6.

Install the starter relay.

7.

Install the fuse box cover.

EEA -26

ENGINE ELECTRICAL SYSTEM(D4FA - DSL1.5)

PREHEATING SYSTEM
COMPONENT

E5D24EED

0.8 ~ 1.5
(0.08 ~ 0.15, 0.6 ~ 1.1)
3
15 ~ 20
(1.5 ~ 2.0, 11 ~ 14)

TORQUE : N.m(kgf.m, lbf.ft)

1. Glow plug connector
2. Glow plug plate

3. Glow plug
LCGF123A

PREHEATING SYSTEM
INSPECT PREHEATING SYSTEM

EEA -27
E6757D67

Conditions before inspection :

Battery voltage : 12V
Cooling water temperature : Below 30 C (86 F)
(Disconnect the water temperature sensor connector).

INSPECT GLOW PLUS

1.

Check the continuity between the terminal and body

as illustrated. Replace if discontinuity or with large
resistance.

Standard value : 0.25

CAUTION
Reconnect the water temperature sensor connector after inspection.
1.

Connect voltmeter between glow plug plate and plug

body (ground).

2.

Check indicated value on voltmeter with ignition

switch ON.

3.

Check that preheat indication lamp lights for about 6

seconds and indicates battery voltage (about 9V or
over) for about 36 seconds immediately after ignition
switch is turned on. [At cooling water temperature
20 C (68.0 F)]

CAUTION
Remove oil from plug before measuring as glowplug resistance is very small.
2.

Check for rust on glow plug plate.

3.

Check glow plug for damage.

NOTE
Continuity time varies depending upon cooling water
temperature.
4.

After checking 3, set ignition switch at START position.

5.

The system is normal if battery voltage (about 9V or

over) is generated for about 6 seconds during engine
cranking and after start operation. [at cooling water
temperature 20 C (68.0 F)]

6.

When the voltage or continuity time is not normal,

check the terminal voltage in glow control unit, and
single parts.

EBKD300O

EBKD300P

EEA -28

ENGINE ELECTRICAL SYSTEM(D4FA - DSL1.5)

INSPECT GLOW PLUG RELAY

1.

Remove the glow plug relay.

2.

Inspect the relay continuity.

Using an ohmmeter, check that there is continuity
between terminals 2 and 4.
If there is no continuity, replace the relay.
Check that there is no continuity between terminals 1 and 5.
If there is continuity, replace the relay.

2
1
5
4

LBGF035A

3.

Inspect the relay operation.

Apply battery positive voltage across terminals 2
and 4.
Using an ohmmeter, check that there is continuity
between terminals 1 and 5.
If there is no continuity, replace the relay.

2
1
5
4

LBGF036A

4.

Install the glow plug relay.