02 engine electrical system

8/3/2019 02 Engine Electrical System

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ENGINEELECTRICALSYSTEMReturn To Main Table of ContentsGENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 8

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GENERAL

GENERAL

SPECIFICATIONS

Distributor MPI FBC

Type Contact pointless type

Advance mechanismControlled by electronic control unit

Firing order 1 - 3 - 4 - 2

Centrifugal and vacuum type

Ignition coilMPI FBC

TypePrimary coil resistance

Secondary coil resistance

Identification No.Diamond

Poong Sung

Dae Joon

Mold single-coil

0.8 ± 0.08 CI

12.1 ± 1.8 Kfi

F - 0 8 8

PC88

DSA-117

1.2 ± 0.12D

13.7 ± 2.1 Kfl

-

PN22C-

Spark plug (MPI, FBC)

TypeNGK

Champion

Plug gap

BUR6EA-11

BPR6ES-11

RN9YC4

1.0-1.1 mm (0.039-0.043 in.)

2 7 - 2



GENERAL

Starter motor (MPI, FBC)

TypeRated output

Rated time

No-load characteristics

Terminal voltage

Amperage

Maximum speed

No. of pinion teeth

Pinion gap

A/T, Power Steering

Direct drive type

12V 0.9 KW

30 sec

11.5V

60A or less

6,600 rpm or more

8

0.0197-0.079 in. (0.5-2 mm)

M / T

l2V 0.7 KW

6,500 rpm or more

AlternatorMPI FBC

TypeRated output

Voltage regulator type

Regulator setting voltage

Temperature compensation

Identification No.

Melco

Mando

Battery voltage sensing

12V 75A (13.5V in case of Mando products)

Electronic built-in type

14.4 ± 0.3V

-10 ± 3 mV/°C

A2T09493

AB175015

13.5V 65A

14.7 ± 0.3V

-7 ± 3 mV/°C

-

AB165014

Battery (MPI, FBC)

Type MF 60AH-B (Maintenance-free battery)

Ampere hours (5HR) 48 Ah or more

(20HR) 60 Ah or moreCold cranking [at -17.8°C (0°F)] 420 A or more

Reserve capacity 92 min.

Specific gravity [at 25°C (77°F)] 1.270 ± 0.01

NOTE

COLD CRANK AMPERAGE is the amperage a battery can deliver for 30 seconds and maintain a terminal

voltage of 7.2 or greater at a specified temperature.

RESERVE CAPACITY RATING is the amount of time a battery can deliver 25A and maintain a minimum

terminal voltage of 10.5 at 26.7°C (80°F).

2 7 - 3



IGNITION SYSTEM (MPI)

IGNITION SYSTEM

GENERAL INFORMATION

Ignition timing is controlled by the electronic control ignition

timing system. The standard reference ignition timing data for

the engine operation conditions are programmed in the memory

of the electronic control unit (ECU).

The engine conditions (rpm, load, warm-up condition, etc.) are

detected by the various sensors. Based upon these sensor

signals and the ignition timing data, signals to interrupt the

primary current are sent to the power transistor. The ignition coil

is activated, and timing is controlled this way.

TROUBLESHOOTING

Probable condition Probable cause

Engine will not start or is Incorrect ignition timing

Remedy

Adjust ignition timing

hard to start. (Cranks OK)Ignition coil faulty Inspect ignition coil

Power transistor faulty

Distributor faulty

Inspect power transistor

Inspect distributor

High tension cable faulty

Spark plugs faulty

Inspect high tension cable

Replace plugs

Ignition wiring disconnected or broken Inspect wiring

Rough idle or stalls Spark plugs faulty Replace plugs

Ignition wiring faulty

Incorrect ignition timing

Inspect wiring


Ignition coil faulty Inspect ignition coil

Power transistor faulty

High tension cord faulty

Spark plugs faulty

Ignition wiring faulty


Spark plugs faulty



Inspect power transistor

Inspect high tension cord

Replace plugs

Inspect wiring

Adjust timing

Replace plugs



Engine hesitates/poor

acceleration

Poor mileage

Engine overheats

2 7 - 4




IGNITION TIMING

Adjustment conditions:

Coolant temperature: 80-95°C (1 70-205°F)

Lamps, cooling fan, and all accessories: Off

Transaxle: Neutral (N or P for A/T)

Parking brake: On

Adjustment Procedures

1.

2.

3.

4.

5.

6.

7.

Connect timing light.

Start engine and run at curb idle speed.

Curb idle speed: 700 ± 100 rpm

With the engine stopped, connect a lead wire with alligator

clips to the terminal for ignition-timing adjustment (located

in the engine compartment), and ground it.

Start and run the engine at curb idle speed.

Check basic ignition timing and adjust if necessary.

Basic ignition timing: 5° ± 2°BTDC

If the timing is incorrect, loosen the distributor mounting nut,

and rotate the distributor until the timing is correct.

NOTE

The ignition timing will be advanced if the distributor is

turned to the left and retarded if it is turned to the right.

After adjustment, securely tighten the mounting nut.

Tightening torque: 10-13 Nm (100-130 kg.cm, 7-9 lb.ft)

CAUTION

Be careful, when tightening the nut, that the distributor

does not move.

8. Stop the engine.

9. Disconnect the lead wire connected at step 3.

10. Start and run the engine at curb idle speed.

11. Check to be sure that the idling ignition timing is the correct

timing.

Actual ignition timing: 10°BTDC

2 7 - 5




CHECKING IGNITION COILS

1. Measurement of the primary coil resistance.

Measure the resistance of the positive (+) terminal and

negative (-) terminal of the ignition coil.

Standard value: 0.8 ± 0.08n

2. Measurement of the secondary coil resistance.

Measure the resistance between the ignition coil’s positive

(+) terminal and the high-voltage terminal.

Standard value: 12.1 ± 1.8 KR

POWER TRANSISTOR

1. Connect the negative (-) terminal of the 3V power supply

to terminal 2 of the power transistor; then check whether

there is continuity between terminal 3 and terminal 2 when

terminal 1 and the positive (+) terminal are connected and

disconnected.

Terminal 1 and (+) terminal Terminal 3 and terminal 2

Connected Continuity

Disconnected No continuity

2. Replace the power transistor if there is a malfunction.

CHECKING SPARK PLUG

Inspection and Cleaning

1. Disconnect the spark plug cable from the spark plug.

NOTE

Pull on the spark plug cable boot when removing the spark

plug cable, not the cable, as it may be damaged.

2. Using a plug spark wrench, remove all of the spark plugs

from the cylinder head.

CAUTIONTake care not to allow contaminants to enter through the

spark plug holes.

3. Check the spark plugs for the following:

1) Broken insulator

2) Worn electrode

3) Carbon deposits

4) Damaged or broken gasket

5) Condition of the porcelain insulator at the tip of the spark

plug

2 7 - 6




4. Check the spark plug gap using a wire gap gauge, and adjust

if necessary.

Standard value: 1.0-1.1 mm (0.039-0.043 in.)

5. Re-insert the spark plug and tighten to the specified torque.

If it is overtorqued, damage to the threaded portion of

cylinder head might result.

Spark plug: 20-30 Nm (204-306 kg.cm, 15-21 lb.ft)

Analyzing Spark Plug

Engine conditions can be analyzed by the tip deposits near the

electrode.

Condition Dark deposits White deposits

Description o Too rich a fuel o Too lean a fuel mixture

mixture o Advanced ignition timing

o Low air intake o Insufficient plug tightening

2 7 - 7




SPARK PLUG TEST(When engine can be cranked)

Connect the spark plug to the high tension cable. Ground the

outer electrode (main body), and crank the engine. In the

atmosphere, only short sparks are produced because of the small

discharge gap. If the spark plug is good, however, sparks will

occur in the discharge gap (between the electrodes). In a

defective spark plug, no sparks will occur because of a leak

through the insulation.

CHECKING SPARK PLUG CABLES

1. Check the cap and outer shell for cracks.2. Measure the resistance.

Unit: KO

No.1 No.2 No.3 No.4

Resistance 10.1 11.8 11.8 14.2

NOTE

Resistance should not be higher than 10,000~ per foot

of cable. If resistance is higher, replace the cable.

2 7 - 8




REMOVAL AND INSTALLATION OF COMPONENTS

TORQUE Nm (kg.cm, lb.ft)

DISTRIBUTOR

Removal

1. Disconnect the battery ground cable.

2. Remove the two distributor cap retaining clips and move cap

to one side.

3. Disconnect the lead wire connector.

4. Remove the distributor mounting nut and remove the

distributor assembly.

Installation

1. Turn the crankshaft so that No.1 piston cylinder is at top

dead center.

2. Align the distributor housing and gear mating marks.

3. Install the distributor in to the engine while aligning the fine

cut groove (or protection) of the distributor’s installation

flange with the center of the distributor installation stud.



DISASSEMBLY AND ASSEMBLY OF DISTRIBUTOR

DISASSEMBLY

1. Lightly clamp the distributor in a vise equipped with softjaws.

2. Pull off the rotor from the rotor shaft.

3. Remove the packing rubber.

4. Lift off the cover.

5. Remove the rotor shaft by using a driver.

6. Remove the disc and spacer.

7. Disconnect the lead wire connector.

8. Lift off the plate and unit by removing the three mounting

screws.

2 7 - 1 0




9.

10.

11.

12.

Remove the shaft bearing tightening screws.

Make a position identification mark (for the driven gear) on

the distributor shaft.

Place the driven gear on a soft base (wooden block) to

prevent damaged.

Punch out the roll pin by using a pin punch.

INSPECTION OF CAP & ROTOR

After checking the following, repair or replace if a problem is

found.

1. There must be no cracking in the cap.2. There must be no damage to the cap’s electrode or the

rotor’s electrode.

3. There must be no carbon tracking.

4. Clean away any dirt from the cap and rotor.

REASSEMBLY

Distributor ShaftAfter coating the shaft with a small amount of engine oil insert

it into the housing.

CAUTION

Do not use solvent or similar products.

Driven Gear

1. Align the driven gear with the mark made at the time of

disassembly, and install the gear to the distributor shaft.

2. When aligning the driven gear’s mating mark and the

housing’s mating mark, make sure that notch “A” at the

shaft end is at the position shown in the figure, and then

align the roll pin hole and drive in a new roll pin.

CAUTION

Drive in the roll pin so that the slits are at a right angle

relative to the shaft.

2 7 - 1 1




Disc

Insert the disc into the sensor part of the pick up unit and install

in alignment with the spacer.

CAUTION

The disc’s slits must not be restricted.

Cover

Install the cover so that the cover’s indentation “A” is aligned

with the housing’s notch “B”.

2 7 - 1 2



IGNITION SYSTEM (FBC)

GNITION TIMING

Adjustment conditions:

Coolant temperatur e: 80-95°C (1 70-205°F)

Lamps and all accessories: Off

Transmission: Neutral (N or P for A/T)

Parking brake: On

Adjustment Procedures

1. Connect tachometer and timing light.

2. Start engine and run at curb idle speed.

Curb idle speed : 700 ± 50 rpm

3. Check basic ignition timing and adjust if necessary.

Basic ignition timing : 5° ± 1oBTDC

4. To adjust ignition timing, loosen the distributor mounting nut

and rotate the distributor until the timing is correct.

5. After adjustment, securely tighten the mounting nut.

CHECKING SPARK PLUG

nspection and Cleaning

1.

2.

3.

Disconnect the spark plug cable from the spark plug.

NOTE:

Pull on the spark plug cable boot when removing the spark

plug cable, not the cable, as it may be damaged.

Using a plug spark wrench, remove all of the spark plugs

from the cylinder head.

CAUTION:

Take care not to allow contaminants to enter through the

spark plug holes.

Check the spark plugs for the follows:

1) Broken insulator

2) Worn electrode

3) Carbon deposits

4) Damaged or broken gasket

5) Condition of the porcelain insulator at the tip of the spark

plug.

2 7 - 1 3




SPARK PLUG TEST(when engine can be cranked)

Connect the spark plug to the high tension cable. Ground the

outer electrode (main body), and crank the engine. In

atmosphere, only short sparks are produced because of the small

discharge gap. If the spark plug is good, however, sparks will

occur in the discharge gap (between the electrodes). In adefective spark plug, no sparks will occur because of a leak

through the insulation.

CHECKING SPARK PLUG CABLES

1. Check the cap and outer shell for cracks.

2. Measure the resistance.

No.1 No.2 No.3 No.4

Resistance 10.1 11.8 11.8 14.2

NOTE:

Resistance should not be higher than 10,000~ per foot of

cable. If resistance is higher, replace the cable.

2 7 - 1 4




4. Check the spark plug gap using a wire gap gauge, and adjust

if necessary.

Standard value : 1.0-1.1 mm (0.039-0.043 in.)

5. Re-insert the spark plug and tighten to the specified torque.

If it is overtorqued, damage to the threaded portion of

cylinder head might result.

Spark plug : 20-30 Nm (204-306 kg.cm, 15-21 Ib.ft)

Analyzing Spark Plug

Engine conditions can be analyzed by the tip deposits near the

electrode.

Condition Dark deposits White deposits

Description o Too rich a fuel o Too lean a fuel mixture

mixture o Advanced ignition timing

o Low air intake o Insufficient plug

tightening

2 7 - 1 5




DISTRIBUTOR

COMPONENTS

1. Breather2. Cap

3. Contact carbon

4. Rotor

5. Cable assembly

6. Ground wire

7. Igniter

8. Spring pin

9. Signal rotor

10. Breaker base

11. Vacuum controller-Dual diaphragm type

12. Rotor shaft

13. Spring retainer14. Governor spring

15. Governor weight

16. Distributor shaft

17. Oil seal

18. Packing

19. Housing

20. O-ring

21. Washer

22. Driven gear

23. Pin

2 7 - 1 6




REMOVAL

1. Disconnect battery ground cable.

2. Disconnect high tension cable and spark plug cables from

distributor.

3. Disconnect wiring harness from the distributor lead wire.

4. Disconnect vacuum hoses from vacuum controller.5. Remove distributor mounting nut and remove distributor

assembly from engine cylinder head.

DISASSEMBLY

1.

2.

3.

4.

5.

Lightly clamp distributor in a vise equipped with soft jaws.

Remove retaining clips and lift off distributor cap and seal

ring.

Pull off rotor from rotor shaft.

Remove two vacuum controller attaching screws.

Remove link of controller from pin on the breaker base, then

remove vacuum controller.

6. Remove two screws and remove igniter.

7. Remove lead wire (black).

8. Remove signal rotor shaft tightening screw and two breaker

plate retaining screws.

9. Remove signal rotor shaft and breaker plate assembly.

2 7 - 1 7




10. Remove signal rotor shaft from signal rotor.

11. Remove two spring retainers with pliers and then remove

two governor spring.

12. Remove two governor weights.

13. Mark location of drive gear on distributor shaft.

14. Place drive gear on soft base (wood block) so that roll pincan be removed.

15. Using a pin punch, remove roll pin.

16. Remove drive gear and washer.

17. Remove distributor shaft from housing.

REASSEMBLY

1. Clean and inspect all parts.

2. Install shaft into housing.

3. Install drive gear into distributor shaft at previously marked

location. Then install new roll pin.

2 7 - 1 8




4. Install governor weights on the governor plate.

5. Install governor springs and spring retainer.

6. Install signal rotor shaft into distributor shaft.

7. Install breaker plate to housing. Fit the breaker plate so that

the projection (A) fits into the groove (8).

8. Tighten two breaker plate retaining screw.

9. Install signal rotor to rotor shaft. Fit the signal rotor so that

the spring pin fits on the rotor shaft.

10. Install ignition to breaker plate and install two screws.

11. Connect one end of lead wire to igniter attaching screw and

other end to breaker plate.

2 7 - 1 9




12. Adjust air gap between signal rotor and pick-up of igniter.

Air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.8 mm (0.03 in.)

13. Connect vacuum control link to breaker plate and tighten two

vacuum controller screws.

14. Install rotor to rotor shaft.

15. Install seal ring and distributor cap to housing and set theretaining clips.

IGNITION COIL

Inspection

1. Using a circuit tester, measure resistance. An open or short

circuited coil should be replaced.

[Standard value]

Primary coil resistance . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2 n

Secondary coil resistance . . . . . . . . . . . . . . . . . . . . . 13.7 K0

External resistor resistance . . . . . . . . . . . . . . . . . . . . 1.35 a

2 7 - 2 0



CHARGING SYSTEM

CHARGING SYSTEM

GENERAL INFORMATION

The charging system includes a battery, an alternator with a

built-in regulator, and the charging indicator light and wires. The

alternator has six built-in diodes (three positive and three

negative), 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 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.

TROUBLESHOOTING

Symptom Probable cause 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 faulty.

Charging warning

indicator does not

go out with engine

running.

(Battery requires

frequent recharging).

Discharge battery.

Drive belt loose or worn.

Battery cables loose, corroded or worn.

Fuse blown.

Fusible link blown.

Electronic voltage regulator or alternator

faulty.

Wiring faulty.

Drive belt loose or worn.

Wiring connection loose or open circuit.

Fusible link blown.

Poor grounding.

Electronic voltage regulator or alternator

faulty.

Battery life.

Check fuses.

Replace light.

Tighten loose connections.

Replace voltage regulator.

Adjust tension or replace drive belt.

Repair or replace cables.

Check fuses.

Replace fusible link.

Test alternator.

Repair wiring.

Adjust tension or replace drive belt.

Tighten loose connection or repair

wiring.

Replace fusible link.

Repair.

Test alternator.

Replace battery.

Overcharge Electronic voltage regulator faulty. Replace voltage regulator.

Voltage sensing wire faulty. Repair wire.

2 7 - 2 1



CHARGING SYSTEM

INSPECTION OF CHARGING SYSTEM

VOLTAGE DROP TEST OF ALTERNATOR OUTPUTWIRE

This test determines whether or not the wiring between the

alternator “B” terminal and the battery (+) terminal is good by

the voltage drop method.

Preparation

1. Turn the ignition switch to “OFF”.


3. Disconnect the alternator output lead from the alternator “B”

terminal.

4. Connect a DC ammeter (0 to 100A) in series to the “B”

terminal and disconnected the output lead. Connect the (+)

lead of the ammeter to the “B” terminal and the. (-) lead

to the disconnected output wire.

NOTE

Use a clamp type ammeter that can measure current

without disconnecting the harness. The reason is that

when checking a vehicle that has a low output current due

to poor connection of the alternator “B” terminal, such a

poor connection is corrected as the “B” terminal is

loosened and a test ammeter is connected in its place. As

a result, causes for the trouble may not be determined.

5. Connect a digital voltmeter between the alternator “B”

terminal and battery (+) terminal. Connect the (+) lead wire

of the voltmeter to the “B” terminal and the (-) lead wire

to the battery (+) terminal.

6. Connect the battery ground cable.

7. Leave the hood open.

Test

1. Start the engine.

2. Turn on the headlamps and adjust the engine speed so that

the ammeter reads 20A and read the voltmeter under this

condition.

Result1. It is okay if the voltmeter indicates the standard value.

Standard value: 0.2V max.

2. If the voltmeter indicates a value that is larger than the

standard value, poor wiring is suspected. In this case check

the wiring from the alternator “B” terminal to the fusible link

to the battery (+) terminal. Check for loose connections, color

change due to an overheated harness, etc. Correct them

before testing again.

2 7 - 2 2



CHARGING SYSTEM

3. Upon completion of the test, set the engine speed at idle.

Turn off the head lamps and the ignition switch.


5. Disconnect the ammeter and voltmeter that have been

connected for testing.

6. Connect the alternator output wire to the alternator “B”

terminal.7. Connect the battery ground cable.

OUTPUT CURRENT TEST

This test judges whether or not the alternator gives an output

current that is equivalent to the nominal output.

Prepa ra t ion

. Prior to the test, check the following items and correct as

necessary.

1) Check the battery installed in the vehicle to ensure that

it is in good condition*. The battery checking method is

described in “BATTERY”.

NOTE

*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.

2) Check the tension of the alternator drive belt. The belt

tension check method is described in the section“COOLING”.

2.

3.

4.

Turn off the ignition switch.

Disconnect the battery ground cable.

Disconnect the alternator output wire form the alternator “B”

terminal.

5. Connect a DC ammeter (0 to 100A) 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

Tighten each connection securely, as a heavy current will

flow. Do not rely on clips.

6.

7.

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.

Attach an engine tachometer and connect the battery ground

cable.

8. Leave the engine hood open.

2 7 - 2 3



CHARGING SYSTEM

Test

1. Check to see that the voltmeter reads the same value as the

battery voltage.

If the voltmeter reads 0V, and open circuit in the wire

between the alternator “B” terminal and battery (-)

terminal, a blown fusible link or poor grounding is suspected.

2. Start the engine and turn on the headlights.

3. Set the headlights 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.

NOTE

After the engine startup, 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:

52.5 A min . . . . . . . . . . . . . . . . . . . . . . 75A alternator (MPI)

45A min . . . . . . . . . . . . . . .. .... 65A alternator (FBC)

NOTE

1) The nominal output current value is shown on the

nameplate affixed to the alternator body.

2) 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 headlights on

to 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 testingagain.

2. Upon completion of the output current test, lower the engine

speed to idle and turn off the ignition switch.


4. Remove’ the ammeter and voltmeter and the engine

tachometer.


terminal.


2 7 - 2 4



REGULATED VOLTAGE TEST

The purpose of this test is to check that the electronic voltage

regulator controls voltage correctly.

Preparation

1.

2.

3.

4.

5.

6.

7.

Prior to the test, check the following items and correct ifnecessary.

1) Check the battery installed on the vehicle to see that it

is fully charged. For battery checking method, see

“BATTERY”.

2) Check the alternator drive belt tension. For belt tension

check, see section, “COOLING”.

Turn ignition switch to “OFF”.

Disconnect the battery ground cable.

Connect a digital voltmeter between the “S(L)” terminal of

the alternator and ground. Connect the (+) lead of the

voltmeter to the “S(L)” terminal of the alternator. Connect

the (-) lead to good ground or the battery (-) terminal.

Disconnect the alternator output wire from the alternator “B”

terminal.

Connect a DC ammeter (0 to 100A) in series between the

“B” terminal and the disconnected output wire. Connect the

(-) lead wire of the ammeter to the disconnected output

wire.

Attach the engine tachometer and connect the battery

ground cable.

Test

1. Turn on the ignition switch and check to see that the

voltmeter indicates the following value.

Voltage: Battery voltage

If it reads 0V, there is an open circuit in the wire between

the alternator “S(L)” terminal and the battery (+), or the

fusible link is blown.

2. Start the engine. Keep all lights and accessories off.

3. Run the engine at a speed of about 2,500 rpm and read thevoltmeter when the alternator output current drops to 10A

or less.

2 7 - 2 5



CHARGING SYSTEM

Result

1. 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.

Regulating Voltage Table

Voltage regulator ambient Regulating voltage V

temperature °C (°F) 75A alternator 65A alternator

-20 (-4) 14.2-15.4 14.4-15.6

20 (68) 13.9-14.9 14.2-15.2

60 (140) 13.4-14.6 13.8-15.1

80 (176) 13.1-14.5 13.6-15.0

2. Upon completion of the test, reduce the engine speed to idle,

and turn off the ignition switch.


4. Remove the voltmeter and ammeter and the engine

tachometer.


terminal.


2 7 - 2 6



CHARGING SYSTEM

ALTERNATOR

REMOVAL AND INSTALLATION

TORQUE : Nm (kg.cm, lb.ft)

1. Disconnect the negative terminal from the battery.

2. Loosen the belt tension and remove the belt.

3. Raise the vehicle.

4. Remove the mud guard-LH.

5. Disconnect the alternator B+ terminal wire.

6. Remove the alternator assembly.

7. Installation is the reverse order of removal.

2 7 - 2 7



CHARGING SYSTEM

COMPONENTS (75A)

1. Pulley

2. Seal

3. Rotor assembly

4. Rear bearing

5. Bearing retainer

6. Front bearing

7. Front bracket

8. Stator

9. Plate

10. Voltage regulator and brush holder

11. Brush

12. Brush spring

13. Slinger

14. Rectifier

15. Rear bracket

2 7 - 2 8



CHARGING SYSTEM

COMPONENTS (65A)

1. Pulley

2. Seal

3. Rotor assembly

4. Rear bearing

5. Bearing retainer

6. Front bearing

7. Front bracket

8. Stator

9. Terminal

10. Plate

11. Brush

12. Brush spring

13. Slinger

14. Rectifier assembly

15. Rear bracket

2 7 - 2 9



DISASSEMBLY

1. Remove the three through bolts.

2. Insert a flat screwdriver between the front bracket and stator

core, and pry downward.

CAUTION

1) Do not insert the screwdriver too deeply, as there is

a danger of damaging the stator coil.

2) The rear cover may be hard to remove because a ring

is used to lock the outer race of the rear bearing. To

facilitate removal of rear cover, heat just the bearing

box section with a 200-watt soldering iron.

Do not use a heat gun, as it may damage the diode

assembly.

3. Secure the rotor in a vise with the pulley side up.

CAUTIONBe careful that the vise jaws do not damage the rotor.

4. Remove the pulley nut, then remove the spring washer, then

the pulley, and then the spacer.

5. Remove the front bracket and two seals.

6. Remove the rotor from the vise.

7. Remove the brush holder screws, the rectifier screws, and

the nut from the B terminal.

8. Remove the stator assembly from the rear bracket.

9. Detach the slinger from the brush holder.

10. When the stator is to be removed, unsolder the three statorleads to the main diodes on the rectifier.

CAUTION

1) When soldering or unsoldering, use care to make sure

that heat of soldering iron is not transmitted to the

diodes for a long period.

2) Use care that excessive force is not exerted on the

leads of the diodes.

11. When separating the rectifier from the brush holder,

unsolder the two plates soldered to the rectifier.

2 7 - 3 0



CHARGING SYSTEM

INSPECTION

Rotor

1. Check the rotor coil for continuity. Check to make sure that

there is continuity between the slip rings.

If resistance is extremely low, it means that there is a short.

If there is no continuity or if there is a short circuit, replacethe rotor assembly.

Resistance value: Approx. 3.1 fl

2. Check the rotor coil for ground. Check to make sure that there

is no continuity between slip the ring and the core.

If there is continuity, replace rotor assembly.

Stator

1. Make a continuity check on the stator coil. Check to make

sure that there is continuity between the coil leads.

If there is no continuity, replace stator assembly.

. Check the coil for grounding. Check to make sure that thereis no continuity between the coil and the core.

If there is continuity, replace the stator assembly.

2 7 - 3 1



CHARGING SYSTEM

Rectifiers

Positive rectifier test

Check for continuity between the positive rectifier and stator coil

lead connection terminal with an ohmmeter. The ohmmeter

should read continuity in only one direction. If there is continuity

in both directions, a diode is shorted.Replace the rectifier ‘assembly.

Negative rectifier test

Check for continuity between the negative rectifier and the stator

coil lead connection terminal. The ohmmeter should read

continuity in only one direction. If there is continuity in bothdirections, a diode is shorted, and the rectifier assembly must

be replaced.

Diode trio test

Check the three diodes for continuity by connecting an ohmmeterto both ends of each diode. Each diode should have continuity

in only one direction.

If continuity is present in both directions, a diode is defective and

the heatsink assembly must be replaced.

BRUSH REPLACEMENT

Replace the brushes if they are worn to limit line.

2 7 - 3 2



CHARGING SYSTEM

1. Unsolder the pigtail and remove the old brush and spring.

2. Install the brush spring and a new brush in the brush holder,

3. Insert the brush to where there is a space 2 to 3 mm (0.079

to 0.118 in.) between the limit line and the end of the brush

holder.4. Solder the pigtail to the brush holder.

REASSEMBLY

Perform reassembly in the reverse procedure of disassembly. Pay

attention to the following:

Before the rotor is attached to the rear bracket, insert a wire

hrough the small hole in the rear bracket to lock the brush. After

he rotor has been installed, the wire can be removed.

NSTALLATION

.

.

.

Position the alternator and insert the support bolt. (Do not

attach the nut.)

Push the alternator forward and determine how many

spacers (thickness: 0.198 mm) should be inserted between

the front leg of the alternator and the front case (space A

in the illustration). (There should be enough spacers so that

they do not fall out when you let go of them.)

Insert the spacers (space A in the illustration), attach the nut,

and complete the installation.

2 7 - 3 3



BATTERY (MAINTENANCE FREE TYPE)

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 maintenance-free

battery.

3. The battery is completely sealed, except for small vent holesin the cover.

4. The battery contains a visual inspection indicator.

BATTERY VISUAL INSPECTION (1)

2 7 - 3 4



CHARGING SYSTEM

2 7 - 3 5



CHARGING SYSTEM

SPECIFIC GRAVITY CHECK CHART

The specific gravity of battery electrolyte changes with

temperature. Heat thins the solution and lowers the specific

gravity. Cold thickens the solution and raises the specific gravity.

A fully charged battery should have a specific gravity between1.260 and 1.280, with the electrolyte temperature at 80°F, the

specific gravity reading must be corrected by adding 4 points

(.004) for each 10o

above 80°F or subtracting 4 points for every

10o below 80°F.

For example : The hydrometer reading is 1.280, and the

electrolyte temperature reading is 10oF. By using the chart, the

specific gravity must be lowered by 0.028 points. The true

corrected reading is 1.252.

1 .280 - 0.028 = 1.252

You should never take a hydrometer reading immediately after

water has been added. The water and electrolyte must be mixed

by either charging for a few minutes at a low rate or by allowing

the battery to sit for an hour.

CAUTION

A difference of 50 points (0.050) or more between one or

more cells indicates a defective battery. It should be replaced.

BATTERY CHARGE RATE

Charge method

Specific gravity

Below 1.100

1.100 - 1.130

1.130 - 1.160

1.160 - 1.190

1.190 - 1.220

Above 1.220

Slow charge (5A) Fast charge (20A)

14 hours 4 hours

12 hours 3 hours

10 hours 2.5 hours

8 hours 2.0 hours

6 hours 1.5 hours

4 hours 1.0 hours

2 7 - 3 6



BATTERY VISUAL INSPECTION (2)

1. Make sure ignition switch is in the Off position and all

accessories are Off.

2. Disconnect the battery cables (negative first)

3. Remove the battery from the vehicle.

CAUTION

Care should be taken in the event the battery case is

cracked or leaking, to protect your skin from the

electrolyte. A suitable pair of rubber gloves (not household

type) should be worn when removing the battery.

4. Inspect the battery carrier for damage caused by the loss of

acid from the battery. 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 bristle

brush and wipe off with a cloth moistened with baking sodaand water.

5. Clean the top of the battery with the same solution as

described in Step (4).

6. Inspect the battery case, and cover, for cracks. If cracks are

present, the battery must be replaced.

7. Clean the battery posts with a suitable battery post cleaner.

8. Clean the inside surface of the terminal clamps with a

suitable battery terminal cleaning tool. Replace damaged or

frayed cables and broken terminal clamps.

9. Install the battery in the vehicle.

10. Connect the cable terminals to the battery post, making sure

the top of the terminals are flush with the top of the post.

11. Tighten the terminal nut 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 circuits at the terminals of the batteriesbeing charged. A spark will occur where the circuit is

broken.

Keep all open flames away from the battery.



STARTING SYSTEM

GENERAL INFORMATION

The starting system includes the battery, starter motor, solenoid

switch, ignition switch, inhibitor switch (A/T only), connection

wires, and the battery cables.

When the ignition key is turned to the start position, current

flows and energizes the coil of the starter motor’s solenoid.When this happens, the solenoid plunger and the 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.

TROUBLESHOOTING

2 7 - 3 8



STARTING SYSTEM

STARTER

REMOVAL AND INSTALLATION


2. Remove the E.G.R. valve assembly (U.S.A. Cal. only).

3. Remove the speed meter cable.

4. Disconnect the starter motor connector and terminal.

5. Remove the starter motor assembly.

6. Installation is the reverse order of removal.

E.G.R. valve mounting bolt tightening torque:

10-15 Nm (100-150 kg .cm, 7 -11 lb . f t )



STARTING SYSTEM



STARTING SYSTEM

INSPECTION (After removal)

Pinion Gap Adjustment

1. Disconnect the wire from the M-terminal.

2. Connect a 12V battery between the S-terminal and the

M-terminal.

3. Set the switch to “ON”, and the the pinion will move out.

CAUTION

This test must be performed quickly (in less than 10

seconds) to prevent coil from burning.

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

feeler gauge.

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

removing washers between the solenoid and the front

bracket.

Pinion Gap: 0.5-2.0 mm (0.0197-0.079 in)

Solenoid Pull-in Test

1. Disconnect the connector from the M-terminal.2. Connect a 12V battery between the S-terminal and

M-terminal.

CAUTION


seconds) to prevent the coil from burning.

3. If the pinion moves out, the pull-in coil is good. If it doesn’t,

replace the solenoid.

Solenoid Hold-in Test

1. Disconnect the connector from the M-terminal.

2. Connect a 12V battery between the S-terminal and the body.

CAUTION


seconds) to prevent the coil from burning.

3. If the pinion remains out, everything is in order. If the pinion

moves in, the hold-in circuit is open. Replace the magnetic

switch.



STARTING SYSTEM

Solenoid Return Test

1. Disconnect the connector from the M-terminal.

2. Connect a 12V battery between the M-terminal and the

body.

CAUTION

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

3. Pull out the pinion and then release it. If the pinion returns

quickly to its original position, everything is in order. If it

doesn’t replace the solenoid.

Performance Test (No-load)

1. Make the no-load circuit test as shown.

2. After adjusting the rheostat until the battery voltage shown

on the voltmeter reads 11.5 volts, confirm that the maximum

amperage draw is within the specifications and that the

starter motor turns smoothly and freely.

Current : 60A or less

DISASSEMBLY

To remove the overrunning clutch from the armature shaft, thestop ring must be removed.

Move the stop ring toward the pinion and remove the snap ring,

now the stop ring can be removed from shaft.

INSPECTION (After disassembly)

Armature Coil Ground Test

Using an ohmmeter, check to make sure that there is no

continuity between the commutator and the armature coil core.

If there is continuity, replace armature assembly.

2 7 - 4 2



STARTING SYSTEM

Armature Coil Short-Circuit Test

Test the armature coil in a growler. Replace the coil if there are

signs of a short. If the blade attached to the core vibrates while

the core is turned, the armature is shorted.

Armature Coil Open-Circuit Test

Using an ohmmeter, check for continuity between the

commutator segments. If there is no continuity, the commutator

segments are open. Replace the armature assembly.

Field Coil Open-Circuit Test

Using an ohmmeter, check the field coil for continuity. If there

is no continuity, the field coil is open. Replace the field coil

assembly.

Field Coil Ground Test

With the field coil mounted to the yoke, check for continuity

between the field coil and the yoke using an ohmmeter. If there

is continuity, replace the field coil.

2 7 - 4 3



STARTING SYSTEM

Brush

A brush worn down to the wear limit line should be replaced.

Brush Holder

Check for continuity between the (+) side brush holder and brush

holder base. If there is continuity, replace the holder assembly.

Overrunning Clutch

Inspect the pinion and spline teeth for wear or damage. Replaceif damaged. Also inspect the flywheel ring gear for damage.

Rotate the pinion. It should turn freely in a clockwise direction,

and lock when turned counterclockwise.

BRUSH REPLACEMENT

1. Remove the worn brush while taking care not to damage the

pigtail.

2. Sand the pigtail end with sandpaper to ensure a good

soldering, joint.

3. Solder the end of the pigtail.

2 7 - 4 4



STARTING SYSTEM

REAR BRACKET BUSHING REPLACEMENT

1. Before the bushing is removed, measure and record the

pressed-in position (depth) of the bushing.

2. The bushing can be removed by the use of a puller as shown

in the illustration.

3. Press a new bushing in, up to the position recorded under

Step. 1.

REASSEMBLY

1. Install the overrunning clutch to the front end of the

armature shaft.

2. Install the stop ring and the snap ring from the front end

of the armature shaft. Push the stop ring all the way toward

the snap ring.

3. When the lever is mounted to the front bracket, pay attention

to its direction. If it is mounted in a reverse direction, the

pinion will remain in an outward position and fail to operateproperly.

2 7 - 4 5



STARTING SYSTEM

INSPECTION OF CLUTCH START SYSTEM(IGNITION LOCK SYSTEM)

Check c lu t ch peda l

Check that pedal height, pedal freeplay and clutch pedal clevis

pin play are correct. (Refer to clutch group)

Check s ta r te r re lay

Remove the starter relay and check continuity between theterminals. If the continuity is not as specified, replace the relay.

Check ign i t ion lock sw i tch

1. Check for continuity between terminals when the switch is

ON (pushed).

2. Check for no continuity between terminals when the switch

is OFF (free).

02 engine electrical system

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