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ENGINEELECTRICALSYSTEMReturn To Main Table of ContentsGENERAL .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . .2
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 4
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
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STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
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GENERAL
GENERAL
SPECIFICATIONS
Distributor MPI FBC
Type Contact pointless typeAdvance mechanism Controlled by
electronic control unit
Firing order 1 - 3 - 4 - 2
Centrifugal and vacuum type
Ignition coilMPI FBC
TypePrimary coil resistanceSecondary coil
resistanceIdentification No.
DiamondPoong SungDae Joon
Mold single-coil0.8 0.08 CI12.1 1.8 Kfi
F -088PC88DSA-117
1.2 0.12D13.7 2.1 Kfl
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PN22C-
Spark plug (MPI, FBC)
TypeNGK
Champion
Plug gap
BUR6EA-11BPR6ES-11RN9YC41.0-1.1 mm (0.039-0.043 in.)
2 7 - 2
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GENERAL
Starter motor (MPI, FBC)
TypeRated outputRated timeNo-load characteristics
Terminal voltageAmperageMaximum speed
No. of pinion teethPinion gap
A/T, Power SteeringDirect drive type12V 0.9 KW
30 sec
11.5V60A or less6,600 rpm or more
80.0197-0.079 in. (0.5-2 mm)
M / T
l2V 0.7 KW
6,500 rpm or more
AlternatorMPI FBC
TypeRated outputVoltage regulator typeRegulator setting
voltageTemperature compensationIdentification No.
MelcoMando
Battery voltage sensing12V 75A (13.5V in case of Mando
products)Electronic built-in type14.4 0.3V-10 3 mV/C
A2T09493AB175015
13.5V 65A
14.7 0.3V-7 3 mV/C
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AB165014
Battery (MPI, FBC)
Type MF 60AH-B (Maintenance-free battery)Ampere hours (5HR) 48
Ah or more
(20HR) 60 Ah or more
Cold cranking [at -17.8C (0F)] 420 A or more
Reserve capacity 92 min.
Specific gravity [at 25C (77F)] 1.270 0.01
NOTECOLD CRANK AMPERAGE is the amperage a battery can deliver
for 30 seconds and maintain a terminalvoltage 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 minimumterminal
voltage of 10.5 at 26.7C (80F).
2 7 - 3
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IGNITION SYSTEM (MPI)
IGNITION SYSTEM
GENERAL INFORMATION
Ignition timing is controlled by the electronic control
ignitiontiming system. The standard reference ignition timing data
forthe engine operation conditions are programmed in the memoryof
the electronic control unit (ECU).The engine conditions (rpm, load,
warm-up condition, etc.) aredetected by the various sensors. Based
upon these sensorsignals and the ignition timing data, signals to
interrupt theprimary current are sent to the power transistor. The
ignition coilis 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
Adjust ignition timing
Ignition coil faulty Inspect ignition coil
Power transistor faulty
High tension cord faulty
Spark plugs faulty
Ignition wiring faulty
Incorrect ignition timing
Spark plugs faulty
Incorrect ignition timing
Incorrect ignition timing
Inspect power transistor
Inspect high tension cord
Replace plugs
Inspect wiring
Adjust timing
Replace plugs
Adjust ignition timing
Adjust ignition timing
Engine hesitates/pooracceleration
Poor mileage
Engine overheats
2 7 - 4
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IGNITION SYSTEM (MPI)
IGNITION TIMING
Adjustment conditions:Coolant temperature: 80-95C
(170-205F)Lamps, cooling fan, and all accessories: OffTransaxle:
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 alligatorclips
to the terminal for ignition-timing adjustment (locatedin 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 2BTDC
If the timing is incorrect, loosen the distributor mounting
nut,and rotate the distributor until the timing is correct.
NOTEThe ignition timing will be advanced if the distributor
isturned 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)
CAUTIONBe careful, when tightening the nut, that the
distributordoes 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: 10BTDC
2 7 - 5
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IGNITION SYSTEM (MPI)
CHECKING IGNITION COILS
1. Measurement of the primary coil resistance.Measure the
resistance of the positive (+) terminal andnegative (-) terminal of
the ignition coil.
Standard value: 0.8 0.08 n
2. Measurement of the secondary coil resistance.Measure the
resistance between the ignition coils 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 supplyto
terminal 2 of the power transistor; then check whetherthere is
continuity between terminal 3 and terminal 2 whenterminal 1 and the
positive (+) terminal are connected anddisconnected.
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.
NOTEPull on the spark plug cable boot when removing the
sparkplug cable, not the cable, as it may be damaged.
2. Using a plug spark wrench, remove all of the spark plugsfrom
the cylinder head.
CAUTIONTake care not to allow contaminants to enter through
thespark plug holes.
3. Check the spark plugs for the following:1) Broken insulator2)
Worn electrode3) Carbon deposits4) Damaged or broken gasket5)
Condition of the porcelain insulator at the tip of the spark
plug
2 7 - 6
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IGNITION SYSTEM (MPI)
4. Check the spark plug gap using a wire gap gauge, and adjustif
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
ofcylinder 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
theelectrode.
Condition Dark deposits White deposits
Description o Too rich a fuel o Too lean a fuel mixturemixture o
Advanced ignition timing
o Low air intake o Insufficient plug tightening
2 7 - 7
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IGNITION SYSTEM (MPI)
SPARK PLUG TEST(When engine can be cranked)
Connect the spark plug to the high tension cable. Ground
theouter electrode (main body), and crank the engine. In
theatmosphere, only short sparks are produced because of the
smalldischarge gap. If the spark plug is good, however, sparks
willoccur in the discharge gap (between the electrodes). In
adefective spark plug, no sparks will occur because of a
leakthrough 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
NOTEResistance should not be higher than 10,000~ per footof
cable. If resistance is higher, replace the cable.
2 7 - 8
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IGNITION SYSTEM (MPI)
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
topdead 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 distributors
installationflange with the center of the distributor installation
stud.
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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
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IGNITION SYSTEM (MPI)
9.10.
11.
12.
Remove the shaft bearing tightening screws.Make a position
identification mark (for the driven gear) onthe distributor
shaft.Place the driven gear on a soft base (wooden block) toprevent
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
isfound.1. There must be no cracking in the cap.2. There must be no
damage to the caps electrode or the
rotors electrode.3. There must be no carbon tracking.4. Clean
away any dirt from the cap and rotor.
REASSEMBLY
Distributor Shaft
After coating the shaft with a small amount of engine oil
insertit into the housing.
CAUTIONDo not use solvent or similar products.
Driven Gear
1. Align the driven gear with the mark made at the time
ofdisassembly, and install the gear to the distributor shaft.
2. When aligning the driven gears mating mark and thehousings
mating mark, make sure that notch A at theshaft end is at the
position shown in the figure, and thenalign the roll pin hole and
drive in a new roll pin.
CAUTIONDrive in the roll pin so that the slits are at a right
anglerelative to the shaft.
2 7 - 1 1
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IGNITION SYSTEM (MPI)
Disc
Insert the disc into the sensor part of the pick up unit and
installin alignment with the spacer.
CAUTIONThe discs slits must not be restricted.
Cover
Install the cover so that the covers indentation A is
alignedwith the housings notch B.
2 7 - 1 2
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IGNITION SYSTEM (FBC)
IGNITION TIMING
Adjustment conditions:Coolant temperature: 80-95C
(170-205F)Lamps and all accessories: OffTransmission: 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
nutand rotate the distributor until the timing is correct.
5. After adjustment, securely tighten the mounting nut.
CHECKING SPARK PLUG
Inspection 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
sparkplug cable, not the cable, as it may be damaged.
Using a plug spark wrench, remove all of the spark plugsfrom the
cylinder head.
CAUTION:Take care not to allow contaminants to enter through
thespark plug holes.
Check the spark plugs for the follows:1) Broken insulator2) Worn
electrode3) Carbon deposits4) Damaged or broken gasket5) Condition
of the porcelain insulator at the tip of the spark
plug.
2 7 - 1 3
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IGNITION SYSTEM (FBC)
SPARK PLUG TEST(when engine can be cranked)
Connect the spark plug to the high tension cable. Ground
theouter electrode (main body), and crank the engine. Inatmosphere,
only short sparks are produced because of the smalldischarge gap.
If the spark plug is good, however, sparks willoccur in the
discharge gap (between the electrodes). In adefective spark plug,
no sparks will occur because of a leakthrough 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
ofcable. If resistance is higher, replace the cable.
2 7 - 1 4
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IGNITION SYSTEM (FBC)
4. Check the spark plug gap using a wire gap gauge, and adjustif
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
ofcylinder 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
theelectrode.
Condition Dark deposits White deposits
Description o Too rich a fuel o Too lean a fuel mixturemixture o
Advanced ignition timing
o Low air intake o Insufficient plugtightening
2 7 - 1 5
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IGNITION SYSTEM (FBC)
DISTRIBUTOR
COMPONENTS
1. Breather2. Cap3. Contact carbon4. Rotor5. Cable assembly6.
Ground wire7. Igniter8. Spring pin9. Signal rotor
10. Breaker base11. Vacuum controller-Dual diaphragm type12.
Rotor shaft
13. Spring retainer14. Governor spring15. Governor weight16.
Distributor shaft17. Oil seal18. Packing19. Housing20. O-ring21.
Washer22. Driven gear23. Pin
2 7 - 1 6
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IGNITION SYSTEM (FBC)
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
sealring.Pull off rotor from rotor shaft.Remove two vacuum
controller attaching screws.Remove link of controller from pin on
the breaker base, thenremove vacuum controller.
6. Remove two screws and remove igniter.7. Remove lead wire
(black).
8. Remove signal rotor shaft tightening screw and two
breakerplate retaining screws.
9. Remove signal rotor shaft and breaker plate assembly.
2 7 - 1 7
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IGNITION SYSTEM (FBC)
10. Remove signal rotor shaft from signal rotor.
11. Remove two spring retainers with pliers and then removetwo
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 pin
can 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
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IGNITION SYSTEM (FBC)
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
thatthe 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
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IGNITION SYSTEM (FBC)
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
twovacuum controller screws.
14. Install rotor to rotor shaft.15. Install seal ring and
distributor cap to housing and set the
retaining clips.
IGNITION COIL
Inspection
1. Using a circuit tester, measure resistance. An open or
shortcircuited coil should be replaced.
[Standard value]Primary coil resistance . . . . . . . . . . . .
. . . . . . . . . . . . . .1.2 n
Secondary coil resistance. . . . . . . . . . . . . . . . . . . .
.13.7 K0External resistor resistance. . . . . . . . . . . . . . . .
. . . . 1.35 a
2 7 - 2 0
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CHARGING SYSTEM
CHARGING SYSTEM
GENERAL INFORMATION
The charging system includes a battery, an alternator with
abuilt-in regulator, and the charging indicator light and wires.
Thealternator 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 regulatedby the battery
voltage detection system. The main componentsof the alternator are
the rotor, stator, rectifier, capacitor, brushes,bearings and
V-ribbed belt pulley. The brush holder contains abuilt-in
electronic voltage regulator.
TROUBLESHOOTING
Symptom Probable cause Remedy
Charging warningindicator does notlight with ignitionswitch ON
andengine off.
Fuse blown.
Light burned out.
Wiring connection loose.
Electronic voltage regulator faulty.
Charging warningindicator does notgo out with
enginerunning.(Battery requiresfrequent recharging).
Discharge battery.
Drive belt loose or worn.
Battery cables loose, corroded or worn.
Fuse blown.
Fusible link blown.
Electronic voltage regulator or alternatorfaulty.
Wiring faulty.
Drive belt loose or worn.
Wiring connection loose or open circuit.
Fusible link blown.
Poor grounding.
Electronic voltage regulator or alternatorfaulty.
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 repairwiring.
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
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CHARGING SYSTEM
INSPECTION OF CHARGING SYSTEM
VOLTAGE DROP TEST OF ALTERNATOR OUTPUTWIRE
This test determines whether or not the wiring between
thealternator B terminal and the battery (+) terminal is good bythe
voltage drop method.
Preparation1. Turn the ignition switch to OFF.2. Disconnect the
battery ground cable.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. (-) leadto the
disconnected output wire.
NOTEUse a clamp type ammeter that can measure currentwithout
disconnecting the harness. The reason is thatwhen checking a
vehicle that has a low output current dueto poor connection of the
alternator B terminal, such apoor connection is corrected as the B
terminal isloosened and a test ammeter is connected in its place.
Asa result, causes for the trouble may not be determined.
5. Connect a digital voltmeter between the alternator Bterminal
and battery (+) terminal. Connect the (+) lead wireof the voltmeter
to the B terminal and the (-) lead wireto the battery (+)
terminal.
6. Connect the battery ground cable.7. Leave the hood open.
Test1. Start the engine.2. Turn on the headlamps and adjust the
engine speed so that
the ammeter reads 20A and read the voltmeter under
thiscondition.
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
thestandard value, poor wiring is suspected. In this case checkthe
wiring from the alternator B terminal to the fusible linkto the
battery (+) terminal. Check for loose connections, colorchange due
to an overheated harness, etc. Correct thembefore testing
again.
2 7 - 2 2
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CHARGING SYSTEM
3. Upon completion of the test, set the engine speed at
idle.Turn off the head lamps and the ignition switch.
4. Disconnect the battery ground cable.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
outputcurrent that is equivalent to the nominal output.
Preparation
1. Prior to the test, check the following items and correct
asnecessary.1) Check the battery installed in the vehicle to ensure
that
it is in good condition*. The battery checking method
isdescribed in BATTERY.
NOTE*The battery that is used to test the output current
should be one that has been partially discharged. Witha fully
charged battery, the test may not be conductedcorrectly due to an
insufficient load.
2) Check the tension of the alternator drive belt. The
belttension check method is described in the sectionCOOLING.
2.3.4.
Turn off the ignition switch.Disconnect the battery ground
cable.Disconnect the alternator output wire form the alternator
Bterminal.
5. Connect a DC ammeter (0 to 100A) in series between theB
terminal and the disconnected output wire. Be sure toconnect the
(-) lead wire of the ammeter to thedisconnected output wire.
NOTETighten each connection securely, as a heavy current
willflow. Do not rely on clips.
6.
7.
Connect a voltmeter (0 to 20V) between the B terminal andground.
Connect the (+) lead wire to the alternator Bterminal and (-) lead
wire to a good ground.Attach an engine tachometer and connect the
battery groundcable.
8. Leave the engine hood open.
2 7 - 2 3
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CHARGING SYSTEM
Test
1. Check to see that the voltmeter reads the same value as
thebattery voltage.If the voltmeter reads 0V, and open circuit in
the wirebetween 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 2,500rpm
and read the maximum output current value indicatedby the
ammeter.
NOTEAfter the engine startup, the charging current quicklydrops.
Therefore, the above operation must be donequickly 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 goodcondition, remove
the alternator from the vehicle and test it.
Limit value:52.5 A min . . . . . . . . . . . . . . . . . . . . .
. 75A alternator (MPI)45A min. . . . . . . . . . . . . . .. ....65A
alternator (FBC)
NOTE1) 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 beobtained. If such is the case,
keep the headlights onto cause discharge of the battery, or use the
lights ofanother vehicle to increase the electrical load.The
nominal output current may not be obtained if thetemperature of the
alternator itself or ambienttemperature is too high.In such a case,
reduce the temperature before testingagain.
2. Upon completion of the output current test, lower the
enginespeed 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.
2 7 - 2 4
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REGULATED VOLTAGE TEST
The purpose of this test is to check that the electronic
voltageregulator 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, seeBATTERY.
2) Check the alternator drive belt tension. For belt
tensioncheck, see section, COOLING.
Turn ignition switch to OFF.Disconnect the battery ground
cable.Connect a digital voltmeter between the S(L) terminal ofthe
alternator and ground. Connect the (+) lead of thevoltmeter to the
S(L) terminal of the alternator. Connectthe (-) lead to good ground
or the battery (-) terminal.Disconnect the alternator output wire
from the alternator Bterminal.
Connect a DC ammeter (0 to 100A) in series between theB terminal
and the disconnected output wire. Connect the(-) lead wire of the
ammeter to the disconnected outputwire.Attach the engine tachometer
and connect the batteryground cable.
Test
1. Turn on the ignition switch and check to see that
thevoltmeter indicates the following value.
Voltage: Battery voltage
If it reads 0V, there is an open circuit in the wire betweenthe
alternator S(L) terminal and the battery (+), or thefusible 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 the
voltmeter when the alternator output current drops to 10Aor
less.
2 7 - 2 5
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CHARGING SYSTEM
Result
1. If the voltmeter reading. agrees with the value listed in
theRegulating Voltage Table below, the voltage regulator
isfunctioning correctly. If the reading is other than thestandard
value, the voltage regulator or the alternator isfaulty.
Regulating Voltage Table
Voltage regulator ambient Regulating voltage V
temperature C (F) 75A alternator 65A alternator
-20 (-4) 14.2-15.4 14.4-15.620 (68) 13.9-14.9 14.2-15.260 (140)
13.4-14.6 13.8-15.180 (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.
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.
2 7 - 2 6
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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
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CHARGING SYSTEM
COMPONENTS (75A)
1. Pulley2. Seal3. Rotor assembly4. Rear bearing5. Bearing
retainer6. Front bearing7. Front bracket8. Stator9. Plate
10. Voltage regulator and brush holder11. Brush12. Brush
spring13. Slinger14. Rectifier15. Rear bracket
2 7 - 2 8
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CHARGING SYSTEM
COMPONENTS (65A)
1. Pulley2. Seal3. Rotor assembly4. Rear bearing5. Bearing
retainer6. Front bearing7. Front bracket8. Stator
9. Terminal10. Plate11. Brush12. Brush spring13. Slinger14.
Rectifier assembly15. Rear bracket
2 7 - 2 9
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DISASSEMBLY
1. Remove the three through bolts.2. Insert a flat screwdriver
between the front bracket and stator
core, and pry downward.
CAUTION1) 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 ringis used to
lock the outer race of the rear bearing. Tofacilitate removal of
rear cover, heat just the bearingbox section with a 200-watt
soldering iron.Do not use a heat gun, as it may damage the
diodeassembly.
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, thenthe
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 stator
leads to the main diodes on the rectifier.
CAUTION1) When soldering or unsoldering, use care to make
sure
that heat of soldering iron is not transmitted to thediodes for
a long period.
2) Use care that excessive force is not exerted on theleads of
the diodes.
11. When separating the rectifier from the brush holder,unsolder
the two plates soldered to the rectifier.
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CHARGING SYSTEM
INSPECTION
Rotor
1. Check the rotor coil for continuity. Check to make sure
thatthere 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
thereis 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 makesure
that there is continuity between the coil leads.If there is no
continuity, replace stator assembly.
2. 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.
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CHARGING SYSTEM
Rectifiers
Positive rectifier test
Check for continuity between the positive rectifier and stator
coillead connection terminal with an ohmmeter. The ohmmetershould
read continuity in only one direction. If there is continuityin
both directions, a diode is shorted.Replace the rectifier
assembly.
Negative rectifier test
Check for continuity between the negative rectifier and the
statorcoil lead connection terminal. The ohmmeter should
readcontinuity in only one direction. If there is continuity in
bothdirections, a diode is shorted, and the rectifier assembly
mustbe replaced.
Diode trio test
Check the three diodes for continuity by connecting an
ohmmeterto both ends of each diode. Each diode should have
continuityin only one direction.If continuity is present in both
directions, a diode is defective andthe heatsink assembly must be
replaced.
BRUSH REPLACEMENT
Replace the brushes if they are worn to limit line.
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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
brushholder.
4. Solder the pigtail to the brush holder.
REASSEMBLY
Perform reassembly in the reverse procedure of disassembly.
Payattention to the following:Before the rotor is attached to the
rear bracket, insert a wirethrough the small hole in the rear
bracket to lock the brush. Afterthe rotor has been installed, the
wire can be removed.
INSTALLATION
1.
2.
3.
Position the alternator and insert the support bolt. (Do
notattach the nut.)Push the alternator forward and determine how
manyspacers (thickness: 0.198 mm) should be inserted betweenthe
front leg of the alternator and the front case (space Ain the
illustration). (There should be enough spacers so thatthey 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.
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BATTERY (MAINTENANCE FREE TYPE)
1. The maintenance-free battery is, as the name implies,
totallymaintenance free and has no removable battery cell caps.
2. Water never needs to be added to the
maintenance-freebattery.
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)
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CHARGING SYSTEM
2 7 - 3 5
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CHARGING SYSTEM
SPECIFIC GRAVITY CHECK CHART
The specific gravity of battery electrolyte changes
withtemperature. Heat thins the solution and lowers the
specificgravity. 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 80F,
thespecific gravity reading must be corrected by adding 4
points(.004) for each 10o above 80F or subtracting 4 points for
every10o below 80F.
For example : The hydrometer reading is 1.280, and
theelectrolyte temperature reading is 10oF. By using the chart,
thespecific gravity must be lowered by 0.028 points. The
truecorrected reading is 1.252.
1.280 -0.028 = 1.252
You should never take a hydrometer reading immediately
afterwater has been added. The water and electrolyte must be
mixedby either charging for a few minutes at a low rate or by
allowingthe battery to sit for an hour.
CAUTIONA difference of 50 points (0.050) or more between one
ormore cells indicates a defective battery. It should be
replaced.
BATTERY CHARGE RATE
Charge methodSpecific 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
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BATTERY VISUAL INSPECTION (2)
1. Make sure ignition switch is in the Off position and
allaccessories are Off.
2. Disconnect the battery cables (negative first)3. Remove the
battery from the vehicle.
CAUTIONCare should be taken in the event the battery case
iscracked or leaking, to protect your skin from theelectrolyte. A
suitable pair of rubber gloves (not householdtype) should be worn
when removing the battery.
4. Inspect the battery carrier for damage caused by the loss
ofacid from the battery. If acid damage is present, it will
benecessary to clean the area with a solution of clean warm,water
and baking soda. Scrub the area with a stiff bristlebrush and wipe
off with a cloth moistened with baking sodaand water.
5. Clean the top of the battery with the same solution
asdescribed in Step (4).
6. Inspect the battery case, and cover, for cracks. If cracks
arepresent, 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
orfrayed 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.
CAUTIONWhen batteries are being charged, an explosive gas
formsbeneath the cover of each cell. Do not smoke nearbatteries
being charged or which have recently beencharged.Do not break live
circuits at the terminals of the batteriesbeing charged. A spark
will occur where the circuit isbroken.Keep all open flames away
from the battery.
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STARTING SYSTEM
GENERAL INFORMATION
The starting system includes the battery, starter motor,
solenoidswitch, ignition switch, inhibitor switch (A/T only),
connectionwires, and the battery cables.When the ignition key is
turned to the start position, currentflows and energizes the coil
of the starter motors solenoid.When this happens, the solenoid
plunger and the clutch shiftlever 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 thestarter armature when the engine starts, the clutch
pinion gearoverruns.
TROUBLESHOOTING
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STARTING SYSTEM
STARTER
REMOVAL AND INSTALLATION
1. Disconnect the battery ground cable.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 )
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STARTING SYSTEM
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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.
CAUTIONThis test must be performed quickly (in less than
10seconds) to prevent coil from burning.
4. Check the pinion to stopper clearance (pinion gap) with
afeeler gauge.If the pinion gap is out of specification, adjust by
adding orremoving washers between the solenoid and the
frontbracket.
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.
CAUTIONThis test must be performed quickly (in less than
10seconds) to prevent the coil from burning.
3. If the pinion moves out, the pull-in coil is good. If it
doesnt,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.
CAUTIONThis test must be performed quickly (in less than
10seconds) to prevent the coil from burning.
3. If the pinion remains out, everything is in order. If the
pinionmoves in, the hold-in circuit is open. Replace the
magneticswitch.
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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.
CAUTIONThis 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
returnsquickly to its original position, everything is in order. If
itdoesnt 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
maximumamperage draw is within the specifications and that
thestarter 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 nocontinuity
between the commutator and the armature coil core.If there is
continuity, replace armature assembly.
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STARTING SYSTEM
Armature Coil Short-Circuit Test
Test the armature coil in a growler. Replace the coil if there
aresigns of a short. If the blade attached to the core vibrates
whilethe 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
commutatorsegments are open. Replace the armature assembly.
Field Coil Open-Circuit Test
Using an ohmmeter, check the field coil for continuity. If
thereis no continuity, the field coil is open. Replace the field
coilassembly.
Field Coil Ground Test
With the field coil mounted to the yoke, check for
continuitybetween the field coil and the yoke using an ohmmeter. If
thereis continuity, replace the field coil.
2 7 - 4 3
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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
brushholder 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
thepigtail.
2. Sand the pigtail end with sandpaper to ensure a
goodsoldering, joint.
3. Solder the end of the pigtail.
2 7 - 4 4
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STARTING SYSTEM
REAR BRACKET BUSHING REPLACEMENT
1. Before the bushing is removed, measure and record
thepressed-in position (depth) of the bushing.
2. The bushing can be removed by the use of a puller as shownin
the illustration.
3. Press a new bushing in, up to the position recorded
underStep. 1.
REASSEMBLY
1. Install the overrunning clutch to the front end of
thearmature shaft.
2. Install the stop ring and the snap ring from the front endof
the armature shaft. Push the stop ring all the way towardthe snap
ring.
3. When the lever is mounted to the front bracket, pay
attentionto its direction. If it is mounted in a reverse direction,
thepinion will remain in an outward position and fail to
operateproperly.
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STARTING SYSTEM
INSPECTION OF CLUTCH START SYSTEM(IGNITION LOCK SYSTEM)
Check clutch pedal
Check that pedal height, pedal freeplay and clutch pedal
clevispin play are correct. (Refer to clutch group)
Check starter relay
Remove the starter relay and check continuity between
theterminals. If the continuity is not as specified, replace the
relay.
Check ignition lock switch
1. Check for continuity between terminals when the switch isON
(pushed).
2. Check for no continuity between terminals when the switchis
OFF (free).
2 7 - 4 6