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GROUP 16
ENGINE
ELECTRICAL
CONTENTS
CHARGING SYSTEM
GENERAL INFORMATION
M1161000100425
The charging system uses the alternator output to The average output voltage fluctuates slightly with
keep the battery charged at a constant level under the alternator load condition.
various electrical loads. When the ignition switch is turned on, current flows in
OPERATION the field coil and initial excitation of the field coil
occurs.
Voltage
When the stator coil begins to generate power after
the engine is started, the field coil is excited by the
output current of the stator coil.
The alternator output voltage rises as the field
Approximately current increases and it falls as the field current
14.4 V decreases. When the battery voltage (alternator "S"
terminal voltage) reaches a regulated voltage of
approximately 14.4 V, the field current is cut off.
Time When the battery voltage drops below the regulated
AKX00183 AC voltage, the voltage regulator regulates the output
Rotation of the excited field coil generates AC voltage to a constant level by controlling the field
voltage in the stator. current.
This alternating current is rectified through diodes to In addition, when the field current is constant, the
DC voltage having a waveform shown in the alternator output voltage rises as the engine speed
illustration. increases.
SYSTEM DIAGRAM
Alternator
Stator
coil
Engine-ECU
<M/T> or
Engine-A/T-ECU
<A/T>
Field coil
G
S
+
L
Voltage
regulator FR Ignition
Charging switch-IG Battery
warning lamp
Combination meter -
AK304842 AB
ENGINE ELECTRICAL
CHARGING SYSTEM
16-3
ALTERNATOR SPECIFICATIONS
Item Specification
Type Battery voltage sensing
Rated output V/A 12/110
Voltage regulator Electronic built-in type
SERVICE SPECIFICATIONS
M1161000300377
SPECIAL TOOLS
M1161000600367
DO NOT USED
MB991911
MB991825
MB991826
MB991955
Ammeter (clamp-type)
Alternator
Voltmeter (digital-type)
Battery
"B" terninal
AK203361AD
This test determines whether the wiring from the 5. Connect a digital-type voltmeter between the
alternator "B" terminal to the battery (+) terminal alternator "B" terminal and the battery (+)
(including the fusible line) is in a good condition or terminal. [Connect the (+) lead of the voltmeter to
not. the "B" terminal and the connect the (-) lead of the
1. Always be sure to check the following before the voltmeter to the battery (+) cable].
test. 6. Reconnect the negative battery cable.
• Alternator installation 7. Connect the MUT-III (to show the engine speed).
• Drive belt tension
8. Leave the hood open.
(Refer to P.11A-7, GROUP 11A − On-Vehicle
Service.) 9. Start the engine.
• Fusible link 10.With the engine running at 2,500 r/min, turn the
• Abnormal noise from the alternator while the headlamps and other lamps on and off to adjust
engine is running the alternator load so that the value displayed on
2. Turn the ignition switch to the "LOCK" (OFF) the ammeter is slightly above 30 A.
position. Adjust the engine speed by gradually decreasing
3. Disconnect the negative battery cable. it until the value displayed on the ammeter is 30
4. Connect a clamp-type DC test ammeter with a A. Take a reading of the value displayed on the
range of 0 − 150 A to the alternator "B" terminal voltmeter at this time.
output wire. Limit: maximum 0.3 V
NOTE: The way of disconnecting the alternator NOTE: When the alternator output is high and the
output wire and of connecting the ammeter is value displayed on the ammeter does not
possibly not found the problem that the output decrease until 30 A, set the value to 40 A. Read
current is dropping due to the insufficient the value displayed on the voltmeter at this time.
connection between terminal "B" and the output When the value range is 40 A, the limit is
wire. maximum 0.4 V.
16-6 ENGINE ELECTRICAL
CHARGING SYSTEM
11.If the value displayed on the voltmeter is above 12.After the test, run the engine at idle.
the limit value, there is probably a malfunction in 13.Turn off all lamps.
the alternator output wire, so check the wiring 14.Turn the ignition switch to the "LOCK" (OFF)
between the alternator "B" terminal and the position.
battery (+) terminal (including fusible link).
15.Remove the MUT-III.
If a terminal is not sufficiently tight or if the 16.Disconnect the negative battery cable.
harness has become discolored due to
overheating, repair and then test again. 17.Disconnect the ammeter and voltmeter.
18.Connect the negative battery cable.
Load
Ammeter
Voltmeter (clamp-type)
- +
Combination meter
Ignition Charging
switch-IG warning lamp B
FR
L
S
G
Alternator
Engine-ECU
+ <M/T> or
Engine-A/T-ECU
Battery <A/T>
AK304843 AB
This test determines whether the alternator output • Drive belt tension
current is normal. (Refer to P.11A-7, GROUP 11A − On-Vehicle
1. Before the test, always be sure to check the Service.)
following. • Fusible link
• Alternator installation • Abnormal noise from the alternator while the
• Battery (Refer to P.54A-6, GROUP 54A − Battery engine is running.
− On-Vehicle Service.) 2. Turn the ignition switch to the "LOCK" (OFF)
NOTE: The battery should be slightly discharged. position.
The load needed by a fully-charged battery is 3. Disconnect the negative battery cable.
insufficient for an accurate test.
ENGINE ELECTRICAL
CHARGING SYSTEM
16-7
CAUTION Limit: 70 % of normal current output
Never use clips but tighten bolts and nuts to NOTE: .
connect the line. Otherwise loose connections • For the nominal current output, refer to the
(e.g. using clips) will lead to a serious accident Alternator Specifications.
because of high current. • Because the current from the battery will soon
4. Connect a clamp-type DC test ammeter with a drop after the engine is started, the above step
range of 0 − 150 A to the alternator "B" terminal should be carried out as quickly as possible in
output wire. order to obtain the maximum current output
value.
NOTE: The way of disconnecting the alternator
• The current output value will depend on the
output wire and of connecting the ammeter is
electrical load and the temperature of the
possibly not found the problem that the output
alternator body.
current is dropping due to the insufficient
• If the electrical load is small while testing, the
connection between terminal "B" and the output
specified level of current may not be output
wire.
even though the alternator is normal. In such
5. Connect a voltmeter with a range of 0 − 20 V cases, increase the electrical load by leaving
between the alternator "B" terminal and the earth the headlamps turned on for some time to
[Connect the (+) lead of the voltmeter to the "B" discharge the battery or by using the lighting
terminal, and then connect the (-) lead of the system in another vehicle, and then test again.
voltmeter to the earth]. • The specified level of current also may not be
6. Connect the negative battery cable. output if the temperature of the alternator body
7. Connect the MUT-III (to show the engine speed). or the ambient temperature is too high. In such
8. Leave the hood open. cases, cool the alternator and then test again.
9. Check that the reading on the voltmeter is equal 12.The reading on the ammeter should be above the
to the battery voltage. limit value. If the reading is below the limit value
and the alternator output wire is normal, remove
NOTE: If the voltage is 0 V, the cause is probably
the alternator from the engine and check the
an open circuit in the wire or fusible link between
alternator.
the alternator "B" terminal and the battery (+)
terminal. 13.Run the engine at idle after the test.
10.Turn the light switch on to turn on headlamps and 14.Turn the ignition switch to the "LOCK" (OFF)
then start the engine. position.
11.Immediately after setting the headlamps to high 15.Remove the MUT-III.
beam and turning the heater blower switch to the 16.Disconnect the negative battery cable.
high revolution position, increase the engine 17.Disconnect the ammeter and voltmeter.
speed to 2,500 r/min and read the maximum 18.Connect the negative battery cable.
current output value displayed on the ammeter.
16-8 ENGINE ELECTRICAL
CHARGING SYSTEM
Load
Ammeter (clamp-type)
Combination meter
Ignition Charging
switch-IG warning lamp
MB991519 Black
B
FR
L Alternator
S
G
Engine-ECU
+ <M/T> or Blue
Engine-A/T- Red Yellow
Battery ECU <A/T>
Voltmeter (digital-type)
+ -
AK304844 AB
This test determines whether the voltage regulator 5. Connect a clamp-type DC test ammeter with a
correctly controlling the alternator output voltage. range of 0 − 150 A to the alternator "B" terminal
1. Always be sure to check the following before the output wire.
test. NOTE: The way of disconnecting the alternator
• Alternator installation output wire and of connecting the ammeter is
• Check that the battery installed in the vehicle is possibly not found the problem that the output
fully charged. current is dropping due to the insufficient
(Refer to P.54A-6, GROUP 54A − Battery − connection between terminal "B" and the output
On-Vehicle Service.) wire.
• Drive belt tension 6. Reconnect the negative battery cable.
(Refer to P.11A-7, GROUP 11A − On-Vehicle
Service.) 7. Connect the MUT-III (to show the engine speed).
• Fusible link 8. Turn the ignition switch to the "ON" position and
• Abnormal noise from the alternator while the check that the reading on the voltmeter is equal to
engine is running the battery voltage.
2. Turn the ignition switch to the "LOCK" (OFF) NOTE: If the voltage is 0 V, the cause is probably
position. an open circuit in the wire or fusible link between
3. Disconnect the negative battery cable. the alternator "S" terminal and the battery (+)
terminal.
4. Use the special tool Alternator test harness
(MB991519) to connect a digital voltmeter 9. Turn all lamps and accessories off.
between the alternator "S" terminal and earth 10.Start the engine.
[Connect the (+) lead of the voltmeter to the "S" 11.Increase the engine speed to 2,500 r/min.
terminal, and then connect the (-) lead of the 12.Read the value displayed on the voltmeter when
voltmeter to a secure earth or to the battery (-) the alternator output current alternator becomes
terminal]. 10 A or less.
ENGINE ELECTRICAL
CHARGING SYSTEM
16-9
13.If the voltage reading conforms to the value in the 16.Remove the MUT-III.
voltage regulation, then the voltage regulator is 17.Disconnect the negative battery cable.
operating normally. 18.Disconnect the ammeter and voltmeter.
If the voltage is not within the standard value, 19.Connect the alternator output wire to the
there is a malfunction of the voltage regulator or of alternator "B" terminal.
the alternator. 20.Remove the special tool, and return the connector
14.After the test, lower the engine speed to the idle to the original condition.
speed. 21.Connect the negative battery cable.
15.Turn the ignition switch to the "LOCK" (OFF)
position.
Voltage Regulation Table
Standard value:
Inspection terminal Voltage regulator ambient Voltage V
temperature °C
Terminal "S" −20 14.2 − 15.4
20 13.9 − 14.9
60 13.4 − 14.6
80 13.1 − 14.5
CH1
STANDARD WAVEFORM
Observation Conditions
Function Special pattern
Pattern height Variable
Variable knob Adjust while viewing the waveform.
Pattern selector Raster
Engine speed Curb idle speed
16-10 ENGINE ELECTRICAL
CHARGING SYSTEM
(V)
0.4
0.2
Voltage at
alternator 0
"B" terminal
–0.2
–0.4
Time
AKX00189AG
AKX00190
AKX00191
AKX00192
AKX00193
AKX00194
16-12 ENGINE ELECTRICAL
CHARGING SYSTEM
ALTERNATOR ASSEMBLY
REMOVAL AND INSTALLATION
M1161001400742
3
11 ± 1 N·m
4
1 7
14 ± 3 N·m
2 5
49 ± 9 N·m
49 ± 9 N·m 10
49 ± 9 N·m
11 ± 1 N·m
9 8
44 ± 10 N·m AC313042 AB
1
4
3
4.4 ± 1.0 N·m
5
7 6
118± 19 N·m
12
10
9
14
8
13
11
AK301524AD
Wire
AK304673 AB
AK304671
CAUTION
• Use a 180 − 250 W soldering iron, and finish
unsoldering within four seconds. Diodes will Wire
be damaged by heat if unsoldering time is too
long.
• Avoid applying undue force to the diode
leads.
1. Unsolder the stator leads from the main diode of
the rectifier assembly when the stator is removed. AK304673 AB
ROTOR
AK304679
AK304680
STATOR
AK304681
BRUSH
Protrusion
length
AK304682
AK304683 AB
3. Check the condition of the diode trio by testing
continuity of each of the three diodes using a 1. Measure the length of the protrusion of the brush.
circuit tester connected to both sides of the diode. Replace the brush if the protrusion length is
Connect in a polarity and then reverse the polarity shorter than the limit.
for each test.
Limit: 2 mm minimum
If continuity exists or no continuity exists for both
2. Unsolder the lead of the brush. The brush will
polarities, the diode is defective. Replace the
come out, becoming ready for removal.
rectifier assembly if any of the diodes is defective.
Solder
AK304684AB
STARTING SYSTEM
GENERAL INFORMATION
M1162000100310
If the ignition switch is turned to the "START" When the ignition switch is returned to the "ON"
position, current flows in the pull-in and holding coils position after starting the engine, the starter clutch is
provided inside magnetic switch, attracting the disengaged from the ring gear.
plunger, When the plunger is attracted, the lever An overrunning clutch is provided between the pinion
connected to the plunger is actuated to engage the and the armature shaft, to prevent damage to the
starter clutch. starter.
On the other hand, attracting the plunger will turn on
the magnetic switch, allowing the "B" terminal and
"M" terminal to conduct. Thus, current flows to
engage the starter motor.
ENGINE ELECTRICAL
STARTING SYSTEM
16-17
SYSTEM DIAGRAM
Pull-in coil
Lever
B Overrunning clutch
Ignition switch - ST M
Pinion gear
S
+ Armature
Battery
Brush
Yoke
AK202970 AD
SERVICE SPECIFICATIONS
M1162000300079
30 ± 3 N·m
5
2
3
4
13 ± 2 N·m
1
AC311197AB
AKX01242 AE
1. Disconnect the field coil wire from the M-terminal
of the magnetic switch. 1. Disconnect the field coil wire from the M-terminal
2. Connect a 12-volt battery between the S-terminal of the magnetic switch.
and M-terminal. CAUTION
CAUTION This test must be performed quickly (in less than
This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning.
10 seconds) to prevent the coil from burning. 2. Connect a 12-volt battery between the S-terminal
3. Set the switch to "ON", and the pinion will move and M-terminal.
out. 3. If the pinion moves out, the pull-in coil is good. If it
doesn't, replace the magnetic switch.
S
Pinion M
B
Battery
Pinion gap
AKX00198 AC
Starter Wire
4. Check the pinion-to-stopper clearance (pinion motor
gap) with a feeler gauge.
AKX01244AE
Standard value: 0.5 − 2.0 mm
1. Disconnect the field coil wire from the M-terminal
of the magnetic switch.
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal
and body.
3. Manually pull out the pinion as far as the pinion
stopper position.
AKX00199
4. If the pinion remains out, everything is in order. If
5. If the pinion gap is out of specification, adjust by the pinion moves in, the hold-in circuit is open.
adding or removing gasket(s) between the Replace the magnetic switch.
magnetic switch and front bracket.
16-20 ENGINE ELECTRICAL
STARTING SYSTEM
Ammeter
A
MAGNETIC SWITCH RETURN TEST
S
Carbon-pile
rheostat
M B
S
Battery
Starter V M
motor Voltmeter B
Battery
battery to the starter motor as follows: 1. Disconnect the field coil wire from the M-terminal
2. Connect a test ammeter (100-ampere scale) and of the magnetic switch.
carbon pile rheostat in series between the positive
battery terminal and starter motor terminal.
CAUTION
This test must be performed quickly (in less than
3. Connect a voltmeter (15-volt scale) across the 10 seconds) to prevent the coil from burning.
starter motor.
2. Connect a 12-volt battery between the M-terminal
4. Rotate the rheostat to full-resistance position.
and body.
5. Connect the battery cable from the negative
battery terminal to the starter motor body. WARNING
6. Adjust the rheostat until the battery positive
Be careful not to get your fingers caught
voltage shown on the voltmeter is 11 V. when pulling out the pinion.
7. Confirm that the maximum amperage is within the 3. Pull the pinion out and release. If the pinion
specifications and that the starter motor turns quickly returns to its original position, everything is
smoothly and freely. operating properly. If it doesn't, replace the
magnetic switch.
ENGINE ELECTRICAL
STARTING SYSTEM
16-21
DISASSEMBLY AND REASSEMBLY
M1162001200257
11
14 12
10
13
2 19
18
17
1 16
4
15
3
20
7 5
9
AK304675 AB
Overrunning
clutch
the stop ring toward the pinion gear side. Use a suitable puller to pull the stop ring until it gets
over the snap ring.
Snap ring
Snap ring
pliers Pinion gear
INSPECTION
M1162001300191
Overrunning
clutch COMMUTATOR
AK304686 AB
AK304689
Undercut
Segment BRUSHES
Mica
Brush
height
AK304690 AB
ARMATURE COIL
1. Check the armature coil for short circuit as
AK202897
follows.
Push the brush into the brush holder to make sure
Growler
that the spring is working on the brush.
If the spring is not working, replace the brush holder.
OVERRUNNING CLUTCH
AK304692AB
Free
2. Set the armature in a growler.
CAUTION
Lock Clean the surface of the armature thoroughly
AK304691AB
before performing the test.
3. While holding a thin strip of iron against the
1. Make sure that the pinion cannot be turned armature in parallel with its axis, turn the armature
counterclockwise and can be turned clockwise slowly. The armature is normal if the iron strip is
freely. not attracted to the armature or it does not vibrate.
16-24 ENGINE ELECTRICAL
IGNITION SYSTEM
B terminal
AK304693
AK202892 AB
B terminal
AK304694
IGNITION SYSTEM
GENERAL INFORMATION
M1163000100380
This system is equipped with four ignition coils with Interruption of the primary current flowing in the
built-in power transistors for each of the cylinders. primary side of an ignition coil generates a high
voltage in the secondary side of ignition coil. The
high voltage thus generated is applied to the spark
plugs to generate sparks. The engine-ECU <M/T> or
ENGINE ELECTRICAL
IGNITION SYSTEM
16-25
engine-A/T-ECU <A/T> turns the power transistors When the engine is cold or running at high altitudes,
inside the ignition coils alternately on and off.This the ignition timing is slightly advanced to provide
causes the primary currents in the ignition coils to be optimum performance. Furthermore, if knocking
alternately interrupted and allowed to flow to fire the occurs, the ignition timing is gradually retarded until
cylinders in the order 1-3-4-2. knocking ceases.
The engine-ECU <M/T> or engine-A/T-ECU <A/T>
determines which ignition coil should be controlled
by means of the signals from the camshaft position
sensor and the crank angle sensor. It also detects
the crankshaft position, in order to provide ignition at
the most appropriate timing in response to the
engine operation conditions.
SYSTEM DIAGRAM
Ignition
switch
Air flow sensor Battery
Spark plug
Cylinder No. 1 2 3 4
AK303631 AC
SERVICE SPECIFICATIONS
M1163000300232
SPARK PLUG
Item Standard value Limit
Spark plug gap mm 0.7 − 0.8 1.2
SPECIAL TOOL
M1163000600200
ON-VEHICLE SERVICE
Iridium tip
AKX00383 AN
10 ± 2 N·m
1
2
3
25 ± 5 N·m
AC313043AB
16-28 ENGINE ELECTRICAL
IGNITION SYSTEM
11 ± 1 N·m
3N
AC302233AC
Removal steps
1. Timing belt lower cover bracket
2. Crankshaft position sensor
ENGINE ELECTRICAL
IGNITION SYSTEM
16-29
DETONATION SENSOR
REMOVAL AND INSTALLATION
M1163002800697
CAUTION
Do not drop or hit the detonation sensor against other components. Internal damage may result, and
the detonation sensor will need to be replaced.
23 ± 2 N·m
6 5
11 ± 1 N·m
2
4
31 ± 3 N·m
3
AC302234AC
MD998773
AC103370AC