16-1

GROUP 16

ENGINE
ELECTRICAL
CONTENTS

CHARGING SYSTEM . . . . . . . . . . . . 16-2 GLOW SYSTEM . . . . . . . . . . . . . . . . . 16-18

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GENERAL INFORMATION. . . . . . . . . . . . . 16-2 GENERAL INFORMATION . . . . . . . . . . . . . 16-18
SERVICE SPECIFICATION(S) . . . . . . . . . . 16-4 SERVICE SPECIFICATION(S) . . . . . . . . . . 16-21
SPECIAL TOOL(S) . . . . . . . . . . . . . . . . . . . 16-5 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . 16-22
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . 16-6 GLOW PLUG CHECK <Euro5> . . . . . . . . . 16-22
ALTERNATOR OUTPUT LINE VOLTAGE DROP SELF-REGULATING GLOW SYSTEM CHECK
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-6 <Except Euro5> . . . . . . . . . . . . . . . . . . . . . . 16-22
OUTPUT CURRENT TEST. . . . . . . . . . . . . 16-7 CHECK THE ENGINE ECU TERMINALS <Euro5>
REGULATED VOLTAGE TEST . . . . . . . . . 16-9 ...................................... 16-23
WAVE PATTERN CHECK USING AN CHECK THE ENGINE ECU TERMINALS <Except
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . . . 16-10 Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-23
ALTERNATOR ASSEMBLY . . . . . . . . . . . . 16-13 GLOW PLUG RELAY CHECK <Except Euro5>
...................................... 16-23
ALTERNATOR ASSEMBLY REMOVAL AND
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 16-13 GLOW PLUG CHECK <Except Euro5> . . . 16-24
ENGINE COOLANT TEMPERATURE SENSOR
STARTING SYSTEM . . . . . . . . . . . . . 16-14 CHECK <Except Euro5> . . . . . . . . . . . . . . . 16-24

GENERAL INFORMATION. . . . . . . . . . . . . 16-14 GLOW PLUG . . . . . . . . . . . . . . . . . . . . . . . . 16-25

SERVICE SPECIFICATION(S) . . . . . . . . . . 16-15 GLOW PLUG REMOVAL AND INSTALLATION

...................................... 16-25
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . 16-16
GLOW PLUG RELAY <Except Euro5> . . . . 16-25
STARTER RELAY CONTINUITY CHECK . 16-16
GLOW PLUG RELAY REMOVAL AND INSTALLATION
STARTER MOTOR ASSEMBLY. . . . . . . . . 16-16 ...................................... 16-25
STARTER MOTOR ASSEMBLY REMOVAL AND GLOW CONTROL UNIT <Euro5> . . . . . . . . 16-26
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 16-16
GLOW CONTROL UNIT REMOVAL AND
STARTER MOTOR ASSEMBLY INSPECTION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 16-26
...................................... 16-17
16-2 ENGINE ELECTRICAL
CHARGING SYSTEM

CHARGING SYSTEM
GENERAL INFORMATION
M1161000102045
The charging system uses the alternator output to When the ignition switch is turned on, current flows in
keep the battery charged at a constant level under the field coil and initial excitation of the field coil
various electrical loads. occurs.
OPERATION When the stator coil begins to generate power after
the engine is started, the field coil is excited by the
Voltage output current of the stator coil.
The alternator output voltage rises as the field cur-
rent increases and it falls as the field current
decreases. When the battery voltage (alternator "S"
Approximately terminal voltage) reaches a regulated voltage of
14.4 V
approximately 14.4 V, the field current is cut off.
When the battery voltage drops below the regulated
Time
voltage, the voltage regulator regulates the output
voltage to a constant level by controlling the field cur-
AK400075AB
rent.
Rotation of the excited field coil generates AC volt- In addition, when the field current is constant, the

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age in the stator. alternator output voltage rises as the engine speed
This alternating current is rectified through diodes to increases.
DC voltage having a waveform shown in the illustra- CAUTION
tion.
When the specified alternator is not used, each
The average output voltage fluctuates slightly with
ECU would probably fail.
the alternator load condition.
 ENGINE ELECTRICAL
CHARGING SYSTEM
16-3
<Except Euro 5>

Alternator

B
Stator
coil

Field coil S
+
L
Voltage
regulator Charging
warning lamp Ignition
switch Battery
Combination
meter

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–

AK403859 AB

<Euro 5>

Alternator

Engine-ECU

Stator coil Stator coil

G
Field coil S
L Ignition
Voltage Charging
regulator FR switch-IG
warning lamp
Combination
meter Battery

AK802592AE

ALTERNATOR SPECIFICATIONS
16-4 ENGINE ELECTRICAL
CHARGING SYSTEM

Item Except Euro 5 Euro 5

Type Battery voltage sensing Battery voltage sensing
Rated output V/A 12/90 <Standard> 12/95 <Standard>
12/120 <Cold climate zone> 12/130 <Cold climate zone>
Voltage regulator Electronic built-in type Electronic built-in type

SERVICE SPECIFICATIONS
M1161000301370

Item Standard value Limit

Alternator output line voltage drop (at 30 A) V − Maximum 0.3
Regulated voltage ambient −20°C 14.2 − 15.4 −
temperature at voltage regulator 20°C 13.9 − 14.9 −
(vehicle stationary) V
60°C 13.4 − 14.6 −
80°C 13.1 − 14.5 −
Output current − 70 % of normal output current

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 ENGINE ELECTRICAL
CHARGING SYSTEM
16-5
SPECIAL TOOL
M1161000600646

Tool Number Name Use

MB991955 M.U.T.-III sub assembly • Checking the engine speed
A A: • A: Vehicle CAUTION
MB991824 communication For vehicles with CAN
B: interface (V.C.I.) communication, use M.U.T.-III main
MB991827 • B: M.U.T.-III USB harness A to send simulated
MB991824 C: cable vehicle speed. If you connect
B MB991910 • C: M.U.T.-III main M.U.T.-III main harness B instead,
D: harness A (Vehicles the CAN communication does not
MB991911 with CAN function correctly.
E: communication
MB991827 MB991825 system)
F: • D: M.U.T.-III main
C
MB991826 harness B (Vehicles
without CAN
communication
system)

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MB991910
• E: M.U.T.-III
D measurement adapter
• F: M.U.T.-III trigger
DO NOT USE
harness

MB991911

MB991825

MB991826

MB991955

MB991519 Alternator test harness Checking the alternator

("S" terminal voltage)
16-6 ENGINE ELECTRICAL
CHARGING SYSTEM

ON-VEHICLE SERVICE

ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST

M1161000900926

Ammeter (clamp-type)

Alternator

Voltmeter (digital-type)

Battery
"B" terminal

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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 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 M.U.T.-III or tachometer
• Drive belt tension
8. Leave the hood open.
(Refer to GROUP 11A − On-Vehicle Service − Alter-
nator and Power Steering Oil Pump Drive Belt 9. Start the engine.
Tension Check and Adjustment ). 10.With the engine running at 2,500 r/min, turn the
• Fusible link headlamps and other lamps on and off to adjust
• Abnormal noise from the alternator while the the alternator load so that the value displayed on
engine is running the ammeter is slightly above 30 A.
2. Turn the ignition switch to the "LOCK" (OFF) Adjust the engine speed by gradually decreasing
position. it until the value displayed on the ammeter is 30
3. Disconnect the negative battery cable. A. Take a reading of the value displayed on the
4. Connect a clamp-type DC test ammeter with a voltmeter at this time.
range of 0 − 100 A to the alternator "B" terminal Limit: Maximum 0.3 V
output wire. NOTE: When the alternator output is high and the
NOTE: The way of disconnecting the alternator value displayed on the ammeter does not
output wire and of connecting the ammeter is pos- decrease until 30 A, set the value to 40 A. Read
sibly not found the problem that the output current the value displayed on the voltmeter at this time.
is dropping due to the insufficient connection When the value range is 40 A, the limit is maxi-
between terminal "B" and the output wire. mum 0.4 V.
 ENGINE ELECTRICAL
CHARGING SYSTEM
16-7
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 M.U.T.-III or tachometer.
If a terminal is not sufficiently tight or if the 16.Disconnect the negative battery cable.
harness has become discoloured due to
overheating, repair and then test again. 17.Disconnect the ammeter and voltmeter.
18.Connect the negative battery cable.

OUTPUT CURRENT TEST

M1161001002427

Load

Ammeter
Voltmeter (clamp-type)

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– +

Combination meter
Ignition Charging
switch-IG warning lamp B

L
S
G

Alternator
+
Engine-ECU
Battery <Euro 5>

AKB00234 AB

This test determines whether the alternator output • Drive belt tension
current is normal. (Refer to GROUP 11A − On-Vehicle Service − Alter-
1. Before the test, always be sure to check the nator and Power Steering Oil Pump Drive Belt
following. Tension Check and Adjustment .)
• Alternator installation • Fusible link
• Battery (Refer to GROUP 54A − Battery − On- • Abnormal noise from the alternator while the
Vehicle Service − Battery Test .) engine is running.
NOTE: The battery should be slightly discharged. 2. Turn the ignition switch to the "LOCK" (OFF)
The load needed by a fully-charged battery is position.
insufficient for an accurate test. 3. Disconnect the negative battery cable.
16-8 ENGINE ELECTRICAL
CHARGING SYSTEM

CAUTION Limit: 70% of normal current output

Never use clips but tighten bolts and nuts to con- NOTE: .
nect the line. Otherwise loose connections (e.g. • For the nominal current output, refer to the
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 − 100 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 pos-
electrical load and the temperature of the
sibly not found the problem that the output current
alternator body.
is dropping due to the insufficient connection
• If the electrical load is small while testing, the
between terminal "B" and the output wire.
specified level of current may not be output
5. Connect a voltmeter with a range of 0 − 20 V even though the alternator is normal. In such
between the alternator "B" terminal and the earth cases, increase the electrical load by leaving
[Connect the (+) lead of the voltmeter to the "B" the headlamps turned on for some time to dis-
terminal, and then connect the (−) lead of the charge the battery or by using the lighting sys-
voltmeter to the earth]. tem in another vehicle, and then test again.

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6. Connect the negative battery cable. • The specified level of current also may not be
7. Connect the M.U.T.-III or tachometer. output if the temperature of the alternator body
8. Leave the hood open. or the ambient temperature is too high. In such
cases, cool the alternator and then test again.
9. Check that the reading on the voltmeter is equal
to the battery voltage. 12.The reading on the ammeter should be above the
limit value. If the reading is below the limit value
NOTE: If the voltage is 0 V, the cause is probably
and the alternator output wire is normal, remove
an open circuit in the wire or fusible link between
the alternator from the engine and check the
the alternator "B" terminal and the battery (+) ter-
alternator.
minal.
13.Run the engine at idle after the test.
10.Turn the light switch on to turn on headlamps and
then start the engine. 14.Turn the ignition switch to the "LOCK" (OFF)
position.
11.Immediately after setting the headlamps to high
beam and turning the heater blower switch to the 15.Remove the M.U.T.-III or tachometer.
high revolution position, increase the engine 16.Disconnect the negative battery cable.
speed to 2,500 r/min and read the maximum 17.Disconnect the ammeter and voltmeter.
current output value displayed on the ammeter. 18.Connect the negative battery cable.
 ENGINE ELECTRICAL
CHARGING SYSTEM
16-9
REGULATED VOLTAGE TEST
M1161001102457

Load
Ammeter (clamp-type)

Combination meter

Ignition Charging MB991519

switch-IG warning lamp
Blue

L Alternator
S
G

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+ Black

Engine-ECU Yellow Red

Battery
<Euro 5>
–

Voltmeter (digital-type)
+ –

AKB00235 AB

This test determines whether the voltage regulator 4. Use the special tool Alternator test harness
correctly controlling the alternator output voltage. (MB991519) to connect a digital voltmeter
1. Always be sure to check the following before the between the alternator "S" terminal and earth
test. [Connect the (+) lead of the voltmeter to the "S"
• Alternator installation terminal, and then connect the (−) lead of the
• Check that the battery installed in the vehicle is voltmeter to a secure earth or to the battery (−)
fully charged. terminal].
(Refer to GROUP 54A − Battery − On-Vehicle Serv- 5. Connect a clamp-type DC test ammeter to the
ice − Battery Test .) alternator "B" terminal output wire.
• Drive belt tension 6. Reconnect the negative battery cable.
(Refer to GROUP 11A − On-Vehicle Service − Alter-
7. Connect the M.U.T.-III or tachometer.
nator and Power Steering Oil Pump Drive Belt
Tension Check and Adjustment .) 8. Turn the ignition switch to the "ON" position and
• Fusible link check that the reading on the voltmeter is equal to
• Abnormal noise from the alternator while the the battery voltage.
engine is running NOTE: If the voltage is 0 V, the cause is probably
2. Turn the ignition switch to the "LOCK" (OFF) an open circuit in the wire or fusible link between
position. the alternator "S" terminal and the battery (+) ter-
3. Disconnect the negative battery cable. minal.
9. Turn all lamps and accessories off.
10.Start the engine.
NOTE: Do not drive the vehicle after the engine
starts.
11.Increase the engine speed to 2,500 r/min.
16-10 ENGINE ELECTRICAL
CHARGING SYSTEM

12.Read the value displayed on the voltmeter when 14.After the test, lower the engine speed to the idle
the alternator output current alternator becomes speed.
10 A or less. 15.Turn the ignition switch to the "LOCK" (OFF)
13.If the voltage reading conforms to the value in the position.
voltage regulation, then the voltage regulator is 16.Remove the M.U.T.-III or tachometer.
operating normally. 17.Disconnect the negative battery cable.
If the voltage is not within the standard value, 18.Disconnect the ammeter and voltmeter.
there is a malfunction of the voltage regulator or of 19.Remove the special tool, and return the connector
the alternator. to the original condition.
20.Connect the negative battery cable.
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

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60 13.4 − 14.6
80 13.1 − 14.5

WAVEFORM CHECK USING AN OSCILLOSCOPE

M1161001201428

MEASUREMENT METHOD Connect the oscilloscope special patterns pick-up to

the alternator "B" terminal.
Alternator

CH1

"B" terminal AK701885AC

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
 ENGINE ELECTRICAL
CHARGING SYSTEM
16-11

0.4

0.2
Voltage
at alternator 0
"B" terminal
-0.2

-0.4

Time
AK701886AB

NOTE: when the voltage waveform reaches an excessively

high value (approximately 2 V or higher at idle), it
often indicates an open circuit due to a brown fuse

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between alternator "B" terminal and battery, but not a
defective alternator.

AK701862

The voltage waveform of the alternator "B" terminal

can undulate as shown in the illustration. This wave-
form is produced when the regulator operates
according to fluctuations in the alternator load (cur-
rent), and is normal for the alternator. In addition,
EXAMPLE OF ABNORMAL WAVEFORMS
NOTE: .
1. The size of the waveform patterns differs largely, depending on the adjustment of the variable knob on the
oscilloscope.
2. Identification of abnormal waveforms is easier when there is a large output current (regulator is not oper-
ating). (Waveforms can be observed when the headlamps are illuminated.)
3. Check the conditions of the charging warning lamp (illuminated/not illuminated). Also, check the charging
system totally.
16-12 ENGINE ELECTRICAL
CHARGING SYSTEM

Abnormal waveform Problem cause

Except Euro 5 Euro 5
Example 1 Example 1 Open diode

AK703778

AK502669

Example 2 Example 2 Short in diode

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AK703780

AK502670

Example 3 Example 3 Broken wire in

stator coil

AK703781

AK502671

Example 4 Example 4 Short in stator

coil

AK703782

AK502672
 ENGINE ELECTRICAL
CHARGING SYSTEM
16-13
ALTERNATOR ASSEMBLY

REMOVAL AND INSTALLATION

M1161001403804

CAUTION
When the specified alternator is not used, each ECU would probably fail.
Pre-removal Operation Post-installation Operation
• Air Cleaner Assembly Removal (Refer to GROUP 15 − Air • A/C Compressor Drive Belt, Alternator and Power Steer-
Cleaner ). ing Oil Pump Drive Belt Installation (Refer to GROUP 11A
• Intercooler Inlet Air Hose Removal (Refer to GROUP 15 − − Crankshaft Pulley ).
Intercooler ) <Except Euro5>. • Intercooler Inlet Air Hose Installation (Refer to GROUP 15
• Intercooler Inlet Air Hose Removal (Refer to GROUP 15 − − Intercooler ) <Except Euro5>.
Intercooler ) <Euro5>. • Intercooler Inlet Air Hose Installation (Refer to GROUP 15
• A/C Compressor Drive Belt, Alternator and Power Steer- − Intercooler ) <Euro5>.
ing Oil Pump Drive Belt Removal (Refer to GROUP 11A − • Air Cleaner Assembly Installation (Refer to GROUP 15 −
Crankshaft Pulley ). Air Cleaner ).
• Alternator and Power Steering Oil Pump Drive Belt Ten-
sion Check (Refer to GROUP 11A − On-vehicle Service,
Alternator and Power Steering Oil Pump Drive Belt Ten-
sion Check ).
• A/C Compressor Drive Belt Tension Check and Adjust-

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ment (Refer to GROUP 11A − On-vehicle Service, A/C
Compressor Drive Belt Tension Check and Adjustment ).

14 ± 4 N·m
3 2
1
44 ± 10 N·m

23 ± 2 N·m

AC503001AC

Removal steps Removal steps (Continued)

1. Alternator connector connection 2. Alternator terminal connection
<<A>> 3. Alternator assembly
16-14 ENGINE ELECTRICAL
STARTING SYSTEM

REMOVAL SERVICE POINT 1. Remove the rubber shield from the wheelhouse
<<A>> ALTERNATOR ASSEMBLY REMOVAL (RH), and put the pipe, hose, etc. to side so that
they will not be a hindrance when removing and
installing the alternator assembly.
2. Remove the alternator assembly from the
wheelhouse (RH).

ACB00699AB

STARTING SYSTEM
GENERAL INFORMATION

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M1161000100845
If the ignition switch is turned to the "START" posi- When the ignition switch is returned to the "ON" posi-
tion, current flows in the pull-in and holding coils pro- tion after starting the engine, the starter clutch is dis-
vided inside magnetic switch, attracting the plunger, engaged from the ring gear.
When the plunger is attracted, the lever connected to An overrunning clutch is provided between the pinion
the plunger is actuated to engage the starter clutch. and the armature shaft, to prevent damage to the
On the other hand, attracting the plunger will turn on starter.
the magnetic switch, allowing the "B" terminal and
"M" terminal to conduct. Thus, current flows to
engage the starter motor.
 ENGINE ELECTRICAL
STARTING SYSTEM
16-15
SYSTEM DIAGRAM

Holding coil Plunger

Pull-in coil
Lever

B Overrunning clutch

Ignition switch - ST M
Pinion gear
S

+ Armature

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Battery

Brush Field coil

Yoke

AK500030 AB

STARTER MOTOR SPECIFICATIONS

Item Specification
Type Reduction drive with planetary gear
Rated output kW/V 2.2/12
Number of pinion teeth 10

SERVICE SPECIFICATIONS
M1161000300689

Item Standard value Limit

Pinion gap mm 0.5 − 2.0 −
16-16 ENGINE ELECTRICAL
STARTING SYSTEM

ON-VEHICLE SERVICE Battery voltage Terminal No. to Continuity test

be connected results
STARTER RELAY CHECK to tester
M1162001401113
Not applied 3−4 Open circuit
Connect 3−4 Continuity (Less
Starter relay
terminal No.2 than 2 Ω)
and battery (+)
terminal.
Connect
terminal No.1
and battery (−)
terminal.

Engine compartment relay box STARTER MOTOR ASSEMBLY

AC501631

REMOVAL AND INSTALLATION

M1162001003296

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AC503883 AB

Pre-removal Operation Post-installation Operation

• Under Skid Plate and Engine Room Under Cover • Under Skid Plate and Engine Room Under Cover Installa-
Removal (Refer to GROUP 51 − Under Cover ). tion (Refer to GROUP 51 − Under Cover ).

2
11 ± 1 N·m 3

30 ± 3 N·m

AC601313AD

Removal steps REMOVAL SERVICE POINT

1. Starter connector connection <<A>> STARTER ASSEMBLY REMOVAL
2. Starter terminal connection <2WD>
<<A>> 3. Starter assembly
Remove the starter assembly from below the vehicle.
 ENGINE ELECTRICAL
STARTING SYSTEM
16-17
<4WD>
Remove the rubber shield from the wheelhouse (LH),
and remove the starter assembly.

ACB00700AB

STARTER MOTOR ASSEMBLY INSPECTION

M1162001101112
PINION GAP ADJUSTMENT

Switch
B

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battery S
M

Starter Wire
motor
AKX00199

AK403864 AB
5. If the pinion gap is out of specification, adjust by
1. Disconnect the field coil wire from the M-terminal adding or removing gasket(s) between the
of the magnetic switch. magnetic switch and front bracket.
2. Connect a 12-volt battery between the S-terminal
and M-terminal.
MAGNETIC SWITCH PULL-IN TEST
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
3. Set the switch to "ON", and the pinion will move B
out.
Battery M S

Stopper
Starter Wire
motor

AK403868 AB

1. Disconnect the field coil wire from the M-terminal

of the magnetic switch.
Pinion
CAUTION
Pinion gap
AKX00198 AC This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
4. Check the pinion-to-stopper clearance (pinion
gap) with a feeler gauge. 2. Connect a 12-volt battery between the S-terminal
and M-terminal.
Standard value: 0.5 − 2.0 mm
3. If the pinion moves out, the pull-in coil is good. If it
doesn't, replace the magnetic switch.
16-18 ENGINE ELECTRICAL
GLOW SYSTEM

MAGNETIC SWITCH HOLD-IN TEST 2. Connect a voltmeter (15-volt scale) across the
starter motor.
3. Rotate the rheostat to full-resistance position.
B
4. Connect the battery cable from the negative
battery terminal to the starter motor body.
Battery S 5. Adjust the rheostat until the battery positive
M voltage shown on the voltmeter is 11 V.
Starter
6. Confirm that the maximum amperage is within the
Wire
motor specifications and that the starter motor turns
smoothly and freely.
AK403869 AB
Current: Maximum 130 A
1. Disconnect the field coil wire from the M-terminal
of the magnetic switch. MAGNETIC SWITCH RETURN TEST
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
B
2. Connect a 12-volt battery between the S-terminal

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and body. S
Battery
3. Manually pull out the pinion as far as the pinion M
stopper position.
Starter Wire
4. If the pinion remains out, everything is in order. If motor
the pinion moves in, the hold-in circuit is open.
Replace the magnetic switch. AK403871 AB

1. Disconnect the field coil wire from the M-terminal

FREE RUNNING TEST of the magnetic switch.
Ammeter CAUTION
A This test must be performed quickly (in less than
B 10 seconds) to prevent the coil from burning.
Carbon-pile
rheostat
S 2. Connect a 12-volt battery between the M-terminal
M
and body.
Battery
Starter V WARNING
motor Voltmeter Be careful not to get your fingers caught
when pulling out the pinion.
AK403870 AB 3. Pull the pinion out and release. If the pinion
quickly returns to its original position, everything is
1. Connect a test ammeter (150-ampere scale or
operating properly. If it doesn't, replace the
more) and carbon pile rheostat in series between
magnetic switch.
the positive battery terminal and starter motor
terminal.

GLOW SYSTEM
GENERAL INFORMATION The glow control unit carries out the duty control to
M1164000100178 the energization of the glow plug, in accordance with
GLOW SYSTEM <EURO5> the signal from the engine-ECU.This achieves the
GLOW CONTROL optimum voltage of the glow plug in accordance with
The glow control unit of the glow system employs the the engine conditions at the after glow to stabilize the
method of energizing the glow plug of each cylinder combustion. Also the combustion noise or hydrocar-
respectively. bon (HC) emissions are reduced.
 ENGINE ELECTRICAL
GLOW SYSTEM
16-19
System Configuration Diagram

Combination
Glow indicator meter
Engine control relay lamp
Battery

Engine coolant
temperature sensor

Control Ignition switch-IG

signal
Engine-ECU Ignition switch-ST
Glow plug Diagnosis
control circuit signal
Crank angle sensor

Intake air temperature

sensor

Manifold absolute

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Power pressure sensor
MOSFET

Glow control unit Glow plug

AKB00122 AB

The engine-ECU determines the glow start, the glow Glow Indicator Lamp Control
time and the energization duty cycle of the glow plug. When the engine coolant temperature is below a pre-
The engine-ECU outputs the PWM signal of the glow determined level, engine-ECU illuminates the glow
operation request to the glow control unit when the indicator lamp. This causes the glow indicator lamp
following conditions are satisfied. to illuminate, in order to inform the driver of the timing
for starting the engine.
Before starting (Pre-glow control)
• Ignition switch: ON GLOW CONTROL UNIT
• Engine coolant temperature is 60°C or less.
Under the conditions of the engine not starting, the
maximum energization time of the glow plug (duty of
100%) is 20 seconds.
While running a cold engine (After-glow control)
• Ignition switch: ON
• Engine coolant temperature is 70°C or less.
• Engine speed is 350 r/min or more.
NOTE: The glow duty is determined in accordance
with the engine coolant temperature and the intake AKB00123
air temperature (at the air flow sensor). The glow control unit is installed to the fuel filter pro-
The maximum energization time of the glow plug is tector. The engine-ECU supplies the power to the
300 seconds. control part of the glow control unit when the ignition
switch is turned ON. The energization to the glow
plug from the battery is controlled by installing the
power-MOSFET (Metal Oxide Semiconductor Field
16-20 ENGINE ELECTRICAL
GLOW SYSTEM

Effect Transistor) to the glow control unit for each cyl-

Heated portion temperature (˚C)
inder. When receiving the signal from the engine-
ECU through the control signal wire, the glow control
unit controls the Power-MOSFET, based on the sig- 1000
nal duty, to control the voltage for each glow plug. If
When 11 V is applied
detecting the open or short circuit of the glow plug, or
communication failures to the engine-ECU, the glow
control unit sends the malfunction signal to the 500
engine-ECU through the diagnosis signal wire.

GLOW PLUG
Driving current (A)

5
When 11 V is applied

Ceramic heating element

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AK802950 AB 0
30
Energization time (s)
The glow plug is installed to each cylinder of the cyl- AK802953AB
inder head. The glow plug performs preheating of the
combustion chamber with the ceramic heating ele- The self control resistance is built in the ceramic
ment on the acral part. The heating temperature of heating element of the glow plug. When the current
the glow plug is changed by adjusting the voltage is going through the glow plug, the heating element
applied to the glow plug through the duty control of heats up and the self control resistance increases,
the glow control unit. too.This gradually decreases the current going
through the heating element to restrict the amount of
heating the glow plug.

SELF-REGULATING GLOW SYSTEM

<EXCEPT EURO 5>
The self-regulating glow system enables the vehicle
to start ideally at low temperature by preheating the
glow plug at super speed. When the ignition switch is
turned to the ON position, the engine-ECU supplies
electric currents and controls the glow lamp illumina-
tion in accordance with the engine coolant tempera-
ture. The control resistance wire built in the glow plug
has a higher resistance as the glow plug temperature
becomes higher. Because of this, the currents in the
heater wire gradually decrease. The glow plug is sta-
bilized at the specified temperature. After the engine
start at low temperature, the current going to the
glow plug is controlled to perform the stable combus-
tion.
 ENGINE ELECTRICAL
GLOW SYSTEM
16-21

Battery

Engine
control
relay

Ignition
switch
Engine-ECU

Glow plug
OFF relay
ON
Engine coolant
temperature sensor
Glow lamp
Ignition switch-IG

Ignition switch-ST
Glow plugs
Crank angle sensor

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AK403873AB

SERVICE SPECIFICATION
M1164000300194

<EURO5>
Item Standard value
Glow plug resistance (at 20°C) Ω 0.6 − 1.4

<EXCEPT EURO5>
Item Standard value
Resistance between glow plug plate and glow plug body (parallel 0.15 − 0.25
resistance for 4 glow plugs) (at 20°C) Ω
Voltage between glow plug plate and Immediately after ignition 9 − 11 (Drops to 0 V after 4 − 8
glow plug body V switch is turned to ON seconds have passed)
(without starting the engine)
While engine is cranking 6 or more
While engine is warning up 12 − 15 (Drops to 0 V when the
engine coolant temperature
increases to 60°C or more or if
180 seconds have passed since
the engine was started)
Glow plug relay resistance (at 20°C) Ω 18 − 22
Glow plug resistance (at 20°C) Ω 0.6 − 1.0
16-22 ENGINE ELECTRICAL
GLOW SYSTEM

ON-VEHICLE SERVICE

GLOW PLUG CHECK <EURO5>

M1164003400305
1. Disconnect the glow plug connector.
2. Measure the resistance between the glow plug
terminal and the body, or the glow plug terminal
and the cylinder head.
(-) Standard value: 0.6 − 1.4 Ω (at 20°C)

(+)
AK403892AC

SELF-REGULATING GLOW SYSTEM CHECK <EXCEPT EURO5>

M1164001000260
SELF-REGULATING GLOW SYSTEM CHECK 4. Connect a voltmeter between the glow plug plate

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1. Check that the battery voltage is 11 − 13 V. and the glow plug body (earth).
2. Check that the engine coolant temperature is 5. Measure the voltage immediately after the ignition
40°C or less. switch is turned to ON (without starting the
NOTE: If the engine coolant temperature is too engine).
high, disconnect the engine coolant temperature Standard value: 9 − 11 V (Drops to 0 V after 4
sensor connector. − 8 seconds have passed)
In addition, check to be sure that the glow indicator
lamp (red) illuminates immediately after the ignition
switch is turned to ON.
NOTE: The time during which the voltage appears
(-) (energizing time) will depend on the engine cool-
ant temperature.
6. Measure the voltage while the engine is cranking.
Standard value: 6 V or more
(+)
AK403875AC 7. Start the engine and measure the voltage while
the engine is warming up.
3. Measure the resistance between the glow plug
However, if the engine coolant temperature rises
plate and the glow plug body (earth).
above 60°C or when 180 seconds have passed
Standard value: 0.15 − 0.25 Ω (at 20°C) since the engine was started, the voltage will
NOTE: The resistance value is the parallel resist- always return to 0 V (Refer to the Glow Plug
ance value for the four glow plugs. Energization Timing Chart).
Standard value: 12 − 15 V
 ENGINE ELECTRICAL
GLOW SYSTEM
16-23
Glow Plug Energization Timing Chart <Reference>

Ignition START
switch
ON
OFF
T1
Glow ON
lamp
OFF
T2 T3
Glow plug ON
relay
OFF

Crank angle Idle

sensor
0 r/min

T1: Glow lamp

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T2: Glow plug relay drive time after ignition switch is turned ON
T3: Glow plug relay drive time after engine starts (after glow)

NOTE
After glow time T3 becomes longer as the engine coolant temperature drops

AK403877 AG

CHECK AT THE ECU TERMINALS <EURO5>

M1164003600246
Refer to GROUP 13A − Troubleshooting − Check at
the engine-ECU terminals .

CHECK AT THE ECU TERMINALS <EXCEPT EURO5>

M1164003600257
Refer to GROUP 13A − Troubleshooting − Check at
the engine-ECU terminals.

GLOW PLUG RELAY CHECK <EXCEPT EURO5>

M1164003300160
1. Disconnect the glow plug relay connector.
2. Measure resistance between terminal C and
Glow plug relay
terminal E.
Standard value: 18 − 22 Ω (at 20°C)
3. Use jumper cables to connect terminal C of the
glow plug relay to the battery (+) terminal and
terminal E to the battery (−) terminal.

AK403878AB
16-24 ENGINE ELECTRICAL
GLOW SYSTEM

CAUTION 4. Check the continuity between glow plug relay

1. Always be sure to disconnect the harnesses terminals B and G while disconnecting and
connected to glow plug relay terminals B and connecting the jumper cable at the battery (+)
G before using the jumper cable. terminal.
2. The terminals of the disconnected harnesses
must not be shorted to earth.
3. When connecting the jumper cable, be very
careful not to make a mistake in connecting
the terminal, as this will cause damage to the
relay.

B G C E

B terminal
G terminal

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C E
AK403881AB

Jumper cable at battery (+) Continuity between

terminal terminals B − G
Connected Continuity (0.01 Ω or less)
Disconnected No continuity (infinite
resistance)

GLOW PLUG CHECK <EXCEPT EURO5> 1. Remove the glow plug plate.
M1164003400316
2. Measure the resistance between the glow plug
terminals and the body.
Standard value: 0.6 − 1.0 Ω (at 20°C)

ENGINE COOLANT TEMPERATURE

(-)
SENSOR CHECK <EXCEPT EURO5>
M1164003500067
Refer to GROUP 13A − On-vehicle service − Engine
coolant temperature sensor check.
(+)
AK403892AC
 ENGINE ELECTRICAL
GLOW SYSTEM
16-25
GLOW PLUG

REMOVAL AND INSTALLATION

M1164001800512

Pre-removal Operation Post-installation Operation

• Throttle Body Assembly Removal (Refer to GROUP 13A • EGR Valve and EGR Valve Pipe Installation (Refer to
− Throttle Body ). GROUP 17 − EGR Valve and EGR Cooler ).
• EGR Valve and EGR Valve Pipe Removal (Refer to • Throttle Body Assembly Installation (Refer to GROUP
GROUP 17 − EGR Valve and EGR Cooler ). 13A − Throttle Body ).

5.0 ± 1.0 N·m

1.8 ± 0.2 N·m

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1
17 ± 2 N·m

AC503049AE

Removal steps GLOW PLUG RELAY <Except Euro5>

1. Glow plug connecting plate
<Except Euro5> REMOVAL AND INSTALLATION
2. Glow plug M1164002400023

5.0 ± 1.0 N·m

1
9.0 ± 1.0 N·m

9.0 ± 1.0 N·m

2
3

AC807146 AB
16-26 ENGINE ELECTRICAL
GLOW SYSTEM

Removal steps GLOW CONTROL UNIT <Euro5>

1. Glow plug control relay terminal
connection REMOVAL AND INSTALLATION
2. Glow plug control relay M1164002100077
3. Glow plug relay bracket

9.0 ± 1.0 N·m

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ACB00697AB

Removal Set the connector of the glow control unit to the area
>>A<< 1. Glow control unit shown in the figure, and tighten the mounting nut to
the specified torque.
INSTALLATION SERVICE POINT Tightening torque: 9.0 ± 1.0 N⋅m
>>A<< GLOW CONTROL UNIT INSTALLATION

4˚
30˚ ACB00698 AB