ENGINE ELECTRICAL SYSTEM

SECTION EE
CONTENTS
SERVICE DATA AND SPECIFICATIONS (SDS) ............2 IC Ignition System Troubleshooting...........................16
STARTING SYSTEM .......................................................3 Distributor...................................................................21
Wiring Diagram ............................................................3 GLOW AND AIR HEATER SYSTEMS (TD27)..............22
Troubleshooting ...........................................................5 System Diagram ........................................................22
Starter Motor (H20-II, H25)..........................................8 Troubleshooting .........................................................23
Starter Motor (TD27) ...................................................9 ENGINE CONTROL SYSTEM (H20-II, H25).................27
CHARGING SYSTEM ....................................................10 System Diagram ........................................................27
Wiring Diagram ..........................................................10 Circuit Diagram ..........................................................28
Troubleshooting .........................................................11 Unit Layout.................................................................29
Alternator ...................................................................13 Component Inspection...............................................30
IGNITION SYSTEM (H20-II, H25) .................................15 Trouble Diagnoses.....................................................30
Wiring Diagram ..........................................................15
 SERVICE DATA AND SPECIFICATIONS (SDS)

BATTERY
Engine H20-II, H25 TD27
Type 55D23L 95D31L
Capacity V-AH 12-60 12-80
Full charge specific gravity at 20°C (68°F) 1.28

STARTER MOTOR
Engine H20-II, H25 TD27
M3T21882 M001T60381 S13-327
Type
Reduction gear type Reduction gear type Reduction gear type
System voltage V 12 12
No-load
Terminal voltage V 11.5 11.0 11.0
Current A Less than 60 Less than 90 Less than 160
Revolutions rpm More than 6,500 More than 3,000 More than 4,000
Outer diameter of commutator mm (in) More than 31.4 (1.484) More than 28.8 (1.134) More than 35.5 (1.398)
Wear limit length of brush mm (in) 11.5 (0.453) 11.5 (0.453) 9.0 (0.354)
16.7 - 21.6 12.7 - 24.5 26.5 - 32.4
Brush spring tension N (kg, lb)
(1.7 - 2.2, 3.7 - 4.9) (1.3 - 2.5, 2.9 - 5.5) (2.7 - 3.3, 6.0 - 7.3)
Movement “” in height of
0.5 - 2.0 (0.020 - 0.079) 0.3 - 1.5 (0.012 - 0.059)
pinion assembly mm (in)

ALTERNATOR
Engine H20-II, H25 TD27
Type A7T033 LR150-221 LR150-430S
Applicable model D01, D02 series D01 series D02 series
Nominal rating V-A 12-35 12-60 12-60
Ground polarity Negative Negative Negative
Minimum revolutions at 14 volts
Less than 1,300 Less than 1,000 Less than 1,000
under no load rpm
More than 27.5/2,500
Output current A/rpm More than 50/5,000 More than 50/5,000
More than 35/5,000
Regulated output voltage V 14.1 - 14.7 14.2 - 14.7 14.4 - 15.0
Brush wear limit mm (in) More than 5 (0.20) More than 7.0 (0.276) More than 6.0 (0.236)
2.648 - 5.590 2.501 - 3.383 1.765 - 3.531
Brush spring pressure N (g, oz)
(270 - 570, 9.52 - 20.10) (255 - 345, 8.99 - 12.17) (180 - 360, 6.35 - 12.70)
Slip ring outer diameter mm (in) More than 32.4 (1.276) More than 30.6 (1.205) More than 30.6 (1.205)

DISTRIBUTOR
T006T87772 (H20-II engine) T006T87775 (H25 engine)
Type
IC type
Firing order 1-3-4-2
Rotating direction Counterclockwise
Air gap mm (in) 0.35 - 0.45 (0.0138 - 0.0177)
Cap insulation resistance MΩ More than 50
Rotor head insulation resistance MΩ More than 50
Cap carbon point length mm (in) More than 10 (0.39)
0°/15.3 - 16.7 0°/14.7 - 18.0
Vacuum advance
(153 - 167, 115 - 125, 4.53 - 4.92) (147 - 180, 110 - 135, 4.33 - 5.31)
[Distributor degree/distributor
11° - 13°/66.7 7.5° - 9.5°/66.7
kPa (mbar, mmHg, inHg)]
(667, 500, 19.69) (667, 500, 19.69)
Centrifugal advance 0°/500 - 550 0°/700 - 730
[Distributor degree/distributor rpm] 11° - 13°/1,600 7.5° - 9.5°/1,200

SPARK PLUG

Type BP4ES, BPR4ES

14 x 19
Size (Screw dia. x reach) mm (in)
(0.55 x 0.75)
0.8 - 0.9
Plug gap mm (in)
(0.031 - 0.035)

EE-2
 STARTING SYSTEM

WARNING:
Before starting to work on any part of electrical system, be sure to turn key switch “OFF” and then
disconnect battery ground cable.
Wiring Diagram

EEM0071

EE-3
 STARTING SYSTEM
Wiring Diagram (Cont’d)
LPG SOLENOID VALVE (LPG model)

EEM0072

EE-4
 STARTING SYSTEM

Troubleshooting
CAUTION:
If any abnormality is found, immediately disconnect battery negative terminal.

Engine does not start.

Does engine turn by No Does starter motor No

A
cranking? turn?

Yes Yes

No Does gear shaft turn?

Yes

Check pinion roller

clutch for damage.
Replace if necessary.

Check reduction gear,

armature and gear shaft
for damage.
Replace if necessary.

No
Does engine turn nor- (Turns slowly) Check battery for charg- NG
C
mally? ing condition and bat-
tery terminals for con-
Yes
nections and corrosion.

OK

Check ignition system Does engine turn by

Yes
and fuel system. replacing starter motor
with a new one?

No

Check inside of engine.

Repair or replace starter

motor.

EE-5
STARTING SYSTEM
Troubleshooting (Cont’d)
A

Is battery normal? Yes

B

No

Is engine stop Yes Refer to BE section.

switch system nor-
mal?

No

Is starting system Yes Refer to trouble of

D
normal? starting system

No

Is creep system Yes Refer to BE section.

normal?

No

Check inside of
engine.

EE-6
 STARTING SYSTEM
Troubleshooting (Cont’d)
D B C

Check battery for charg- Charge or replace

ing condition and bat- NG battery.
tery terminals for con- Repair connections
nections and corrosion. and corrosion of bat-
tery terminals.
OK

Check and repair wiring

system of anti-restart
Can you hear anti-re- No
relay.
start relay operating?
Key switch
Yes Anti-restart relay
Connections

Check and repair wir-

Can you hear magnetic
No ing up to magnetic
switch of starter motor
switch.
operating?
Repair or replace
Yes magnetic switch.

Adjust dimension .
Check shift lever for
deformation, return
Is meshing condition of spring for fatigue and
No
pinion and ring gear pinion for sliding con-
OK? dition.
Correct meshing con-
Yes
dition of pinion and
ring gear. Replace if
necessary.

EEM0108

Remove starter motor Check armature

from engine. Does No assembly, field coil,
starter motor turn under and brush.
no load by connecting Replace if necessary.
battery terminal to M
terminal of starter motor
and battery terminal
to starter motor body?
EEM0087 Yes
Check magnetic switch
contacts.
Replace if necessary.

Starter motor does not Repair or replace key

stop if key switch is switch, starter relay or
turned off. magnetic switch.

EE-7
 STARTING SYSTEM

Starter Motor (H20-II, H25)

REDUCTION GEAR TYPE

EEM0088

EE-8
STARTING SYSTEM

Starter Motor (TD27)

EEM0106

EE-9
 CHARGING SYSTEM

WARNING:
Before starting to work, be sure to turn ignition switch “OFF” and then disconnect battery ground
cable.
Wiring Diagram

EEM0073

EE-10
 CHARGING SYSTEM

Troubleshooting
Before conducting an alternator test, make sure that the battery is
fully charged.
A 30-volt voltmeter and suitable test probes are necessary for the
test.
The alternator can be checked easily by referring to the Inspection
Table.

Burned-out
A Disconnect bulb.
*1
connector Replace bulb
Ignition C.W.L. “OFF”
C.W.L. “OFF” from combi- ........................................................ with new one
switch “ON”
nation meter. and proceed
to A .

*2 *3
Connect con- Damaged
nector (S, L IC-RG.
C.W.L. “ON” C.W.L. “ON” ..............
or R) and Replace
ground F ter- IC-RG with
minal. new one.

*4
C.W.L. “OFF” .............. Damaged
A.C.G.

Check or
Damaged
C.W.L. “ON” Engine idling C.W.L. “ON” replace fan C.W.L. “ON” ..............
A.C.G.
belt.

C.W.L. “OFF” .............. OK

Damaged
C.W.L. “OFF” C.W.L. “ON” ...................................................................................................
A.C.G.

Damaged
Engine speed: Alternator B terminal volt-
IC-RG.
1,500 rpm age:
Replace
Lighting switch ............................
More than 15.5V IC-RG with
“ON”
new one.
C.W.L. “OFF”

13 to 15V OK
............................

*1: C.W.L. ..... Charge warning lamp

*2: Method of grounding F terminal
*3: IC-RG ..... IC regulator
*4: A.C.G. ..... Alternator parts except IC regulator
OK: ..... IC alternator is in good condition.
Contact tip of wire with brush and attach wire to alternator body.

EEM0090

EE-11
CHARGING SYSTEM
Troubleshooting (Cont’d)

Ignition switch turns

A
ON position.

Does changer No Disconnect L and

B
warning lamp come S connectors from
on? alternator.

Yes

Check fan belt and

alternator.

Reference
Fan belt
Fan belt deflection: 11 - 13 mm (0.43 - 0.51 in)
Pushing force: 98 N (10 kg, 22 lb)
Regulated output voltage (v)
H20-II, H25: 14.1 - 14.7
TD27 (D01 series): 14.2 -14.7
TD27 (D02 series): 14.4 - 15.0

Does changer No Check warning lamp

B
warning lamp come bulb and fuse.
on? Replace bulb or
fuse with new one
Yes
and go to A .

Check alternator.

EE-12
 CHARGING SYSTEM

Alternator
H20-II, H25

EEM0074

EE-13
 CHARGING SYSTEM
Alternator (Cont’d)
TD27

EEM0075

EE-14
 IGNITION SYSTEM (H20-II, H25)

WARNING:
Before starting to work, be sure to turn ignition switch “OFF” and then disconnect battery ground
cable.
Wiring Diagram

EEM0077

EE-15
IGNITION SYSTEM (H20-II, H25)

IC Ignition System Troubleshooting

WARNING:
When current is flowing, never touch with bare hand high ten-
sion cables or any other parts with high voltage. If parts are
moist, touching them could cause an electric shock, even if
they are insulated. Always wear dry, well-insulated gloves or
wrap affected parts with dry cloth before handling.

Engie cranks but does not start.

Engine turns erratically.

Check ignition timing. NG Adjust.

OK

Attach adapter *1 to high ten- OK Check for burned or fouled spark

EEM0091 sion cable and position tip of plug.
adapter approx. 6 mm (0.24 in)
NG OK
away from cylinder block. With
adapter held in that position,
crank engine to see if spark
jumps across gaps between tip
and cylinder block at regular
intervals.
Before cranking, disconnect
fuel cut solenoid harness.
Before operation, make sure
there is no inflammable mate-
EEM0093
rial. Clean or Check fuel
*1: replace. system.
Preparation of spark plug for
checking
Many things can be utilized as
an adapter. However, it is rec-
ommended that a used spark
plug whose threaded portion
has been half cut off as shown
in the figure.

NG
A

EE-16
IGNITION SYSTEM (H20-II, H25)
IC Ignition System Troubleshooting (Cont’d)
A

Check air gap between reluctor and NG Adjust the air gap.
stator.

OK

Check IC ignition system. NG Follow the steps in the sequence

IC Ignition System is checked using indicated. If a fault is found, cor-
a volt-ohm-milliam-meter (VOM). rect the problem before continu-
ing. If all tests indicate “OK”,
SEM0092 OK
replace the IC Ignition Unit. DO
NOT REPLACE THE UNIT UNTIL
ALL TESTS HAVE BEEN COM-
PLETED AND INDICATE “OK”.
NOTE:
1. When performing the follow-
ing tests, use a multitester
which can measure accu-
rately in the following
ranges; 0 to 20V DC; 0 to
1,000Ω; 0 to 10V AC; 0 to
50,000Ω.
2. If possible, start the vehicles
and let it run for 5 to 15 min-
utes with the hood closed.
Go to “TEST TABLE”.
This will bring all compo-
nents to normal operating
temperature, and will make it
easier to diagnose intermit-
tent problems.
3. It is not necessary to discon-
nect the harness connectors
when performing the tests
which follow. Simply insert
the meter probes into the
back of appropriate connec-
tor cavity.

EE-17
 IGNITION SYSTEM (H20-II, H25)
IC Ignition System Troubleshooting (Cont’d)
TEST TABLE

TEST TEST METHOD CONDITIONS RESULT ACTION

1. Secondary 1. Connect ohmmeter Resistance readings Distribution cap and
Wiring as illustrated and less than 30,000 high tension cables —
measure the resis- ohms OK
tance of each high Proceed to Step 2.
tension cable.

Resistance readings Replace high tension

greater than 30,000 cable(s) and/or dis-
ohms tributor cap as
required.
EEM0094

2. Ignition Coil 1. Ignition key in 20,000 - 29,000 ohms Ignition coil secondary
Secondary “OFF” position. windings — OK
Circuit 2. Connect ohmmeter
between positive
terminal or negative
terminal and high-
tension terminal as Resistance reading Faulty ignition coil —
illustrated. not between 20,000 - replace.
29,000 ohms.

EEM0095

3. Power Supply 1. Connect voltmeter Above 11 volts Proceed to Step 4.

Circuit as illustrated and
set to appropriate
scale.
2. Turn ignition key to
“ON” position. Below 11 volts Check wiring from
ignition switch to IC
unit.

EEM0096

4. Power Supply 1. Connect voltmeter Voltage reading is Proceed to Step 5.

Circuit as illustrated and less than 1 volt below
(Cranking) set to appropriate battery cranking volt-
scale. age and is greater
2. Turn key to than 8.6 volts.
“START” position
and observe volt- Voltage reading is Check ignition switch
meter while engine more than 1 volt and wiring from switch
is cranking. below battery crank- to IC unit.
ing voltage and/or is
below 8.6 volts.
EEM0097

EE-18
 IGNITION SYSTEM (H20-II, H25)
IC Ignition System Troubleshooting (Cont’d)
TEST TEST METHOD CONDITIONS RESULT ACTION
5. Ignition Pri- 1. Connect voltmeter Above 11 volts Proceed to Step 7.
mary Circuit as illustrated and
set to appropriate
scale.
2. Ignition key in “ON”
position.
Below 11 volts Proceed to Step 6.

EEM0098

6. Ignition Coil 1. Ignition key in 0.9 - 1.2 ohms Ignition coil primary
Primary Cir- “OFF” position winding OK
cuit 2. Connect ohmmeter Check ignition switch
as illustrated. and wiring from igni-
tion switch to coil and
IC unit.

Resistance reading Faulty ignition coil —

not between 0.9 - 1.2 replace.
ohms

EEM0099

7. IC Unit 1. Connect voltmeter 0.5 volts or less Proceed to Step 8.

Ground Circuit as illustrated and
set to appropriate
scale.
2. Turn key to
“START” position More than 0.5 volts Check distributor
and observe volt- ground, wiring from
meter while engine chassis ground to bat-
is cranking. tery including battery
cable connections.

EEM0100

8. Cap and 1. Measure insulation 50 megaohms or Cap and rotor head

Rotor Head resistance between more — OK
electrodes on igni- Proceed to Step 9.
tion coil and side of
spark plug.

Less than 50 megao- Replace cap and rotor

hms head.

SEL656B

EE-19
 IGNITION SYSTEM (H20-II, H25)
IC Ignition System Troubleshooting (Cont’d)
TEST TEST METHOD CONDITIONS RESULT ACTION
9. Pickup Coil 1. Remove IC ignition 420 - 540 ohms Pickup coil — OK
unit and pickup Proceed to Step 10.
coil.
2. Connect ohmmeter
as illustrated.
3. Ensure ohmmeter
pointer deflects Resistance reading Replace pickup coil.
when screwdriver not between 420 -
blade passes near 540 ohms
pickup assembly’s
iron core.

EEM0101

10. IC Ignition If all tests are good, replace IC ignition unit assembly.

EE-20
IGNITION SYSTEM (H20-II, H25)

Distributor

EEM0102

EE-21
 GLOW AND AIR HEATER SYSTEMS (TD27)

WARNING:
Before starting to work, be sure to turn ignition switch “OFF” and then disconnect battery ground
cable.
System Diagram

EEM0078

EE-22
GLOW AND AIR HEATER SYSTEMS (TD27)

Troubleshooting
1. Engine does not start.

Check fusible links, FL1, FL2 NG Replace faulty fusible link(s).

and FL3.

OK

Check fuse F1. NG Replace.

OK

Check engine stop switch sys- NG Adjust or replace.

tem.

OK

Resistance between timer termi- No Check wiring.

nal 3 and GND is 0Ω.

Yes

Turn ignition switch to “ON”.

Battery voltage is applied to No Check continuity between battery

timer terminal 7 . and timer terminal 7 .

Yes

Battery voltage is applied to No Check operation of water tempera-

timer terminal 5 for a period of ture sensor when coolant tempera-
time in response to pre-glow ture is lower than 50°C (122°F).
timer.
OK NG
Yes

Replace timer. Replace water

temperature
sensor.

Battery voltage is applied to No Check continuity between relay ter-

glow plug terminal (g) for a minal (g) and timer terminal 5 , and
period of time in response to (e) terminal and GND.
pre-glow timer.

Yes

Battery voltage is applied to No Check continuity between battery

glow plug relay terminal (B). and relay terminal (B).

Yes

Go to A on the next page.

EE-23
GLOW AND AIR HEATER SYSTEMS (TD27)
Troubleshooting (Cont’d)
A

Battery voltage is applied to No Replace glow plug relay.

glow plug relay terminal (G) for
a period of time in response to
pre-glow timer.

Yes

Battery voltage is applied to sec- No Check continuity between glow

tions (shown below) of all glow plugs and connectors, and between
plugs for a period of time in glow relay-terminal (G) and glow
response to pre-glow timer. plugs.

EEM0103

Yes

Turn ignition switch to “ST”.

Battery voltage is applied to No Check continuity between battery

timer terminal 1 while cranking and timer terminal 1 .
engine.

Yes

Battery voltage is applied to No Replace timer.

timer terminal 5 for specified
period of time while cranking
engine.

EEM0104

Yes

Disconnect glow plug connector No Replace glow plug.

and check continuity in each
glow plug circuit.

Yes

System is OK.
[Trouble is located in parts other
than QGS (Quick Glow System).]

EE-24
GLOW AND AIR HEATER SYSTEMS (TD27)
Troubleshooting (Cont’d)
2. After-glow system does not
operate when coolant tem-
perature is below 50°C
(122°F).

Turn ignition switch from “ST” to

“ON”.

Battery voltage is applied to No Check continuity between battery

timer terminal 7 after engine and timer terminal 7 .
starts.

Yes

Battery voltage is applied to No Replace timer.

timer terminal 5 for a specified
period of timer after engine
starts.

EEM0105

Yes
Glow-system is OK.

EE-25
GLOW AND AIR HEATER SYSTEMS (TD27)
Troubleshooting (Cont’d)
3. Glow pilot lamp comes
on when ignition switch No
is turned to “ON”.

Yes

Check fuse F2. NG Repair faulty part and

replace fuse.
OK

Check pilot lamp. NG

Replace lamp.
OK

Turn ignition
switch to “ON”.

Battery voltage is
applied to glow Check continuity between
No
lamp positive battery and lamp positive
terminal. terminal.

Yes

Voltage applied
to timer terminal
No
4 is less than Replace timer.
approx. 3V.

Yes

Check continuity
between lamp
positive terminal
and timer termi-
nal 4 .

Glow pilot lamp goes out

No Check water temperature
after time set by lamp timer
sensor.
has elapsed.
OK NG
Yes

Replace water
temperature sen-
sor.

Check harness between

lamp negative terminal and
timer terminal 4 .

OK NG

Replace water
Replace timer. temperature sen-
Glow system is OK.
sor.

EE-26
ENGINE CONTROL SYSTEM (H20-II, H25)

System Diagram

EEM0109

EE-27
ENGINE CONTROL SYSTEM (H20-II, H25)

Circuit Diagram

EEM0080

EE-28
ENGINE CONTROL SYSTEM (H20-II, H25)

Unit Layout

EEM0081

EE-29
ENGINE CONTROL SYSTEM (H20-II, H25)

Component Inspection
IDLE SWITCH
Check the continuity using a multitester.
Accelerator pedal Not depressed Depressed
Condition
Throttle valve Closed Open
Continuity between terminal C and
No Yes
carburetor body
Idle switch OFF ON
The switch is turned off when idling.
EEM0082

VACUUM SWITCH
Measure the negative pressure.
Before measurement, check the maximum rotation speed
under load.
Negative pressure
Measurement condition
kPa (mbar, mmHg, inHg)
Maximum rotation speed under load −16.0 (−160, −120, −4.72) or lower
Continuity between terminals 1 and 2 Yes

EEM0083

Trouble Diagnoses
PRECAUTION
Before removing or inserting engine control unit connectors,
turn the ignition switch to the OFF position and remove the
battery cable “−” terminal. Failure to do so may cause a mal-
function in the engine control unit.
Make sure the engine control unit connectors cord is free from
twisting when the connector is removed or inserted. A twisted
cord may cause poor connectors contact. When removing the
connector, always hold the connector body and do not pull on
the cord.
Before performing self-diagnosis, check idle speed and maxi-
mum speed.
SELF-DIAGNOSIS
System failures (water temperature sensor, Oxygen sensor,
feedback solenoids and disconnection of the harness) can be
checked by performing a self-diagnosis using the diagnostic
monitor.

EEM0084

EE-30
ENGINE CONTROL SYSTEM (H20-II, H25)
Trouble Diagnoses (Cont’d)
HOW TO READ THE TROUBLE CODE LIST
Explanation of the flash codes
1. The codes are indicated in the order starting from the smallest
number.
2. Explanation of flashing code
First-digit code:
The count of flashing corresponds to the code number.
It lights up/goes off for 0.4 seconds in turns in accordance
with the code number.
Second-digit code:
In the tenth place, it lights up for 1.2 seconds, and goes
off for 1.5 seconds. Then, it flashes for the first place by
the same method of the first digit.
Indication of shift/repeat:
The code shifts/repeats after it goes off for 4.0 seconds.
Then it flashes in accordance with the code number.

EEM0085

EE-31
ENGINE CONTROL SYSTEM (H20-II, H25)
Trouble Diagnoses (Cont’d)
SELF-DIAGNOSIS PROCEDURE

EEM0086

CAUTION:
Keep the test switch of the diagnostic monitor in OFF position
all the time.
1. Turn the ignition switch OFF, and disconnect the “−” terminal of
battery cable.
2. Disconnect the connector A and B of body harness.
3. Connect the connector B to the connector C of diagnostic
monitor.
4. Connect the “−” terminal of battery cable.
5. Perform the diagnosis in accordance with the table below.
When the self-diagnosis is being performed, keep the test
switch OFF.

Engine status Fail lamp Monitor lamp

After the ignition key is
turned ON, all fail lamps After the ignition key is
light up for 3 seconds. turned ON, all monitor
Stopped (IGN ON)
Then, the trouble code lamps will light up for 3
display function is avail- seconds.
able.
Trouble code display func- Rotation signal monitor
Running
tion function (Flash)

EE-32
ENGINE CONTROL SYSTEM (H20-II, H25)
Trouble Diagnoses (Cont’d)
Explanation of the functions

Functions Description
Turn on lamps (fail and monitor
All lamps light up. lamps) to check for breaks to the
fail and monitor lamps.
Flashes the monitor lamp according
Rotation monitor function
to rotation signal pulses.
Flashes the fail lamp to display
Trouble code display function
trouble codes.

5. Self-diagnosis results
Failure detection condition
Trouble code Device name When the engine When the engine
is off (IGN ON) is running
Engine coolant
09 temperature sen-
sor
15 Oxygen sensor
Oxygen sensor
17
fixed
18 F/BSOL 1
19 F/BSOL 2 (LPG)

EE-33