16-1

ENGINE
ELECTRICAL
CONTENTS

CHARGING SYSTEM . . . . . . . . . . . . . . . . 2 IGNITION SYSTEM . . . . . . . . . . . . . . . . . 26

GENERAL INFORMATION . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . 26
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . 3 SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 27
SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIAL TOOL . . . . . . . . . . . . . . . . . . . . . . . . . 27
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . . 4 ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 28
Alternator Output Line Voltage Drop Test . . . . . . 4 Ignition Coil (With Built-in Power Transistor)
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Output Current Test . . . . . . . . . . . . . . . . . . . . . . . . 5
Resistive Cord Check . . . . . . . . . . . . . . . . . . . . . 28
Regulated Voltage Test . . . . . . . . . . . . . . . . . . . . . 7
Spark Plug Check, Cleaning and Replacement 29
Waveform Check Using An Analyzer . . . . . . . . . . 8
Camshaft Position Sensor Check . . . . . . . . . . . 29
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Crank Angle Sensor Check . . . . . . . . . . . . . . . . 29
STARTING SYSTEM . . . . . . . . . . . . . . . . 17 Detonation Sensor Check . . . . . . . . . . . . . . . . . . 29
Waveform Check Using An Analyzer . . . . . . . . 30
GENERAL INFORMATION . . . . . . . . . . . . . . . 17
SERVICE SPECIFICATIONS . . . . . . . . . . . . . . 17 IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . 34
ON-VEHICLE SERVICE . . . . . . . . . . . . . . . . . . 18 CAMSHAFT POSITION SENSOR . . . . . . . . . 35
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
CRANK ANGLE SENSOR . . . . . . . . . . . . . . . . 35

DETONATION SENSOR . . . . . . . . . . . . . . . . . 37
16-2 ENGINE ELECTRICAL - Charging System

CHARGING SYSTEM
GENERAL INFORMATION
The charging system uses the alternator output
to keep the battery charged at a constant level
under various electrical loads.

Voltage OPERATION
Rotation of the excited field coil generates AC voltage in
the stator.
This alternating current is rectified through diodes to DC
Approximately voltage having a waveform shown in the illustration at left.
14.4 V The average output voltage fluctuates slightly with the
alternator load condition.

Time

When the ignition switch is turned on, current flows of approximately 14.4 V, the field current is cut
in the field coil and initial excitation of the field off. When the battery voltage drops below the
coil occurs. regulated voltage, the voltage regulator regulates
When the stator coil begins to generate power after the output voltage to a constant level by controlling
the engine is started, the field coil is excited by the field current.
the output current of the stator coil. In addition, when the field current is constant, the
The alternator output voltage rises as the field alternator output voltage rises as the engine speed
current increases and it falls as the field current increases.
decreases. When the battery voltage (alternator
S terminal voltage) reaches a regulated voltage

SYSTEM DIAGRAM

B
Stator coil

Engine-ECU

Field coil G
S
L
Voltage
regulator FR Ignition
switch Battery
Charging
warning lamp
 ENGINE ELECTRICAL - Charging System 16-3
ALTERNATOR SPECIFICATIONS
Items Specifications

Type Battery voltage sensing

Rated output V/A 12/90

Voltage regulator Electronic built-in type

SERVICE SPECIFICATIONS
Items Standard value Limit

Alternator output line voltage drop (at 30 A) V - max. 0.3

Regulated voltage ambient - 20_C 14.2 - 15.4 -

temp at voltage regulator V
temp.
20_C 13.9 - 14.9 -

60_C 13.4 - 14.6 -

80_C 13.1 - 14.5 -

Output current - 70 % of normal output current

Rotor coil resistance Ω Approx. 3 - 5 -

Protrusion length of brush mm - 2

SPECIAL TOOL
Tool Number Name Use
MB991519 Alternator test Checking the alternator (S terminal voltage)
harness
16-4 ENGINE ELECTRICAL - Charging System

ON-VEHICLE SERVICE
ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST

+ -

Alternator Ammeter
Voltmeter

Battery
Terminal B + -

This test determines whether the wiring from the between the “B” terminal and the disconnected
alternator “B” terminal to the battery (+) terminal output wire. (Connect the (+) lead of the
(including the fusible line) is in a good condition ammeter to the “B” terminal, and then connect
or not. the ( - ) lead of the ammeter to the disconnected
(1) Always be sure to check the following before output wire.)
the test. NOTE
D Alternator installation An inductive-type ammeter which enables
D Alternator drive belt tension measurements to be taken without
(Refer to GROUP 11 - On-vehicle Service.) disconnecting the alternator output wire should
D Fusible link be recommended. Using this equipment will
D Abnormal noise from the alternator while lessen the possibility of a voltage drop caused
the engine is running by a loose “B” terminal connection.
(2) Turn the ignition switch to the “LOCK” (OFF)
position. (5) Connect a digital-type voltmeter between the
(3) Disconnect the negative battery cable. alternator “B” terminal and the battery (+)
(4) Disconnect the alternator output wire from the terminal. (Connect the (+) lead of the voltmeter
alternator “B” terminal and connect a DC test to the “B” terminal and the connect the ( - ) lead
ammeter with a range of 0 - 100 A in series of the voltmeter to the battery (+) cable.)
 ENGINE ELECTRICAL - Charging System 16-5
(6) Reconnect the negative battery cable. (11)If the value displayed on the voltmeter is above
(7) Connect a tachometer or the MUT-II. the limit value, there is probably a malfunction
(Refer to GROUP 11 - On-vehicle Service.) in the alternator output wire, so check the wiring
(8) Leave the hood open. between the alternator “B” terminal and the
(9) Start the engine. battery (+) terminal (including fusible link).
(10)With the engine running at 2,500 r/min, turn If a terminal is not sufficiently tight or if the
the headlamps and other lamps on and off harness has become discolored due to
to adjust the alternator load so that the value overheating, repair and then test again.
displayed on the ammeter is slightly above 30 (12)After the test, run the engine at idle.
A. (13)Turn off all lamps and the ignition switch.
Adjust the engine speed by gradually (14)Remove the tachometer or the MUT-II.
decreasing it until the value displayed on the (15)Disconnect the negative battery cable.
ammeter is 30 A. Take a reading of the value (16)Disconnect the ammeter and voltmeter.
displayed on the voltmeter at this time. (17)Connect the alternator output wire to the
Limit: max. 0.3 V alternator “B” terminal.
(18)Connect the negative battery cable.
NOTE
When the alternator output is high and the value
displayed on the ammeter does not decrease
until 30 A, set the value to 40 A. Read the
value displayed on the voltmeter at this time.
When the value range is 40 A, the limit is max.
0.4 V.

OUTPUT CURRENT TEST

Load

Voltmeter
Ammeter
Charging warning lamp

Ignition switch
- + + -
Alternator relay

B
FR
L
S
G
Battery
Alternator

Engine-ECU
16-6 ENGINE ELECTRICAL - Charging System

This test determines whether the alternator output (10)Turn the light switch on to turn on headlamps
current is normal. and then start the engine.
(1) Before the test, always be sure to check the (11)Immediately after setting the headlamps to high
following. beam and turning the heater blower switch to
D Alternator installation the high revolution position, increase the engine
D Battery (Refer to GROUP 54 - Battery.) speed to 2,500 r/min and read the maximum
NOTE current output value displayed on the ammeter.
The battery should be slightly discharged. Limit: 70 % of normal current output
The load needed by a fully-charged battery NOTE
is insufficient for an accurate test. D For the nominal current output, refer to the
D Alternator drive belt tension Alternator Specifications.
(Refer to GROUP 11 - On-vehicle Service.) D Because the current from the battery will
D Fusible link soon drop after the engine is started, the
D Abnormal noise from the alternator while above step should be carried out as quickly
the engine is running. as possible in order to obtain the maximum
(2) Turn the ignition switch to the “LOCK” (OFF) current output value.
position. D The current output value will depend on
(3) Disconnect the negative battery cable. the electrical load and the temperature of
(4) Disconnect the alternator output wire from the the alternator body.
alternator “B” terminal. Connect a DC test D If the electrical load is small while testing,
ammeter with a range of 0 - 100 A in series the specified level of current may not be
between the “B” terminal and the disconnected output even though the alternator is normal.
output wire. (Connect the (+) lead of the In such cases, increase the electrical load
ammeter to the “B” terminal. Connect the ( - ) by leaving the headlamps turned on for
lead of the ammeter to the disconnected output some time to discharge the battery or by
wire.) using the lighting system in another vehicle,
Caution and then test again.
Never use clips but tighten bolts and nuts D The specified level of current also may not
to connect the line. Otherwise loose be output if the temperature of the alternator
connections (e.g. using clips) will lead to body or the ambient temperature is too
a serious accident because of high current. high. In such cases, cool the alternator and
then test again.
NOTE
An inductive-type ammeter which enables (12)The reading on the ammeter should be above
measurements to be taken without the limit value. If the reading is below the limit
disconnecting the alternator output wire should value and the alternator output wire is normal,
be recommended. remove the alternator from the engine and
check the alternator.
(5) Connect a voltmeter with a range of 0 - 20 V (13)Run the engine at idle after the test.
between the alternator “B” terminal and the (14)Turn the ignition switch to the “LOCK” (OFF)
earth. (Connect the (+) lead of the voltmeter position.
to the “B” terminal, and then connect the ( - ) (15)Remove the tachometer or the MUT-II.
lead of the voltmeter to the earth.) (16)Disconnect the negative battery cable.
(6) Connect the negative battery cable. (17)Disconnect the ammeter and voltmeter.
(7) Connect a tachometer or the MUT-II. (18)Connect the alternator output wire to the
(Refer to GROUP 11 - On-vehicle Service.) alternator “B” terminal.
(8) Leave the hood open. (19)Connect the negative battery cable.
(9) Check that the reading on the voltmeter is equal
to the battery voltage.
NOTE
If the voltage is 0 V, the cause is probably
an open circuit in the wire or fusible link between
the alternator “B” terminal and the battery (+)
terminal.
 ENGINE ELECTRICAL - Charging System 16-7
REGULATED VOLTAGE TEST

Load
Ammeter
Ignition MB991519
switch

Black
B FR
L Alternator
S
G
Voltmeter Blue
Battery Red Yellow
Engine-ECU

This test determines whether the voltage regulator (6) Connect a DC test ammeter with a range of
is correctly controlling the alternator output voltage. 0 - 100 A in series between the “B” terminal
(1) Always be sure to check the following before and the disconnected output wire. (Connect
the test. the (+) lead of the ammeter to the “B” terminal.
D Alternator installation Connect the ( - ) lead of the ammeter to the
D Check that the battery installed in the disconnected output wire.)
vehicle is fully charged. (7) Reconnect the negative battery cable.
(Refer to GROUP 54 - Battery.) (8) Connect a tachometer or the MUT-II. (Refer
D Alternator drive belt tension to GROUP 11 - On-vehicle Service.)
(Refer to GROUP 11 - On-vehicle Service.) (9) Turn the ignition switch to the ON position and
D Fusible link check that the reading on the voltmeter is equal
D Abnormal noise from the alternator while to the battery voltage.
the engine is running NOTE
(2) Turn the ignition switch to the “LOCK” (OFF) 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 (+)
(4) Use the special tool (Alternator test harness: terminal.
MB991519) to connect a digital voltmeter
between the alternator S terminal and earth. (10)Turn all lamps and accessories off.
(Connect the (+) lead of the voltmeter to the (11)Start the engine.
“S” terminal, and then connect the (−) lead of (12)Increase the engine speed to 2,500 r/min.
the voltmeter to a secure earth or to the battery (13)Read the value displayed on the voltmeter when
(−) terminal.) the alternator output current alternator
(5) Disconnect the alternator output wire from the becomes 10 A or less.
alternator “B” terminal.
16-8 ENGINE ELECTRICAL - Charging System

(14)If the voltage reading conforms to the value (17)Remove the tachometer or the MUT-II.
in the voltage regulation, then the voltage (18)Disconnect the negative battery cable.
regulator is operating normally. (19)Disconnect the ammeter and voltmeter.
If the voltage is not within the standard value, (20)Connect the alternator output wire to the
there is a malfunction of the voltage regulator alternator “B” terminal.
or of the alternator. (21)Remove the special tool, and return the
(15)After the test, lower the engine speed to the connector to the original condition.
idle speed. (22)Connect the negative battery cable.
(16)Turn the ignition switch to the “LOCK” (OFF)
position.

Voltage Regulation Table

Standard value:
Inspection terminal Voltage regulator ambient temperature _C Voltage V

Terminal “S” - 20 14.2 - 15.4

20 13.9 - 14.9

60 13.4 - 14.6

80 13.1 - 14.5

Special WAVEFORM CHECK USING AN ANALYZER

patterns Analyzer
Alternator pickup MEASUREMENT METHOD
Connect the analyzer special patterns pick-up to the alternator
B terminal.

B terminal

STANDARD WAVEFORM
Observation Conditions
FUNCTION SPECIAL PATTERNS

PATTERN HEIGHT VARIABLE

VARIABLE knob Adjust while viewing the wave-

form.

PATTERN SELECTOR RASTER

Engine speed Curb idle speed

 ENGINE ELECTRICAL - Charging System 16-9

0.4

0.2
Voltage at
alternator 0
B terminal
- 0.2

- 0.4

Time

NOTE
The voltage waveform of the alternator B terminal can undulate
as shown at left. This waveform is produced when the regulator
operates according to fluctuations in the alternator load
(current), and is normal for the alternator.
In addition, 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 between
alternator B terminal and battery, but not a defective alternator.
16-10 ENGINE ELECTRICAL - Charging System

EXAMPLES OF ABNORMAL WAVEFORMS

NOTE
1. The size of the waveform patterns differs largely, depending on the adjustment of the variable knob
on the analyzer.
2. Identification of abnormal waveforms is easier when there is a large output current (regulator is not
operating). (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.
Abnormal waveforms Problem Abnormal waveforms Problem
cause cause
Example 1 Open diode Example 4 Short in
stator coil

Example 2 Short in diode Example 5 Open

supplementa-
ry diode

Example 3 Broken wire

in stator coil

At this time, the charging warning lamp

is illuminated.

ALTERNATOR
REMOVAL AND INSTALLATION
Caution
If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact
the parts or tools to the caliper because the paint of caliper will be scratched.
Pre-removal and Post-installation Operation
D Under Cover Removal and Installation (Refer to GROUP 51 - Front Bumper.)
D Drive Belt Tension Check (Refer to GROUP 11A - On-vehicle Service.) <After installation only>
D Strut Tower Bar Removal and Installation (Refer to GROUP 42.)
D Crossmember Bar Removal and Installation (Refer to GROUP 32 - Engine Roll Stopper, Centermember.)
D Front Exhaust Pipe Assembly Removal and Installation (Refer to GROUP 15.)
 ENGINE ELECTRICAL - Charging System 16-11

8 9

5.0 ± 1.0 N·m

11 ± 1 N·m

1
9.0 ± 1.0 N·m 4
3 10
13 ± 1 N·m 6 7
11
17

5
36 ± 6 N·m 18
9.0 ± 1.0 N·m

14 ± 3 N·m
(Engine oil) 20 ± 2 N·m

13
2

16
22 ± 4 N·m
15
44 ± 10 N·m

23 ± 3 N·m 8.8 ± 1.0 N·m

14

12

Removal steps
1. Oil level gauge and guide assembly 10. Insulator
2. O-ring 11. Insulator
3. Fuel pressure solenoid valve AB" 12. Drive belt
connector 13. Alternator connector
4. Fuel pressure solenoid valve D Engine mounting
assembly (Refer to GROUP 32.)
5. Detonation sensor connector AC" 14. Alternator
6. Purge control solenoid valve 15. Water pump pulley
connector 16. Alternator brace
7. Purge control solenoid valve assembly 17. Oxygen sensor connector
8. Injector connector 18. Alternator brace stay
AA" 9. Delivery pipe, injector, and fuel
pressure regulator assembly
16-12 ENGINE ELECTRICAL - Charging System

REMOVAL SERVICE POINTS

AA" DELIVERY PIPE, INJECTOR, AND FUEL
PRESSURE REGULATOR ASSEMBLY REMOVAL
After loosening the installed parts, set the related parts
aside to make some space for removing the alternator.

AB" DRIVE BELT REMOVAL

Due to the adoption of the Serpentine drive system with
the auto-tensioner, the following operation is required:
1. Insert the 12.7sq. spinner handle into the tool hole of
the auto-tensioner and rotate it counterclockwise until
the auto-tensioner reaches to the stopper.
2. Align hole A with hole B for fixing by inserting the L-shaped
hexagon wrench, then remove the drive belt.
Hole B Caution
Hole A When the drive belt is reused, use a chalk to
indicate an arrow of rotation direction on the
back of the belt so that it can be re-assembled in
the same direction as before.

L-shaped
hexagon
wrench

AC"ALTERNATOR REMOVAL
Push up the engine with a garage jack to the top and
remove the alternator upward from the engine room.
 ENGINE ELECTRICAL - Charging System 16-13
DISASSEMBLY AND REASSEMBLY

1 4
3

5
6
7

4
2

12
10
9

8
14

13

11

Disassembly steps
AA" 1. Front bracket assembly AC" 8. Stator
AB" 2. Alternator pulley 9. Plate
"BA 3. Rotor AC" "AA 10. Regulator assembly
4. Rear bearing 11. Brush
5. Bearing retainer 12. Packing
6. Front bearing 13. Rectifier
7. Front bracket 14. Rear bracket
16-14 ENGINE ELECTRICAL - Charging System

DISASSEMBLY SERVICE POINTS

AA" FRONT BRACKET ASSEMBLY REMOVAL
Insert a flat tip screwdrivers or the like in the clearance between
the front bracket assembly and stator core, to pry open and
separate the stator and front bracket.
Caution
Do not insert a screwdriver too far, or the stator coil gets
damaged.

AB" ALTERNATOR PULLEY REMOVAL

Face pulley side upward, fix the rotor with a work bench
and remove the pulley.
Caution
Use care not to damage the rotor.
AC" STATOR/REGULATOR ASSEMBLY REMOVAL
1. Unsolder the stator with a soldering iron (180 to 250
W). Complete this work within four seconds not to transfer
heat to the diode.
2. When removing rectifier from the regulator assembly,
remove the soldered sections to rectifier.
Rectifier Soldered Caution
assembly (1) Use care to make sure that the heat of the soldering
iron is not transmitted to the diodes for a long period.
(2) Use care that no undue force is exerted to the
lead wires of the diodes.

Soldered

REASSEMBLY SERVICE POINTS

Wire
"AA REGULATOR ASSEMBLY INSTALLATION
After installing the regulator assembly, insert a wire into the
hole provided on the rear bracket while pressing in the brush
to fix the brush.
NOTE
The brush is fixed when a wire is inserted, making rotor
installation easier.

Rear bracket
Wire
Brush
ENGINE ELECTRICAL - Charging System 16-15
"BA ROTOR INSTALLATION
Wire
After installing the rotor, remove the wire used to fix the brush.

INSPECTION
ROTOR CHECK
1. Check the continuity between the rotor coil slip rings,
and replace the rotor if the resistance value is not at
the standard value.
Standard value: 3 - 5 Ω

2. Check the continuity between the slip ring and core, and
if there is continuity, replace the rotor.

STATOR CHECK
1. Check the continuity between the coil leads, and if there
is continuity, replace the stator.

2. Check the continuity between the coil and core, and if

there is continuity, replace the stator.
16-16 ENGINE ELECTRICAL - Charging System

RECTIFIERS CHECK
1. Inspect the (+) heat sink by checking the continuity
between the (+) heat sink and stator coil lead wire
connection terminal using a tester probe.
If there is a continuity at both, the diode is short circuited,
so replace the rectifier.

2. Inspect the ( - ) heat sink by checking the continuity

between the ( - ) heat sink and stator coil lead wire
connection terminal using a tester probe.
If there is a continuity at both, the diode is short circuited,
so replace the rectifier.

3. Check the diode trio by connecting an ohmmeter to both

ends of each diode and check the continuity of the three
diodes.
If there is a continuity at both ends, or if there is no
continuity, the diode is damaged so replace the rectifier.

BRUSH CHECK
1. Measure the length of the brush protrusion shown in the
illustration, and replace the brush if the measured value
is below the limit value.
Protrusion Limit: 2 mm or less
length

2. The brush can be removed if the solder of the brush

Soldered lead wire is removed.
3. When installing a new brush, insert the brush into the
holder as shown in the illustration, and then solder the
lead wires.
 ENGINE ELECTRICAL - Starting System 16-17

STARTING SYSTEM
GENERAL INFORMATION
If the ignition switch is turned to the “START” and M terminal to conduct. Thus, current flows to
position, current flows in the pull-in and holding engage the starter motor.
coils provided inside magnetic switch, attracting When the ignition switch is returned to the “ON”
the plunger. When the plunger is attracted, the position after starting the engine, the starter clutch
lever connected to the plunger is actuated to is disengaged from the ring gear.
engage the starter clutch. An overrunning clutch is provided between the
On the other hand, attracting the plunger will turn pinion and the armature shaft, to prevent damage
on the magnetic switch, allowing the B terminal to the starter.

SYSTEM DIAGRAM
Holding coil Plunger
Pull-in coil Lever

Over-running
clutch

Pinion shaft

Ignition
switch

Armature
Battery

Brush
Yoke

STARTER MOTOR SPECIFICATIONS

Items Specifications
Type Reduction drive with planetary gear
Rated output kW/V 1.2/12
No. of pinion teeth 8

SERVICE SPECIFICATIONS
Items Standard value Limit
Pinion gap mm 0.5 - 2.0 -
Commutator outer diameter mm 29.4 28.8
Commutator runout mm 0.05 0.1
Commutator undercut mm 0.5 0.2
Brush length mm - 7.0
16-18 ENGINE ELECTRICAL - Starting System

STARTER
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
D Under Cover Removal and Installation (Refer to GROUP51 - Front Bumper.)
D Crossmember Bar Removal and Installation (Refer to GROUP 32 - Engine Roll Stopper, Centermember.)
D Front Exhaust Pipe Assembly Removal and Installation (Refer to GROUP 15.)

13 ± 2 N·m

1
30 ± 3 N·m

30 ± 3 N·m

Removal steps
1. Starter connector
2. Starter

INSPECTION
Switch
PINION GAP ADJUSTMENT
S
1. Disconnect field coil wire from M-terminal of magnetic
B M
Battery switch.
2. Connect a 12 V battery between S-terminal and
M-terminal.
Field coil wire
3. Set switch to “ON” position, and pinion will move out.
Caution
This test must be performed quickly (in less than
10 seconds) to prevent coil from burning.
4. Check pinion to stopper clearance (pinion gap) with a
thickness gauge.
Standard value: 0.5 - 2.0 mm

Stopper
Pinion gap

Pinion
 ENGINE ELECTRICAL - Starting System 16-19
5. If pinion gap is out of specification, adjust by adding or
removing gaskets between magnetic switch and front
bracket.

MAGNETIC SWITCH PULL-IN TEST

S 1. Disconnect field coil wire from M-terminal of magnetic
switch.
B M 2. Connect a 12 V battery between S-terminal and
Battery
M-terminal.
Caution
Field coil wire
This test must be performed quickly (in less than
10 seconds) to prevent coil from burning.
3. If pinion moves out, then pull-in coil is good. If it doesn’t,
replace magnetic switch.
MAGNETIC SWITCH HOLD-IN TEST
1. Disconnect field coil wire from M-terminal of magnetic
S switch.
2. Connect a 12 V battery between S-terminal and body.
Caution
Battery
This test must be performed quickly (in less than 10
seconds) to prevent coil from burning.
Field coil wire 3. Manually pull out the pinion as far as the pinion stopper
position.
4. If pinion remains out, everything is in order. If pinion moves
in, hold-in circuit is open. Replace magnetic switch.

Carbon-pile rheostat FREE RUNNING TEST

1. Place starter motor in a vise equipped with soft jaws
S and connect a fully-charged 12 V battery to starter motor
B M A as follows:
Ammeter 2. Connect a test ammeter (100-ampere scale) and carbon
Starter pile rheostat in series with battery positive post and starter
motor V
Battery motor terminal.
Voltmeter 3. Connect a voltmeter (15 V scale) across starter motor.
4. Rotate carbon pile to full-resistance position.
5. Connect battery cable from battery negative post to starter
motor body.
6. Adjust the rheostat until the battery voltage shown by
the voltmeter is 11 V Reduction.
7. Confirm that the maximum amperage is within the
specifications and that the starter motor turns smoothly
and freely.
Current:
max. 90 A
16-20 ENGINE ELECTRICAL - Starting System

MAGNETIC SWITCH RETURN TEST

1. Disconnect field coil wire from M-terminal of magnetic
switch.
M
Battery
2. Connect a 12 V battery between M-terminal and body.
Caution
This test must be performed quickly (in less than
Field coil wire
10 seconds) to prevent coil from burning.
3. Pull pinion out and release. If pinion quickly returns to
its original position, everything is in order. If it doesn’t,
replace magnetic switch.
Caution
Be careful not to get your fingers caught when pulling
out the pinion.
 ENGINE ELECTRICAL - Starting System 16-21
DISASSEMBLY AND REASSEMBLY

3 11

13
16 14

12

15

21
2
20

19
17 18 5

22

4 1

6
8

10

Disassembly steps 12. Packing A

1. Cover 13. Packing B
2. Screw 14. Plate
AA" 3. Magnetic switch 15. Planetary gear
4. Screw 16. Lever
5. Through AC" "AA 17. Snap ring
6. Rear bracket AC" "AA 18. Stop ring
7. Brush holder 19. Overrunning clutch
8. Rear bearing 20. Internal gear
AB" 9. Armature 21. Planetary gear holder
10. Yoke assembly 22. Front bracket
AB" 11. Ball
16-22 ENGINE ELECTRICAL - Starting System

DISASSEMBLY SERVICE POINTS

“B” terminal “S” terminal
AA" MAGNETIC SWITCH REMOVAL
Disconnect field coil wire from “M” terminal of magnetic switch.
“M” terminal Field coil
wire

AB" ARMATURE/BALL REMOVAL

Caution
When removing the armature, take care not to lose the
ball (which is used as a bearing) in the armature end.

AC"SNAP RING/STOP RING REMOVAL

Socket 1. Press stop ring off snap ring with a suitable socket.

Stop ring
Pinion gear
Overrunning
clutch

2. Remove snap ring with snap ring pliers and then remove
Snap ring stop ring and overrunning clutch.
Snap ring pliers
Pinion gear
Overrunning
clutch

STARTER MOTOR PARTS CLEANING

1. Do not immerse parts in cleaning solvent. Immersing the
yoke and field coil assembly and/or armature will damage
insulation. Wipe motor assembly with a cloth only.
2. Do not immerse drive unit in cleaning solvent. Overrunning
clutch is pre-lubricated at the factory and solvent will wash
lubrication from clutch
3. The drive unit may be cleaned with a brush moistened
with cleaning solvent and wiped dry with a cloth.
 ENGINE ELECTRICAL - Starting System 16-23
REASSEMBLY SERVICE POINT
"AA STOP RING/SNAP RING INSTALLATION
Using a suitable pulling tool, pull overrunning clutch stop ring
over snap ring.
Stop ring
Overrunning
Stop ring clutch

Snap ring

INSPECTION
COMMUTATOR CHECK
1. Place the armature in a pair of “V” blocks and check
the runout with a dial indicator.
Standard value: 0.05 mm
Limit: 0.1 mm

2. Measure the commutator outer diameter.

Standard value: 29.4 mm
Limit: 28.8 mm

3. Check the undercut depth between segments.

Undercut
Standard value: 0.5 mm
Segment
Mica
Limit: 0.2 mm

BRUSH HOLDER CHECK

Confirm that the spring is activated when the brush is pressed
into the brush holder by hand.
Replace the brush holder if the spring is not activated.
16-24 ENGINE ELECTRICAL - Starting System

OVERRUNNING CLUTCH CHECK

1. While holding clutch housing, rotate the pinion. Drive
pinion should rotate smoothly in one direction, but should
not rotate in opposite direction. If clutch does not function
Free properly, replace overrunning clutch assembly.
2. Inspect pinion for wear or burrs. If pinion is worn or burred,
replace overrunning clutch assembly. If pinion is damaged,
Lock also inspect ring gear for wear or burrs.

FRONT AND REAR BRACKET BUSHING CHECK

Inspect bushing for wear or burrs. If bushing is worn or burred,
replace front bracket assembly or rear bracket assembly.

BRUSH REPLACEMENT
1. Check the surface contacting the commutator for
roughness and the brush length.
Limit value: 7.0 mm
Length 2. If the limit is exceeded, replace the brush holder.

Growler
ARMATURE TEST
ARMATURE COIL SHORT-CIRCUIT TEST
1. Check that the armature coil is not grounded.
2. Place armature in a growler.
3. Hold a thin steel blade parallel and just above while rotating
armature slowly in growler. A shorted armature will cause
blade to vibrate and be attracted to the core. Replace
shorted armature.

ARMATURE COIL EARTH TEST

Check the insulation between each commutator segment and
armature coil core.
If there is no continuity, the insulation is in order.
 ENGINE ELECTRICAL - Starting System 16-25
ARMATURE COIL OPEN-CIRCUIT INSPECTION
Check the continuity between segments. If there is continuity,
the coil is in order.

MAGNETIC SWITCH
A
COIL DISCONNECTION TEST
D Confirm that there is continuity between the “M” terminal
and body A.
D If there is no continuity, replace the magnetic switch.

“M” terminal

CONTACT CONTACTING STATE CHECK

D Confirm that there is no continuity between the “B” terminal
“B” terminal
and “M” terminal.
D If there is continuity, replace the magnetic switch.

“M” terminal

CONTACT CONTACTING STATE CHECK

“B” terminal
D Press the end of the magnetic switch in with force, and
close the internal contact. Confirm that there is continuity
between the “B” terminal and “M” terminal in this state.
D If there is no continuity, replace the magnetic switch.

“M” terminal
16-26 ENGINE ELECTRICAL - Ignition System

IGNITION SYSTEM
GENERAL INFORMATION
This system is equipped with two ignition coils (A causes the primary currents in the ignition coils
and B) with built-in power transistors for the No. to be alternately interrupted and allowed to flow
1 and No. 4 cylinders and the No. 2 and No. 3 to fire the cylinders in the order 1-3-4-2.
cylinders respectively. The Engine-ECU determines which ignition coil
Interruption of the primary current flowing in the should be controlled by means of the signals from
primary side of ignition coil A generates a high the camshaft position sensor which is incorporated
voltage in the secondary side of ignition coil A. in the camshaft and from the crank angle sensor
The high voltage thus generated is applied to the which is incorporated in the crankshaft. It also
spark plugs of No. 1 and No. 4 cylinders to generate detects the crankshaft position in order to provide
sparks. At the time that the sparks are generated ignition at the most appropriate timing in response
at both spark plugs, if one cylinder is at the to the engine operation conditions. It also detects
compression stroke, the other cylinder is at the the crankshaft position in order to provide ignition
exhaust stroke, so that ignition of the compressed at the most appropriate timing in response to the
air/fuel mixture occurs only for the cylinder which engine operation conditions.
is at the compression stroke. When the engine is cold or operated at high
In the same way, when the primary current flowing altitudes, the ignition timing is slightly advanced
in ignition coil B is interrupted, the high voltage to provide optimum performance.
thus generated is applied to the spark plugs of When the automatic transmission shifts gears, the
No. 2 and No. 3 cylinders. ignition timing is also retarded in order to reduce
The Engine-ECU turns the two power transistors output torque, thereby alleviating shifting shocks.
inside the ignition coils alternately on and off. This

SYSTEM DIAGRAM

Ignition switch Battery

Air flow sensor
Barometric pressure sensor

Intake air temperature sensor

Engine coolant temperature sensor
Engine-ECU
Camshaft position sensor
Crank angle sensor Ignition coil A Ignition coil B
Ignition switch - ST

Vehicle speed signal

Detonation sensor

Spark plug

To tachometer
Cylinder No. 4 1 2 3
 ENGINE ELECTRICAL - Ignition System 16-27
IGNITION COIL SPECIFICATIONS
Items Specifications

Type Molded 2-coil

SPARK PLUG SPECIFICATIONS

Items Specifications

NGK IGR7A-G

DENSO VW22PR-DA7

SERVICE SPECIFICATIONS
IGNITION COIL
Items Standard value

Secondary coil resistance kΩ 8.5 - 11.5

SPARK PLUG
Items Standard value Limit

Spark plug gap mm 0.6 - 0.7 0.75

RESISTIVE CORD
Items Limit

Resistance kΩ max. 22

SPECIAL TOOL
Tool Number Name Use
MD998773 Detonation sensor Detonation sensor removal and installation
wrench
16-28 ENGINE ELECTRICAL - Ignition System

ON-VEHICLE SERVICE
IGNITION COIL (WITH BUILT-IN POWER
TRANSISTOR) CHECK
Check by the following procedure, and replace if there is
a malfunction.
SECONDARY COIL RESISTANCE CHECK
Measure the resistance between the high-voltage terminals
of the ignition coil.
Standard value: 8.5 - 11.5 kΩ
PRIMARY COIL AND POWER TRANSISTOR
CONTINUITY CHECK
NOTE
1. An analogue-type circuit tester should be used.
2. Connect the negative ( - ) prove of the circuit tester to
terminal 1.
Caution
This test must be performed quickly (in less than 10
seconds) to prevent coil from burning and power
transistor from breakage.
1.5V power across 2 - 3 Continuity across 1 - 2
When energized Yes
When not energized No

RESISTIVE CORD CHECK

Measure the resistance of the all spark plug cables.
1. Check cap and coating for cracks.
2. Measure resistance.
Limit: Max. 22 kΩ
 ENGINE ELECTRICAL - Ignition System 16-29
SPARK PLUG CHECK, CLEANING AND REPLACEMENT
SPARK PLUG GAP CHECK
Caution
1. Do not adjust the gap of the iridium plug.
2. Cleaning of the iridium plug could damage the tip of the electrode. Thus, if the plug must
be cleaned because of soot, etc., use a plug cleaner and clean within a short time of 20 seconds
or less to protect the electrode. Do not use a wire brush, etc.
3. Even when the functions of the iridium plug are normal, the electrode section may be blackened.
However, the adhered carbon has properties that easily burned off compared to the conventional
type, so there is no problem. Check the quality of the spark plug by checking the insulation
resistance.
Check the plug gap, and replace if the checked value is more than the limit value.
Standard value, limit value:

Maker Model Standard value (mm) Limit value (mm)

NGK IGR7A-G 0.6 - 0.7 0.75

DENSO VW22PR-DA7 0.6 - 0.7 0.75

SPARK PLUG INSULATION RESISTANCE CHECK

Measure the insulation resistance of the spark plug, and
replace if the measured value is less than the limit value.
Limit value: 1 MΩ

CAMSHAFT POSITION SENSOR CHECK

Refer to GROUP 13A - Troubleshooting.
CRANK ANGLE SENSOR CHECK
Refer to GROUP 13A - Troubleshooting.
DETONATION SENSOR CHECK
Check the detonation sensor circuit if self-diagnosis code,
No. 31 is shown.
NOTE
For information concerning the self-diagnosis codes, refer
to GROUP 13A - Troubleshooting.
16-30 ENGINE ELECTRICAL - Ignition System

WAVEFORM CHECK USING AN ANALYZER

Ignition Secondary Voltage Waveform Check
MEASUREMENT METHOD
1. Clamp the secondary pickup around the spark plug cable.
NOTE
(1) The peak ignition voltage will be reversed when the
spark cables No. 2 and No. 4, or No. 1 and No.
3 cylinders are clamped.
(2) Because of the two-cylinder simultaneous ignition
system, the waveforms for two cylinders in each group
appear during waveform observation (No. 1 cylinder
- No. 4 cylinder, No. 2 cylinder - No. 3 cylinder).
However, waveform observation is only applicable
for the cylinder with the spark plug cable clamped
by the secondary pickup.
(3) Identifying which cylinder waveform is displayed can
be difficult. For reference, remember that the
waveform of the cylinder attached to the secondary
pickup will be displayed as stable.
2. Clamp the spark plug cable with the trigger pickup.
NOTE
Clamp the trigger pickup to the same spark plug cable
clamped by the secondary pickup.
 ENGINE ELECTRICAL - Ignition System 16-31
STANDARD WAVEFORM
Observation Conditions

Function Secondary

Pattern height High (or Low)

Pattern selector Raster

Engine revolutions Curb idle speed

kV Spark line (point A)

Ignition voltage
(point D)

Wave damping
reduction section
(point B)
Dwell
section
Secondary
ignition
voltage
waveform
Point C

Time

Observation Condition (The only change from above condition is the pattern selector.)

Pattern selector Display

kV

No. 4 cylinder No. 1 cylinder No. 3 cylinder

No. 2 cylinder ignition noise
ignition noise

Secondary
ignition Time
voltage
waveform 0
Neutral section
2
16-32 ENGINE ELECTRICAL - Ignition System

WAVEFORM OBSERVATION POINTS

Point A: The height, length and slope of the spark line show the following trends (Refer to abnormal
waveform examples, 1, 2, 3 and 4).

Spark line Plug gap Condition of Compression Concentration of Ignition timing Spark plug
electrode force air mixture cable

Length Long Small Normal Low Rich Advanced Leak

Short Large Large wear High Lean Retarded High

resistance

Height High Large Large wear High Lean Retarded High

resistance

Low Small Normal Low Rich Advanced Leak

Slope Large Plug is fouled - - - -

Point B: Number of vibration in reduction vibration section (Refer to abnormal waveform example 5)

Number of vibrations Coil and condenser

Three or more Normal

Except above Abnormal

Point C: Number of vibrations at beginning of dwell section (Refer to abnormal waveform example 5)

Number of vibrations Coil

5 - 6 or higher Normal

Except above Abnormal

Point D: Ignition voltage height (distribution per each cylinder) shows the following trends.

Ignition Plug gap Condition of Compression Concentration of Ignition timing Spark plug cable
voltage electrode force air mixture

High Large Large wear High Lean Retarded High resistance

Low Small Normal Low Rich Advanced Leak

 ENGINE ELECTRICAL - Ignition System 16-33
EXAMPLES OF ABNORMAL WAVEFORMS

Abnormal waveform Wave characteristics Cause of problem

Example 1 Spark line is high and short. Spark plug gap is too large.

01P0215

Example 2 Spark line is low and long, and is Spark plug gap is too small.
sloping.
Also, the second half of the spark line
is distorted. This could be a result of
misfiring.

Example 3 Spark line is low and long, and is Spark plug gap is fouled.
sloping. However, there is almost no
spark line distortion.

Example 4 Spark line is high and short. Spark plug cable is nearly falling off.
Difficult to distinguish between this (Causing a dual ignition)
and abnormal waveform example 1.

Example 5 No waves in wave damping section. Layer short in ignition coil

16-34 ENGINE ELECTRICAL - Ignition System

IGNITION COIL
REMOVAL AND INSTALLATION
Pre-removal and Post-installation Operation
Center Cover Removal and Installation (Refer to GROUP 11A - Camshaft and Camshaft Oil Seal.)

10 ± 2 N·m

10 ± 2 N·m

2
1

1 4

4 3
5

25 ± 4 N·m

Removal steps
1. Ignition coil connector 4. Ignition coil
2. Spark plug cable No.1 5. Spark plug
3. Spark plug cable No.3
 ENGINE ELECTRICAL - Ignition System 16-35
CAMSHAFT POSITION SENSOR
REMOVAL AND INSTALLATION

2
3 1

8.8 ± 1.0 N·m

Removal steps
1. Camshaft position sensor connector
2. Camshaft position sensor
3. O-ring

CRANK ANGLE SENSOR

REMOVAL AND INSTALLATION
Caution
If the vehicle is equipped with the Brembo disc brake, during maintenance, take care not to contact
the parts or tools to the caliper because the paint of caliper will be scratched.

Pre-removal and Post-installation Operation

D Center Cover Removal and Installation (Refer to GROUP 11A - Camshaft and Camshaft Oil Seal.)
D Timing Belt Removal and Installation (Refer to GROUP 11A.)
D Reserve Tank Removal and Installation (Refer to GROUP 14 - Radiator.)
16-36 ENGINE ELECTRICAL - Ignition System

8.8 ± 1.0 N·m

12 ± 2 N·m
22 ± 4 N·m

22 ± 4 N·m
2
12 ± 2 N·m

7
5
1
22 ± 4 N·m

3 40 ± 5 N·m
49 ± 9 N·m
4

49 ± 9 N·m

8.8 ± 1.0 N·m

Removal steps
1. Power steering oil pressure switch 4. Power steering oil pump bracket
connector 5. Crank angle sensor connector
2. Heat protector 6. Crank angle sensor
AA" 3. Power steering oil pump, bracket and 7. Connector bracket
oil reservoir assembly

REMOVAL SERVICE POINT

AA" POWER STEERING OIL PUMP, BRACKET AND
OIL RESERVOIR ASSEMBLY REMOVAL
Remove the power steering oil pump, bracket and oil reservoir
assembly with the hose attached from the bracket.
NOTE
Tie the removed oil pump with a rope and set aside where
they cannot hinder the removal of the power steering oil pump
bracket.
 ENGINE ELECTRICAL - Ignition System 16-37
DETONATION SENSOR
REMOVAL AND INSTALLATION
Caution
Do not give any impact during removal and installation of detonation sensor.

Pre-removal and Post-installation Operation

Intake Manifold Stay Removal and Installation (Refer to GROUP 15 - Intake Manifold.)

2
23 ± 2 N·m

Removal steps
1. Detonation sensor connector
AA" "AA 2. Detonation sensor

REMOVAL SERVICE POINT

AA" DETONATION SENSOR REMOVAL

INSTALLATION SERVICE POINT

"AA DETONATION SENSOR INSTALLATION

MD998773
NOTES