16-1

GROUP 16

CONTENTS

CHARGING SYSTEM . . . . . . . . 16-2 SPECIAL TOOLS . . . . . . . . . . . . . . 16-28

GENERAL DESCRIPTION . . . . . . 16-2 ON-VEHICLE SERVICE . . . . . . . . . 16-28

SPARK PLUG CABLE TEST . . . . . . . . . 16-28
CHARGING SYSTEM
SPARK PLUG TEST . . . . . . . . . . . . . . . 16-28
DIAGNOSIS . . . . . . . . . . . . . . . . . . 16-3
IGNITION COIL CHECK . . . . . . . . . . . . 16-29
SPECIAL TOOL . . . . . . . . . . . . . . . 16-5 SPARK PLUG CABLE RESISTANCE
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 16-30
ON-VEHICLE SERVICE. . . . . . . . . 16-5
SPARK PLUG CHECK AND
GENERATOR OUTPUT LINE VOLTAGE CLEANING . . . . . . . . . . . . . . . . . . . . . . 16-30
DROP TEST . . . . . . . . . . . . . . . . . . . . . 16-5
CAMSHAFT POSITION SENSOR AND
OUTPUT CURRENT TEST . . . . . . . . . . 16-6 CRANKSHAFT POSITION SENSOR
REGULATED VOLTAGE TEST . . . . . . . 16-8 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 16-30
WAVE PATTERN CHECK USING AN IGNITION SECONDARY VOLTAGE WAVE
OSCILLOSCOPE. . . . . . . . . . . . . . . . . . 16-9 PATTERN CHECK USING AN
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . 16-30
GENERATOR ASSEMBLY . . . . . . 16-12
IGNITION PRIMARY VOLTAGE WAVE
REMOVAL AND INSTALLATION . . . . . 16-12 PATTERN CHECK USING AN
DISASSEMBLY AND ASSEMBLY. . . . . 16-13 OSCILLOSCOPE . . . . . . . . . . . . . . . . . . 16-34
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-15
IGNITION COIL. . . . . . . . . . . . . . . . 16-40
REMOVAL AND INSTALLATION. . . . . . 16-40
STARTING SYSTEM . . . . . . . . . 16-18
CAMSHAFT POSITION SENSOR . 16-41
GENERAL DESCRIPTION . . . . . . 16-18 REMOVAL AND INSTALLATION. . . . . . 16-41
STARTING SYSTEM CRANKSHAFT POSITION SENSOR 16-42
DIAGNOSIS . . . . . . . . . . . . . . . . . . 16-19 REMOVAL AND INSTALLATION. . . . . . 16-42
STARTER MOTOR ASSEMBLY . . 16-20 KNOCK SENSOR . . . . . . . . . . . . . . 16-42
REMOVAL AND INSTALLATION . . . . . 16-20 REMOVAL AND INSTALLATION. . . . . . 16-42
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-21
DISASSEMBLY AND ASSEMBLY. . . . . 16-23
SPECIFICATIONS . . . . . . . . . . 16-43
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-25
FASTENER TIGHTENING
IGNITION SYSTEM . . . . . . . . . . 16-27 SPECIFICATIONS . . . . . . . . . . . . . 16-43

GENERAL SPECIFICATIONS . . . . 16-44

GENERAL DESCRIPTION . . . . . . 16-27
SERVICE SPECIFICATIONS . . . . . 16-44
16-2 ENGINE ELECTRICAL
CHARGING SYSTEM

CHARGING SYSTEM
GENERAL DESCRIPTION
M1161000100135
The charging system charges the battery with the
generator output to keep the battery charged at a
constant level during varying electrical load.
Operation
When the ignition switch is turned on, current flows in
VOLTAGE the field coil and initial excitation of the field coil
occurs.
When the stator coil begins to generate power after
APPROXIMATELY
the engine is started, the field coil is excited by the
14.4 V output current of the stator coil.
The generator output voltage rises as the field cur-
rent increases and it falls as the field current
decreases. When the battery positive voltage (gener-
TIME
AKX00183 AB
ator S terminal voltage) reaches a regulated voltage
of approximately 14.4 V, the field current is cut off.
Rotation of the excited field coil generates AC volt- When the battery positive voltage drops below the
age in the stator. regulated voltage, the voltage regulator regulates the
This alternating current is rectified through diodes to output voltage to a constant level by controlling the
DC voltage having a waveform shown in the illustra- field current.
tion at left. In addition, when the field current is constant, the
The average output voltage fluctuates slightly with generator output voltage rises as the engine speed
the generator load condition. increases.

GENERATOR

B
STATOR
COIL
IGNITION
SWITCH

FIELD COIL CHARGING

L
WARNING LIGHT
S +
VOLTAGE
REGULATOR BATTERY
-

AK101130 AB

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 ENGINE ELECTRICAL
CHARGING SYSTEM
16-3
CHARGING SYSTEM DIAGNOSIS
M1161000700104

TROUBLESHOOTING HINTS
Charging warning light dose not go on when the ignition switch
is turned to ON, before the engine starts.
• Check the bulb.
Charging warning light dose not switch off after the engine
starts.
• Check the IC voltage regulator inside the generator.
Discharged or overcharged battery.
• Check the IC voltage regulator inside the generator.
The charging warning light illuminates dimly.
• Check the diode (inside the combination meter) for a
short-circuit.

TROUBLESHOOTING GUIDE
The charging system troubleshooting guide is shown in the fol-
lowing steps.

STEP 1.
Q: Is the battery in good condition? (Refer to GROUP 54A,
Battery − Battery check P.54A-4.)
YES : Go to Step 2.
NO : Charge or replace the battery.

STEP 2.
Q: Is the generator drive belt in good condition? (Refer to
GROUP 00, Maintenance Service P.00-39.)
YES : Go to Step 3.
NO : Adjust the belt tension or replace the belt.

STEP 3.
Q: Does the charging warning light shine brightly when the
ignition switch is turned on?
YES : Go to Step 4.
NO : • Check the ignition switch. (Refer to GROUP 54,
Ignition switch P.54A-31.)
• Check for burned- out charging warning light.
• Check the generator. (Refer to Generator −
Disassembly and assembly P.16-15.)
• Check the charging warning light-related circuits.

STEP 4.
Q: Does the charging warning light go out after starting the
engine?
YES : Go to Step 5.
NO : Check the generator. (Refer to Generator −
Disassembly and assembly P.16-15.)

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16-4 ENGINE ELECTRICAL
CHARGING SYSTEM

STEP 5.
Q: Is an oscilloscope available?
YES : Go to Step 6.
NO : Go to Step 7.

STEP 6.
Q: Does the oscilloscope show a normal wave pattern?
(Refer to Charging system − Wave pattern check using a
oscilloscope P.16-9.)
YES : Go to Step 7.
NO : Check the generator. (Refer to Generator −
Disassembly and assembly P.16-15.)

STEP 7.
• Engine: 2,500 r/min
• Headlight: ON (high beam)
• Voltage between generator terminal B and the positive bat-
tery terminal
OK: 0.5 V or less
• Voltage between the negative battery terminal and genera-
tor body
OK: 0.5 V or less
Q: Are the generator output line and ground line in good
condition?
YES : Go to Step 8.
NO : Check the generator output line and ground line

STEP 8.
Q: Is the output current normal? (Refer to Charging system
− On vehicle service − Output current test P.16-6.)
YES : Go to Step 9.
NO : Check the generator. (Refer to Generator −
Disassembly and assembly P.16-15.)

STEP 9.
Q: Is the regulated voltage normal? (Refer to Charging
system − On vehicle service − Regulated voltage test
P.16-8.)
YES : Go to Step 10.
NO : Check the generator. (Refer to Generator −
Disassembly and assembly P.16-15.)

STEP 10.
Q: Is the voltage drop on the generator output line normal?
YES : Generator is normal. Check other systems.
NO : Check the output line.

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 ENGINE ELECTRICAL
CHARGING SYSTEM
16-5
SPECIAL TOOL
M1161000600022

TOOL TOOL NUMBER AND SUPERSESSION APPLICATION

NAME
MB991502 MB991496-OD Checking of engine idle
Scan tool (MUT-II) speed

B991502

ON-VEHICLE SERVICE
GENERATOR OUTPUT LINE VOLTAGE DROP TEST
M1161000900175

AMMETER

GENERATOR

VOLTMETER
(DIGITAL-TYPE)

BATTERY
"B"TERMINAL
–

AKX00185 AB

Required Special Tool: 3. Disconnect the negative battery cable.

MB991502: Scan Tool 4. Disconnect the generator output wire from the
This test determines whether the wiring from the generator "B" terminal and connect a DC test
generator "B" terminal to the positive battery terminal ammeter with a range of 0 − 100 A in series
(including the fusible link) is in good condition or not: between the "B" terminal and the disconnected
WARNING output wire. (Connect the positive lead of the
Battery posts, terminals and related acces- ammeter to the "B" terminal, and then connect the
sories contain lead and lead compounds. negative lead of the ammeter to the disconnected
WASH HANDS AFTER HANDLING. output wire.)
1. Always be sure to check the following before the NOTE: A clamp-type ammeter which enables
test. measurements to be taken without disconnecting
• Generator installation the generator output wire is recommended. If the
• Generator drive belt tension (Refer to GROUP voltage may have dropped due to a bad connec-
00, Maintenance Service − Drive belts P.00-39.) tion at generator "B" and the generator "B" termi-
• Fusible link nal is loosened when the test ammeter is
• Abnormal noise from the generator while the connected, the connection will be completed at
engine is running this time and the possibility of finding problems
2. Turn the ignition switch to the "OFF" position. will be reduced.

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16-6 ENGINE ELECTRICAL
CHARGING SYSTEM

5. Connect a digital-type voltmeter between the 11.If the value displayed on the voltmeter is above
generator "B" terminal and the positive battery the limit value, there is probably a malfunction in
terminal. (Connect the positive lead of the the generator output wire, Check the wiring
voltmeter to the "B" terminal, and then connect the between the generator "B" terminal and the
negative lead of the voltmeter to the positive positive battery terminal (including fusible link). If
battery cable.) a terminal is not sufficiently tight or if the harness
6. Reconnect the negative battery cable. has become discolored due to overheating, repair
7. Connect a tachometer or scan tool MB991502. and then test again.
8. Leave the hood open. 12.After the test, run the engine at idle.
9. Start the engine. 13.Turn off all lights and turn the ignition switch to the
"LOCK" (OFF) position.
10.With the engine running at 2,500 r/min, turn the
headlights and other lights on and off to adjust the 14.Disconnect the tachometer or scan tool
generator load so that the value displayed on the MB991502.
ammeter is slightly above 30 A. 15.Disconnect the negative battery cable.
Limit value: maximum 0.3 V 16.Disconnect the ammeter and voltmeter and
tachometer.
NOTE: When the generator output is high and the
value displayed on the ammeter does not 17.Connect the generator output wire to the
decrease to 30 A, set the value to 40 A. Read the generator "B" terminal.
value displayed on the voltmeter at this time. 18.Connect the negative battery cable.
In this case the limit value becomes maximum 0.4
V. Adjust the engine speed by gradually decreas-
ing it until the value displayed on the ammeter is
30 A. Take a reading of the value displayed on the
voltmeter at this time.
OUTPUT CURRENT TEST
M1161001000164

IGNITION GENERATOR LOAD

SWITCH CHARGING INDICATOR

L
B
BRAKE WARNING LIGHT S

VOLTMETER
AMMETER

BATTERY

AKX00186 AB

Required Special Tool: WARNING

MB991502: Scan Tool (MUT-II) Battery posts, terminals and related acces-
This test determines whether the generator outputs sories contain lead and lead compounds.
normal current.
WASH HANDS AFTER HANDLING.
1. Before the test, always be sure to check the
following.

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 ENGINE ELECTRICAL
CHARGING SYSTEM
16-7
• Generator installation 10.After turning the light switch on and turning on the
• Battery (Refer to GROUP 54A, Battery − On- headlights, start the engine.
vehicle Service − Battery Check P.54A-4.) NOTE: Because the current from the battery will
NOTE: The battery to be used should be slightly soon drop after the engine is started, step11
discharged. The load in a fully-charged battery should be carried out as quickly as possible in
will be insufficient and the test may not be able to order to obtain the maximum current output value.
be carried out correctly. 11.Immediately after setting the headlights to high
• Generator drive belt tension (Refer to GROUP beam and turning the heater blower switch to the
00, Maintenance Service − Drive Belts P.00-39.) high revolution position, increase the engine
• Fusible link speed to 2,500 r/min and read the maximum
• Abnormal noise from the generator while the current output value displayed on the ammeter.
engine is running
Limit value: 70 % of nominal current output
2. Turn the ignition switch to the "LOCK" (OFF)
NOTE: For the nominal current output, refer to the
position.
Generator Specifications
3. Disconnect the negative battery cable.
NOTE: The current output value will depend on
WARNING the electrical load and the temperature of the gen-
Never use clips to connect the line. Loose erator body.
connections (e.g. using clips) will lead to a NOTE: If the electrical load is small while testing,
serious accident because of high current. the specified level of current may not be output
4. Disconnect the generator output wire from the even though the generator is normal. In such
generator "B" terminal and connect a DC test cases, increase the electrical load by leaving the
ammeter with a range of 0 − 100 A in series headlights turned on for some time to discharge
between the "B" terminal and the disconnected the battery.
output wire. (Connect the positive lead of the NOTE: The specified level of current also may not
ammeter to the "B" terminal, and then connect the be output if the temperature of the generator body
negative lead of the ammeter to the disconnected or the ambient temperature is too high. In such
output wire.) cases, cool the generator and then test again.
NOTE: A clamp-type ammeter which enables 12.The reading on the ammeter should be above the
measurements to be taken without disconnecting limit value. If the reading is below the limit value
the generator output wire is recommended. and the generator output wire is normal, remove
5. Connect a voltmeter with a range of 0 − 20 V the generator from the engine and check the
between the generator "B" terminal and the generator.
ground. (Connect the positive lead of the 13.Run the engine at idle speed after the test.
voltmeter to the "B" terminal, and then connect the 14.Turn the ignition switch to the "LOCK" (OFF)
negative lead of the voltmeter to the ground.) position.
6. Connect the negative battery cable. 15.Disconnect the tachometer or scan tool
7. Connect a tachometer or scan tool MB991502. MB991502.
8. Leave the hood open. 16.Disconnect the negative battery cable.
9. Check to be sure that the reading on the voltmeter 17.Disconnect the ammeter and voltmeter and
is equal to the battery positive voltage. tachometer.
NOTE: If the voltage is 0 V, the cause is probably 18.Connect the generator output wire to the
an open circuit in the wire or fusible link between generator "B" terminal.
the generator "B" terminal and the battery positive 19.Connect the negative battery cable.
terminal.

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16-8 ENGINE ELECTRICAL
CHARGING SYSTEM

REGULATED VOLTAGE TEST

M1161001100172

IGNITION LOAD
SWITCH(IG1) CHARGING INDICATOR GENERATOR

L
B
BRAKE WARNING LIGHT S
VOLTMETER
(DIGITAL-TYPE)
AMMETER

BATTERY
-

AKX00187AB

Required Special Tool: 6. Connect a DC test ammeter with a range of 0 −

MB991502: Scan Tool (MUT-II) 100 A in series between the "B" terminal and the
This test determines whether the voltage regulator is disconnected output wire. (Connect the positive
correctly controlling the generator output voltage. load of the ammeter to the "B" terminal, and then
WARNING connect the negative lead of the ammeter to the
Battery posts, terminals and related acces- disconnected output wire.)
sories contain lead and lead compounds. 7. Reconnect the negative battery cable.
WASH HANDS AFTER HANDLING. 8. Connect a tachometer or the scan tool
1. Always be sure to check the following before the MB991502.
test: 9. Turn the ignition switch to the "ON" position and
• Generator installation check that the reading on the voltmeter is equal to
• Check to be sure that the battery installed in the the battery positive voltage.
vehicle is fully charged (Refer to GROUP 54A, NOTE: If the voltage is 0 V, the cause is probably
Battery − On-vehicle Service − Battery Check an open circuit in the wire or fusible link between
P.54A-4.) the generator "S" terminal and the battery positive
• Generator drive belt tension (Refer to GROUP terminal.
00, Maintenance Service − Drive Belts P.00-39.) 10.Check to be sure that all lights and accessories
• Fusible link are off.
• Abnormal noise from the generator while the
11.Start the engine.
engine is running
12.Increase the engine speed to 2,500 r/min.
2. Turn the ignition switch to the "LOCK" (OFF)
position. 13.Read the value displayed on the voltmeter when
the current output by the generator becomes 10 A
3. Disconnect the negative battery cable.
or less.
4. Connect a digital-type voltmeter between the
14.If the voltage reading conforms to the value in the
generator "S" terminal and the ground. (Connect
voltage regulation table, then the voltage regulator
the positive lead of the voltmeter to the "S"
is operating normally.
terminal, and then connect the negative lead of
the voltmeter to a secure ground or to the battery If the voltage is outside the standard value, there
negative terminal.) is a malfunction of the voltage regulator or the
5. Disconnect the generator output wire from the generator (Refer to the following table).
generator "B" terminal.

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 ENGINE ELECTRICAL
CHARGING SYSTEM
16-9
15.After the test, lower the engine speed to the idle 18.Disconnect the ammeter, voltmeter and
speed. tachometer.
16.Turn the ignition switch to the "LOCK" (OFF) 19.Connect the generator output wire to the
position. generator "B" terminal.
17.Disconnect the negative battery cable. 20.Connect the negative battery cable.
VOLTAGE REGULATION TABLE
INSPECTION TERMINAL VOLTAGE REGULATOR STANDARD VALUE (V)
AMBIENT TEMPERATURE [°C
(°F)]
Terminal "S" −20 (−4) 14.2 − 15.4
20 (68) 13.9 − 14.9
60 (140) 13.4 − 14.5
80 (176) 13.1 − 14.5

WAVE PATTERN CHECK USING A

OSCILLOSCOPE
M1161001200027
.

MEASUREMENT METHOD
OSCILLOSCOPE Connect the oscilloscope special patterns pick-up to the gener-
GENERATOR ator "B" terminal.
PROBE

"B" TERMINAL
AKX00188AB

STANDARD WAVEFORM
Observation Conditions
FUNCTION SPECIAL PATTERNS
Pattern height Variable
Variable knob Adjust while viewing the wave
pattern
Pattern selector Raster
Engine revolutions Curb idle speed

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16-10 ENGINE ELECTRICAL
CHARGING SYSTEM

(V)

0.4

0.2
VOLTAGE AT
GENERATOR 0
"B" TERMINAL
–0.2

–0.4

TIME

AKX00189 AB

NOTE: The voltage waveform of the generator "B" terminal can

undulate as shown at left. This waveform is produced when the
regulator operates according to fluctuations in the generator
load (current), and is normal for the generator.
If the ripple height is abnormally high (approximately 2 V or
more during idling), the wires between the generator "B" termi-
nal and the battery have broken due to fuse blowing, etc. The
generator is usually operating properly.
.

AKX00190 ABNORMAL WAVEFORMS EXAMPLES

NOTE: The size of the waveform patterns can differ greatly,
depending on the adjustment of the variable knob on the oscil-
loscope.
NOTE: Identification of abnormal waveforms is easier when
there is a large output current (regulator is not operating).
(Waveforms can be observed when the headlights are illumi-
nated.)
NOTE: Check the conditions of the charging indicator light (illu-
minated/not illuminated) also, and carry out a total check.
ABNORMAL WAVEFORMS
• Example 1
PROBABLE CAUSE: Open circuit in diode

AKX00191

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 ENGINE ELECTRICAL
CHARGING SYSTEM
16-11
• Example 2
PROBABLE CAUSE: Short-circuit in diode

AKX00192

• Example 3
PROBABLE CAUSE: Open circuit in stator coil

AKX00193

• Example 4
PROBABLE CAUSE: Short-circuit in stator coil

AKX00194

• Example 5
PROBABLE CAUSE: Open circuit in supplementary diode

AKX00195

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16-12 ENGINE ELECTRICAL
CHARGING SYSTEM

GENERATOR ASSEMBLY
REMOVAL AND INSTALLATION
M1161001400377

Pre-removal Operation Post-installation Operation

• Under Cover Removal • Drive Belt Tension Adjustment (Refer to GROUP 11A, On-
• Air Cleaner Removal (Refer to GROUP 15, Air Cleaner vehicle Service P.11A-5.)
P.15-6.) • Under Cover
• Air Cleaner Installation (Refer to GROUP 15, Air Cleaner
P.15-6.)

2
44 ± 10 N·m
33 ± 7 ft-lb

22 ± 4 N·m
16 ± 3 ft-lb

AC204070 AB

REMOVAL STEPS
1. DRIVE BELT
2. GENERATOR

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 ENGINE ELECTRICAL
CHARGING SYSTEM
16-13
DISASSEMBLY AND ASSEMBLY
M1161001600025

1
4.4 ± 1.0 N·m 3
39 ± 9 in-lb

4
5
7 6

3.7 ± 0.7 N·m

33 ± 6 in-lb
2

14

13

12
10
9

11
3.7 ± 0.7 N·m
33 ± 6 in-lb

AKX00354 AB

DISASSEMBLY STEPS DISASSEMBLY STEPS

<<A>> 1. FRONT BRACKET ASSEMBLY <<C>> 8. STATOR
<<B>> 2. GENERATOR PULLEY 9. PLATE
>>B<< 3. ROTOR ASSEMBLY >>A<< 10. REGULATOR ASSEMBLY
4. REAR BEARING 11. BRUSH
5. BEARING RETAINER 12. SLINGER
6. FRONT BEARING 13. RECTIFIER
7. FRONT BRACKET 14. REAR BRACKET

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16-14 ENGINE ELECTRICAL
CHARGING SYSTEM

DISASSEMBLY SERVICE POINTS

.

<<A>> FRONT BRACKET ASSEMBLY REMOVAL

CAUTION
Do not insert a screwdriver too deep. The stator coil will be
damaged.
Insert a flat-tipped screwdriver between the front bracket
assembly and the stator core, and pry it downward to separate
the stator and front bracket assembly.

AKX00355

<<B>> GENERATOR PULLEY REMOVAL

CAUTION
Make sure not to damage the rotor.
Set the pulley upward, clamp the rotor in a vise, and remove
the pulley.

AKX00356

<<C>> STATOR REMOVAL

CAUTION
SOLDERED
• Check that the heat from the soldering iron is not trans-
RECTIFIER mitted to the diode for a long time.
• Use care that no undue force is exerted to leads of
diodes.
1. Use a soldering iron (180 to 250 W) to unsolder the stator.
This work should complete within approximately four
seconds to prevent heat from transferring to the diode.
2. When removing the rectifier from the regulator assembly,
SOLDERED
unsolder the points soldered on the rectifier.
AKX00357AB

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 ENGINE ELECTRICAL
CHARGING SYSTEM
16-15
ASSEMBLY SERVICE POINTS
.

>>A<< REGULATOR ASSEMBLY INSTALLATION

After installing the regulator assembly, insert a wire through the
hole provided on the rear bracket while pressing down on the
brush, and secure the brush.
NOTE: By inserting a wire, the brush will be secured in place,
and the installation of the rotor will be easier.

WIRE

REAR BRACKET
BRUSH

WIRE

AKX00358 AB

>>B<< ROTOR ASSEMBLY INSTALLATION

After installing the rotor, remove the wire used to secure the
brush.

WIRE

AKX00359 AB

INSPECTION
M1161001700022
.

ROTOR CHECK
1. Check the continuity between the slip rings of the field coil. If
the resistance value is not within the standard value, replace
the rotor.
Standard value: approximately 2 − 5 Ω

AKX00360

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16-16 ENGINE ELECTRICAL
CHARGING SYSTEM

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

AKX00361

STATOR CHECK
1. Check the continuity between the coil lead. If there is no
continuity, replace the stator.

AKX00362

2. Check the continuity between the coil and the core. If there
is continuity, replace the stator.

AKX00363

RECTIFIER CHECK
1. Check the continuity between the positive rectifier and the
stator coil lead connection terminal with a tester. If there is
continuity between the terminals, the diode is shorted, so
replace the rectifier.

AKX00364

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 ENGINE ELECTRICAL
CHARGING SYSTEM
16-17
2. Check the continuity between the negative rectifier and the
stator coil lead connection terminal with a tester. If there is
continuity between the terminals, the diode is grounded, so
replace the rectifier.

AKX00365

3. Check the continuity of the three diodes by connecting an

ohmmeter to both ends of each diode. If there is continuity
between the directions, or if there is no continuity, the diode
is damaged, so replace the rectifier.

AKX00366

BRUSH CHECK
1. Replace the brush if the brush protrusion length shown in
the illustration is below the minimum limit value.
Minimum limit: 2 mm (0.08 inch)

PROTRUSION
LENGTH

AKX00367AB

2. The brush can be removed by unsoldering the brush lead

SOLDERED wire.
3. When installing a new brush, push the brush in to the brush
holder, and solder the lead wire.

AKX00368 AB

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16-18 ENGINE ELECTRICAL
STARTING SYSTEM

STARTING SYSTEM
GENERAL DESCRIPTION
M1162000100149
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 coil provided inside mag- tion after starting the engine, the starter clutch is dis-
netic switch, attracting the plunger. When the plunger engaged from the ring gear.
is attracted, the lever connected to the plunger is An overrunning clutch is provided between the pinion
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.

HOLDING
COIL
PLUNGER
PULL-IN COIL
LEVER

PINION SHAFT
IGNITION
SWITCH
OVERRUNNING
CLUTCH

+ ARMATURE

BATTERY

BRUSH
YOKE

AKX00196 AB

OPERATION
• For models equipped with A/T, when the ignition
switch is switched to the "ST" position while the
selector lever is at the "P" or "N" position, the
contact (magnetic switch) of the starter is
switched ON and the starter motor is activated.

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 ENGINE ELECTRICAL
STARTING SYSTEM
16-19
STARTING SYSTEM DIAGNOSIS
M1162000700204

TROUBLESHOOTING HINTS
The starter motor dose not operate at all.
• Check the starter (coil).
• Check for poor contact at the battery terminals and
starter.
• Check the transmission range switch.
The starter motor doesn’t stop.
• Check the starter (magnetic switch).

TROUBLESHOOTING GUIDE
The starting system troubleshooting guide is shown in the fol-
lowing chart.

STEP 1.
Q: Is the battery in good condition? (Refer to GROUP 54A,
Battery − Battery check P.54A-4.)
YES : Go to Step 2.
NO : Charge or replace the battery.

STEP 2.
• Disconnect the starter motor S (solenoid) terminal connec-
tor.
• Using a jumper wire, apply battery voltage to the starter
motor S (solenoid) terminal.
• Check the engine condition.
OK: Turns normally
Q: Does the starter motor operate normally?
YES : • Check the ignition switch. (Refer to GROUP 54,
Ignition switch P.54A-31.)
• Check the starter relay
• Check the transmission range switch.(Refer to
GROUP 23A, Automatic Transaxle On-vehicle
Service P.23Aa-20.)
• Check the line between the battery and starter
motor S (solenoid) terminal.
NO : Go to Step 3.

STEP 3.
• Check the cable between starter B (battery) terminal and
battery positive terminal for connection and continuity.
Q: Is the starter cable in good condition?
YES : Go to Step 4.
NO : Repair or replace the cable

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16-20 ENGINE ELECTRICAL
STARTING SYSTEM

STEP 4.
• Check the connection and the continuity of the cable
between the starter motor body and the negative battery
terminal
Q: Is the ground line in good condition?
YES : Go to Step 5.
NO : Repair or replace the cable

STEP 5.
Q: Is the starter motor in good condition? (Refer to Starting
system − Starter motor − Inspection P.16-21.)
YES : Excessive rotational resistance of the engine.
NO : Replace the starter motor.

STARTER MOTOR ASSEMBLY

REMOVAL AND INSTALLATION
M1162001000435

Pre-removal and Post-installation Operation

• Under Cover Removal and Installation

30 ± 3 N·m
22 ± 2 ft-lb

4
3
ACX02077AB

REMOVAL STEPS REMOVAL STEPS (Continued)

1. STARTER COVER 3. BATTERY CABLE
2. STARTER CONNECTOR 4. STARTER ASSEMBLY

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 ENGINE ELECTRICAL
STARTING SYSTEM
16-21
INSPECTION
M1162001100023
.

PINION GAP ADJUSTMENT

1. Disconnect the field coil wire from the M-terminal of the
SWITCH magnetic switch.
2. Connect a 12-volt battery between the S-terminal and M-
S terminal.
M
B CAUTION
This test must be performed quickly (in less than 10 sec-
BATTERY
onds) to prevent the coil from burning.
STARTER
MOTOR
WIRE 3. Set the switch to "ON", and the pinion will move out.
AKX00197 AB

4. Check the pinion-to-stopper clearance (pinion gap) with a

feeler gauge.
STOPPER
Standard value: 0.5 − 2.0 mm (0.02 − 0.07 inch)

PINION

PINION GAP AKX00198 AB

5. If the pinion gap is out of specification, adjust by adding or

removing gasket(s) between the magnetic switch and front
bracket.

AKX00199

MAGNETIC SWITCH PULL-IN TEST

1. Disconnect the field coil wire from the M-terminal of the
magnetic switch.
CAUTION
S
This test must be performed quickly (in less than 10 sec-
M
B onds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal and M-
BATTERY
terminal.
STARTER
WIRE 3. If the pinion moves out, the pull-in coil is good. If it doesn't,
MOTOR
replace the magnetic switch.
AKX00200 AB

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16-22 ENGINE ELECTRICAL
STARTING SYSTEM

MAGNETIC SWITCH HOLD-IN TEST

1. Disconnect the field coil wire from the M-terminal of the
magnetic switch.
CAUTION
S
This test must be performed quickly (in less than 10 sec-
B M onds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal and body.
BATTERY
3. Manually pull out the pinion as far as the pinion stopper
STARTER
MOTOR position.
WIRE 4. If the pinion remains out, everything is operating properly. If
AKX00201AB
the pinion moves in, the hold-in circuit is open. Replace the
magnetic switch.
.

FREE RUNNING TEST

1. Place the starter motor in a vise equipped with soft jaws and
CARBON-PILE connect a fully-charged 12-volt battery to the starter motor
RHEOSTAT
S as follows:
AMMETER
M 2. Connect a test ammeter (100-ampere scale) and carbon pile
B
rheostat in series between the positive battery terminal and
BATTERY starter motor terminal.
STARTER 3. Connect a voltmeter (15-volt scale) across the starter motor.
MOTOR VOLTMETER
4. Rotate carbon pile to full-resistance position.
5. Connect the battery cable from the negative battery terminal
AKX00202 AB
to the starter motor body.
6. Adjust the rheostat until the battery positive voltage shown
by the voltmeter is 11 V.
7. Confirm that the maximum amperage is within the
specifications and that the starter motor turns smoothly and
freely.
Current: maximum 90 Amps
.

MAGNETIC SWITCH RETURN TEST

1. Disconnect the field coil wire from the M-terminal of the
magnetic switch.

S
CAUTION
This test must be performed quickly (in less than 10 sec-
B M onds) to prevent the coil from burning.
2. Connect a 12-volt battery between the M-terminal and body.
BATTERY
STARTER WARNING
MOTOR
WIRE
Be careful not to get your fingers caught when pulling
AKX00203AB
out the pinion.
3. Pull the pinion out and release. If the pinion quickly returns
to its original position, everything is operating properly. If it
doesn't, replace the magnetic switch.

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 ENGINE ELECTRICAL
STARTING SYSTEM
16-23
DISASSEMBLY AND ASSEMBLY
M1162001200075

12
15 13
10
11
14
2 20

5.8 ± 1.6 N·m

52 ± 14 in-lb 19
5.8 ± 1.6 N·m
18 52 ± 14 in-lb
3.4 ± 1.0 N·m
1 17 30 ± 9 in-lb
4
16
3

21

7 5
9

8
AK101266AB

DISASSEMBLY STEPS DISASSEMBLY STEPS

1. SCREW 12. PACKING B
2. MAGNETIC SWITCH 13. PLATE
3. SCREW 14. PLANETARY GEAR
4. SCREW 15. LEVER
5. REAR BRACKET <<B>> >>A<< 16. SNAP RING
6. BRUSH HOLDER ASSEMBLY <<B>> >>A<< 17. STOP RING
7. REAR BEARING 18. OVERRUNNING CLUTCH
<<A>> 8. ARMATURE 19. INTERNAL GEAR
9. YOKE ASSEMBLY 20. PLANETARY GEAR HOLDER
<<A>> 10. BALL 21. FRONT BRACKET
11. PACKING A

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16-24 ENGINE ELECTRICAL
STARTING SYSTEM

DISASSEMBLY SERVICE POINTS

.

<<A>> ARMATURE AND BALL REMOVAL

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

STOP RING
PINION GEAR

OVERRUNNING
CLUTCH

AKX00370 AB

<<B>> SNAP RING AND STOP RING REMOVAL

SNAP-RING 1. Press a long socket wrench of appropriate size to the stop
SNAP RING PLIERS ring. Then tap the socket wrench to remove the stop ring to
the pinion gear side.
PINION GEAR 2. After removing the snap ring (by using snap-ring pliers),
OVERRUNNING remove the stop ring and the overrunning clutch.
CLUTCH

AKX00371AB

STARTER MOTOR PART CLEANING

1. Do not immerse parts in cleaning solvent. Immersing the
yoke and field coil assembly and/or armature will damage
insulation. Wipe these parts with a shop towel only.
2. Do not immerse the drive unit in cleaning solvent.
Overrunning clutch is pre-lubricated at the factory and
solvent will wash lubrication from the clutch.
3. The drive unit may be cleaned with a brush moistened with
cleaning solvent and wiped dry with a shop towel.
ASSEMBLY SERVICE POINT
.

>>A<< STOP RING AND SNAP RING INSTALLATION

Using a suitable pulling tool, pull the overrunning clutch stop
ring over the snap ring.

STOP
RING
OVERRUNNING
STOP RING CLUTCH

SNAP RING
AKX00372 AB

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 ENGINE ELECTRICAL
STARTING SYSTEM
16-25
INSPECTION
M1162001300049
.

COMMUTATOR CHECK
1. Place the armature on a pair of V-blocks, and check the
deflection by using a dial gauge.
Standard value: 0.05 mm (0.002 inch)
Limit: 0.1 mm (0.004 inch)

AKX00373

2. Check the outer diameter of the commutator.

Standard value: 29.4 mm (1.16 inches)
Minimum limit: 28.8 mm (1.13 inches)

AKX00374

UNDERCUT 3. Check the depth of the undercut between segments.

SEGMENT
Standard value: 0.5 mm (0.02 inch)
Minimum limit: 0.2 mm (0.008 inch)
MICA

AKX00375 AB

BRUSH CHECK
1. Check the brush for roughness of the surface that contacts
the commutator and check the brush length.Replace the
brush holder if this measurement exceeds the limit.
Minimum limit: 7.0 mm (0.28 inch)

LIMIT LENGTH
2. .In the case contacting surface has been corrected or the
brush has been replaced, correct the contacting surface by
winding sandpaper around the commutator

AK101390 AB

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16-26 ENGINE ELECTRICAL
STARTING SYSTEM

OVERRUNNING CLUTCH CHECK

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

AKX00378 AB

FRONT AND REAR BRACKET BUSHING CHECK

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

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

AKX00379 AB

4. Check the insulation between the armature coil cores and

the commutator segments. They are normal if there is no
continuity.

AKX00380

5. Check for continuity between the segments. The condition is

normal if there is continuity.

AKX00381

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 ENGINE ELECTRICAL
IGNITION SYSTEM
16-27
IGNITION SYSTEM
GENERAL DESCRIPTION
M1163000100186
This system is provided with three ignition coils (A, B The engine control module controls the three ignition
and C) with built-in three ignition power transistors power transistors to turn them alternately ON and
for the number 1 and number 4 cylinders, number 2 OFF. This causes the primary currents in the ignition
and number 5 cylinders and number 3 and number 6 coils (A, B and C) to be alternately interrupted and
cylinders respectively. allowed to flow to fire the cylinders in the order 1-2-3-
Interruption of the primary current flowing in the pri- 4-5-6.
mary side of ignition coil A generates a high voltage The engine control unit determines which ignition coil
in the secondary side of ignition coil A. should be controlled by means of the signals from
The high voltage thus generated is applied to the the camshaft position sensor which is incorporated in
spark plugs of number 1 and number 4 cylinders to the camshaft and from the crankshaft position sensor
generate sparks. At the time that the sparks are gen- which is incorporated in the crankshaft.
erated at both spark plugs, if one cylinder is at the It also detects the crankshaft position to provide igni-
compression stroke, the other cylinder is at the tion at the most appropriate timing in response to the
exhaust stroke, so that ignition of the compressed engine operation conditions.
air/fuel mixture occurs only for the cylinder which is When the engine is cold or operated at high alti-
at the compression stroke. tudes, the ignition timing is slightly advanced to pro-
In the same way, when the primary current flowing in vide optimum performance.
ignition coil B is interrupted, the high voltage thus
generated is applied to the spark plugs of number 2
and number 5 cylinders, and when the primary cur-
rent flowing in ignition coil C is interrupted, the high
voltage thus generated is applied to the spark plugs
of number 3 and number 6 cylinders.
TO TACHOMETER

IGNITION COIL A

IGNITION
SWITCH
PCM IGNITION COIL B

BATTERY
IGNITION COIL C

SPARK PLUGS

CYLINDER NO. 6 3 5 2 4 1
AK200804 AB

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16-28 ENGINE ELECTRICAL
IGNITION SYSTEM

SPECIAL TOOLS
M1163000600028

TOOL TOOL NUMBER AND SUPERSESSION APPLICATION

NAME
MB991348 MB991348-01 Inspection of ignition
Test harness set primary voltage (ignition
power transistor
connection)
MB991348

MD998773 − Knock sensor removal

Knock sensor wrench and installation

ON-VEHICLE SERVICE

SPARK PLUG CABLE TEST

M1163000900029

WARNING
Wear rubber gloves while performing this test.
1. Disconnect, one at a time, each of the spark plug cables
while the engine is idling to check whether the engine's
running performance changes or not.
2. If the engine performance does not change, check the
resistance of the spark plug cable, and check the spark plug
itself.
SPARK PLUG CABLE

AKX00431AB

SPARK PLUG TEST

M1163001500024
1. Remove the spark plug and connect to the spark plug cable.

SPARK PLUG

AKX00432 AB

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 ENGINE ELECTRICAL
IGNITION SYSTEM
16-29
2. Ground the spark plug outer electrode (body), and crank the
DEFECTIVE INSULATION engine.
DEFECTIVE
INSULATION Check that there is an electrical discharge between the
electrodes at this time.

DEFECTIVE INSULATION GOOD

AKX00277 AB

IGNITION COIL CHECK

M1163001200153
Check by the following procedure, and replace the coil 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

AKX01264

PRIMARY COIL AND IGNITION POWER TRANSISTOR

CONTINUITY CHECK
NOTE: An analog-type ohmmeter should be used.
NOTE: Connect the negative probe of the ohmmeter to termi-
1.5 V nal 1.
CAUTION
This test must be performed quickly (in less than 10 sec-
– + 1 2 3 onds) to prevent coil from burning and ignition power tran-
sistor from breaking.
1. Connect and disconnect 1.5 V battery between terminals 2
and 3, and observe the ohmmeter whether there is
AKX01265AB continuity or not.
2. If results do not agree with the table below, replace the
primary coil and ignition power transistor assembly.
1.5 V POWER SUPPLY CONTINUITY BETWEEN
BETWEEN 2 − 3 1−2
Current flowing Yes
Current not flowing No

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16-30 ENGINE ELECTRICAL
IGNITION SYSTEM

SPARK PLUG CABLE RESISTANCE CHECK

M1163001400083
Measure the resistance of the all spark plug leads.
1. Check the cap and coating for cracks.
2. Measure the resistance.
Limit: 19 kΩ

AKX00382

SPARK PLUG CHECK AND CLEANING

M1163004300212

CAUTION
• Do not attempt to adjust the gap of the iridium plug.
• Cleaning of the iridium plug may result in damage to
the iridium and platinum tips. Therefore, if carbon
deposits must be removed, use a plug cleaner and
complete cleaning within 20 seconds to protect the
electrode. Do not use a wire brush.
IRIDIUM
TIP Check the plug gap and replace if the limit is exceeded.
Standard value: 0.7 − 0.8 mm (0.028 − 0.031 inch)
PLATINUM Limit: 1.0 mm (0.039 inch)
TIP AKX01327AB

CAMSHAFT POSITION SENSOR AND

CRANKSHAFT POSITION SENSOR CHECK
M1163002600110
Refer to GROUP 13A, Diagnostic Trouble Code Procedures −
DTC P0335: Crankshaft Position Sensor Circuit P.13Ac-360.
Refer to GROUP 13A, Diagnostic Trouble Code Procedures −
DTC P0340: Camshaft Position Sensor Circuit P.13Ac-377.

IGNITION SECONDARY VOLTAGE WAVE

PATTERN CHECK USING A OSCILLOSCOPE
M1163001700028
.

MEASUREMENT METHOD
1. Clamp the spark plug cable (Number 1, 3 or 5) with the
secondary pickup.
NOTE: Because of the two-cylinder simultaneous ignition
system, the waves for two cylinders in each group appear
during wave observation. However, wave observation is car-
ried out for the cylinder (Number 1, 3 or 5) with the spark
plug cable which has been clamped by the secondary
pickup.
NOTE: Identification of which cylinder wave pattern is dis-
played can be difficult, but the wave pattern of the cylinder
which is clamped by the secondary pickup will be stable, so
this can be used as a reference for identification.

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 ENGINE ELECTRICAL
IGNITION SYSTEM
16-31
2. Clamp the spark plug cable (Number 1, 3 or 5) with the
trigger pickup.
NOTE: Clamp the same spark plug cable as the one which
has been clamped by the secondary pickup.
.

STANDARD WAVEPATTERN
Observation Conditions
FUNCTION SECONDARY
Pattern height High (or low)
Pattern selector Raster
Engine revolutions Curb idle speed

SPARK LINE (POINT A)

kV

IGNITION VOLTAGE
(POINT D)

SECONDARY
IGNITION
VOLTAGE
WAVE PATTERN WAVE DAMPING REDUCTION SECTION (POINT B)

DWELL SECTION

POINT C

TIME

AKX00278 AB

Observation Conditions (Only pattern selector below

changes from the above conditions.)
Pattern selector Display

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16-32 ENGINE ELECTRICAL
IGNITION SYSTEM

kV

NO.1 CYLINDER NO.3 CYLINDER NO.4 CYLINDER NO.6 CYLINDER

SECONDARY IGNITION NOISE (WAVE PATTERN IGNITION NOISE
IGNITION NO.2 CYLINDER IS DISTURBED)
VOLTAGE IGNITION NOISE NO.5 CYLINDER
WAVE PATTERN IGNITION NOISE

0 NEUTRAL
SECTION

TIME

AKX00279 AB
.

WAVEFORM OBSERVATION POINTS

Point A:
The height, length and slope of the spark line (refer to
abnormal waveform examples 1, 2, 3 and 4) show the fol-
lowing trends.
SPARK LINE PLUG GAP STATUS OF COMPRESSION CONCENTRATION IGNITION TIMING SPARK PLUG
ELECTRODES FORCE OF AIR MIXTURE CABLE

Length Long Small Normal Low Rich Advanced Leak

Length Short Large Large wear High Lean Retarded High
resistance
Height High Large Large wear High Lean Retarded High
resistance
Height Low Small Normal Low Rich Advanced Leak
Slope Large Plug is − − − −
fouled

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 ENGINE ELECTRICAL
IGNITION SYSTEM
16-33
Point B:
Number of vibrations in reduction vibration section (Refer to
Abnormal Waveform Example 5)
NUMBER OF VIBRATIONS COIL AND CAPACITOR
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 COMPRESSION CONCENTRATION IGNITION TIMING SPARK PLUG
VOLTAGE OF FORCE OF AIR MIXTURE CABLE
ELECTRODE

High Large Large wear High Lean Retarded High resistance

Low Small Normal Low Rich Advanced Leak
.

ABNORMAL WAVEFORMS EXAMPLES

Example 1
• Wave characteristics
Spark line is high and short.
• Cause of problem
Spark plug gap is too large.

AKX00280

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

AKX00281

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16-34 ENGINE ELECTRICAL
IGNITION SYSTEM

Example 3
• Wave characteristics
Spark line is low and long, and is sloping. However,
there is almost no spark line distortion.
• Cause of problem
Spark plug gap is fouled.

AKX00282

Example 4
• Wave characteristics
Spark line is high and short.
Difficult to distinguish between this and abnormal wave
pattern example 1.
• Cause of problem
Spark plug cable is not properly connected. (Causing a
dual ignition)

AKX00283

Example 5
• Wave characteristics
No waves in wave damping section
• Cause of problem
Layer short in ignition coil.

AKX00284

IGNITION PRIMARY VOLTAGE WAVE PATTERN

CHECK USING A OSCILLOSCOPE
M1163004600019
.

MEASUREMENT METHOD
Required Special Tools:
MB991348: Test Harness Set
1. Disconnect the ignition power transistor connector and
connect the test harness set of the special tool (MB991348)
in between. All terminals should be connected.

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 ENGINE ELECTRICAL
IGNITION SYSTEM
16-35
2. When observing the number 1 − 4 cylinder group, connect
OSCILLOSCOPE
the primary pickup of the oscilloscope probe to ignition
power transistor side connector terminal (13).
1112 13 For the number 2 − 5 cylinder group, connect to terminal
(12) and for the number 3 − 6 cylinder group, connect to
terminal (11).
3. Ground the primary pickup ground terminal.
PRIMARY
PICKUP 4. Clamp the spark plug cable with the trigger pickup.
NOTE: Clamp the spark plug cable of cylinder number 1, 3
AKX00285 AB
or 5 which belongs to the same group as the cylinder to
which the primary pickup is connected.
NOTE: The wave pattern of any cylinder in the same group
appears from the left side of the screen.
.

STANDARD WAVE PATTERN

Observation conditions
FUNCTION SECONDARY
Pattern height High (or low)
Pattern selector Raster
Engine speed Curb idle speed

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16-36 ENGINE ELECTRICAL
IGNITION SYSTEM

(V)
ZENER
VOLTAGE
(POINT C)

SPARK LINE
(POINT A)
100
(APPROXIMATELY
40 × 10 V)

WAVE DAMEPING REDUCTION

SECTION (POINT B)

DWELL SECTION
PRIMARY
VOLTAGE
WAVE PATTERN
TIME
0

AKX00286 AB

Observation conditions (Only pattern selector below

changes from the above conditions.)
Pattern selector Display

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 ENGINE ELECTRICAL
IGNITION SYSTEM
16-37

NO.2 (OR NO.5)

CYLINDER
IGNITION NOISE

NO.1 (OR NO.4) NO.4 (OR NO.1) NO.6 (OR NO.3)

CYLINDER NO.3 (OR NO.6) CYLINDER CYLINDER
CYLINDER NO.5 (OR NO.2) IGNITION NOISE
IGNITION NOISE CYLINDER
IGNITION NOISE

NEUTRAL
SECTION

PRIMARY
IGNITION VOLTAGE
WAVE PATTERN
TIME

AKX00287 AB

WAVEFORM OBSERVATION POINTS

Point A:
The height, length and slope of the spark line (refer to
abnormal waveform examples 1, 2, 3 and 4) show the fol-
lowing trends.
SPARK LINE PLUG GAP CONDITION COMPRESSION CONCENTRATION OF IGNITION SPARK PLUG
OF FORCE AIR MIXTURE TIMING CABLE
ELECTRODE

Length Long Small Normal Low Rich Advanced Leak

Length Short Large Large wear High Lean Retarded High
resistance
Height High Large Large wear High Lean Retarded High
resistance
Height Low Small Normal Low Rich Advanced Leak
Slope Large Plug is − − − −
fouled

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16-38 ENGINE ELECTRICAL
IGNITION SYSTEM

Point B:
Number of vibration in reduction vibration section
(Refer to Abnormal Waveform Example 5)
NUMBER OF VIBRATIONS COIL, CAPACITOR
3 or higher Except above
Normal Abnormal

Point C:
Height of Zener voltage
HEIGHT OF ZENER PROBABLE CAUSE
VOLTAGE
High Problem in zener diode
Low Abnormal resistance in
primary coil circuit
.

ABNORMAL WAVEFORMS EXAMPLES

Example 1
• Wave characteristics
Spark line is high and short.
• Cause of problem
Spark plug gap is too large.

AKX00288

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

AKX00289

Example 3
• Wave characteristics
Spark line is low and long, and is sloping. However,
there is almost no spark line distortion.
• Cause of problem
Spark plug gap is fouled.

AKX00290

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 ENGINE ELECTRICAL
IGNITION SYSTEM
16-39
Example 4
• Wave characteristics
Spark line is high and short
• Cause of problem
Spark plug cable is not properly connected. (Causing a
dual ignition)

AKX00291

Example 5
• Wave characteristics
No waves in wave damping section
• Cause of problem
Layer short in ignition coil.

AKX00292

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16-40 ENGINE ELECTRICAL
IGNITION SYSTEM

IGNITION COIL
REMOVAL AND INSTALLATION
M1163004000307

Pre-removal and Post-installation Operation

• Air Cleaner Removal and Installation (Refer to GROUP
15, Air Cleaner P.15-7.)

4
25 ± 5 N·m
18 ± 4 ft-lb
10 ± 2 N·m
3 89 ± 17 in-lb

5 2 1

25 ± 5 N·m
18 ± 4 ft-lb

AC204093 AB

REMOVAL STEPS REMOVAL STEPS (Continued)

1. IGNITION COIL CONNECTOR • INTAKE MANIFOLD PLENUM
2. SPARK PLUG CABLE (REFER TO GROUP 15, INTAKE
CONNECTION MANIFOLD P.15-7.)
3. IGNITION COIL ASSEMBLY 4. SPARK PLUG CABLE
5. SPARK PLUG

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 ENGINE ELECTRICAL
IGNITION SYSTEM
16-41
CAMSHAFT POSITION SENSOR
REMOVAL AND INSTALLATION
M1163003400346

CAMSHAFT POSITION
SENSOR

11 ± 1 N·m
98 ± 8 in-lb

AC204096AB

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16-42 ENGINE ELECTRICAL
IGNITION SYSTEM

CRANKSHAFT POSITION SENSOR

REMOVAL AND INSTALLATION
M1163003500332

Pre-removal and Post-installation Operation

• Timing Belt Lower Cover Removal and Installation (Refer
to GROUP 11A, Timing Belt P.11A-33.)

10 ± 2 N·m
89 ± 17 in-lb

CRANKSHAFT POSITION
SENSOR

8.5 ± 0.5 N·m

76 ± 4 in-lb
AC204073 AB

KNOCK SENSOR
REMOVAL AND INSTALLATION
M1163002800341

Pre-removal and Post-installation Operation

• Intake Manifold Removal and Installation (Refer to
GROUP 15, Intake Manifold P.15-7.)

23 ± 2 N·m
17 ± 1 ft-lb

1
AC204095 AB

<<A>> >>A<< 1. KNOCK SENSOR

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 ENGINE ELECTRICAL
SPECIFICATIONS
16-43
Required Special Tool:
MD998773: Knock Sensor Wrench

REMOVAL SERVICE POINT

.

<<A>> KNOCK SENSOR REMOVAL

Use special tool MD998773 to remove the knock sensor.

MD998773

ACX02082AB

INSTALLATION SERVICE POINT

.

>>A<< KNOCK SENSOR INSTALLATION

Use special tool MD998773 to install the knock sensor.

SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
M1161002100465

ITEM SPECIFICATION
Charging system
Generator bolt 22 ± 4 N⋅m (16 ± 3 ft-lb)
Generator bolt 44 ± 10 N⋅m (33 ± 7 ft-lb)
Starting system
Starter bolt 30 ± 3 N⋅m (22 ± 2 ft-lb)
Ignition system
Camshaft position sensor bolt 11 ± 1 N⋅m (98 ± 8 in-lb)
Crankshaft position sensor bolt 8.5 ± 0.5 N⋅m (76 ± 4 in-lb)
Ignition coil bolt 10 ± 2 N⋅m (89 ± 17 in-lb)
Knock sensor 23 ± 2 N⋅m (17 ± 1 ft-lb)
Spark plug cable support bolt 10 ± 2 N⋅m (89 ± 17 in-lb)
Spark plug 25 ± 5 N⋅m (18 ± 4 ft-lb)

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16-44 ENGINE ELECTRICAL
SPECIFICATIONS

GENERAL SPECIFICATIONS
M1161000200217

ITEMS SPECIFICATIONS
Generator
Type Positive battery positive voltage sensing
Identification number A3TB2891
Part No. MD370480
Rated output V/A 12/100
Voltage regulator Electronic built-in type
Starter motor
Type Reduction drive with planetary gear
Identification number M0T20471
Part No. MD379687
Rated output kW/V 1.3/12
Voltage regulator 8
Ignition coil
Type Molded 3-coil
Spark plugs
NGK FR6S
DENSO SK20PR-A8
CHAMPION −

SERVICE SPECIFICATIONS
M1161000300247

ITEMS STANDARD VALUE LIMIT

Generator
Regulated voltage −20°C (−4°F) 14.2 − 15.4 −
(Ambient temperature at voltage
20°C (68°F) 13.9 − 14.9 −
regulator)
60°C (140°F) 13.4 − 14.6 −
80°C (176°F) 13.1 − 14.5 −
Generator output line voltage drop (at 30A) V − Maximum 0.3
Output current − 70% of normal output
current
Field coil resistance Ω Approximately 2 − 5 −
Brush protrusion length mm (in) − 2 (0.08)
Starter motor
Free running characteristics Terminal voltage 11 −
V
Current A 90 −
Speed r/min 2,500 or more −
Pinion gap mm (in) 0.5 − 2.0 (0.02 − 0.07) −
Commutator run-out mm (in) 0.05 (0.002) 0.1 (0.004)
Commutator diameter mm (in) 29.4 (1.16) Minimum 28.8 (1.13)

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 ENGINE ELECTRICAL
SPECIFICATIONS
16-45
ITEMS STANDARD VALUE LIMIT
Undercut depth mm (in) 0.5 (0.02) Minimum 0.2 (0.008)−
Ignition parts
Ignition coil resistance at 20°C (68°F9) Ω 8.5 − 11.5 −
Spark plug gap mm (in) 0.7 −0.8 (0.039 − 1.0 (0.039)
0.0313)
Resistor wire resistance kΩ − Maximum 19

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NOTES