GENERAL ALTERNATOR

BATTERY

IGNITION SYSTEM
STARTING SYSTEM
STARTER
CHARGING SYSTEM STARTER RELAY
EE -2 ENGINE ELECTRICAL SYSTEM

GENERAL
GENERAL E12522AB

SPECIFICATION
IGNITION SYSTEM

Specification
Items
1.6 CVVT 1.4 DOHC
Primary resistance 0.7 ± 15 % ( ) 0.87 ± 10 % ( )
Ignition coil
Secondary resistance - 13.0 ± 15 % (k )
NGK BKR5ES-11 ←
Spark plugs CHAMPION RC10YC4 ←
Gap 1.0 ~ 1.1 mm

STARTING SYSTEM

Specification
Items
1.6 CVVT 1.4 DOHC
Rated voltage 12 V, 0.9 kW
No. of pinion teeth 8
Voltage 11.5 V
No-load
Ampere 35A, MAX
characteristics
Starter Speed 4,350 rpm, MIN
Commutator
Standard 29.3 ~ 29.4 mm (1.1535 ~1.1575in.)
diameter
Standard 0.4 ~ 1.0 mm (0.0157 ~ 0.0394in.)
Under cut depth
Limit 0.2 mm (0.0079in.)
GENERAL EE -3

CHARGING SYSTEM

Specification
Items
1.6 CVVT 1.4 DOHC
Type Battery voltage sensing
Rate voltage 13.5 V, 90A
Speed in use 1,000 ~ 18,000 rpm
Alternator
Voltage regulator Electronic built-in type
Regulator setting voltage 14.55 ± 0.2 V
Temperature compensation -7 ± 3 mV / C
Type MF 55AH MF 45AH
Cold cranking amperage
500 A 410 A
Battery [at -18 C(-0.4 F)]
Reserve capacity 85 min 80 min
Specific gravity [at 20 C(68 F)] 1.280 ± 0.01 1.280 ± 0.01

CAUTION
• COLD CRANKING AMPERAGE is the amper-
age a battery can deliver for 30 seconds and
maintain a terminal voltage of 7.2V or greater
at a specified temperature.
• RESERVE CAPACITY RATING is amount of
time a battery can deliver 25A and main-
tain a minimum terminal voltage of 10.5V at
26.7 C(80.1 F).
EE -4 ENGINE ELECTRICAL SYSTEM

TROUBLESHOOTING EF5DCBCE

IGNITION SYSTEM

Symptom Suspect area Remedy

Engine will not start or is hard Ignition lock switch Inspect ignition lock switch, or
to start (Cranks OK) replace as required
Ignition coil Inspect ignition coil, or replace as required
Spark plugs Inspect spark plugs, or replace
as required
Ignition wiring disconnected or broken Repair wiring, or replace as required
Spark plugs cable Inspect cable, or replace as required
Rough idle or stalls Ignition wiring Repair wiring, or replace as required
Ignition coil Inspect ignition coil, or replace as required
Spark plugs cable Inspect cable, or replace as required
Engine hesitates / poor Spark plugs and spark plug cables Inspect spark plugs / cable, or
acceleration replace as required
Ignition wiring Repair wiring, or replace as required
Poor mileage Spark plugs and spark plug cables Inspect spark plugs / cable, or
replace as required

CHARGING SYSTEM

Symptom Suspect area Remedy

Charging warning indicator does Fuse blown Check fuses
not light with ignition switch Light burned out Replace light
"ON" and engine off. Wiring connection loose Tighten loose connection
Electronic voltage regulator Replace voltage regulator
Charging warning indicator Drive belt loose or worn Adjust belt tension or replace belt
does not go out with engine Battery cable loose, corroded or worn Inspect cable connection, repair
running. (Battery requires or replace cable
frequent recharging) Electronic voltage regulator or Replace voltage regulator or alternator
alternator
Wiring Repair or replace wiring
Overcharge Electronic voltage regulator Replace voltage regulator
Voltage sensing wire Repair or replace wiring
Discharge Drive belt loose or worn Adjust belt tension or replace belt
Wiring connection loose or Inspect wiring connection, repair
short circuit or replace wiring
Electronic voltage regulator or Replace voltage regulator or alternator
alternator
Poor grounding Inspect ground or repair
Worn battery Replace battery
GENERAL EE -5

STARTING SYSTEM

Symptom Suspect area Remedy

Engine will not crank Battery charge low Charge or replace battery
Battery cables loose, corroded Repair or replace cables
or worn out
Transaxle range switch (Vehicle with Refer to TR group-automatic transaxle
automatic transaxle only)
Fuse blown Replace fuse
Starter motor faulty Replace
Ignition switch faulty Replace
Engine cranks slowly Battery charge low Charge or replace battery
Battery cables loose, corroded Repair or replace cables
or worn out
Starter motor faulty Replace
Starter keeps running Starter motor Replace
Ignition switch Replace
Starter spins but engine will Short in wiring Repair wiring
not crank Pinion gear teeth broken or starter motor Replace
Ring gear teeth broken Replace fly wheel or torque converter
EE -6 ENGINE ELECTRICAL SYSTEM

IGNITION SYSTEM 4. Install the spark plug to the spark plug cable.
(1.4 DOHC)

DESCRITION E9724F12 5. Install the spark plug to the ignition coil. (1.6 CVVT)

Ignition timing is controlled by the electronic control ignition 6. Ground the spark plug to the engine.
timing system. The standard reference ignition timing data
for the engine operating conditions are pre-programmed in
the memory of the ECM (Engine Control Module).

The engine operating conditions (speed, load, warm-up

condition, etc.) are detected by the various sensors.
Based on these sensor signals and the ignition timing
data, signals to interrupt the primary current are sent
to the ECM. The ignition coil is activated, and timing is
controlled.

ON-VEHICLE INSPECTION E4F36345

SPARK TEST
ABGE001A
1. Remove the spark plug cable. (1.4 DOHC)
7. Check is spark occurs while engine is being cranked.

NOTE
To prevent fuel being injected from injectors while the
engine is being cranked, remove the fuel pump(A) re-
lay from the fuse box.
Crank the engine for no more than 5 ~ 10 seconds.

ACGE002A A

2. Remove the ignition coil. (1.6 CVVT)

ABJF010A

8. Inspect all the spark plugs.

9. Using a spark plug socket, install the spark plug.

10. Install the spark plug cable. (1.4 DOHC)

11. Install the ignition coil. (1.6 CVVT)

ADGE021A

3. Using a spark plug socket, remove the spark plug.

IGNITION SYSTEM EE -7

LBJF001A
EE -8 ENGINE ELECTRICAL SYSTEM

INSPECT SPARK PLUG

1. Remove the spark plug cable. (1.4 DOHC)

NOTE
When removing the spark plug cable, pull on the spark
plug cable boot (not the cable), as it may be damaged.

A
B

ABGE003A

3. Using a spark plug socket, remove the spark plug.

CAUTION
Be careful that no contaminates enter through the
spark plug holes.

ACGE002A 4. Inspect the electrodes (A) and ceramic insulator (B).

2. Remove the ignition coil with bolt. (1.6 CVVT)

A B

EBKD002K

ADGE021A INSPECTION OF ELECTRODES

NOTE Condition Dark deposits White deposits

When removing the ignition coil connector, pull the
lock pin(A) and push the clip(B). - Fuel mixture
too lean
- Fuel mixture - Advanced
Description
too rich ignition timing
- Low air intake - Insufficient
plug tightening
torque
IGNITION SYSTEM EE -9

5. Check the electrode gap (A). INSPECT SPARK PLUG CABLE (1.4 DOHC)

Standard : 1.0 ~ 1.1 mm (0.0394 ~ 0.0433 in.) 1. Carefully remove the spark plug cable by pulling on
the rubber boots (A).
Check the condition of the spark plug cable terminals
(B), if any terminal is corroded, cleans it, and if it bro-
ken or distorted, replace the spark plug cable.

A
(A)
B

EBKD002L

ABGE009A

2. Connect the ohmmeter probes and measure resis-

tance.

RESISTANCE : 5.6kΩ /m ± 20%

EBKD002P

3. Resistance should not be higher than 10kΩ /m.

If resistance is higher, replace the cable.
EE -10 ENGINE ELECTRICAL SYSTEM

INSPECT IGNITION COIL (1.4 DOHC) INSPECT IGNITION COIL (1.6 CVVT)

1. Measure the primary coil resistance between termi- 1. Measure the primary coil resistance between termi-
nals (+) and (-). nals (+) and (-).

(-) (+)
No. 1 and 4
ignition coils
No. 2 and 3
ignition coils

LBJF002A ABGE004A

Standard value: 0.87Ω ± 10% Standard value: 0.7Ω ± 15%

2. Measure the secondary coil resistance between the

high-voltage terminals for the No.1 and No. 4 cylin-
ders, and between the high voltage terminals for the
No. 2 and No. 3 cylinders.

Standard value: 13.0kΩ ± 15%

CAUTION
Be sure, when measuring the resistance of the
secondary coil, to disconnect the connector of
the ignition coil.

EBKD002C
IGNITION SYSTEM EE -11

REPLACEMENT E0AFE6B4 IGNITION COIL (1.6 CVVT)

IGNITION COIL (1.4 DOHC) 1. Remove the engine cover.

1. Remove the engine cover. 2. Remove the ignition coil with bolt.

2. Disconnect the spark plug cables and the ignition coil

connector.

ADGE021A

NOTE
ACGE002A
When removing the ignition coil connector, pull the
3. Remove the ignition coil (A). lock pin(A) and push the clip(B).

A
B

EBKD003A ABGE003A

4. Installation is the reverse of removal. 3. Installation is the reverse of removal.

EE -12 ENGINE ELECTRICAL SYSTEM

CHARGING SYSTEM ON-VEHICLE INPECTION E0EDEC50

CAUTION
DESCRIPTION E024309A
• Check that the battery cables are connected
The charging system included a battery, an alternator with to the correct terminals.
a built-in regulator, and the charging indicator light and • Disconnect the battery cables when the bat-
wire. tery is given a quick charge.
The Alternator has eight built-in diodes, each rectifying AC • Never disconnect the battery while the engine
current to DC current. is running.
Therefore, DC current appears at alternator "B" terminal.
In addition, the charging voltage of this alternator is regu- CHECK BATTERY VOLTAGE
lated by the battery voltage detection system.
1. If 20 minutes have not passed since the engine was
The alternator is regulated by the battery voltage detec-
stopped, turn the ignition switch ON and turn on the
tion system. The main components of the alternator are
electrical system (headlamp, blower motor, rear de-
the rotor, stator, rectifier, capacitor brushes, bearings and
fogger etc.) for 60 seconds to remove the surface
V-ribbed belt pulley. The brush holder contains a built-in
charge.
electronic voltage regulator.
2. Turn the ignition switch OFF and turn off the electrical
systems.

3. Measure the battery voltage between the negative (-)

and positive (+) terminals of the battery.

Standard voltage : 12.5 ~ 12.9V at 20 C(68 F)

If the voltage is less than specification, charge the

battery.

CHECK THE BATTERY TERMINALS AND FUSES

1. Check that the battery terminals are not loose or cor-

roded.
LBJF003A
2. Check the fuses for continuity.
CHARGING SYSTEM EE -13

INSPECT DRIVE BELT NOTE

1. Visually check the belt for excessive wear, frayed - "New belt" refers to a belt which has been used
cords etc. less than 5 minutes on a running engine.
If any defect has been found, replace the drive belt. - "Used belt" refers to a belt which has been used
on a running engine for 5 minutes or more.
NOTE - After installing a belt, check that it fits properly in
the ribbed grooves.
Cracks on the rib side of a belt are considered accept- - Check with your hand to confirm that the belt has
able. If the belt has chunks missing from the ribs, it not slipped out of the groove on the bottom of the
should be replaced. pulley.
- After installing a new belt, run the engine for
about 5 minutes and recheck the belt tension.

VISUALLY CHECK ALTERNATOR WIRING AND

LISTEN FOR ABNORMAL NOISES

1. Check that the wiring is in good condition.

2. Check that there is no abnormal noise from the alter-

nator while the engine is running.

CHECK DISCHARGE WARNING LIGHT CIRCUIT

1. Warm up the engine and then turn it off.

2. Turn off all accessories.

EBKD004B
3. Turn the ignition switch "ON". Check that the dis-
2. Measure the drive belt tension and adjust it. charge warning light is lit.
Apply a force of 98N (10kg, 22lb), and measure the
deflection between the alternator and the water pump 4. Start the engine. Check that the light is lit.
pulley. If the light does not go off as specified, troubleshoot
the discharge light circuit.
DEFLECTION

3.3 ~ 3.7mm
New belt
(0.1299 ~ 0.1457in.)
4.2 ~ 4.7mm
Used belt
(0.1654 ~ 0.1850in.)

If the belt tension is not as specified, adjust it.

10kg

ABJF002A
EE -14 ENGINE ELECTRICAL SYSTEM

INSPECT CHARGING SYSTEM RESULT

VOLTAGE DROP TEST OF ALTERNATOR OUTPUT 1. The voltmeter may indicate the standard value.
WIRE
Standard value: 0.2V max
This test determines whether or not the wiring between the
alternator "B" terminal and the battery (+) terminal is good
by the voltage drop method. 2. If the value of the voltmeter is higher than expected
(above 0.2V max.), poor wiring is suspected. In this
PREPARATION case check the wiring from the alternator "B" terminal
to the battery (+) terminal. Check for loose connec-
1. Turn the ignition switch to "OFF".
tions, color change due to an over-heated harness,
2. Disconnect the output wire from the alternator "B" ter- etc. Correct them before testing again.
minal. Connect the (+) lead wire of ammeter to the
3. Upon completion of the test, set the engine speed at
"B" terminal of alternator and the (-) lead wire of am-
idle.
meter to the output wire. Connect the (+) lead wire of
Turn off the headlamps, blower motor and the ignition
voltmeter to the "B" terminal of alternator and the (-)
switch.
lead wire of voltmeter to the (+) terminal of battery.

Alternator

Ammeter

Voltmeter Battery

BBGE002A

TEST

1. Start the engine.

2. Turn on the headlamps and blower motor, and set the

engine speed until the ammeter indicates 20A.
And then, read the voltmeter at this time.
CHARGING SYSTEM EE -15

OUTPUT CURRENT TEST 8. Leave the engine hood open.

This test determines whether or not the alternator gives an

output current that is equivalent to the normal output. Ioad
Voltmeter Ammeter
PREPARATION

1. Prior to the test, check the following items and correct

as necessary. Check engine
Check the battery installed in the vehicle to ensure
that it is good condition. The battery checking method L
S or DUMMY
is described in the section "Battery".
The battery that is used to test the output current
should be one that has been partially discharged.
With a fully charged battery, the test may not be con-
ducted correctly due to an insufficient load.
Check the tension of the alternator drive belt. The
belt tension check method is described in the section EBKD013H

"Inspect drive belt".

TEST
2. Turn off the ignition switch.
1. Check to see that the voltmeter reads as the same
3. Disconnect the battery ground cable. value as the battery voltage. If the voltmeter reads 0V,
and the open circuit in the wire between alternator "B"
4. Disconnect the alternator output wire from the alter- terminal and battery (-) terminal or poor grounding is
nator "B" terminal. suspected.

5. Connect a DC ammeter (0 to 150A) in series between 2. Start the engine and turn on the headlamps.
the "B" terminal and the disconnected output wire. Be
sure to connect the (-) lead wire of the ammeter to the 3. Set the headlamps to high beam and the heater
disconnected output wire. blower switch to HIGH, quickly increase the engine
speed to 2,500 rpm and read the maximum output
current value indicated by the ammeter.
NOTE
Tighten each connection securely, as a heavy current NOTE
will flow. Do not rely on clips.
After the engine start up, the charging current quickly
6. Connect a voltmeter (0 to 20V) between the "B" termi- drops.
nal and ground. Connect the (+) lead wire to the alter- Therefore, the above operation must be done quickly
nator "B" terminal and (-) lead wire to a good ground. to read the maximum current value correctly.

7. Attach an engine tachometer and connect the battery

ground cable.
EE -16 ENGINE ELECTRICAL SYSTEM

RESULT REGULATED VOLTAGE TEST

1. The ammeter reading must be higher than the limit The purpose of this test is to check that the electronic volt-
value. If it is lower but the alternator output wire is in age regulator controls voltage correctly.
good condition, remove the alternator from the vehicle
and test it. PREPARATION

1. Prior to the test, check the following items and correct

Limit value (90A alternator): 63A min.
if necessary.
Check that the battery installed on the vehicle is fully
NOTE charged. The battery checking method is described
in the section "Battery".
• The nominal output current value is shown on the Check the alternator drive belt tension. The belt ten-
nameplate affixed to the alternator body. sion check method is described in the section "Inspect
• The output current value changes with the elec- drive belt".
trical load and the temperature of the alternator
itself. 2. Turn ignition switch to "OFF".
Therefore, the nominal output current may not be
obtained. If such is the case, keep the head- 3. Disconnect the battery ground cable.
lamps on the cause discharge of the battery, or
use the lights of another vehicle to increase the 4. Connect a digital voltmeter between the "B" terminal
electrical load. of the alternator and ground. Connect the (+) lead
The nominal output current may not be obtained if of the voltmeter to the "B" terminal of the alternator.
the temperature of the alternator itself or ambient Connect the (-) lead to good ground or the battery (-)
temperature is too high. terminal.
In such a case, reduce the temperature before
testing again. 5. Disconnect the alternator output wire from the alter-
nator "B" terminal.
2. Upon completion of the output current test, lower the
6. Connect a DC ammeter (0 to 150A) in series between
engine speed to idle and turn off the ignition switch.
the "B" terminal and the disconnected output wire.
3. Disconnect the battery ground cable. Connect the (-) lead wire of the ammeter to the dis-
connected output wire.
4. Remove the ammeter and voltmeter and the engine
tachometer. 7. Attach the engine tachometer and connect the battery
ground cable.
5. Connect the alternator output wire to the alternator
"B" terminal.
Ioad
6. Connect the battery ground cable. Voltmeter Ammeter

Check engine

L
S or DUMMY

EBKD013H
CHARGING SYSTEM EE -17

TEST ALTERNATOR
1. Turn on the ignition switch and check to see that the
voltmeter indicates the following value. REPLACEMENT EAFC6680

Voltage: Battery voltage 1. Disconnect the battery negative terminal first, then the
positive terminal.
If it reads 0V, there is an open circuit in the wire be- 2. Remove the drive belts.
tween the alternator "B" terminal and the battery and
the battery (-) terminal.

2. Start the engine. Keep all lights and accessories off.

3. Run the engine at a speed of about 2,500 rpm and

read the voltmeter when the alternator output current
drops to 10A or less

RESULT

1. If the voltmeter reading agrees with the value listed in

the regulating voltage table below, the voltage regula-
tor is functioning correctly. If the reading is other than
the standard value, the voltage regulator or the alter-
nator is faulty.
ACJF002A
REGULATING VOLTAGE TABLE
3. Disconnect the alternator connector (A), and remove
Voltage regulator ambient the cable (B) from alternator "B" terminal.
Regulating voltage (V)
temperature C ( F)
-20 (-4) 14.2 ~ 15.4
20 (68) 14.0 ~ 15.0 A
60 (140) 13.7 ~ 14.9
80 (176) 13.5 ~ 14.7

2. Upon completion of the test, reduce the engine speed

to idle, and turn off the ignition switch. B

3. Disconnect the battery ground cable.

4. Remove the voltmeter and ammeter and the engine

tachometer.

5. Connect the alternator output wire to the alternator

"B" terminal. ACGE014A

6. Connect the battery ground cable. 4. Remove the power steering pump. (Refer to ST group
- power steering pump)

5. Remove the power steering pump bracket.

EE -18 ENGINE ELECTRICAL SYSTEM

6. Remove the adjusting bolt (A) and mounting bolt (B),

then remove the alternator drive belt.

7. Pull out the through bolt (C) and then remove the al-
ternator (D).

D B

ABJF003A

8. Installation is the reverse order of removal.

9. Adjust the alternator belt tension after installation.

10. Install the power steering pump and adjust the power
steering belt tension. (Refer to ST group - power
steering pump)
CHARGING SYSTEM EE -19

COMPONENT E3F8E95F

LBGE008A
EE -20 ENGINE ELECTRICAL SYSTEM

DISASSEMBLY E43E1C51 4. Remove the nut, pulley(A) and spacer.

1. Remove the alternator cover(A) using a screw

driver(B).

B
A

EBKD301D

5. Loosen the 4 through bolts(A).

ABJF004A

2. Loosen the mounting bolts(A) and disconnect the A

brush holder assembly(B).

EBKD301E

6. Disconnect the rotor(A) and cover(B).

EBKD301B

3. Remove the slip ring guide(A). A

EBKD301G

7. Reassembly is the reverse of disassembly.

EBKD301C
CHARGING SYSTEM EE -21

INSPECTION EECF033F ALTERNATOR BELT INSPECTION AND

ADJUSTMENT
INSPECT ROTOR
NOTE
1. Check that there is continuity between the slip rings
When using a new belt, first adjust the deflection or
(A).
tension to the values for the new belt, then readjust
the deflection or tension to the value for the used belt
after running engine for five minutes.
A
DEFLECTION METHOD:

Apply a force of 98N (10kg, 22lb), and measure the de-

flection between the alternator and the water pump pulley.

Deflection
Used belt: 4.2 ~ 4.7 mm (0.1654 ~ 0.1850 in)
New belt: 3.3 ~ 3.7 mm (0.1299 ~ 0.1457 in)

C
B NOTE
If the belt is worn or damaged, replace it.
EBKD008A

2. Check that there is no continuity between the slip rings

and the rotor (B) or rotor shaft (C).
10kg
3. If the rotor fails either continuity check, replace the
alternator.
INSPECT STATOR

1. Check that there is continuity between each pair of

leads (A).

ABJF002A

EBKD008B

2. Check that there is no continuity between each lead

and the coil core.

3. If the coil fails either continuity check, replace the al-

ternator.
EE -22 ENGINE ELECTRICAL SYSTEM

BELT TENSION GAUGE METHOD: IF ADJUSTMENT IS NECESSARY:

Attach the belt tension gauge to the belt and measure the 1. Loosen adjusting bolt (A) and the lock bolt (B).
tension. Follow the gauge manufacturer’s instructions.
2. Move the alternator to obtain the proper belt tension,
Tension then retighten the nuts.
Used belt: 392.3 ~ 490.3N (40 ~ 50kg, 88.2 ~ 110.2lb)
New belt: 637.4 ~ 735.5N (65 ~ 75kg, 143.3 ~ 165.3lb)
A
NOTE
If the belt is worn or damaged, replace it. B

EBKD008E

3. Recheck the deflection or tension of the belt.

NOTE
For the power steering pump belt and A/C compressor
belt adjustments, refer to ST group - power steering
pump and HA group - air compressor.

EBKD008D
CHARGING SYSTEM EE -23

BATTERY

DESCRIPTION EFAA5B7B

1. The maintenance-free battery is, as the name implies,

totally maintenance free and has no removable bat-
tery cell caps.

2. Water never needs to be added to the maintenance-

free battery.

3. The battery is completely sealed, except for small vent

holes in the cover.

EBJD008A
EE -24 ENGINE ELECTRICAL SYSTEM

INSPECTION EFCD68F1

BATTERY DIAGNOSTIC TEST (1)

CHECKING FLOW

Step 1: Visual inspection Terminal & case of

Check for obvious damage such as a cracked or cover damage,
broken terminal and case or cover that could permit electrolyte leakage
leakage of electrolyte. Replace battery
Determine the cause of damage and correct as
needed.
Clean any corrosion with as solution of baking soda
and water.

OK

Step 2: Measure battery voltage Below 11.0V

Check the voltage after at least one day in case of Replace battery
recharging the battery, and the recharging should be
made in accordance with the charging instructions.
Above 12.5V
OK (11.0 ~ 12.4V) Charging system
inspection

Charge battery

Step 3: Load test Refer to load test

Perform an electrical load using the appropriate load Replace battery
test amperage specifications for the battery.

OK

Battery is good

BBGE007A
CHARGING SYSTEM EE -25

LOAD TEST BATTERY DIAGNOSTIC TEST (2)

1. Perform the following steps to complete the load test 1. Make sure the ignition switch and all accessories are
procedure for maintenance free batteries. in the OFF position.
2. Connect the load tester clamps to the terminals and
2. Disconnect the battery cables (negative first).
proceed with the test as follow:

1) If the battery has been on charge, remove the 3. Remove the battery from the vehicle.
surface charge by connect a 300ampere load for
15 seconds. CAUTION
2) Connect the voltmeter and apply the specified Care should be taken in the event the battery case
load. is cracked or leaking, to protect your skin from the
electrolyte.
3) Read the voltage after the load has been applied Heavy rubber gloves (not the household type)
for 15 seconds. should be wore when removing the battery.

4) Disconnect the load.

5) Compare the voltage reading with the minimum

and replace the battery if battery test voltage is
below that shown in the voltage table.

Voltage Temperature
9.6V 20 C (68.0 F) and above
9.5V 16 C (60.8 F)
9.4V 10 C (50.0 F)
9.3V 4 C (39.2 F)
9.1V -1 C (30.2 F)
8.9V -7 C (19.4 F) EBJD008B

8.7V -12 C (10.4 F)

4. Inspect the battery tray for damage caused by the loss
8.5V -18 C (-0.4 F) of electrolyte. If acid damage is present, it will be
necessary to clean the area with a solution of clean
warm water and baking soda. Scrub the area with a
NOTE stiff brush and wipe off with a cloth moistened with
- If the voltage is greater shown in the table, the baking soda and water.
battery is good.
- If the voltage is less than shown in the table, re- 5. Clean the top of the battery with the same solution as
place the battery. described above.

6. Inspect the battery case and cover for cracks. If

cracks are present, the battery must be replaced.

7. Clean the battery posts with a suitable battery post

tool.

8. Clean the inside surface of the terminal clamps with

a suitable battery cleaning tool. Replace damaged or
frayed cables and broken terminal clamps.

9. Install the battery in the vehicle.

10. Connect the cable terminals to the battery post, mak-

ing sure tops of the terminals are flush with the tops
of the posts.
EE -26 ENGINE ELECTRICAL SYSTEM

11. Tighten the terminal nuts securely.

12. Coat all connections with light mineral grease after

tightening.

CAUTION
When batteries are being charged, an explosive
gas forms beneath the cover of each cell. Do
not smoke near batteries being charged or which
have recently been charged. Do not break live cir-
cuit at the terminals of batteries being charged.
A spark will occur when the circuit is broken.
Keep open flames away form battery.

EBJD008A
STARTING SYSTEM EE -27

STARTING SYSTEM 2. With the shift lever in N or P (A/T) or clutch pedal

pressed (M/T), turn the ignition switch to "START"

DESCRIPTION E16E5DEF If the starter normally cranks the engine, starting sys-
tem is OK. If the starter will not crank the engine at
The starting system includes the battery, starter, solenoid all, go to next step.
switch, ignition switch, inhibitor switch (A/T), ignition lock
switch, connection wires and the battery cable. If it won’t disengage from the ring gear when you re-
When the ignition key is turned to the start position, current lease key, check for the following until you find the
flows and energizes the starter motor’s solenoid coil. cause.
The solenoid plunger and clutch shift lever are activated,
and the clutch pinion engages the ring gear. • Solenoid plunger and switch malfunction.
The contacts close and the starter motor cranks. In order • Dirty pinion gear or damaged overrunning clutch.
to prevent damage caused by excessive rotation of the
starter armature when the engine starts, the clutch pinion 3. Check the battery condition. Check electrical connec-
gear overruns. tions at the battery, battery negative cable connected
to the body, engine ground cables, and the starter for
looseness and corrosion. Then try starting the engine
again.

If the starter cranks normally the engine, repairing the

loose connection repaired the problem. The starting
system is now OK.
If the starter still does not crank the engine, go to next
step.

4. Disconnect the connector from the S-terminal of so-

lenoid. Connect a jumper wire from the B-terminal of
solenoid to the S-terminal of solenoid.

If the starter cranks the engine, go to next step.

LBHE003A If the starter still does not crank the engine, remove
the starter, and repair or replace as necessary.

STARTER CIRCUIT 5. Check the following items in the order listed until you
TROUBLESHOOTING E0F08581
find the open circuit.

• Check the wire and connectors between the

NOTE driver’s under-dash fuse/relay box and the igni-
The battery must be in good condition and fully tion switch, and between the driver’s under-dash
charged. fuse/relay box and the starter.
• Check the ignition switch (Refer to BE group -
1. Remove the fuel pump relay from the fuse box. ignition system)
• Check the transaxle range switch connector or
ignition lock switch connector.
• Inspect the starter relay.

ABJF010A
EE -28 ENGINE ELECTRICAL SYSTEM

STATER SOLENOID TEST FREE RUNNING TEST

1. Disconnect the field coil wire from the M-terminal of 1. Place the starter motor in a vise equipped with soft
solenoid switch. jaws and connect a fully-charged 12-volt battery to
starter motor as follows.
2. Connect a 12V battery between S-terminal and the
starter body. 2. Connect a test ammeter (100-ampere scale) and car-
bon pile rheostats shown is the illustration.

3. Connect a voltmeter (15-volt scale) across starter mo-

tor.

BBGE004A

3. Connect the field coil wire to the M-terminal.

BBGE005A
CAUTION
This test must be performed quickly (in less than 4. Rotate carbon pile to the off position.
10 seconds) to prevent the coil from burning.
5. Connect the battery cable from battery’ s negative
4. If the pinion moves out, the pull-in coil of solenoid is post to the starter motor body.
working properly.
If the pinion does not move, replace the solenoid. 6. Adjust until battery voltage shown on the voltmeter
reads 11volts.
5. Diconnect the field coil wire from the M-terminal.
7. Confirm that the maximum amperage is within
6. If the pinion has moved out, the hold-in coil of the the specifications and that the starter motor turns
solenoid is working properly. smoothly and freely.
If the pinion moves in, replace the solenoid.
Current : 35A max
Speed : 4350 rpm
STARTING SYSTEM EE -29

STARTER 4. Disconnect the starter cable (A) from the B terminal

(B) on the solenoid (C), then disconnect the connector
(D) from the S terminal (E).
REPLACEMENT E2F9D550

1. Disconnect the battery negative cable.

A B
2. Remove the air cleaner assembly. (Refer to EM- ) C

D
C E
B

ABGE024A

A
5. Remove the 2 bolts holding the starter, then remove
the starter.

6. Installation is the reverse of removal.

ACJF007A

7. Connect the battery negative cable to the battery.

B

ACJF008A

3. Remove the shift cable and bracket. (M/T)

ACJF025A
EE -30 ENGINE ELECTRICAL SYSTEM

COMPONENT EB04E4D2

8
10

9
7

6 15
1

16

5
3 4

14

13
2

12
11

1. Screw 9. Armature assembly

2. Front bracket assembly 10. Yoke assembly
3. Stop ring 11. Brush (-)
4. Stopper 12. Brush holder assembly
5. Overruning clutch assembly 13. Brush (+)
6. Lever 14. Rear bracket
7. Lever packing 15. Through bolt
8. Magnet switch assembly 16. Screw
LBJF004A
STARTING SYSTEM EE -31

DISASSEMBLY EEA12C44 4. Remove the rear bracket (A) and brush holder assem-
bly (B).
1. Disconnect the M-terminal (A) on the magnet switch
assembly (B).

A B

ABHE006A

ABHE003A
5. Remove the yoke (A) and armature (B).

2. After loosening the 2 screws (A), detach the magnet

switch assembly (B). B

ABHE007A

6. Remove the, lever plate (A) and packing (B).

ABHE004A

3. Loosen the brush holder mounting screw (A) and A

through bolts (B).

ABJF006A

ABHE005A
EE -32 ENGINE ELECTRICAL SYSTEM

7. Remove the overrunning clutch (A) and lever (B). 10. Remove the stopper (A), stop ring (B), overrunning
clutch (C) and armature (D).

B
A
ABHE009A
ABHE010A
8. Press the stop ring (A) using a socket (B).
11. Reassembly is the reverse of disassembly.

NOTE
Using a suitable pulling tool (A), pull the overrunning
clutch stop ring (B) over the stopper (C).
B

EBKD011K

9. After removing the stopper (A) using stopper pliers

(B). B

EBKD011O
A

EBKD011L
STARTING SYSTEM EE -33

INSPECTION E6B30AA7 5. Check the commutator diameter. If the diameter is

below the service limit, replace the armature.
ARMATURE INSPECTION AND TEST
Commutator diameter
1. Remove the starter. Standard (New) : 29.3 ~ 29.4 mm (1.1535 ~ 1.1575 in)
2. Disassemble the starter as shown at the beginning of
this procedure.

3. Inspect the armature for wear or damage from con-

tact with the permanent magnet. If there is wear or
damage, replace the armature.

EBKD012C

6. Measure the commutator (A) runout.

- If the commutator runout is within the service
limit, check the commutator for carbon dust or
brass chips between the segments.
ABHE011A - If the commutator run out is not within the service
limit, replace the armature.
4. Check the commutator (A) surface. If the surface is
dirty or burnt, resurface with emery cloth or a lathe Commutator runout
within the following specifications, or recondition with Standard (New): 0.02mm (0.0008in.) max
#500 or #600 sandpaper (B). Service limit: 0.05mm (0.0020in.)

B A

EBKD012B
EBKD012D
EE -34 ENGINE ELECTRICAL SYSTEM

7. Check the mica depth (A). If the mica is too high (B), 9. Check with an ohmmeter that no continuity exists be-
undercut the mica with a hacksaw blade to the proper tween the commutator (A) and armature coil core (B),
depth. Cut away all the mica (C) between the com- and between the commutator and armature shaft (C).
mutator segments. The undercut should not be too If continuity exists, replace the armature.
shallow, too narrow, or v-shaped (D).

Commutator mica depth

Standard (New) : 0.4 ~ 1.0 mm (0.0157 ~ 0.0394 in.)
Limit : 0.2mm (0.0079 in.)

D
B C

C A
B

A EBKD012G

EBKD012E

8. Check for continuity between the segments of the

commutator. If an open circuit exists between any
segments, replace the armature.

EBKD012F
STARTING SYSTEM EE -35

INSPECT STARTER BRUSH INSPECT OVERRUNNING CLUTCH

Brushes that are worm out, or oil-soaked, should be re- 1. Slide the overrunning clutch along the shaft.
placed. Replace it if does not slide smoothly.

2. Rotate the overrunning clutch both ways.

Does it lock in one direction and rotate smoothly in
reverse? If it does not lock in either direction of it locks
in both directions, replace it.

BBGE008A

NOTE
To seat new brushes, slip a strip of #500 or #600 sand-
paper, with the grit side up, between the commutator ABHE013A
and each brush, and smoothly rotate the armature.
The contact surface of the brushes will be sanded to 3. If the starter drive gear is worn or damaged, replace
the same contour as the commutator. the overrunning clutch assembly. (the gear is not
available separately).
STARTER BRUSH HOLDER TEST
Check the condition of the flywheel or torque con-
1. Check that there is no continuity between the (+) verter ring gear if the starter drive gear teeth are dam-
brush holder (A) and (-) brush holder (B). If there is aged.
no continuity, replace the brush holder assembly. CLEANING

1. Do not immerse parts in cleaning solvent. Immersing

the yoke assembly and/or armature will damage the
A C insulation. Wipe these parts with a cloth only.

2. Do not immerse the drive unit in cleaning solvent. The

overrun clutch is pre-lubricated at the factory and sol-
vent 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 cloth.
B

ABHE012A

NOTE
Use a pipe (C) of suitable size for the brushes not to
get removed from the brush holder.
EE -36 ENGINE ELECTRICAL SYSTEM

STARTER RELAY

INSPECTION E553B0B9

1. Remove the fuse box cover.

2. Remove the starter relay (A).

ABJF011A

3. Using an ohmmeter, check that there is continuity be-

tween each terminal.

Terminal Continuity
30 - 87 NO
85 - 86 YES

4. Apply 12V to terminal 85 and ground to terminal 86.

Check for continuity between terminals 30 and 87.

87 85
30 86

85 87
30 86

LDAD510B

5. If there is no continuity, replace the starter relay.

6. Install the starter relay.

7. Install the fuse box cover.