2. Pulley 9. Plate 3. Rotor

FRONT BRACKET REMOVAL 1. Remove the bolts. 2. Insert a flat-lipped screwdriver between front bracket and stator core and pry downwards. Caution Do not insert a screwdriver too deep, as the stator coil will be damaged. <48> PULLEY REMOVAL With the pulley side facing up, hold the rotor in a vice and remove the pulley. Caution Use care not to damage the rotor. <4@> STATOR REMOVALIREGULATOR ASSEMBLY REMOVAL 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 rectifier from brush holder, unsolder two soldered points to rectifier. Caution 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 leads of diodes.16-14 ENGINE-ELECTRICAL — Charging System 1 ‘Z6EN0879 SENOG0s 3ENO208 REASSEMBLY SERVICE POINT -AFRONT BRACKET ASSEMBLY INSTALLATION 1. Insiall the regulator assembly, insert a wire into the rear bracket hole while pushing in the brush, and hold the brush. NOTE Inserting a wire holds the brush, so that the rotor can be replaced easily. 2. After rotor has been installed, remove the wire. INSPECTION ROTOR 1. Check rotor coil for continuity. Check that there is no continuity between slip rings. If resistance is too small, it means that there is a short circuit. If there is no continuity or if there is a short circuit, replace rotor assembly. Resistance value: Approx. 2 - 5 2 2. Check rotor coil for earthing. Check that there is no continuity between slip ring and core. If there is continuity, replace rotor assembly. STATOR 1. Make continuity test on stator coil. Check that there is continuity between coil leads. If there is no continuity, replace stator assembly.ENGINE ELECTRICAL - Charging System 16-15 2. Check coil for earthing. Check that there is no continuity between coil and core. If there is continuity, replace stator assembly. RECTIFIERS 1. Check for continuity between positive rectifier and stator coil lead connection terminal with an ohmmeter. If there is continuity in both directions, diode is shorted. Replace rectifier assembly. 2. Check for continuity between negative rectifier and stator coil lead connection terminal. If there is continuity in both directions, diode is shorted, and rectifier assembly must be replaced. 3. Check three diodes for continuity by connecting an ammeter to both ends of each diode. If there is no continuity in both directions, diode is faulty and heatsink assembly must be replaced. BRUSH 1. Replace the brush if its protrusion length is less than the limit. Limit: min. 2 mm ‘SENDTS16-16 ENGINE ELECTRICAL - Charging System 2. Unsolder pigtail and remove old brush and spring.ENGINE ELECTRICAL -— Starting System 16-17 STARTING SYSTEM GENERAL INFORMATION If the ignition switch is turned to the “START” position, current flows in the pull-in and holding provided inside magnetic switch, attracting the plunger. When the plunger is attracted, the lever connected to the plunger is actuated to engage the starter clutch. On the other hand, attracting the plunger will turn on the magnetic switch, allowing the B terminal SYSTEM DIAGRAM Ignition ‘switch STARTER MOTOR SPECIFICATIONS and M terminal to conduct. Thus, current flows to engage the starter motor. When the ignition switch is retumed to the "ON” position after starting the engine, the starter clutch is disengaged from the ring gear. An overrunning clutch is provided between the pinion and the armature shaft, to prevent damage ‘to the starter. Holding coil Plunger Putkin coil | ee aaa Pinion shaft Overunning clutch sence Items | 6G7 4M4 [Tyee Reduetion drive with planetary gear_| Reduction drive with planetary gear Rated output KW/V | t.2n2 [2.212 [ No. of pinion teeth is [10 SERVICE SPECIFICATIONS Ttems | Standard value [Limit Pinion gap mm | 06-2.0 = | Commutator outer diameter mm | 867 [294 288 ama [320 314 | Commutator runout mm [0.05 [04 Commutator undercut mm [os 0216-18 ENGINE ELECTRICAL -— Starting System STARTER MOTOR REMOVAL AND INSTALLATION Pre-removal and Post-installation Operation © Under Gover Removal and Installation © Transfer_Roll_ Stopper_Removal and_ Installation ‘© Actuator Assembly Removal and Installation <6G7> <4M4A/T> (Refer to GROUP 32 ~ Rear Engine (Refer to GROUP 26 — Differential Carrier.) Mounting.) ‘© No2 crossmember Removal and Installation <4M4> (Refer to GROUP 32 ~ Rear Engine Mounting.) <6G7> 7 a > 2 10 Nm soivoros <4M4> 5. 10N a 6 48. Nm Removal steps 1. Front engine mount heat protector 3. Starter cover (Refer to GROUP 32 — 4. Starter connector Engine Mounting.) 5. Battery cable 2, Transmission oil cooler tube “> 6. Starter assembly ee (Refer to GROUPENGINE ELECTRICAL -— Starting System 16-19 Switch — S| / ee Mi 50 Ge Battery| \ Wire 7ELO0ST Stopper Pinion gap Pinion 26eL003 REMOVAL SERVICE POINT <4M4> <4Ap STARTER ASSEMBLY REMOVAL Lower the transmission assembly far enough so that the starter mounting bolts can be removed. INSPECTION PINION GAP ADJUSTMENT 1. Disconnect wire from M-terminal of magnetic switch. 2. Connect a 12V battery between S-terminal and M+terminal 3. Set switch to “ON”, 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 5. If pinion gap is out of specification, adjust by adding or removing gaskets between magnetic switch and front bracket. reL0018 ZeL119 MAGNETIC SWITCH PULL-IN TEST 4. Disconnect wire from M-terminal of magnetic switch. , 2. Connect a 12V battery between S-terminal and © | M4erminal. ae | Caution This test must be performed quickly (in less than 10 seconds) to prevent coil from burning. 3. If pinion moves out, then pullin coil is good. If it doesn't, replace magnetic switch.16-20 ENGINE ELECTRICAL - Starting System "7eL0022 MAGNETIC SWITCH HOLD-IN TEST Disconnect wire from M-terminal of magnetic switch. Connect a 12V battery between S-terminal and body. Caution This test must be performed quickly (in less than 10 seconds) to prevent coil from burning. Manually pull out the pinion as far as the pinion stopper position. ifpinion remains out, everything is in order. If pinion moves in, holdin circuit is open. Replace magnetic switch. FREE RUNNING TEST 1. N 2 BAY Place starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to starter motor as follows: Connect a test ammeter (100-ampere scale) and carbon pile rheostat in series with battery positive post and starter motor terminal. Connect a voltmeter (15-volt scale) across starter motor. Rotate carbon pile to fullresistance position. ‘Connect battery cable from battery negative post to starter motor body. Adjust the rheostat until the battery voltage shown by the voltmeter is 11 V. Confirm that the maximum amperage is within the specifications and that the starter motor tums smoothly and freely. Current: max. 90 Amps. MAGNETIC SWITCH RETURN TEST 1 2. Disconnect wire from M-terminal of magnetic switch. Connect a 12V battery between M-terminal and body. Caution This test must be performed quickly (in less than 40 seconds) to prevent coil from buming. Pull pinion out and release. If pinion quickly retums 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 <6G7> \ censzze Disassembly steps 1. Screw 12. Packing A <<“ 2. Magnetic switch 13, Packing B 3. Screw 14. Pl 4. Screw 16, Planetary gear 5. Rear bracket 16. Lever 6. Brush holder PA 17. Snap ting 7. Brush PA 18. Stop ring 8. Rear bearing 49. Overrunning clutch <> . Armature 20. Intemal gear 10. Yoke assembly 21. Planetary gear holder <> 11. Ball 22. Front bracket16-22 <4M4> <<: <> ENGINE ELECTRICAL — Starting System 1 2. 3. 4 R ‘Screw <> 7. 8. 9. . Rear bracket 10. Brush holder assembly 11. Yoke assembly 12. Brush 18. Armature 14. Rear bearing auE0029 Cover Rubber packing A Rubber packing B Plate Ball Planetary gear Lever . Washer Internal gear . Overrunning clutch Front bracketENGINE ELECTRICAL —~ Starting System 16-23 Magnetic switch “S" terminal ‘Stop ring Socket Pinion gear verurning Armature. oe GENOS11 Snap ring Snap ring pliers Armature 6ENO612 DISASSEMBLY SERVICE POINTS <4Ap MAGNETIC SWITCH REMOVAL Disconnect field coil wire from “M” terminal of magnetic switch. <48> 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. SNAP RING/STOP RING REMOVAL <6G7> 1. Press stop ring off snap ring with a suitable socket. 2. Remove snap ring with snap ring pliers and then remove stop ring and overrunning clutch16-24 ENGINE ELECTRICAL - Starting System ___ Front Pinion ‘Magnet switch bracket Lever / 4Me0030 Pinion > 4meo031 <4Dp> PINION REMOVAL <4M4> Remove the pinion with power supplied to the starter and the pinion in its popped-out position. Caution 1. When power is supplied to the starter, the pinion pops out and rotates. Keep your hands away from the pinion at this time. The magnet switch may be extremely hot after inspection. Be careful not to touch it. Do not supply power to the pull-in coil P for more than 10 seconds. Do not supply power to the holding coil H for more than 30 seconds. If these time limits are exceeded, the coil(s) may overheat and burn out. The pinion must be popped out electrically by supplying power to the starter. Do not pop out the pinion by pulling the lever since the front bracket and lever may be damaged when the stopper ring is removed. When the starter is energized, current of more than 400A flows. Thus, heavy-dury cables (as thick as booster cables) must be used to connect the starter for inspection, and all connections must be securely tightened. Connect the starter as shown in the illustration. Here, A: Switch, B: Switch, C: Cable, M: Starter M terminal, S: Starter S terminal. NOTE The following procedure must be carried out with power supplied to the starter. Thus, the pinion must be removed within 30 seconds of turning ON the power. Supply power to the starter by tuming ON switches A and B. The pinion will pop out and rotate.ENGINE ELECTRICAL — Starting System 16-25 12vb0 Pinion Pinion 1iNg stopper Lj ae 4Mzo032 Yoke assembly 4Me0o33 3. NO op Within 5 seconds of the pinion’s rotation, turn OFF switch B to stop the pinion from rotating. Caution With switches A and B turned ON, power is supplied to both the pull-in coil P and holding coil H. No voltage is applied to starter terminal B, so current flows in the pull-in coil while the pinion is rotating. To prevent the pull-in coil from burning out, switch B must therefore be tured OFF within 5 seconds of the pinion’s rotation. Apply a suitable tubular tool to the pinion stopper. Lightly tap the tubular tool with a hammer to remove the stopper ring from the pinion stopper ring groove. Remove the stopper ring and pinion. Turn OFF switch A to cut the supply of power to the starter. Caution When the starter power is cut, the pinion may pop in, causing the stopper ring to go back into the ring groove. If this occurs, switch ON the starter power and repeat the procedure. <4» YOKE ASSEMBLY REMOVAL <4M4> 1. 2. 3. Pull the brush spring at point A and raise the brush. After raising the brush, hold it in place with the brush spring as shown in the illustration. Remove the yoke assembly. 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. Do not immerse drive unit in cleaning solvent. Overrunning clutch is pre-lubricated at the factory and solvent will wash lubrication from clutch. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.16-26 ENGINE ELECTRICAL — Starting System Snapring eno3is ring Ring groove ] Pinion stopper! Pinion {overrunning hut ame 0034 aMe0035 1EN0298 1ENO302 REASSEMBLY SERVICE POINTS PA 29.4 mm <4M4> 32.0 mm Limit: <6G7> 28.8 mm <4M4> 31.4 mmENGINE ELECTRICAL - Starting System 16-27 ‘Segment Undercut Mica 1EN0296 sens224 £no5a2 6ENOGO2 1ENO293 3. Check the undercut depth between segments. ‘Standard value: 0.5 mm Limit: 0.2 mm FIELD COIL OPEN-CIRCUIT TEST <4M4> Check the continuity between field brushes. If there is continuity, the field coil is in order. FIELD COIL, EARTH CHECK <4M4> Check the continuity between field coil brush and yoke. If there is no continuity, the field coil is free from earth. BRUSH HOLDER CHECK Check the continuity between brush holder plate and brush holder. If there is no continuity, the brush holder is in order. OVERRUNNING CLUTCH CHECK 1. While holding clutch housing, rotate the pinion. Drive pinion should rotate smoothly in one direction, but should Tot rotate in opposite direction. If clutch does not function 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, also inspect ring gear for wear or burrs.16-28 ENGINE ELECTRICAL — Starting System Wear limit fine 1ENO292 GENO6O1 i 1ENO299 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 AND SPRING REPLACEMENT 1. Brushes that are worn beyond wear limit line, or oilsoaked, should be replaced. 2. When replacing ground brush, slide the brush from brush holder by prying retaining spring back. ARMATURE TEST ARMATURE SHORT-CIRCUIT TEST 1. Place armature in a growler. 2. Holda 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. ARMATURE COIL OPEN-CIRCUIT INSPECTION Check the continuity between segments. If there is continuity, the coil is in order.ENGINE ELECTRICAL 16-29 IGNITION SYSTEM GENERAL INFORMATION The ignition system has three ignition coils (A, B and C) and three power transistors (A, B and C). Each ignition coil and power transistor supply current to each cylinder pair (the No. 3 and No. 6 cylinders, No. 1 and No. 4 cylinders, and No. 2 and No. 5 cylinder). When the primary current stops suddenly in the ignition coll A, high voltage appears in the secondary side of the coil. The high voltage ignites a cylinder pai But, whenever one cylinder is at the compression stroke, the other cylinder is at the compression stroke, the other cylinder is at the exhaust stroke. So fuel mixture bums only at the compression stroke side cylinder. In the same way, when the primary current stops suddenly in ignition coil B, the high voltage thus generated is applied to the spark plugs of the No. 1 and No. 4 cylinders, and when the primary current stops suddenly in ignition coil C, the high voltage thus generated is applied to the spark plugs of No. 2 and No. 5 cylinders. The engine-ECU controls the three ignition power transistors (A, B and C) to tum them alternately ON and OFF. This causes the primary currents in the ignition coils (A, B and C) to stop alternately and ignite the spark ‘plugs in the order 1 - 2 — 3-4-5-6. The engine-ECU determines which the ignition coils should be controlied by means of the signals from the camshatt position sensor which is incorporated in the crankshaft. It also detects the crankshaft position in order to ignite at the most appropriate timing in response to the engine operation conditions. When the engine is cold or operated at high altitudes, the ignition timing is slightly advanced for optimum performance. Power transistor unit iow ans 869) A Ine a pert sencar ‘on > “y Barone: pressure sensor Engine coolant wmparrare sons ‘ae positon swien open eet of Engine-ECU Comshat postion sensor Crank angle sensor ice spss snsor Ignition aeten ST Cylinder No. EN143516-30 ENGINE ELECTRICAL Ignition System IGNITION COIL SPECIFICATIONS Items | Specifications Type | Moulded 3-coil Identification No. | Fooo20, FC0021 SPARK PLUG SPECIFICATIONS Items | Vehicles with catalytic converter —_| Vehicles without catalytic converter NGK | PFRES-11 | BK6E | DENSO [ PKeOPR-Pit | K20P-U SERVICE SPECIFICATIONS IGNITION COIL tems | Standard value Primary coil resistance Q [0.74 -0.90 Secondary coil resistance _k2 [201-273 SPARK PLUG Item | Standard value | Limit Spark plug gap mm | Vehicies with catalytic converter 10-14 13 Vehicles without catalytic converter | 0.7-0.8 = RESISTIVE CORD Iter | Limit Resistance ka Max. 22 SPECIAL TOOL Too! | Number | Name Use | MB991348 |Testhamess set | Inspection of ignition primary voltage (power | transistor connection) | | | nooreee | | ON-VEHICLE SERVICE £3 IGNITION COIL CHECK FO) PRIMARY COIL RESISTANCE ra Measure the resistance between the terminals for each as cylinder (No.1 — No.4, No.2 - No.5, No.3 — No.6) of the ignition Y coil as shown in the illustration. Hq Standard value: 0.74 - 0.90 2 9eN0470ENGINE ELECTRICAL — Ignition System 16-31 ‘ SENOa7A ‘ ap GE su) 7EL 0087 7ELooge SECONDARY COIL RESISTANCE Measure the resistance between the high-voltage terminals for each cylinder (No.1 — No.4, No.2 — No.5, No.3 — No.6) of the ignition coil as shown in the illustration. Standard value: 20.1 — 27.3 kQ POWER TRANSISTOR CONTINUITY CHECK Check for continuity between the power transistor terminals. If the power transistor is defective, replace it. NOTE ‘An analog-type circuit tester should be used. No. 1 — No. 4 coil side Check the continuity between terminals (4) and (13). 1.5 V Voltage Terminal No. 3s | 4 13 Applied o——o 1 [o-oo | Not applied \ | No. 2 — No. 5 coil side Check the continuity between terminals (4) and (12). 1.5 V Voltage Terminal No. 2 | 12 Applied e—-e | Not applied | | | No. 3 - No. 6 coil side Check the continuity between terminals (4) and (11). 1.5 V Voltage Terminal No. 1 | 4 | WW Applied es a | Not applied i |16-32 ENGINE ELECTRICAL — ignition System 78.0096| Ge OS enn a RESISTIVE CORD CHECK Measure the resistance of the all spark plug cables. 4. Check cap and coating for cracks. 2. Measure resistance. Limit: Max. 22 kQ. SPARK PLUG CHECK 1. Remove the air intake plenum. 2. Remove the spark plug cables. Caution When pulling off the spark plug cable from the plug always hold the cable cap, not the cable. 3. Remove the spark plugs. 4. Check the plug gap and replace if the limit is exceeded. Standard value: 1.0—1.1 mm Limit: 1.3 mm Caution (1) Do not attempt to adjust the gap of the platinum plug. (2) Always use a plug cleaner and finish cleaning within 20 seconds. Do not use wire brushes. Otherwise, the platinum tip may be damaged. 5. Clean the engine plug holes. Caution Be careful not to allow foreign matter in cylinders. 6. Install the spark plugs.ENGINE ELECTRICAL — Ignition System 16-33 Plug gap gauge ‘+, Measurement rection Co rr ono182 SPARK PLUG CHECK AND CLEANING 1 7. Remove the spark plug cables. Caution When pulling off the spark plug cable from the plug always hold the cable cap, not the cable. Remove the spark plugs. Check for bumed out electrode or damaged insulator. Check for even buming. Remove carbon deposits with wire brush or plug cleaner. Remove sand from plug screw with compressed air. Use a plug gap gauge to check that the plug gap is within the standard value range. Standard value: 0.7 — 0.8 mm If the plug gap is not within the standard value range, adjust by bending the earth electrode. Clean the engine plug holes. Caution Be careful not to allow foreign matter in cylinders. Install the spark plugs. WAVEFORM CHECK USING AN ANALYZER Wa inition Primary and Secondary Voltage iveforms) Ignition Setondary Voltage Waveform Check MEASUREMENT METHOD is Clamp the secondary pickup around a spark plug cable. NOTE (1) The peak of the ignition voltage will be reversed when the spark plug cables of No.1, No.3, No.5 cylinders are clamped and when the spark plug cables of No.2, No.4 and No.6 cylinders are clamped. (2) Because of the two-cylinder simultaneous ignition system, the waves for two cylinder in each group appear during wave observation (No.1 cylinder — No.4 cylinder, No.2 cylinder — No.5 cylinder, No.3 — cylinder —No.6 cylinder). However, wave observation is carried out for the cylinder with the spark plug cable clamped by the secondary pickup. Clamp the spark plug cable with the Trigger pickup. NOTE (1) Clamp the spark plug cable for the No.1, No.3 or No.5 cylinder of the same group with the cylinder that is clamped with the secondary pickup. (2) It can be difficult to identify which cylinder waveform is displayed, but the waveform of the cylinder which is clamped with the secondary pickup will be stable, so this can be used as a reference for identification.16-34 ENGINE ELECTRICAL — Ignition System STANDARD WAVEFORM Observation Conditions FUNCTION L SECONDARY PATTERN HEIGHT [ HIGH (or LOW) PATTERN SELECTOR | RASTER | PATTERN SELECTOR _| RASTER ___ Engine Speed | Curb idle speed Wt ' ‘Spark line (point A) Ignition voltage | (GointD} r r j \ ; i Wave damping reduction section t (point | Dwell section Secondary | ignttos | oA voltage —_ waveform ™ Point [ Time verora7 Observation Condition (The only change from previous condition is the pattern selector.) PATTERN SELECTOR | DISPLAY Kv Nod eyinder finder NoZoylinder NoSoylinder| (Wavelorm is disturbed) No.6 cylinder No.t cylinder oO fionnoise ignition nose | © Wavelormisdisturbed) a se i Z No cylinder | ignition noise | fener voltage h Wao j Neutral section| me 7eLOV4sENGINE ELECTRICAL — ignition System 16-35 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 tine T 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 | Largewear | High Lean | Retarded High | | resistance [Height [High [Large | Largewear | High Lean Retarded High | | regetance | Low | Small Normal al Low Rich | Advanced | Leak | Slope Large | Plugis fouled | - i |= Point B: Number of vibration in reduction vibration section (Refer to abnormal waveform example 5) i [ 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 eee 5-6 or higher Normal Except above | Abnormat Point D: Ignition voltage height (distribution per each cylinder) shows the following trends. Ignition | Pluggap | Condition of | Compression | Concentration of | Ignition timing | Spark plug cable | voltage | | electrode | force | air mixture | t } t High [tage | Largewear | High [ bean | Retarded | High resistance | | Low [smatl__| Normal | Low | Rich | Advanced | Leak |16-36 EXAMPLES OF ABNORMAL WAVEFORMS ENGINE ELECTRICAL — Ignition System | sloping. | Also, the second half of the spark line “ | is distorted. This could be a result of | misfiring. ‘Abnormal waveform Wave characteristics Cause of problem Example 1 ‘Spark line is high and short. ‘Spark plug gap is too large. | _ | opoais | Example 2 | Spark line is low and long, and is | Spark plug gap is too small. owen Example 3 ‘Spark line is low and long, and is | Spark plug gap is fouled. sloping. However, there is almost no | — Hh Sorptowen a | Example 4 ‘Spark line is high and short. ‘Spark plug cable is nearly falling off. os Difficult to distinguish between this | (Causing a dual ignition) _ and abnormal waveform example 1 | ons Example 5 No waves in wave damping section. | Layer short in ignition coil ae tte |ENGINE ELECTRICAL ~ ignition System 16-37 Ignition Primary Voltage Waveform Check MEASUREMENT METHOD 1. Disconnect the power transistor connector and connect Tb one tor the special tool (harness connector: MB991348) in connector between. A 2. Connect the analyzer primary pickup to the power Primary transistor connector terminal 13 when observing the No. pickup 1 — No. 4 cylinder group, terminal 12 for the No. 2 - No. 5 cylinder group, and terminal 11 for the No. 3 - No. 6 cylinder group. 3. Connect the primary pickup earth terminal. 4. Clamp the spark plug cable with the trigger pickup. NOTE (1) Clamp the spark plug cable for No. 1, No. 3 and No. 5 cylinders of the same group with the cylinder that is connected to the primary pickup. (2) The wave-form of either cylinder in the same group will appear at the left edge of the screen. 7ELOI3 STANDARD WAVE-FORM Observation Conditions FUNCTION ‘SECONDARY PATTERN HEIGHT | HIGH (or Low) PATTERN SELECTOR RASTER Engine Speed | Curb idte speed ME 4 j j | Zener voltage | t fom) | | bp j 100 | (ora. 4101 Spark tne (point A) r | Wave damping reduction section i [| @ointB) Primary ignition voltage waveform 0) Time 7eLor4916-38 ENGINE ELECTRICAL - Ignition System Observation Conditions (Only pattem selector below changes from the above conditions.) PATTERNSELECTOR —_| DISPLAY om + No.1 (orNNo.4) No.3 (orNo.6) | No.4 (orNo.1) cylinder cylinder oylinder 100 F No.2 (orNo.5) ignition noise No.5(0rNo.2) No. 6 (or No.3) oylinder / gylinder cylinder ignition ignition noise ignition noise huise / / / Neral ston if Primary ignition / voltage waveform Time 7ELOISI 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 following trends. ‘Spark line Plug gap | Condition of | Compression | Concentration of | ignition timing ] High tension electrode —_| force | air mixture cable Length | tong | Small | Normal Low | Rich [Advanced | Leak Short | Large | Large wear | High | ean [Retarded | High | | resistance Height | High | Large | Largewear | High Lean [Retarded | High | | | resistance [tow [sma | Normal Low | Rich ‘Advanced —_| Leak ‘Slope Large Plugis fouled | — [= = = Point B: Number of vibration in reduction vibration section (Refer to abnormal waveform example 5) Number of vibrations Coil, condenser 3 or higher Normat Except above AbnormalENGINE ELECTRICAL - Ignition System 16-39 Point C: Height of Zener voltage Height of Zener voltage | Probable cause High Problem in Zener diode Low | Abnormal resistance in | primary coil circuit EXAMPLES OF ABNORMAL WAVEFORMS Also, the second half of the spark line is distorted. This could be a result of | misfiring. | sloping. ‘Abnormal waveform Wave characteristics | Cause of problem Example 1 | Spark line is high and shor. | ‘Spark plug gap is too large. | | | | 1 | | oe | | i— | | Example 2 ‘Spark line is low and long, and is | Spark plug gap is too small Example 3 | Spark line is low and long, and is | Spark plug gap is fouled. j sloping. However, there is almost no | | spark line distortion. | ie | — Example 4 | ‘Spark line is high and short. ‘Spark plug cable is nearly falling off. | (Causing a dual ignition)16-40 ENGINE ELECTRICAL — Ignition System ‘Abnormal waveform | Wave characteristics ] Cause of problem Example 5 No waves in wave damping section} Layer short in ignition coil | i CAMSHAFT POSITION SENSOR AND CRANKSHAFT ANGLE SENSOR <6G7> REMOVAL AND INSTALLATION Pre-removal and Postinstallation Operation Timing Bett Cover Removal and Installation (Refer to GROUP 11A — Timing Bet.) 40) = ( ‘Asewoose: Removal steps 1. Clip 2. Camshaft position sensor 3. Crankshaft angle sensorENGINE ELECTRICAL — Glow System 16-41 GLOW SYSTEM GENERAL INFORMATION SELF-REGULATING GLOW SYSTEM The self-regulating glow system reduces the time required for starting at low temperatures to provide a degree of starting and operation that is identical to petro-engine vehicles by preheating the glow plugs at super-quick speed. ‘The glow control unit controls both the time during which current is supplied to the glow plugs after the ignition switch is tuned to the ON position and. Glow plug relay | Engine coolant (ro —) also the glow indicator lamp illumination time in accordance with the engine coolant temperature. The resistances of the heating coils which are buitt into the glow plugs increase as the glow plug temperatures become higher. As a result of this, the flow of current gradually decreases, thus stabilizing the glow plug temperature at the specified temperature. Glow control unit —) =H Pre-heat indicator lamp Charge lamp S= ( Allemttor [Starter motdr ub— <2 Ignition switch DENO06216-42 ENGINE ELECTRICAL — Glow System SERVICE SPECIFICATIONS tem ‘Standard value Resistance between glow plug plate and glow plug body (parallel resistance for 4 glow plugs) (at 20 °C) 2 0.10 -0.15 Voltage between glow plugplate and glow plug body V Immediately after igni- | tion switch is turned to | ON (without starting | the engine) 911 (Drops to 0 V after 4—8 seconds have passed) ‘While engine is crank- ing 6 or more While engine is warm- ing up 42 ~ 15 (Drops to 0 V when the engine coolant ‘temperature increases to 60 °C or more or if 180 seconds have passed since the engine was started) Glow plug resistance (at 20 °C) Q | 04-06 SEALANT Item Specified sealant | Remark Engine coolant temperature sensor | 8M Nut Locking Part No.4171 or equivalent | Drying sealantENGINE ELECTRICAL — Glow System 16-43 ON-VEHICLE SERVICE SELF-REGULATING GLOW SYSTEM CHECK 1. 2. Check that the battery voltage is 11 - 13 V. Check that the engine coolant temperature is 40 °C or less. NOTE If the engine coolant temperature is too high, disconnect the engine coolant temperature sensor connector. Measure the resistance between the glow plug plate and the glow plug body (earth). Standard value: 0.10 - 0.15 © (at 20 °C) NOTE The resistance value is the parallel resistance value for the four glow plugs. Connect a voltmeter between the glow plug plate and the glow plug body (earth). Measure the voltage immediately after the ignition switch is turned to ON (without starting the engine). Standard value: 9 — 11 V (Drops to 0 V after 4 — 8 seconds have passed) In addition, check to be sure that the glow indicator lamp. (red) illuminates immediately after the ignition switch is tumed to ON. NOTE The time during which the voltage appears (energizing time) will depend on the engine coolant temperature. Measure the voltage while the engine is cranking, Standard value: 6 V or more Start the engine and measure the voltage while the engine is warming up. However, if the engine coolant temperature rises above 60 °C or when 180 seconds have passed since the engine was started, the voltage will always retum to 0 V. (Refer to the Glow Plug Energization Timing Chart) Standard value: 12 - 15 V16-44 ENGINE ELECTRICAL — Glow System Glow Plug Energization Timing Chart ‘START "anton ‘ON. ( th —n Glow ON indicatorlamp ore 1 Te. Glow plug ON 1 relay OFF ge 0 § Sem Ty Glow ncato am [ ‘Ts: Glow plug relay drive time aftr ignition switch is tumed Ts: Glow plug relay drive time afer engine stars (ater glow) eee NOTE After glow time Ts becomes ionger as the engine coolant temperature drops. GLOW & EGR CONTROL UNIT OR GLOW CONTROL UNIT CHECK Glow & EGR control unit Glow control unit ‘ ‘ Giow a EGR =D) 7 7 ‘control unit or Glow contol oO 0} > Oo 9 ae — | Trees a X6099AAENGINE ELECTRICAL — Glow System 16-45, 1. Measure the voltage at the control unit terminals. NOTE (1) Inspect with the control unit connector connected. (2) When measuring the voltage, connect the control unit terminal (26) (terminal (10) for vehicles without EGR) to the earth. Terminal Voltage Reference Table Inspection _| Inspection item | Inspection condition ‘Standard value terminal | | | 5 | Engine coolant ‘Ignition switch | Engine coolanttemperature:-20°C | 4.3-45V 13° temperature sensor “ON” “OFF” | (Engine coolant | | Engine coolant temperature: 0°C | 3.7~3.9V | temperature detec- | tion) | | Engine coolant temperature: 20°C | 2.8-3.0V | | | Engine coolant temperature: 40°C | 1.9-2.1V | | | [ Engine coolant temperature: 80°C | 05-07 V 12 | Ignition switch (power Ignition switch “OFF” > “START” 8 V or more a supply) | 14 Glow plug relay | Ignition switch “OFF” > “ON” 9-12 Tv (glow time control) —_|_ Engine coolant temperature: 40 °C or less 0-05V after | (Pre-giow function inspection) approx. 8 sec. | (when engine | | coolant tempera- | tureis20°C) | 7 | Glow indicator lamp Ignition switch “OFF” > “ON” O-1V s | Engine coolant temperature: 40 °C or less | 11-13 Vatter | | | approx. 1 sec (when engine | coolant tempera- | | | ture is 20 *C) 23 Alternator charaing _| Ignition switch “OFF” —> “ON" Ji-4v e | signal (L’terminal) | | Engine is iting | 11. V ormore 26,10 | Earth i {= *: indicates vehicles without EGR16-46 ENGINE ELECTRICAL — Glow System - Glow & EGR control unit hamess-side ‘connector as seen from the terminal side 1 feemToguCadpee 2 psesedeseepsboials 17]16115)14) DEMo026 “ Glow control unit hamess-side connector as seen from the terminal side 6(5[4>x{3/2/1 13/12/44/10/ 9 1817 DENO112 Bracket 2) A (cart) DENo253 ADENO2a2 2. Remove the control unit connector and check the continuity between the hamess-side connector terminals. Inspection Inspection item | Continuity terminal | (esistance value) 14-26 Glow plug relay | Continuity 7-10" (approx. 202) indicates vehicles without EGR GLOW PLUG RELAY CHECK 1. Check to be sure that there is continuity (approx. 20 2) between glow plug relay terminal (1) and the bracket (earth). 2. Use jumper cables to connect terminal (1) of the glow plug relay to the battery (+) terminal and the bracket to the battery (-) terminal Caution (1) Always be sure to disconnect the hamesses connected to glow plug relay terminals (2) and (3) before using the jumper cables. (2) The terminals of the disconnected hamesses must not be shorted to earth. (3) When connecting the jumper cables, be very careful not to make a mistake in connecting the terminals, as this will cause damage to the relay. 3. Check the continuity between glow plug relay terminals 2) and (3) while disconnecting and connecting the jumper cable at the battery (+) terminal Jumper cable at battery (+) | Continuity between terminals ‘terminal 2)-(@) Connected Continuity (0.01 © or less) Disconnected No continuity (infinite resistance)ENGINE ELECTRICAL — Giow System 16-47 a ‘Engine coclat temperature ‘gauge unit fengne coolant /-\ /temperature sensor) A2ov00s9| GLOW PLUG CHECK 1. 2. Remove the glow plug plate. Measure the resistance between the glow plug terminals and the body. Standard value: 0.4 - 0.6 © (at 20 °C) ENGINE COOLANT TEMPERATURE SENSOR CHECK 1. 2. Remove the engine coolant temperature sensor. While the sensor section of the engine coolant temperature sensor is immersed, measure the resistance between (B) terminal and the body. [Temperature "O)_—_—=di Resistance value (2) | 0 86 | 40 [15 | 80 03 | Atter applying specified sealant to the threaded portion, tighten to the specified torque. Specified sealant: 3M Nut Locking Part No. 4171 or equivalent Tightening torque: 39 Nm16-48 ENGINE ELECTRICAL — Glow System GLOW PLUG REMOVAL AND INSTALLATION Pre-removal and Postinstallation Operation itercooler and Installation (Relers GROUP 18) Removal steps 1. Connector connection 2. Glow plug plate <> 3. Glow plug ‘so1wo003 REMOVAL SERVICE POINT 44> GLOW PLUG REMOVAL Remove glow plug by hand after loosening with tool as its ceramic part is fragile. Caution Do not use a plug that has been dropped from a height of 10 cm or more. INSPECTION © Check for rust on glow plug plate. © Check glow plug for damage.