Page 1112 of 1254

ELECTRICAL 
SYSTEM
SECTION EL
When  you 
read  wiring 
diagrams:
o  Read 
Gl section,  "HOW 
TO READ  WIRING
DIAGRAMS''.
CONTENTS
STARTING  SYSTEM
STARTING  SYSTEM - 
Starter  - 
...
CHARGING  SYSTEM
CHARGING  SYSTEM* 
Alternator  -
COMBINATION  SWITCH ....
HEADLAMP  - 
Without  Daytime  Light System  and Dim-dip 
Lamp System
HEADLAMP  - 
Daytime  Light 
System  -
HEADLAMP  - 
Dim-dip  Lamp 
System  -
HEADLAMP  - 
Headlamp  Aiming 
Control
HEADLAMP
EXTERIOR  LAMP ............
tNTER|OR  1AMP ............
METER  AND 
GAUGES
WARNING  LAMPS AND BUZZER
WIPER  AND WASHER
HORN,  CIGARETTE  LIGHTER AND 
CLOCK
REAR  WINDOW  DEFOGGER EL- 
2
EL-  3
EL-  6
EL-  11
EL.  18
EL.20
EL-  28
EL-  30
EL-  J/
EL.  39
EL-  40
EL-  42
EL.  44
EL-  49
EL-  CI
EL-  64
EL.  OO
EL-  73
EL-  80
EL-  88
EL-  89
I::L-  J Z
EL-  95
EL-101
EL-  129
LOCATION 
OF ELECTRICAL  UNITS
HARNESS  LAYOUT ...,........
SUPER  MULTIPLE  JUNCTION  (S.M.J.) 
..........
URING  DIAGRAM  REFERENCE  CHART
ENGINE  ROOM FAN
LC S€CTION
E.C.C.S. EF & EC  SECTION
ANTFLOCK  BRAKING SYSTEM
A/T 
CONTROL AT SECTION
BR  SECTION
BF  SECNON
HA  SECNON
POWER 
WINDOU  POWER OOOB LOCK,
S€AT  BELT. 
SUN ROOF. 
OOOR MIRROB
HEATER  ANO AIB 
CONDITIONER HEATED 
SEAT. 
     
        
        Page 1140 of 1254

CHARGING 
SYSTEM
Troubleshooting
Before  conducting  an alternator 
test, make  sure that the 
battery  is fully  charged.  A 
3o-volt  voltmeter 
and
suitable  test probes 
are necessary 
for the  test.  The 
alternator  can be checked 
easily by relerring 
to the
Insoection  Table.
Betore  starting  troubleshooting, 
inspec,t the fusible  link.
WITH  IC REGULATOR
l/Vrrh.lt.rn.to. iid. L r.rm;nel
groundad,  Intcrnal 3ho7t occuri
whln  + 
diod.  ri 
3hoit-crrcurtod. |;;;;-l
I  burb 
Repl.ce 
I
I  end 
Proceed 
I
-  -l'."r-" 
I
\--6;;"*;l
,/ 
lRepleco.  I
)  F"-"r"" 
"c;:l
E."*;;I
-  -lo, 
a.c.c  I
-  F;"d"-l
--F*  _-l
-@
D-|;;;d'cnc'l
/ 
lR6elacs.  I
---l;*  __l
'SGe 
4l lor  grounding  F 
termrnel.
(H  ITACH  I
1)
2l Ur 
lully 
dr.n  d brtr.ty.
Light  : 
Cbrgt  wrming  light
A.C.G.  : 
Alt.nrator  p.rtr 
ax6pt  lC 
lrguhtot
IC.RG  : 
lC  r.!ul 
or
O.K.  : lC-rhrrtt.tor 
it in  good 
@ndhbn.
Wbn  r.aafiing 
"O.nrqad  A.C.G.", rar|oy!
allarnatc  tron 
r.lrida 
||td ditaaxmbla,  intpasr
|rrd  corrrct  or 
aapLc.  fasltY prn!.
'Mrthod  of ero{Ddirt  F 
t.rmin.l 
{HITACHI  mrkc
onlyl Make 
suro connodor
(S,  L) is 
connocted
3)
4) More 
than 15.5V
13  ro l5V
EL-29 
     
        
        Page 1141 of 1254
CHARGING 
SYSTEM _ 
Alternator  _
Removal  and lnstallation
SR2ODE  ENGINE
fq:  N 
m 
{Ko  m. tl-lb)
GA16DE  ENGINE pl 
ro :r t.6-p1 
12 i,,i
."-"'-E
Z|o!  as. so
(4.6  , 
6.1
33  - 
44)
r?)
--'-.! Q re-zr 
t1 
6  21  1p,i5t 
//
t)  Nm 
rr.tjm  a,b)
f) rz 
so (38 
s r 
27  37r  EEL0]3
EL-30 
     
        
        Page 1142 of 1254
CHARGING 
SYSTEM _ 
Alternator  _
Removal  and Installation  (Cont'd)
EL-31 
     
        
        Page 1143 of 1254
CHARGING 
SYSTEM - 
Alternator  -
Construction
SF2ODE  ENGINE  _ 
LR.19O-719
GA16DE  ENGINE _ 
LR-18G735
(n.eu'r6
,"d *>d0
@shM* (v\
".Y\ \. 
.'  .i,
,9
LII20[  ENGINE  - 
9120.335.000
@ Rear 
cover
O  Voltage 
regulator
f,Q  Brush
.9 
Pulley
O  stator
O  Diode 
plate 
assy.
EL.32
O 
Vacuum 
pump
O  Rotor
(D  Front  cover
@  Fan 
     
        
        Page 1144 of 1254

CHARGING 
SYSTEM - 
Alternator  -
Soldering  aron
{200W  capacirv, Disassembly
BEAR  COVER  REMOVAL
CAUTION: Rear  cover  may be hard  to remove  because  a ring  is used  to
lock  outer  race 
of rear  bearing.  To facilitate  removal of rear
cover,  heat 
iust bearing 
box section  with 
a 2oGwatt 
soldering
iron.
Do  not  use  a heat  gun, 
as it can  damage  diode assembly.
Rotor  Slip Ring 
Check
1.  Continuity  test
o  No 
continuity...  Replace rotor.
2.  Insulator 
test
.  Continuity 
exists ... Replace  rotor.
3.  Check  slip ring  for wear.
Slip  ring  minimum 
outer diameter:
Refer  to S.D.S.
Brush  Check
'L  Check  smooth  movement 
of brush.
.  Not 
smooth  ... 
Check  brush holder 
and clean.
2.  Check 
brush for 
wear.
o  Replace 
brush if 
it 
is  worn  down  to the  limit  line.
3.  Check 
brush lead 
wire for 
damage.
o  Damaged... 
Replace.
4.  Check  brush spring  pressure.
Measure  brush spring  pressure 
with brush  projected
approximately  2 mm  (0.08 
in) from 
brush  holder.
Spring  pressure:
Refer  to S.D.S.
o  Not 
within 
the specified  values ... Replace.
Ohmmeter
Erush  woar limiting 
line
2  mm  (0.O8 
in)
EL.33 
     
        
        Page 1145 of 1254
CHARGING 
SYSTEM - 
Alternator  -
Stator  Check
To  test  the stator 
or diode,  separate 
them by unsoldering 
the
connecting  wires.
CAUTION:
Use  only 
as much  heat 
as required 
to melt  solder.  Otherwise,
diodes  will 
be damaged 
by excessive  heat.
1  . 
Continuity  test
o  No 
continuity...  Replace stator.
2.  Ground  test
o  Continuity 
exists... Replace stator.
MAIN  DIODES
r  Use 
an ohmmeter 
to check 
condition  of 
diodes  as indicated
in  chart 
below.
o  lf 
any 
of the  test  results 
is not  satisfactory, 
replace diode
assembly.
Ohmmeter probes
Continuity
Positive  O
Negative 
O
Positive  diode plale
Diode terminals
Yes
Diode  lerminals Positive diode plate
No
Negalive  diode plate
Oiode terminals
No
Oiode  terminals
Negative 
diode plate
Yes
EL-34 
     
        
        Page 1146 of 1254
CHARGING 
SYSTEM - 
Altemator  -
Crolin  .nia|| ,Dod.l
Brurh litt 
rvira Stator 
Check  (Gont'd)
SUB-DIODES
o  Attach 
ohmmeter's  orobe to 
€ach  end of diode  to check  for
continuity.
o  Continuity 
is N.G.  ... Replace  diode 
assembly.
Assembly
Carefully  observe the following  instructions.
o  When 
soldering  each 
stator  coil lead  wire 
to diode  assem-
bly  terminal,  carry 
oul lhe  operation 
as fast 
as possible.
REAR  COVER  INSTALLATION
1.  Before  installing  front 
cover  with pulley 
and rotor  with rear
cover,  push 
brush  up with  lingers 
and retain 
brush  by
inserting  brush lift wire 
into brush  lift 
hole  lrom  outside.
2.  After  installing  front 
and rear 
sides  of 
alternator,  pull 
out
brush  lift wire.
EL€5