Page 1697 of 3342

1. Engine Electrical
A: SPECIFICATIONS
1. EXCEPT 2200 cc MODEL
Item Designation
StarterType Reduction type
ModelMT
TN128000-8311AT
TN128000-8321
Manufacturer NIPPONDENSO TENNESSEE
Voltage and output 12 V — 1.0 kW 12 V — 1.4 kW
Direction of rotation Counterclockwise (when observed from pinion)
Number of pinion teeth 8 9
No-load
characteristicsVoltage 11 V
Current 90 A or less
Rotating
speed3,000 rpm or more 2,900 rpm or more
Load
characteristicsVoltage 8 V
Current 280 A or less 370 A or less
Torque 9.8 N⋅m (1.0 kg-m, 7.2 ft-lb) 13.7 N⋅m (1.4 kg-m, 10.1 ft-lb)
Rotating
speed900 rpm or more 880 rpm or more
Lock
characteristicsVoltage 5 V
Current 800 A or less 1,050 A or less
Torque 27.5 N⋅m (2.8 kg-m, 20.3 ft-lb) or more
GeneratorType Rotating-field three-phase type, Voltage regulator built-in type
Model LR185-701H
Manufacturer HITACHI AUTOMOTIVE PRODUCTS
Voltage and output 12 V — 85 A
Polarity on ground side Negative
Rotating direction Clockwise (when observed from pulley side)
Armature connection 3-phase Y-type
Output current1,500 rpm — 35 A or more
2,500 rpm — 62 A or more
5,000 rpm — 82 A or more
Regulated voltage 14.5
+0.3
0.4V [20°C (68°F)]
Ignition
coilModel F-569-01R
Manufacturer Diamond
Primary coil resistance 0.69Ω±10%
Secondary coil resistance 21.0 kΩ±15%
Insulation resistance between
primary terminal and caseMore than 10 MΩ
Spark
plugType and manufacturerRC10YC4 .......... CHAMPION
Alternate
(BKR6E-11 .......... NGK
K20PR-U11 .......... NIPPONDENSO)
Thread size mm 14, P = 1.25
Spark gap mm (in) 1.0 — 1.1 (0.039 — 0.043)
2
6-1SPECIFICATIONS AND SERVICE DATA
1. Engine Electrical
Page 1698 of 3342

2. 2200 cc MODEL
Item Designation
StarterType Reduction type
ModelMT
TN128000-8311AT
TN128000-8321
Manufacturer NIPPONDENSO TENNESSEE
Voltage and output 12 V—1.0 kW 12 V—1.4 kW
Direction of rotation Counterclockwise (when observed from pinion)
Number of pinion teeth 8 9
No-load
characteristicsVoltage 11 V
Current 90 A or less
Rotating
speed3,000 rpm or more 2,900 rpm or more
Load
characteristicsVoltage 8 V
Current 280 A or less 370 A or less
Torque 9.8 N⋅m (1.0 kg-m, 7.2 ft-lb) 13.7 N⋅m (1.4 kg-m, 10.1 ft-lb)
Rotating
speed900 rpm or more 880 rpm or more
Lock
characteristicsVoltage 5 V
Current 800 A or less 1,050 A or less
Torque 27.5 N⋅m (2.8 kg-m, 20.3 ft-lb) or more
GeneratorType Rotating-field three-phase type, Voltage regulator built-in type
Model LR185-701H
Manufacturer HITACHI AUTOMOTIVE PRODUCTS
Voltage and output 12 V—85 A
Polarity on ground side Negative
Rotating direction Clockwise (when observed from pulley side)
Armature connection 3-phase Y-type
Output current1,500 rpm—35 A or more
2,500 rpm—62 A or more
5,000 rpm—82 A or more
Regulated voltage 14.5
+0.3
0.4V [20°C (68°F)]
Ignition
coilModel FH0047-01R
Manufacturer DEMCO
Primary coil resistance 0.73Ω±10%
Secondary coil resistance 12.8 kΩ±15%
Insulation resistance between
primary terminal and caseMore than 10 MΩ
Spark
plugType and manufacturerRC10YC4 .......... CHAMPION
Alternate
(BKR6E-11 .......... NGK
K20PR-U11 .......... NIPPONDENSO)
Thread size mm 14, P = 1.25
Spark gap mm (in) 1.0—1.1 (0.039—0.043)
3
6-1SPECIFICATIONS AND SERVICE DATA
1. Engine Electrical
Page 1699 of 3342
1. Starter
1. MT: 128000-8311
B6M0412A
1Front ball bearing
2Armature
3Rear ball bearing
4O-ring
5Yoke
6Brush spring
7Brush holder
8End frame
9Screw & washer
10Cover
11Through bolt
12Screw & washer
13Starter housing
14Overrunning clutch
15Steel ball
16Spring
17Retainer
18Roller
19Idle gear
20Nut
21Spring washer
22Magnet switch
23Nut
4
6-1COMPONENT PARTS
1. Starter
Page 1700 of 3342
2. AT: 128000-8321
B6M0413A
1Front ball bearing
2Armature
3Rear ball bearing
4O-ring
5Yoke
6Brush spring
7Brush holder
8End frame
9Cover
10Screw & washer
11Through bolt
12Screw & washer
13Starter housing
14Overrunning clutch
15Steel ball
16Spring
17Retainer
18Roller
19Idle gear
20Nut
21Spring washer
22Magnet switch
23Nut
5
6-1COMPONENT PARTS
1. Starter
Page 1701 of 3342
2. Generator
B6M0414A
1Pulley nut
2Pulley
3Front cover ASSY
4Ball bearing
5Bearing retainer
6Screw
7Rotor
8Stator coil
9IC regulator ASSY
10Condenser
11Diode ASSY
12Bolt
13Bolt
14Brush holder ASSY
15Rear cover
16BAT. terminal
17Nut
18Bolt
19Through bolt
Tightening torque: N⋅m (kg-m, ft-lb)
T1: 3.1 — 4.4 (0.32 — 0.45, 2.3 — 3.3)
T2: 63.7 — 83.4 (6.5 — 8.5, 47.0 — 61.5)
6
6-1COMPONENT PARTS
2. Generator
Page 1702 of 3342
G6M0095
1. Starter
A: REMOVAL AND INSTALLATION
1) Disconnect battery ground cable.
G2M0309
2) Disconnect connector and terminal from starter.
3) Remove starter from transmission.
4) Installation is in the reverse order of removal.
Tightening torque:
50±4 N⋅m (5.1±0.4 kg-m, 36.9±2.9 ft-lb)
B: TEST
1. MAGNETIC SWITCH
CAUTION:
The following magnetic switch tests should be per-
formed with specified voltage applied.
Each test should be conducted within 3 to 5 sec-
onds. Power to be furnished should be one-half the
rated voltage.
B6M0415A
1) Pull-in test
Connect two battery negative leads onto magnetic switch
body and terminal C respectively. Then connect battery
positive lead onto terminal 50. Pinion should extend when
lead connections are made.
B6M0416A
2) Holding-in test
Disconnect lead from terminal C with pinion extended. Pin-
ion should be held in the extended position.
7
6-1SERVICE PROCEDURE
1. Starter
Page 1703 of 3342

B6M0417A
3) Return test
Connect two battery negative leads onto terminal 50 and
onto switch body respectively. Then connect battery posi-
tive lead onto terminal C. Next, disconnect lead from ter-
minal 50. Pinion should return immediately.
2. PERFORMANCE TEST
The starter is required to produce a large torque and high
rotating speed, but these starter characteristics vary with
the capacity of the battery. It is therefore important to use
a battery with the specified capacity whenever testing the
starter.
The starter should be checked for the following three items:
1. No-load test
Measure the maximum rotating speed and current under a
no-load state.
2. Load test
Measure the magnitude of current needed to generate the
specified torque and rotating speed.
3. Stall test
Measure the torque and current when the armature is
locked.
B6M0418A
1) No-load test
Run single starter under no-load state, and measure its
rotating speed, voltage, and current, using the specified
battery. Measured values must meet the following stan-
dards:
No-load test (Standard):
Voltage/Current
11 V/90 A, or more
Rotating speed
TN128000-8311: 3,000 rpm, or more
TN128000-8321: 3,350 rpm, or more
8
6-1SERVICE PROCEDURE
1. Starter
Page 1704 of 3342

B6M0419A
2) Load test (For reference)
Perform this test to check maximum output of starter. Use
test bench which is able to apply load (brake) to starter.
Measure torque value and rotating speed under the speci-
fied voltage and current conditions while controlling brak-
ing force applied to starter.
CAUTION:
Change engagement position of overrunning clutch
and make sure it is not slipping.
Load test (Standard):
TN128000-8311
Voltage/Load
8 V/9.8 N⋅m (1.0 kg-m, 7.2 ft-lb)
Current/Speed
280 A max./900 rpm min.
TN128000-8321
Voltage/Load
8 V/13.7 N⋅m (1.4 kg-m, 10.1 ft-lb)
Current/Speed
370 A, or less/880 rpm, or more
B6M0420A
3) Stall test
Using the same test equipment used for load test, apply
brake to lock starter armature. Then measure voltage,
current, and torque values.
Measured values must meet the following standard.
Stall test (Standard):
TN128000-8311
Voltage/Current
5 V/800 A, or less
Torque
27.5 N⋅m (2.8 kg-m, 20.3 ft-lb) min.
TN128000-8321
Voltage/Current
5 V/1,050 A, or less
Torque
27.5 N⋅m (2.8 kg-m, 20.3 ft-lb) min.
NOTE:
Low rotating speed or excessive current during no-load test
may be attributable to high rotating resistance of starter
due to improper assembling.
Small current and no torque during stall test may be attrib-
utable to excessive contact resistance between brush and
commutator; whereas, normal current and insufficient
torque may be attributable to shorted commutator or poor
insulation.
Starter can be considered normal if it passes no-load and
stall tests; therefore, load test may be omitted.
9
6-1SERVICE PROCEDURE
1. Starter