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DisassemblyEKS0031C
REAR COVER
PKIA0461E
1 Pulley 2 Front cover 3 Front bearing
4 Retainer 5 Rotor 6 Rear bearing
7 Stator 8 IC voltage regulator assembly 9 Diode assembly
10 Rear cover
Through-bolt & nut:
L R1110 -71 3
: 3.14 - 3.9 N·m(0.320 - 0.398 kg-m, 27.8 - 34.5 in-lb)
A3TB0771
: 3.5 - 5.3 N·m(0.36 - 0.54 kg-m, 31.0 - 46.9 in-lb)
Pulley mounting nut:
: 99 - 137 N·m(10.1 - 14.0 kg-m, 73.0 - 101.1 ft-lb)
SEL032Z
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CHARGING SYSTEM
CAUTION:
Rear cover may be hard to remove because a ring is used to lock outer race of rear bearing. To facili-
tate removal of rear cover, heat just bearing box section with a 200W soldering iron.
Do not use a heat gun, as it can damage diode assembly.
REAR BEARING
CAUTION:
lDo not reuse rear bearing after removal. Replace with a new one.
lDo not lubricate rear bearing outer race.
InspectionEKS0031D
ROTOR CHECK
1. Resistance test
lNot within the specified values... Replace rotor.
2. Insulator test
lContinuity exists... Replace rotor.
3. Check slip ring for wear.
lNot within the specified values... Replace rotor.
BRUSH CHECK
1. Check smooth movement of brush.
lNot smooth... Check brush holder and clean.
2. Check brush for wear.
lReplace brush if it is worn down to the limit line.
PULLEY CHECK(WITH CLUTCH TYPE)
1. Check for locking (Outer ring is turned counterclockwise when
viewed from the rear).
lIf it rotates in both directions... Replace pulley.
2. Check for dragging (Outer ring is turned clockwise when viewed
from the rear).
lIf it locks or unusual resistance is felt... Replace pulley. Resistance : Refer to SDS.SC-34,
"Alternator"
Slip ring minimum
outer diameter:Refer to SDS.SC-34,
"Alternator"SEL033Z
SEL631DA
PKIA0458E
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STATOR CHECK
1. Continuity test
lNo continuity... Replace stator.
2. Ground test
lContinuity exists... Replace stator.
AssemblyEKS0031E
RING FITTING IN REAR BEARING
lFix ring into groove in rear bearing so that it is as close to the
adjacent area as possible.
CAUTION:
Do not reuse rear bearing after removal.
REAR COVER INSTALLATION
1. Fit brush assembly, diode assembly, regulator assembly and
stator.
SEL108E
SEL109E
SEL044Z
SEL048Z
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CHARGING SYSTEM
2. Push brushes up with fingers and install them to rotor.
Take care not to damage slip ring sliding surface.
SEL049Z
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STARTING SYSTEM
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STARTING SYSTEMPFP:00011
System DescriptionEKS0031F
M/T MODELS
Power is supplied at all times
lthrough 30A fusible link (letter J, located in the fuse and fusible link box)
lto ignition switch terminal 1.
With the ignition switch in the ON or START position, power is supplied
lfrom ignition switch terminal 5
lto starter motor harness connector terminal 1.
The starter motor plunger closes and provides a closed circuit between the battery and starter motor. The
starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the
engine starts.
A/T MODELS
Power is supplied at all times
lthrough 30A fusible link (letter J, located in the fuse and fusible link box)
lto ignition switch terminal 1.
With the ignition switch in the ON or START position, power is supplied
lthrough 10A fuse [No,13 located in the fuse block (J/B)]
lto park/neutral position relay terminal 1.
With the selector lever in the P or N position, ground is supplied
lto park/neutral position relay terminal 2
lthrough the park neutral position switch terminals 1 and 2,and
lthrough body grounds, F9 and F10.
Then park/neutral position relay is energized and power is supplied
lfrom park/neutral position relay terminal 3
lto starter motor harness connector terminal 1.
The starter motor plunger closes and provides a closed circuit between the battery and starter motor. The
starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the
engine starts.
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Wiring Diagram — START —/M/T models
EKS0031G
TKWA0056E
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Wiring Diagram — START —/A/T modelsEKS0031H
TKWA0057E
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Trouble Diagnoses
EKS0031I
If any abnormality is found, immediately disconnect battery negative terminal.