Page 3506 of 4555

PS-44
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
Steering WheelEGS0004P
Steering AngleEGS0004Q
Steering ColumnEGS0004R
Steering Outer Socket and Inner SocketEGS0004S
Steering wheel axial end play 0 mm (0 in)
Steering wheel play 0 - 35 mm (0 - 1.38 in)
Inner wheel
Degree minute (Decimal degree)Minimum 36° 00′ (36.0°)
Nominal 39° 00′ (39.0°)
Maximum 40° 00′ (40.0°)
Outer wheel
Degree minute (Decimal degree)31° 00′ (31.0°)
Steering column length “L” 405.3 mm (15.96 in)
SGIA0883E
Steering gear type PR24AD
Outer socketSwing torque 0.3 - 2.9 N·m (0.03 - 0.29 kg-m, 3.0 - 25 in-lb)
Measurement on spring balance
Measuring point: cotter pin hole of stud4.84 - 47.4 N (0.49 - 4.84 kg, 1.08 - 10.7 lb)
Rotating torque 0.3 - 2.9 N·m (0.03 - 0.29 kg-m, 3.0 - 25 in-lb)
Axial endplay 0.5 mm (0.02 in) or less
Inner socketSwing torque 1.0 - 7.8 N·m (0.10 - 0.80 kg-m, 9.0 - 69 in-lb)
Measurement on spring balance
Measuring point at* mark shown in the figure5.2 - 41 N (0.53 - 4.1 kg, 1.17 - 9.07 lb)
Axial endplay 0.2 mm (0.008 in) or less
Inner socket length “L” 169.67 mm (6.68 in)
SGIA0950E
Page 3961 of 4555

SC-1
STARTING & CHARGING SYSTEM
K ELECTRICAL
CONTENTS
C
D
E
F
G
H
I
J
L
M
SECTION SC
A
B
SC
STARTING & CHARGING SYSTEM
PRECAUTIONS .......................................................... 2
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 2
Wiring Diagrams and Trouble Diagnosis .................. 2
PREPARATION ........................................................... 3
Special Service Tools ............................................... 3
BATTERY .................................................................... 4
How to Handle Battery ............................................. 4
METHODS OF PREVENTING OVER-DIS-
CHARGE ............................................................... 4
CHECKING ELECTROLYTE LEVEL .................... 4
SPECIFIC GRAVITY CHECK ............................... 5
Battery Test and Charging Chart .............................. 6
CHART I ................................................................ 6
CHART II ............................................................... 7
A: SLOW CHARGE ............................................... 8
B: STANDARD CHARGE ...................................... 9
C: QUICK CHARGE ............................................. 11
Removal and Installation ........................................ 12
CHARGING SYSTEM ............................................... 13
System Description ................................................ 13
Wiring Diagram — CHARGE — /With Gasoline
Engine .................................................................... 14
Wiring Diagram — CHARGE — /With Diesel Engine ... 15
Trouble Diagnosis .................................................. 16
WITH IC REGULATOR ....................................... 16
MALFUNCTION INDICATOR .............................. 16
Removal and Installation ........................................ 17
REMOVAL (QR ENGINE MODELS) ................... 17
REMOVAL (YD ENGINE MODELS) ................... 17
ALTERNATOR PULLEY INSPECTION (QR ENGINE MODELS) ............................................. 17
INSTALLATION ................................................... 18
Disassembly and Assembly .................................... 19
DISASSEMBLY ................................................... 20
INSPECTION ...................................................... 21
ASSEMBLY ......................................................... 22
STARTING SYSTEM ................................................. 23
System Description ................................................. 23
M/T MODELS ...................................................... 23
A/T MODELS ....................................................... 23
Wiring Diagram — START — /M/T Models ............ 24
Wiring Diagram — START — /A/T Models ............. 25
Trouble Diagnosis ................................................... 26
Removal and Installation ........................................ 27
REMOVAL ........................................................... 27
INSTALLATION ................................................... 27
Disassembly and Assembly .................................... 28
QR ENGINE MODELS ........................................ 28
YD ENGINE MODELS ........................................ 30
Inspection ............................................................... 31
MAGNETIC SWITCH CHECK ............................. 31
PINION/CLUTCH CHECK ................................... 31
BRUSH CHECK .................................................. 31
YOKE CHECK ..................................................... 32
ARMATURE CHECK ........................................... 33
Assembly ................................................................ 34
PINION PROTRUSION LENGTH ADJUST-
MENT .................................................................. 34
SERVICE DATA AND SPECIFICATIONS (SDS) ...... 36
Battery .................................................................... 36
Starter ..................................................................... 36
Alternator ................................................................ 36
Page 3991 of 4555

STARTING SYSTEM
SC-31
C
D
E
F
G
H
I
J
L
MA
B
SC
InspectionEKS0031L
MAGNETIC SWITCH CHECK
Before starting to check, disconnect the battery cable from the negative terminal.
Disconnect “M” terminal of starter motor.
1. Continuity test (between “S” terminal and switch body).
No continuity... Replace.
2. Continuity test (between “S” terminal and “M” terminal).
No continuity... Replace.
PINION/CLUTCH CHECK
1. Inspect pinion teeth.
Replace pinion if teeth are worn or damaged. (Also check
condition of ring gear teeth.)
2. Inspect reduction gear teeth (If equipped).
Replace reduction gear if teeth are worn or damaged. (Also
check condition of armature shaft gear teeth.)
3. Check to see if pinion locks in one direction and rotates
smoothly in the opposite direction.
If it locks or rotates in both directions, or unusual resistance is
evident.... Replace.
BRUSH CHECK
Brush
Check wear of brush.
Excessive wear... Replace.
SKIB0458E
SKIB0459E
MEL139L
Wear limit length : Refer to SDS. SC-36, "Starter" .
SEL014Z
Page 3994 of 4555
SC-34
STARTING SYSTEM
5. Check depth of insulating mold from commutator surface.
Less than 0.2 mm (0.008 in)... Undercut to 0.5 to 0.8 mm
(0.020 to 0.031 in).
AssemblyEKS0031M
Apply high-temperature grease to lubricate the bearing, gears and frictional surface when assembling the
starter.
Carefully observe the following instructions.
PINION PROTRUSION LENGTH ADJUSTMENT
Clearance [QR Engine Models (M/T)]
With pinion driven out by magnetic switch, push pinion back to
remove slack and measure clearance “L” between the front edge of
the pinion and the pinion stopper.
Not in the specified value... Adjust by adjusting plate.
SEL022Z
Clearance “L” : Refer to SDS. SC-36, "Starter" .
SKIB0229E
SEL633BA
Page 3996 of 4555

SC-36
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)PFP:00030
BatteryEKS0031Q
StarterEKS0031R
AlternatorEKS0031S
Applied modelQR20, QR25 engine
YD22 engine
Except
for Northern EuropeFor Northern
Europe
Type 55D23L 80D23L 110D26L
Capacity [V - AH] 12-48 12-52 12-64
Applied modelQR20, QR25 engine
YD22 engine
A/T M/T
Ty p eS114-844 M0T87081 M8T71471
HITACHI make MITSUBISHI make
Reduction
System voltage [V] 12
No-loadTerminal voltage [V] 11.0
Current [A] Less than 90 Less than 90 Less than 145
Revolution [rpm] More than 2,700 More than 2,500 More than 3,300
Minimum diameter of commutator [mm (in)] 28.0 (1.102) 28.8 (1.134) 31.4 (1.236)
Minimum length of brush [mm (in)] 10.5 (0.413) 7.0 (0.276) 11.0 (0.433)
Brush spring tension [N (kg, lb)] 16.2 (1.65, 3.64)15.0 - 20.4
(1.5 - 2.1, 3.4 - 4.6)26.7 - 36.1
(2.7 - 3.7, 6.0 - 8.2)
Clearance between bearing metal and armature shaft [mm (in)] Less than 0.2 (0.008) —
Clearance “L” between pinion front edge and pinion
stopper[mm (in)] —0.5 - 2.0
(0.020 - 0.079)—
Movement “L” in height of pinion assembly [mm (in)]0.3 - 2.5
(0.012 - 0.098)—0.5 - 2.0
(0.020 - 0.079)
Applied model QR20, QR25 engine YD22 engine
Ty p eLR1110-713V A3TB0771
HITACHI make MITSUBISHI make
Nominal rating [V - A] 12-110 12-90
Ground polarityNegative
Minimum revolutions under no-load
(When 13.5 V is applied)[rpm] Less than 1,100 Less than 1,300
Hot output current (When 13.5 V is applied) [A/rpm](More than 35/1,300)
More than 70/1,800
More than 91/2,500
More than 110/5,000More than 29/1,300
More than 76/2,500
More than 88/5,000
Regulated output voltage [V] 14.1 - 14.7
Minimum length of brush [mm (in)] More than 6.0 (0.236) More than 5.0 (0.197)
Brush spring pressure [N (g, oz)]1.0 - 3.43
(102 - 350, 3.60 - 12.34)4.8 - 6.0
(490 - 610, 17.28 - 21.51)
Slip ring minimum diameter [mm (in)] More than 26.0 (1.024) More than 22.1 (0.870)
Rotor coil resistance at 20 °C (68 °F) [Ω] 2.16 - 2.46 2.1 - 2.5