SC-18
CHARGING SYSTEM
INSTALLATION
Installation is the reverse order of removal.
Install alternator, and check tension of belt. Refer to EM-13, "Tension Adjustment" (QR engine models) or
EM-140, "
Tension Adjustment" (YD engine models) in EM section.
CAUTION:
Be sure to tighten “B” terminal mounting nut carefully.
QR Engine Models
YD Engine Models
B terminal nut:
: 7.9 - 11.0 N·m (0.8 - 1.11 kg-m, 6.0 - 8.0 ft-lb)
Ground bolt:
: 2.3 - 2.6 N·m (0.23 - 0.27 kg-m, 20 - 23 in-lb)
Alternator mounting bolt:
: 59 - 69 N·m (6.1 - 7.1 kg-m, 45 - 51 ft-lb)
B terminal nut:
: 7.9 - 11.0 N·m (0.8 - 1.11 kg-m, 6.0 -8.0 ft-lb)
Ground bolt:
: 2.3 - 2.6 N·m (0.23 - 0.27 kg-m, 20 - 23 in-lb)
Alternator mounting bolt (upper side):
: 16 - 20 N·m (1.6 - 2.1 kg-m, 12 - 15 ft-lb)
Alternator mounting bolt (lower side):
: 38 - 50 N·m (3.8 - 5.1 kg-m, 28 - 36 ft-lb)
CHARGING SYSTEM
SC-21
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Front Cover (For LR1110-713V)
1. Set rotor to the vise.
CAUTION:
Be careful not to damage the rotor.
Use copper plate or thick cloth for rotor in the vise.
2. Remove pulley cap, using suitable tool.
3. Remove alternator pulley, using alternator pulley adaptor [SST].
INSPECTION
Rotor Check
1. Resistance test
Not within the specified values... Replace rotor.
2. Insulator test
Continuity exists... Replace rotor.
3. Check slip ring for wear.
Not within the specified values... Replace rotor.
Brush Check
1. Check smooth movement of brush.
Not smooth... Check brush holder and clean.
2. Check brush for wear.
Replace brush if it is worn down to the limit line.
SKIB0531E
PKIC1124E
Resistance : Refer to SDS. SC-36,
"Alternator" .
Slip ring minimum
outer diameter: Refer to SDS. SC-36,
"Alternator" .SKIB4525E
SKIB4526E
SC-22
CHARGING SYSTEM
Stator Check
1. Continuity test
No continuity... Replace stator.
2. Ground test
Continuity exists... Replace stator.
ASSEMBLY
Assembly is the reverse order of disassembly.
CAUTION:
Note the tightening torque shown, in the figure.
Rear Bearing
CAUTION:
Never reuse rear bearing. Replace with a new one.
Never lubricate rear bearing outer race.
Rear Cover Installation
1. Fit brush assembly, diode assembly, regulator assembly and
stator.
2. Push brushes up with fingers and install them to rotor.
Take care not to damage slip ring sliding surface.
SKIB4527E
SKIB4528E
SKIB4529E
SKIB4530E
STARTING SYSTEM
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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
SC-32
STARTING SYSTEM
Brush Spring Check
Check brush spring tension with brush spring detached from brush.
Not within the specified values... Replace.
Brush Holder
1. Perform insulation test between brush holder (positive side) and
its base (negative side).
Continuity exists.... Replace.
2. Check brush to see if it moves smoothly.
If brush holder is bent, replace it; if sliding surface is dirty,
clean.
YOKE CHECK
Magnet is secured to yoke by bonding agent. Check magnet to see
that it is secured to yoke and for any cracks. Replace malfunctioning
parts as an assembly.
CAUTION:
Never clamp yoke in a vice or strike it with a hammer.Spring tension
(with new brush): Refer to SDS. SC-36, "
Starter" .
SEL015Z
SEL016Z
SEL305H
STARTING SYSTEM
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ARMATURE CHECK
1. Continuity test (between two segments side by side).
No continuity... Replace.
2. Insulation test (between each commutator bar and shaft).
Continuity exists.... Replace.
3. Check commutator surface.
Rough... Sand lightly with No. 500 - 600 emery paper.
4. Check diameter of commutator.
Less than specified value... Replace.
SKIB0461E
SEL020Z
Commutator minimum
diameter: Refer to SDS. SC-36,
"Starter" .
SEL021Z
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
LT-2 LOW BEAM OPERATION (DAYTIME LIGHT
SYSTEM CANCEL OPERATION) ....................... 41
HIGH BEAM OPERATION/FLASH-TO-PASS
OPERATION ........................................................ 42
DAYTIME LIGHT SYSTEM OPERATION ............ 42
DRIVING LAMP OPERATION ............................. 42
XENON HEADLAMP ........................................... 43
Schematic ............................................................... 44
Wiring Diagram —DTRL— ..................................... 45
Trouble Diagnoses .................................................. 50
DAYTIME LIGHT CONTROL UNIT INSPECTION
TABLE ................................................................. 50
Bulb Replacement .................................................. 50
Aiming Adjustment .................................................. 50
Removal and Installation ........................................ 50
HEADLAMP (WITH DAYTIME) - CONVENTIONAL
TYPE - ....................................................................... 51
System Description ................................................. 51
DESCRIPTION .................................................... 51
LOW BEAM OPERATION (DAYTIME LIGHT
SYSTEM CANCEL OPERATION) ....................... 51
HIGH BEAM OPERATION/FLASH-TO-PASS
OPERATION ........................................................ 52
DAYTIME LIGHT SYSTEM OPERATION ............ 52
DRIVING LAMP OPERATION ............................. 52
Schematic ............................................................... 54
Wiring Diagram —DTRL— ..................................... 55
Trouble Diagnoses .................................................. 60
DAYTIME LIGHT CONTROL UNIT INSPECTION
TABLE ................................................................. 60
Bulb Replacement .................................................. 60
Aiming Adjustment .................................................. 60
Removal and Installation ........................................ 60
HEADLAMP AIMING CONTROL (MANUAL) ........... 61
Wiring Diagram — H/AIM — ................................... 61
Removal and Installation ........................................ 62
Switch Circuit Inspection ........................................ 62
HEADLAMP AIMING CONTROL (AUTO) ................ 63
Component Parts and Harness Connector Location ... 63
System Description ................................................. 63
OUTLINE ............................................................. 63
HEADLAMP AIMING CONTROL OPERATION ... 64
Schematic ............................................................... 65
Wiring Diagram — H/AIM — ................................... 66
LHD MODELS ..................................................... 66
Terminals and Reference Values of Daytime Light
Control Unit ............................................................. 68
Terminals and Reference Values for Height Sensor ... 68
How to Proceed With Trouble Diagnosis ................ 68
CONSULT-II Functions (HEADLAMP LEVELIZER) ... 69
CONSULT-II BASIC OPERATION ....................... 69
WORK SUPPORT ............................................... 70
DATA MONITOR .................................................. 70
ACTIVE TEST ..................................................... 71
SELF-DIAG RESULTS ........................................ 71
Check Aiming Control System ................................ 73
Symptom Chart ....................................................... 74
Headlamp Aiming Motor Does Not Operate (Both
Sides) ..................................................................... 74Headlamp Aiming Motor Does Not Operate (One
Side) ........................................................................ 77
DTC B2081 [INITIAL NOT DONE] .......................... 78
DTC B2082 [SENSOR OUT OF RANGE] ............... 79
DTC B2083 [SEN SIG NOT PLAUSIBLE] .............. 79
DTC B2084 [VOLTAGE UNDER LIMIT] .................. 80
DTC B2085 [LOW BEAM SIG OPEN LINE] ........... 81
DTC B2086 [FRQ. OVER LIMIT] ............................ 82
DTC B2087 [SHORT TO GROUND] ....................... 82
DTC B2088 [SHORT TO BATTERY] ...................... 84
Removal and Installation of Height Sensor ............. 86
REMOVAL ............................................................ 86
INSTALLATION .................................................... 86
TURN SIGNAL AND HAZARD WARNING LAMPS ... 87
System Description ................................................. 87
TURN SIGNAL OPERATION ............................... 87
HAZARD LAMP OPERATION ............................. 88
Wiring Diagram — TURN — ................................... 89
LHD MODELS ...................................................... 89
RHD MODELS ..................................................... 91
Trouble Diagnoses .................................................. 93
Electrical Components Inspection ........................... 93
COMBINATION FLASHER UNIT CHECK ........... 93
Bulb Replacement ................................................... 94
FRONT TURN SIGNAL LAMP ............................. 94
SIDE TURN SIGNAL LAMP ................................. 94
REAR TURN SIGNAL LAMP ............................... 94
Removal and Installation of Front Turn Signal Lamp ... 94
REMOVAL ............................................................ 94
INSTALLATION .................................................... 94
Removal and Installation of Side Turn Signal Lamp ... 95
REMOVAL ............................................................ 95
INSTALLATION .................................................... 95
Removal and Installation of Rear Turn Signal Lamp ... 95
LIGHTING AND TURN SIGNAL SWITCH ................ 96
Removal and Installation ......................................... 96
REMOVAL ............................................................ 96
INSTALLATION .................................................... 96
Switch Circuit Inspection ......................................... 96
HAZARD SWITCH ..................................................... 97
Removal and Installation ......................................... 97
REMOVAL ............................................................ 97
INSTALLATION .................................................... 97
STOP LAMP .............................................................. 98
Wiring Diagram — STOP/L — ................................ 98
Bulb Replacement ................................................... 99
STOP LAMP ........................................................ 99
HIGH-MOUNTED STOP LAMP ........................... 99
Removal and Installation ......................................... 99
STOP LAMP ........................................................ 99
HIGH-MOUNTED STOP LAMP ........................... 99
BACK-UP LAMP .....................................................100
Wiring Diagram — BACK/L — ..............................100
GASOLINE ENGINE ..........................................100
DIESEL ENGINE ...............................................101
Bulb Replacement .................................................102
Removal and Installation .......................................102
PARKING, LICENSE PLATE AND TAIL LAMPS ....103
Wiring Diagram — TAIL/L — .................................103