Page 48 of 800
Page 49 of 800
Page 63 of 800
16-1
GROUP 16
ENGINE
ELECTRICAL
CONTENTS
CHARGING SYSTEM . . . . . . . .16-2
GENERAL INFORMATION . . . . . .16-2
SERVICE SPECIFICATIONS. . . . .16-3
SPECIAL TOOL . . . . . . . . . . . . . . .16-3
ON-VEHICLE SERVICE. . . . . . . . .16-3
ALTERNATOR OUTPUT LINE VOLTAGE
DROP TEST . . . . . . . . . . . . . . . . . . . . . 16-3
OUTPUT CURRENT TEST . . . . . . . . . . 16-5
REGULATED VOLTAGE TEST . . . . . . . 16-7
WAVEFORM CHECK USING AN
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . 16-9
ALTERNATOR ASSEMB LY . . . . .16-12
REMOVAL AND INSTALLATION
<4G1> . . . . . . . . . . . . . . . . . . . . . . . . . . 16-12
REMOVAL AND INSTALLATION
<4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . 16-13
DISASSEMBLY AND REASSEMBLY . . 16-15
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-17
STARTING SYSTEM . . . . . . . . .16-19
GENERAL INFORMATION . . . . . .16-19
SERVICE SPECIFICATIONS. . . . .16-20
STARTER MOTOR ASSEMBLY . .16-21
REMOVAL AND INSTALLATION
<4G1> . . . . . . . . . . . . . . . . . . . . . . . . . . 16-21
REMOVAL AND INSTALLATION
<4G6> . . . . . . . . . . . . . . . . . . . . . . . . . . 16-22
STARTER MOTOR ASSEMBLY
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-23
DISASSEMBLY AND REASSEMBLY . . 16-26
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-27
IGNITION SYSTEM . . . . . . . . . 16-30
GENERAL INFORMATION . . . . . .16-30
SERVICE SPECIFICATIONS . . . . .16-31
SPECIAL TOOL . . . . . . . . . . . . . . .16-31
ON-VEHICLE SERVICE . . . . . . . . .16-32
IGNITION COIL (WITH BUILT-IN
POWER TRANSISTOR) CHECK . . . . . . 16-32
RESISTIVE CORD CHECK . . . . . . . . . . 16-32
SPARK PLUG CHECK AND CLEANING
<4G1>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-32
SPARK PLUG CHECK AND CLEANING
<4G6>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-33
CAMSHAFT POSITION SENSOR
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . 16-33
CRANK ANGLE SENSOR CHECK . . . . 16-33
DETONATION SENSOR CHECK . . . . . 16-33
IGNITION SECONDARY VOLTAGE
WAVEFORM CHECK USING AN
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . 16-33
IGNITION COIL RELAY CHECK . . . . . . 16-37
IGNITION COIL . . . . . . . . . . . . . . . .16-38
REMOVAL AND INSTALLATION
<4G1>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-38
REMOVAL AND INSTALLATION
<4G6>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-39
CAMSHAFT POSITION SENSOR .16-40
REMOVAL AND INSTALLATION . . . . . . 16-40
CRANKSHAFT POSITION SENSOR16-41
REMOVAL AND INSTALLATION
<4G1>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-41
REMOVAL AND INSTALLATION
<4G6>. . . . . . . . . . . . . . . . . . . . . . . . . . . 16-42
DETONATION SENSOR . . . . . . . .16-43
REMOVAL AND INSTALLATION . . . . . . 16-43
Page 81 of 800
STARTING SYSTEM
ENGINE ELECTRICAL16-19
STARTING SYSTEM
GENERAL INFORMATIONM1162000100202
If the ignition switch is turned to the "START" posi-
tion, current flows in the pull-in and holding coils pro-
vided inside magnetic switch, attracting the plunger,
When the plunger is attracted, the lever connected to
the plunger is actuated to engage the starter clutch.
On the other hand, attracting the plunger will turn on
the magnetic switch, allowing the "B" terminal and
"M" terminal to conduct. Thus, current flows to
engage the starter motor.
When the ignition switch is returned to the "ON" posi-
tion after starting the engine, the starter clutch is dis-
engaged from the ring gear.
An overrunning clutch is provided between the pinion
and the armature shaft, to prevent damage to the
starter.
SYSTEM DIAGRAM
AK202970
Pull-in coilHolding coil
Plunger
Lever
Pinion gear
Overrunning clutch
Yo k e
Brush Armature
Ignition switch
Battery
+
–
AB
B
M S
Page 82 of 800
STARTING SYSTEM
ENGINE ELECTRICAL16-20
STARTER MOTOR SPECIFICATIONS
Item4G14G6
Ty p eReduction drive with planetary
gearReduction drive with planetary gear
Rated output kW/V1.2/121.4/12
Number of pinion teeth88
SERVICE SPECIFICATIONSM1162000300068
ItemStandard valueLimit
Pinion gap mm0.5 − 2.0−
Commutator run-out mm−0.05
Commutator diameter mm29.428.8
Undercut depth mm0.5 0.2
Page 83 of 800
Page 85 of 800
STARTING SYSTEM
ENGINE ELECTRICAL16-23
STARTER MOTOR ASSEMBLY INSPECTION
M1162001100205
PINION GAP ADJUSTMENT
AK300648AB
<4G1>
Switch
S M
Wire Battery
Starter
motor
B
AKX01238
<4G6>
B
M S
battery Switch
Starter
motorWire
AG
1.
Disco nnect the field coil wire f r om th e M-te rmin al
of the magnet ic switch.
2.Conn ect a 12-volt b a ttery between the S-termina l
an d M-t e rminal.
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
3. Set the switch to "ON", and the pinion will move out.
AKX00198
Stopper
Pinion gap
Pinion
AC
4. Check the pinion-to-stopper clearance (pinion
gap) with a feeler gauge.
Standard value: 0.5 − 2.0 mm
AKX00199
5. If the pinion gap is out of specification, adjust by adding or removing gasket(s) between the
magnetic switch and front bracket.
MAGNETIC SWITCH PULL-IN TEST
AK300649AB
<4G1>
SM
Wire Battery
Starter
motor
B
AKX01242
<4G6>
SB
M
Battery
Starter
motorWire
AF
1. Disconnect the field coil wire from the M-terminal
of the magnetic switch.
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal and M-terminal.
3. If the pinion moves out, the pull-in coil is good. If it doesn't, replace the magnetic switch.
Page 86 of 800
STARTING SYSTEM
ENGINE ELECTRICAL16-24
MAGNETIC SWITCH HOLD-IN TEST
AK300650AB
<4G1>S
B MWire
Battery
Starter
motor
AKX01244
<4G6>
SB
M
Battery
Starter
motorWire
AF
1.
Disco nnect the field coil wire f r om th e M-te rmin al
of the magnet ic switch.
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
2. Connect a 12-volt battery between the S-terminal and body.
3. Manually pull out the pinion as far as the pinion stopper position.
4. If the pinion remains out, everything is in order. If
the pinion moves in, the hold-in circuit is open.
Replace the magnetic switch.
FREE RUNNING TEST
AK300651AB
<4G1>
S
A
M
V
B
Carbon-pile rheostat
Battery
Voltmeter Ammeter
Starter
motor
AKX01246
<4G6> S
M B Ammeter
Carbon-pile
rheostat
Battery
Starter
motor Voltmeter
AF
A
V
1. Place the starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt
battery to the starter motor as follows:
2. Connect a test ammeter (100-ampere scale) and carbon pile rheostat in series between the battery
(+) terminal and starter motor terminal.
3. Connect a voltmeter (15-volt scale) across the starter motor.
4. Rotate the rheostat to full-resistance position.
5. Connect the battery c able from the battery (-)
terminal to the starter motor body.
6. Adjust the rheostat until the battery voltage shown
on the voltmeter is 11 V.
7. Confirm that the maximum amperage is within the specifications and that the starter motor turns
smoothly and freely.
Current:
<4G1> maximum 95 Amps
<4G6> maximum 90 Amps
