Page 87 of 800
STARTING SYSTEM
ENGINE ELECTRICAL16-25
MAGNETIC SWITCH RETURN TEST
AK300652AB
<4G1>S
B MWire
Battery
Starter
motor
AKX01248
<4G6>
SB
M
Battery
Starter
motorWire
AF
1.
Disco nnect the field coil wire f r om th e M-te rmin al
o f 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 M-terminal and body.
WARNING
Be careful not to ge t your fingers caught
when pulling out the pinion.
3. Pull the pinion out and release. If the pinion
quickly returns to its original position, everything is
operating properly. If it doesn't, replace the
magnetic switch.
Page 89 of 800
STARTING SYSTEM
ENGINE ELECTRICAL16-27
<> SNAP RING/STOP RING REMOVAL
AK100883AC
Socket wrench
Stop ring Pinion Gear
Overrunning
clutch
1. Ap ply a lo ng socket wr ench o f a n ap pro p ria t e size
to the stop ring and strike th e wrench to drive out
th e sto p ring toward th e pin i on g ear side.
AK202791
Snap ring
pliersSnap ring
Pinion gear
Overrunning
clutch
AB
2. Remove the snap ring with sna p ring pliers, th en
remove the stop ring an d overrunning clutch.
STARTER MOT O R P ARTS CLEANING
Never clean in a solvent such st arte r moto r p a rt s as
th e ma gnetic switch, brush hold e r , and arma ture.
If they are soake d in a solven t, their insulat i on
could be imp a ire d . When these p a rt s requ ire
clean ing, wipe of f co nt a m in ation with cloth .
1.Never so ak th e drive un it in a solve n t. If it is
washed in a solvent, th e grea se ha vin g been
p a cke d in th e over run n ing clutch at t he fa ct or y will
be washe d out. Wipe t he drive u n it with cloth if it
req u ires cleaning.
REASSEM BL Y SER V ICE POINT S
>>A<< STOP RING/SNAP RING INST AL-
LATION
AK202911
Overrunning
clutch Stop ring
Snap ring
Stop ring
AB
Use a suit
able puller to pull the stop ring u n til it ge t s
over t
he snap ring.
INSPECTION
M1162 0013 0015 7
COMM.U.T .A T O R
AK202712
1.Sup port the arma ture with a p a ir o f V block a nd
tu rn it t o mea s ure the run out of the surface not
ru bbed b y the brushes u s in g a dial g auge.
St andard va lue: 0.0 5 mm o r l ess
Limit: 0.1 mm
AK202715
2.Measure the diameter o f the commut ator .
St andard va lue: 29 .4 mm
Limit: 28.8 mm
Page 244 of 800
ON-VEHICLE SERVICE
POWER STEERING37-14
POWER STEERING SYSTEM AIR
BLEEDING
M1372002200330
Perform air bleeding procedure as necessary after
replacing the steering gear or the steering fluid lines.
1. Raise and support the front wheels.
2. Disconnect the ignition coil connectors (Refer to GROUP 16, Ignition Coil
P.16-38 or P.16-39).
CAUTION
Perform air bleeding only while cranking the
engine. If air bleeding is performed while the
engine is running, air could enter the fluid. Dur
-
ing air bleeding, refill the steering fluid supply so
that the level never falls below the "MIN" mark on
the oil reservoir.
3. Turn the steering wheel all the way to the left and
right five or six times wh ile using the starter motor
to crank the engine intermittently several times
(for 15 to 20 seconds).
4. Connect the ignition coil connectors (Refer to GROUP 16, Ignition Coil
P.16-38 or P.16-39).
5. Start the engine (idling).
6. Turn the steering wheel to the left and right until there are no air bubbles in the oil reservoir.
7. Confirm that the fluid is not milky, and that the level is between "MAX" and "MIN" marks.
8. Confirm that there is very little change in the fluid
level when the steering wheel is turned left and
right.
CAUTION
If the fluid level rises suddenly after the engine is
stopped, the air has not been completely bled. If
air bleeding is not complete, there will be abnor
-
mal noises from the pump and the flow-control
valve, and this condition could cause reduce the
life of the power steering components.
ACX01131With engine running With engine stoppedAC
Fluid level change: Within 5 mm
9. Confirm that the change in the fluid level is no more than 5 mm when the engine is stopped and
when it is running.
10.If the change of the fluid level is 5 mm or more,
the air has not been completely bled from the
system. The air bleeding procedure must be
repeated.
OIL PUMP PRESSURE TEST
M1372002300315
ACX01133
Temperature
gauge
Oil reservoir
Adapter
(MB991548)
Oil
pump Adapter
(MB991549)
AB
Shut-off valve
(fully closed)
Pressure
gauge
(MB990662)
1. Disconnect the pressure hose from the oil pump,
and then connect the following special tools.
•Power steering oil pressure gauge (MB990662)
•Power steering oil pressure gauge adapter (pump
side) (MB991548)
•Power steering oil pressure gauge adapter (hose
side) (MB991549)
2. Bleed air, then turn the steering wheel several times while the vehicle is not moving so that the
temperature of the fluid rises to approximately 50
−
60
°C.
3. Start the engine and idle it at 750 ± 100 r/min.
CAUTION
The pressure gauge shut-off valve must not
remain closed for more than 10 seconds.
4. Fully close the shut-off valve of the pressure gauge and measure the oil pump relief pressure
to confirm that it is within the standard value
range. Open it again immediately after checking
the pressure.
Standard value: 8.8 − 9.5 MPa
5. If it is not within the standard value, replace the oil pump.
Page 500 of 800
STARTING SYSTEM
CIRCUIT DIAGRAMS90-36
STARTING SYSTEM
STARTING SYSTEM M1901000502269
IGNITION
SWITCH (ST)
STARTER
ENGINE CONTROL
SYSTEM
NOTE
: LHD
: RHD
: 4G1
: 4G6
BATTERY
Wire colour code
B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet PU : Purple
Page 501 of 800
