Page 69 of 800
Page 70 of 800
CHARGING SYSTEM
ENGINE ELECTRICAL16-8
If the voltage is not within the standard value,
there is a malfunction of the voltage regulator or of
the alternator.
14.After the test, lower the engine speed to the idle speed.
15.Turn the ignition switch to the "LOCK" (OFF) position.
16.Remove the tachometer or the M.U.T.-II/III.
17.Disconnect the negative battery cable.
18.Disconnect the ammeter and voltmeter.
19.Connect the alternator output wire to the alternator "B" terminal.
20.Remove the special tool, and return the connector
to the original condition.
21.Connect the negative battery cable.
Voltage Regulation Table
Standard value:
Inspection terminalVoltage regulator ambient
temperature
°C
Voltage V
Terminal "S"−2014.2 − 15.4
2013.9 − 14.9
6013.4 − 14.6
8013.1 − 14.5
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
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 88 of 800
Page 116 of 800
EMISSION CONTROL
ENGINE AND EMISSION CONTROL17-10
SYSTEM DIAGRAM
AK204367AC
Throttle body
Canister
From
fuel
tank
OFF
ON Purge
control
solenoid
valve
Control
relay
Battery Engine-ECU <4G1-M/T, 4G6>,
Engine-A/T-ECU <4G1-A/T>
Air flow sensor <4G6>Engine coolant
temperature sensor
Intake air
temperature sensor
Barometric pressure
sensor <4G6>
Manifold absolute pressure
(MAP) sensor <4G1>
COMPONENT LOCA
TION (EV A PORA TIVE
EMISSION CONTROL SYSTEM)
M1173 0075 0021 6
AK300769
<4G1>
AB
Purge control
solenoid valve
AK300770
<4G6>
AB
Purge control
solenoid valve
PURGE CONTROL SYSTEM CHECK
M1173 0014 0029 9
AK300771
<4G1>
AB
Plug
Vacuum hose
AK300772
<4G6>
AB
Plug
Vacuum hose
1.Disco nnect the vacu um h o se (re d str i pe) fro m
th rottle body and conne ct it to a h and vacu um
pu m p .
Page 117 of 800

EMISSION CONTROL
ENGINE AND EMISSION CONTROL17-11
2. Plug the nipple from which the vacuum hose was removed.
3. When the engine is cold or hot, apply a vacuum of 53 kPa, and check the condition of the vacuum.
When engine is cold
(Engine coolant temperature: 40°C or less)
Engine conditionNormal condition
At idleVacuum is maintained.
3,000 r/min
When engine is hot
(Engine coolant temperature: 80°C or higher)
Engine conditionNormal condition
At idleVacuum is maintained.
3,000 r/min (within 3
minutes after engine
starts)Vacuum will leak.
PURGE PORT VACUUM CHECKM1173001500177
AK300773
<4G1>
AB
Plug
Vacuum hose
AK300774
<4G6>
AB
Plug
Vacuum hose
1.Disco nnect th e vacuum ho se (red st ripe) from the
throttle body and connect a hand vacuum pump to
th e nip p le.
2.Plu g the vacuum hose (red stripe).
AK100011AC
Vac-
uum
Engine speed (r/min)
3.S t art the engine.
4.Check t hat a f a irly co nst ant n egative p r essure is
g enerate d regard l ess of the en gine spee d.
5.If no neg ative pressur e is genera t ed, th e port is
p r obably blocked an d sh ould be cleane d.
PURGE CONTROL SOLENOID VA L V E
CHECK
M1173 0017 0019 3
NOTE: Whe n discon nect i ng th e va cuum hose,
always make a mark so th at it can be reconnected at
original p o sition.
AK100012AC
Battery
A
AK100013
1.
Disco nnect the vacu um h o se f r om th e solenoid
valve.
2.Disco nnect the ha rness connector .
3.Con nect a ha nd vacu um pump to nipp le (A) of the
solen o id valve (ref e r to th e ill ust r ation at le f t ).
4.Check a i rtig htness b y app lying a vacuum with
volt age applied d i rectly from t he batt e ry to the
p u rge con t rol so leno id valve an d without app lying
volt age .