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STARTING SYSTEM
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Removal and InstallationINFOID:0000000001704351
REMOVAL
1. Disconnect the battery negative terminal.
2. Remove air duct (inlet). Refer to EM-16
.
3. Remove reservoir tank. Refer to CO-11
.
4. Remove “S” terminal nut.
5. Remove “B” terminal nut.
6. Remove starter motor bolts.
7. Remove starter motor.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Be sure to tighten “B” terminal nut carefully.
1. "S" terminal harness 2. "B" terminal harness 3. Starter motor
4. Cylinder block Engine front
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< SERVICE INFORMATION >
CHARGING SYSTEM
CHARGING SYSTEM
System DescriptionINFOID:0000000001704352
The generator provides DC voltage to operate the vehicle's electrical system and to keep the battery charged.
The voltage output is controlled by the IC regulator.
Power is supplied at all times to generator terminal 3 through
• 10A fuse (No. 29, located in the fuse and fusible link box).
Power is supplied through terminal 1 to charge the battery and operate the vehicle's electrical system. Output
voltage is monitored at terminal 3 by the IC regulator. The charging circuit is protected by the 120A fusible link
[letter a , located in the fusible link box (battery)].
Ground is supplied
• to generator terminal 5
• through body ground F5, and
• through the generator case to the cylinder block
With the ignition switch in the ON or START position, power is supplied
• through 10A fuse [No. 3, located in the fuse block (J/B)]
• to combination meter terminal 28 for the charge warning lamp.
The IC regulator controls ground to terminal 38 of the combination meter through terminal 2 of the generator.
When the ignition is turned on and power becomes available at terminal 2, this "wakes up" the regulator. The
regulator monitors charge output and grounds terminal 2 or leaves it open depending on charge output. With
power and ground supplied, the charge warning lamp will illuminate. When the generator is providing sufficient
voltage, the ground is opened and the charge warning lamp will go off.
If the charge warning lamp illuminates with the engine running, a malfunction is indicated.
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CHARGING SYSTEM
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Wiring Diagram - CHARGE -INFOID:0000000001704353
Trouble Diagnosis with Starting/Charging System TesterINFOID:0000000001704354
For charging system testing, use Starting/Charging System Tester (J-44373). For details, refer to Technical
Service Bulletin.
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< SERVICE INFORMATION >
CHARGING SYSTEM
WORK FLOW
DIAGNOSTIC PROCEDURE 1
Check Charge Warning Lamp Circuit
1.CHECK CHARGE WARNING LAMP CIRCUIT CONNECTION
Check to see if terminal 2 is clean and tight.
OK or NG
OK >> GO TO 2.
NG >> Repair terminal 2 connection. Confirm repair by performing complete Starting/Charging system
test. Refer to Technical Service Bulletin.
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CHARGING SYSTEM
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2.CHECK CHARGE WARNING LAMP CIRCUIT
1. Disconnect generator connector F1.
2. Apply ground to generator connector F1 terminal 2 with the igni-
tion switch in the ON position.
OK or NG
OK >> GO TO "WORK FLOW" .
NG >> Check the following.
• 10A fuse [No. 3, located in fuse block (J/B)]
• CHARGE lamp
• Harness for open or short between combination meter
and fuse
• Harness for open or short between combination meter and generator
DIAGNOSTIC PROCEDURE 2
Check Battery Circuit
1.CHECK BATTERY CIRCUIT CONNECTION
Check to see if terminal 1 is clean and tight.
OK or NG
OK >> GO TO 2.
NG >> Repair terminal 1 connection. Confirm repair by performing complete Starting/Charging system
test. Refer to Technical Service Bulletin.
2.CHECK BATTERY CIRCUIT
Check voltage between generator connector F2 terminal 1 and
ground using a digital circuit tester.
OK or NG
OK >> GO TO 3.
NG >> Check the following.
• 120A fusible link [letter a , located in fusible link box
(battery)]
• Harness for open or short between generator and fus-
ible link
3.CHECK VOLTAGE DROP ON BATTERY CIRCUIT
Check voltage between generator connector F2 terminal 1 and bat-
tery positive terminal using a digital circuit tester.
OK or NG
OK >> Replace the generator. Refer to SC-24, "Removal and
Installation" . Confirm repair by performing complete
Starting/Charging system test. Refer to Technical Ser-
vice Bulletin.
NG >> Check harness between the battery and the generator
for poor continuity.
DIAGNOSTIC PROCEDURE 3
Check Voltage Regulator Circuit
CHARGE lamp should light up.
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Battery voltage should exist.
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With engine running
at idle and warm: Less than 0.2V
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< SERVICE INFORMATION >
CHARGING SYSTEM
1.CHECK VOLTAGE REGULATOR CIRCUIT CONNECTION
Check to see if terminal 3 is clean and tight.
OK or NG
OK >> GO TO 2.
NG >> Repair terminal 3 connection. Confirm repair by performing complete Starting/Charging system
test. Refer to Technical Service Bulletin.
2.CHECK VOLTAGE REGULATOR CIRCUIT
Check voltage between generator connector F1 terminal 3 and
ground using a digital circuit tester.
OK or NG
OK >> GO TO 3.
NG >> Check the following.
• 10A fuse (No. 29, located in fuse and fusible link box)
• Harness for open or short between generator and fuse
3.CHECK VOLTAGE DROP ON VOLTAGE REGULATOR CIRCUIT
Check voltage between generator connector F1 terminal 3 and bat-
tery positive terminal using a digital circuit tester.
OK or NG
OK >> Replace the generator. Refer to SC-24, "Removal and
Installation" . Confirm repair by performing complete
Starting/Charging system test. Refer to Technical Ser-
vice Bulletin.
NG >> Check harness between the battery and the generator
for poor continuity.
Removal and InstallationINFOID:0000000001704355
Battery voltage should exist.
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With engine running
at idle and warm: Less than 0.2V
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CHARGING SYSTEM
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REMOVAL
1. Disconnect the battery cable from the negative terminal.
2. Remove drive belt. Refer to EM-13, "
Component".
3. Disconnect generator connector.
4. Remove “B” terminal nut.
5. Remove generator bolts.
6. Remove generator assembly from the vehicle.
GENERATOR PULLEY INSPECTION
• Check that the generator pulley does not rattle.
• Check that the generator pulley nut is properly tightened.
INSTALLATION
Installation is in the reverse order of removal.
CAUTION:
Be sure to tighten “B” terminal nut carefully.
1. Generator bracket bolt 2. Generator bracket 3. Generator bolt
4. Generator 5. Generator "B" terminal harness 6. "B" terminal nut
7. Generator connector
Generator pulley nut : 118 N·m (12.0 kg-m, 87 ft-lb)
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< SERVICE INFORMATION >
SERVICE DATA AND SPECIFICATIONS (SDS)
SERVICE DATA AND SPECIFICATIONS (SDS)
BatteryINFOID:0000000001704356
StarterINFOID:0000000001704357
GeneratorINFOID:0000000001704358
M/T, A/T CVT
Type TR4 Gr.51 R
20 hours rate capacity 12 V - 47 AH 12 V - 47 AH
Cold Cranking Amps. (CCA) 470 470
Typ eS114 - 901
HITACHI make
Reduction gear type
System voltage12 V
No-loadTerminal voltage 11 V
Current Less than 110 A
Revolution More than 3,000 rpm
Minimum diameter of commutator 28.0 mm (1.102 in)
Minimum length of brush 10.5 mm (0.413 in)
Brush spring tension 16.2 N (1.65 kg, 3.64 lb)
Clearance between bearing metal and armature shaft Less than 0.2 mm (0.008 in)
Movement “L” in height of pinion assembly 0.3 - 2.5 mm (0.012 - 0.098 in)
Ty p eLR1140 - 803
MITSUBISHI make
Nominal rating12 V - 140 A
Ground polarityNegative
Minimum revolution under no-load (when 13.5 V is applied) Less than 1,200 rpm
Hot output current (when 13.5 V is applied)More than 27 A/1,300 rpm
More than 95 A/2,500 rpm
More than 116 A/5,000 rpm
Regulated output voltage14.1 - 14.7 V
Minimum length of brush More than 6.00 mm (0.236 in)
Brush spring pressure 1.1 - 3.7 N (112 - 378 g, 4.00 - 13.3 oz)
Slip ring minimum outer diameter More than 14.7 mm (0.579 in)
Rotor (field coil) resistance 1.61 - 1.91 Ω