ENGINE ELECTRICAL SYSTEM

PRODUCTIVITY IMPROVEMENT AND CENTER OF

EXCELLENCY

TOT PROGRAM
PROJECT BASED TRANING MANUAL ON

ENGINE ELECTRICAL SYSTEM

PREPARED BY

AUTOMOTIVE DEPARTMENT

August 16

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 ENGINE ELECTRICAL SYSTEM

Contents
1 Introduction...................................................................................................................................3
1.2 Objective................................................................................................................................3
1.3 SPECIFIC OBJECTIVES......................................................................................................3
2 Engine Electrical System..............................................................................................................4
2.1 Specification...........................................................................................................................4
2.2 Special Service Tools.............................................................................................................5
2.3 Troubleshooting.....................................................................................................................6
2.4 Ignition System Description...................................................................................................8
2.4.1 Ignition coil Description................................................................................................10
2.4.2 Spark Plug Description and Operation..........................................................................13
2.5 Charging System Description..............................................................................................17
2.5.1 Alternator Management System and on-vehicle inspection..........................................17
2.5.2 Alternator Description and Operation...........................................................................24
2.6 Starting System Description.................................................................................................33
2.6.1Starter Components and Components Location.............................................................35
2.6.2 Starter Repair procedures..............................................................................................36
2.7 Cruise Control System.........................................................................................................50
2.7.1 Cruise Control Switch Schematic Diagrams.................................................................52
2.7.2 Cruise Control Switch Repair procedures.....................................................................53

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 ENGINE ELECTRICAL SYSTEM

1 Introduction

Because the field of automotive service is an ever-advancing and demanding profession, this
institute (Productivity improvement and center of excellency) has prepared this automotive
training manual (ATM) series it help its trainees to attain a higher degree of technical skills.
Thus as you progress through this training use this Automatic transmission system and related
materials to their fullest for your advancement and improve your and your customer satisfaction.

1.2 Objective

The aim of this training manual is to teach the basic construction, control, operation, and
troubleshooting of the Automatic transmission system. Also after this training the trainee should
have a full understanding of the following, they should also be able to perform related
inspections and repair based on this understanding when appropriate workshop manual is used.

1.3 Specific Objectives

After completing the training lessons in this unit, Trainee should be able to:

 Know how Automatic transmission system function

 Know each Automatic transmission system location and function
 Know how to diagnosis the Automatic transmission system by using diagnosis tools
 Know how to diagnosis the sensor by using basic DOM(digital multi meter)

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2 Engine Electrical System

2.1 Specification
Ignition System
Ignition Coil
Item Specification
Primary Coil Resistance (?) 0.56 ± 10% [20°C (68°F)]
Secondary Coil Resistance (k?) 2.0 ± 15% [20°C (68°F)]

Spark Plug
Item Specification
Type SILZKR7E8G
Gap 0.7 ~ 0.8 mm (0.0275 ~ 0.0314 in.)

Charging System
Alternator
Item Specification
Rated voltage 13.5V, 130A
Speed in use 1,000 ~ 18,000 rpm
Voltage regulator IC Regulator built-in type
External mode Refer to below graph
Regulator Setting Voltage Internal mode 14.55 ± 0.3V
External mode 0 ± 3 mV / °C?
Temperature Gradient Internal mode -3.5 ± 2mV / °C

Battery
?AGM80L-DIN
Item Specification
Model type AGM80L-DIN
Capacity [20HR/5HR] (AH) 80/64
Cold Cranking Amperage (A) 800 (SAE) /640 (EN)
Reserve Capacity (Min) 140

Starting System
Starter

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Item Specification
Rated voltage 12 V, 0.9 kW
The number of pinion teeth 10
Performance Ampere Max. 60 A
[No-load, 11.5 V] Speed Min. 5,500 rpm

2.2 Special Service

Tools
Tool (Number and name) Illustration Use

09373-27000 Removal and installation of alternator

Alternator pulley remover wrench pulley

09964-C1100
SCC reflector Reflector to align the SCC radar

09964-C1200
Calibration beam Laser to detect the center of the vehicle.

09964-C1300 SCC reflector or vertical / horizontal laser

Tripod support.

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2.3
Troubleshooting
Ignition System
Symptom Suspect Area Remedy
Inspect ignition lock switch, or
Ignition lock switch replace as required
Inspect ignition coil, or replace as
Ignition coil required
Inspect spark plugs, or replace as
Spark plugs required
Engine will not start or is hard to Ignition wiring disconnected or
start (Cranks OK) broken Repair wiring, or replace as required
Ignition wiring Repair wiring, or replace as required
Inspect ignition coil, or replace as
Rough idle or stalls Ignition coil required
Inspect spark plugs / cable, or
Spark plugs and spark plug cables replace as required
Engine hesitates/poor acceleration Ignition wiring Repair wiring, or replace as required
Inspect spark plugs / cable, or
Poor mileage Spark plugs and spark plug cables replace as required

Charging System
Symptom Suspect Area Remedy
Fuse blown Check fuses
Light burned out Replace light
Charging warning indicator does
not Wiring connection loose Tighten loose connection
 light with ignition switch "ON" and If light turns off, replace voltage
 engine off. Electronic voltage regulator regulator. 
Drive belt loose or worn Adjust belt tension or replace belt
Battery cable loose, corroded or Inspect cable connection, repair or
worn replace cable
Charging warning indicator does
not Electronic voltage regulator or If light turns off, replace voltage
go out with engine running. (Battery alternator regulator or alternator
requires frequent recharging) Wiring Repair or replace wiring
If light turns off, replace voltage
Electronic voltage regulator regulator. 
Overcharge Voltage sensing wire Repair or replace wiring
Drive belt loose or worn Adjust belt tension or replace belt
Wiring connection loose or short Inspect wiring connection, repair or
circuit replace wiring
Electronic voltage regulator or If light turns off, replace voltage
alternator regulator or alternator
Poor grounding Inspect ground or repair
Discharge Worn battery Replace battery

Starting System

Symptom Suspect Area Remedy

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Battery charge low Charge or replace battery

Battery cables loose, corroded or

worn out Repair or replace cables
Transaxle range switch
(Vehicle with automatic transaxle Refer to AT group-automatic
only) transaxle

Fuse blown Replace fuse

Starter motor faulty Replace

Engine will not crank Ignition switch faulty Replace

Battery charge low Charge or replace battery

Battery cables loose, corroded or

worn out Repair or replace cables

Engine cranks slowly Starter motor faulty Replace

Starter motor faulty Replace

Starter keeps running Ignition switch Replace

Short in wiring Repair or replace wiring
Pinion gear teeth broken or starter
motor Replace

Starter spins but engine will not crank Ring gear teeth broken Replace fly wheel or torque converter

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2.4 Ignition System Description

Ignition timing is controlled by the electronic control ignition timing system. The standard
reference ignition timing data for the engine operating conditions are pre-programmed in the
memory of the ECM (Engine Control Module). The engine operating conditions (speed, load,
warm-up condition, etc.) are detected by the various sensors. Based on these sensor signals and
the ignition timing data, signals to interrupt the primary current are sent to the ECM. The ignition
coil is activated, and timing is controlled.

Inspect ignition coil assembly and Perform spark test

Check for DTCs.
  

1 If a DTC is present, perform troubleshooting in accordance with the procedure for that
. • DTC. (Refer to DTC guide)
Check if sparks occur.
(1
) Remove the engine cover.
(2
) Remove the ignition coils.
(3
) Using a spark plug wrench, remove the spark plugs.
(4
) Disconnect the injector extension connectors.
Ground the spark plug to the engine.

(5
)
(6
) Check if sparks occur at each spark plug while engine is being cranked.
  
2. • Do not crank the engine for more then 5 seonds.
3. If sparks do not occur, perform the following test.

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4. Using a spark plug wrench, install spark plugs.

5. Install the ignition coils.
6. Install the engine cover.
2.4.1 Ignition coil Description
An ignition coil is an induction coil in an engine's ignition system which transforms the battery's
low voltage to the high voltage needed to create an electric spark in the spark plugs to ignite the
fuel. Coils have an internal resistor while others rely on a resistor wire or an external resistor to
limit the current flowing into the coil from the battery 12 V supply.

Ignition Coil Specifications

Item Specification

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Primary Coil Resistance (?) 0.56 ± 10% [20°C (68°F)]

Secondary Coil Resistance (k?) 2.0 ± 15% [20°C (68°F)]

Circuit Diagram

2.4.1.1 Ignition Coil Repair procedures

Removal
1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
2. Remove the engine cover.
3. Disconnect the ignition coil connector (A).

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Remove the ignition coil (A).

  
• When removing the ignition coil connector, pull the lock pin (A) and push the clip (B).

4.
Installation
Install in the reverse order of removal.

Ignition coil installation bolts:

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 Ib-ft)
1.
Inspection

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Measure the primary coil resistance between terminals 1 and 2.

Standard value: 0.56? ± 10%

1.
 2.4.2 Spark Plug Description and Operation

A spark plug is a device for delivering electric current from an ignition system to the combustion
chamber of a spark-ignition engine to ignite the compressed fuel/air mixture therein by means of
an electric spark, while containing combustion pressure within the engine. A spark plug has a
metal threaded shell, electrically isolated from a central electrode by a porcelain insulator.

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 ENGINE ELECTRICAL SYSTEM

Specification
Item Specification
Type SILZKR7E8G
Gap 0.7 ~0.8 mm (0.0275 ~ 0.0314 in.)

Inspection
[On vehicle inspection]
1. Accelerate the engine to about 3,000 rpm 3 times or more.
2. Remove the spark plug.
Check the spark plug visually.
If the electrode is dry, the spark plug is normal.
3. If the electrode is wet, check the damage and electrode gap as below.
[Component Inspection]
Check the spark plug for any damage on its thread and insulator.
1. If there is damage, replace the spark plug.
2. Check the electrode. Measure the insulation resistance with an ohmmeter.
If the resistance is less than the specified value, adjust the electrode gap.

Specification: 10 M? or more

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Check the spark plug electrode gap.

If the gap is greater than the maximum, replace the spark plug.

Specification: 0.7 ~ 0.8 mm ( 0.0275 ~ 0.0314 in.)

  
If adjusting the gap of a new spark plug, bend only the base of the ground electrode. Do not
touch the tip.
• Never attempt to adjust the gap on a used plug.

3.
Cleaning
The combustion temporarily becomes unstable, due to the aged fuel and the carbon
deposits accumulated on the spark plug(s) after long-term storage.
[1st Method]
1. Start the engine and keep the engine running at idle for 2 minutes.
Step on the accelerator pedal and hold it steady at 4500 rpm with the shift lever in N position to
2. warm up  the engine until the temperature of the engine coolant reaches 80°C.
3. Keep the engine running at 2500~3000 rpm in the N position for 15 minutes.

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[2nd Method]

  
• The 2nd method should be performed only if the 1st method fails (the misfire-related codes recur).
1. Start the engine and keep the engine running at idle for 2 minutes.
Drive the vehicle for over 20 minutes, keeping the engine speed above 3500 rpm.
  
If equipped with manual transaxle, shift the gear properly for keeping the engine speed above 3500
• rpm.

2.
Removal
Remove the ignition coil.
. (Refer to Ignition System - "Ignition Coil")
Using a spark plug wrench, remove the spark plug (A).
  
• Be careful that no contaminates enter into spark plug holes.

2
.
Installation
1. Install in the reverse order of removal.

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Tightening torque:
14.7 ~ 24.5 N.m (1.5 ~ 2.5 kgf.m, 10.9 ~ 18.0 Ib-ft)

2.5 Charging System Description

The charging system included a battery, an alternator with a built-in regulator, and the charging
indicator light and wire. The Alternator has eight built-in diodes, each rectifying AC current to
DC current. Therefore, DC current appears at alternator "B" terminal. In addition, the charging
voltage of this alternator is regulated by the battery voltage detection system. The alternator is
regulated by the battery voltage detection system. The main components of the alternator are the
rotor, stator, rectifier, capacitor brushes, bearings and V-ribbed belt pulley. The brush holder
contains a built-in electronic voltage regulator.

2.5.1 Alternator Management System and on-vehicle inspection

Alternator management system controls the charging voltage set point in order to improve fuel
economy, manage alternator load under various operating conditions, keep the battery charged,
and protect the battery from over-charging. ECM controls generating voltage by duty cycle
(charging control, discharging control, normal control) based on the battery conditions and
vehicle operating conditions. The system conducts discharging control when accelerating a
vehicle. Vehicle reduces an alternator load and consumes an electric power form a battery. The
system conducts charging control when decelerating a vehicle. Vehicle increases an alternator
load and charges a battery.

On-vehicle Inspection
  
First of all, check for DTCs. If a DTC is present, perform troubleshooting in accordance with the
• procedure for that DTC. (Refer to DTC guide)
  
• Check that the battery cables are connected to the correct terminals.
• Disconnect the battery cables when the battery is given a quick charge.
• Never disconnect the battery while the engine is running.

[General Inspection]
.

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 Check The Battery Terminals And Fuses

(1
) Check that the battery terminals are not lose or corroded.
(2
) Check the fuses for continuity.
 Inspect Drive Belt
Visually check the belt for excessive wear, frayed cords etc.
If any defect has been found, replace the drive belt.
  
Cracks on the rib side of a belt are considered acceptable. If
the belt has chunks missing from the ribs, it should be
• replaced.

(1
. )
 Drive belt tension measurement and adjustment.
.
Visually Check Alternator Wiring And Listen For Abnormal Noises
(1
) Check that the wiring is in good condition.
(2
) Check that there is no abnormal noise from the alternator while the engine is running.
 Check Discharge Warning Light Circuit
(1
) Warm up the engine and then turn it off.
(2
) Turn off all accessories.
(3
) Turn the ignition switch "ON". Check that the discharge warning light is lit.
(4) Start the engine. Check that the light is lit.
If the light does not go off as specified, troubleshoot the discharge light circuit.

[Electrical Specified Value Inspection]

1  Voltage Drop Test Of Alternator Output Wire

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This test determines whether or not the wiring between the alternator "B" terminal and the battery (+)
terminal is good by the voltage drop method.
Preparation
A
. A, Turn the ignition switch to "OFF".

Disconnect the output wire from the alternator "B" terminal. Connect the (+) lead wire of ammeter to
the "B" terminal of alternator and the (-) lead wire of ammeter to the output wire. Connect the (+) lead
wire of voltmeter to the "B" terminal of alternator and the (-) lead wire of voltmeter to the (+) terminal
of battery.

. B, Start the engine.

Turn on the headlamps and blower motor, and set the engine speed until the ammeter indicates
. 20A And then, read the voltmeter at this time.
Result
The voltmeter may indicate the standard value.

Standard value : 0.2V max

A.
If the value of the voltmeter is higher than expected (above 0.2V max.), poor wiring is
suspected. In this case check th e wiring from the alternator "B" terminal to the battery (+)
terminal. Check for loose connections, color change due to an over-heated harness, etc. Correct
B. them before testing again.
Upon completion of the test, set the engine speed at idle. Turn off the headlamps, blower motor and th
. C. ignition switch.

 Output Current Test

This test determines whether or not the alternator gives an output current that is equivalent to the
normal output.
Preparation

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Prior to the test, check the following items and correct as necessary. Check the battery installed
in the vehicle to ensure that it is good condition. The battery checking method is described in
the section "Battery". The battery that is used to test the output current should be one that has
been partially discharged. With a fully charged battery, the test may not be conducted correctly
due to an insufficient load.
Check the tension of the alternator drive belt. The belt tension check method is described in the
A. section "Inspect drive belt".
B. Turn off the ignition switch.
C. Disconnect the battery ground cable.
D Disconnect the alternator output wire from the alternator "B" terminal.
Connect a DC ammeter (0 to 150A) in series between the "B" terminal and the disconnected
output wire. Be sure to connect the (-) lead wire of the ammeter to the disconnected output
wire.

  
E. • Tighten each connection securely, as a heavy current will flow. Do not rely on clips.
Connect a voltmeter (0 to 20V) between the "B" terminal and ground. Connect the (+) lead wire
F. to the alternator "B" terminal and (-) lead wire to a good ground.
G Attach an engine tachometer and connect the battery ground cable.
Leave the engine hood open.

Test
Check to see that the voltmeter reads as the same value as the battery voltage. If the voltmeter
A reads 0V, and the open circuit in the wire between alternator "B" terminal and battery (+)
. terminal or poor grounding is suspected.
B. Start the engine and turn on the headlamps.
C Set the headlamps to high beam and the heater blower switch to HIGH, quickly increase the
. engine speed to 2,500 rpm and read the maximum output current value indicated by the
ammeter.
  
• After the engine start up, the charging current quickly drops. Therefore, the
above operation must be done quickly to read the maximum current value

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correctly.
Result
The ammeter reading must be higher than the limit value. If it is lower but the alternator output wire is i
good condition, remove the alternator from the vehicle and test it.

Limit value : 60% of the voltage rate

  
The nominal output current value is shown on the nameplate affixed to the alternator
• body.
The output current value changes with the electrical load and the temperature of the
alternator itself.
Therefore, the nominal output current may not be obtained. If such is the case, keep the
headlamps on the cause discharge of the battery, or use the lights of another vehicle to
• increase the electrical load.
The nominal output current may not be obtained if the temperature of the alternator itself
or ambient temperature is too high. In such a case, reduce the temperature before testing
A. • again.
Upon completion of the output current test, lower the engine speed to idle and turn off the
B. ignition switch.
C. Disconnect the battery ground cable.
D Remove the ammeter and voltmeter and the engine tachometer.
E. Connect the alternator output wire to the alternator "B" terminal.
F. Connect the battery ground cable.
3. Regulated Voltage Test
The purpose of this test is to check that the electronic voltage regulator controls voltage correctly.
(1 Preparation
) Prior to the test, check the following items and correct if necessary.
Check that the battery installed on the vehicle is fully charged. The battery checking
method is described in the section "Battery". Check the alternator drive belt tension. The
A. belt tension check method is described in the section "Inspect drive belt".
B. Turn ignition switch to "OFF".
C. Disconnect the battery ground cable.
Connect a digital voltmeter between the "B" terminal of the alternator and ground. Connect
the (+) lead of the voltmeter to the "B" terminal of the alternator. Connect the (-) lead to
D. good ground or the battery (-) terminal.
E. Disconnect the alternator output wire from the alternator "B" terminal.
Connect a DC ammeter (0 to 150A) in series between the "B" terminal and the
disconnected output wire.
F. Connect the (-) lead wire of the ammeter to the disconnected output wire.

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Attach the engine tachometer and connect the battery ground cable.

.
Test
Turn on the ignition switch and check to see that the voltmeter indicates the following
value.

Voltage: Battery
voltage

If it reads 0V, there is an open circuit in the wire between the alternator "B" terminal and
A. the battery and the battery (-) terminal.
B. Start the engine. Keep all lights and accessories off.
(2 Run the engine at a speed of about 2,500 rpm and read the voltmeter when the alternator
) C. output current drops to 10A or less
Result
If the voltmeter reading dosen't agree with the standard value, the voltage regulator or the
A. alternator is faulty.
B. Upon completion of the test, reduce the engine speed to idle, and turn off the ignition switch.
C. Disconnect the battery ground cable.
D. Remove the voltmeter and ammeter and the engine tachometer.
(3 E. Connect the alternator output wire to the alternator "B" terminal.
) F. Connect the battery ground cable.

2.5.2 Alternator Description and Operation

Description
The Alternator has eight built-in diodes, each rectifying AC current to DC current. Therefore,
DC current appears at alternator "B" terminal. In addition, the charging voltage of this alternator
is regulated by the battery voltage detection system. The alternator is regulated by the battery
voltage detection system. The main components of the alternator are the rotor, stator, rectifier,

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capacitor brushes, bearings and V-ribbed belt pulley. The brush holder contains a built-in
electronic voltage regulator.

1.Brush
2.OAD(OverrunningAlternatorDecoupler)
3.Rotor
4. Stator

Specification
Item Specification
Rated voltage 13.5V, 130A
Speed in use 1,000 ~ 18,000 rpm
Voltage regulator IC Regulator built-in type
Regulator Setting External mode Refer to below graph
Voltage Internal mode 14.55 ± 0.3V
External mode 0 ± 3 mV / °C?
Temperature Gradient Internal mode -3.5 ± 2mV / °C

2.5.2.1 Alternator Components and Components Location

Components

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1.OAD(OverrunningAlternatorDecoupler)
2FrontBracket 7.RearBracket
3.FrontBearing 8.BrushHolderAssembly
4.Stator 9.ThroughBolt
5.Rotor 10.RectifierAssembly
6. Rear Bearing 11. Rear Cover

2.5.2.2 Alternator Schematic Diagrams

Circuit Diagram

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COM signal - When controlling the voltage generated, the ECM sends the target voltage data to
• the alternator via a PWM signal.(High voltage: 4V or higher, low voltage: 2V or lower)
FR signal - The transistor activation signal inside the alternator monitors the voltage generated by
the alternator to control the excitation current before it sends the FR signal to the ECM. (At certain
RPM/electric loads, the FR duty can remain static. However, more often, the RPM, electric load,
• target voltage, etc. are always changing in the vehicle, so the FR must also change constantly)
L signal - Turns on the battery warning lamp on the dashboard when the battery charging
system malfunctions. (Conditions for turning on the lamp - overcharge, over discharge, a field
• coil blown inside the alternator)
• B+ terminal - The output voltage from the generator travels to the battery via the B+ terminal.

2.5.2.3 Alternator Repair procedures

Removal

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1. Disconnect the battery negative terminal.

Loosen the mounting bolts (A) and then, turn the adjusting bolt (B) clockwise to loosen tension.

2.
Remove the drive belt (A).

3.
Disconnect the air compressor connector (A) and the alternator connector (B), and remove the
cable from alternator "B" terminal (C).

4
.
5. Remove the alternator (A).

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Installation
1. Install in the reverse order of removal.
Adjust the alternator belt tension after installation.
(Refer to Engine Mechanical System - "Drive Belt")

Alternator installation bolt:

[12mm (0.47in) bolt]
19.6 ~ 26.5 Nm (2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 Ib-ft)
[14mm (0.55in) bolt]
29.4 ~ 41.2 Nm (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 Ib-ft)
2.
Disassembly
Remove the rear cover (A) after removing nuts.

1.
2. Remove the mounting bolts (A) and the brush holder assembly (B).

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 ENGINE ELECTRICAL SYSTEM

Remove the slip ring guide (A) after pulling it.

3.
Remove the OAD(Overrunning Alternator Decoupler) cap.
4   
. • When installing, replace with new OAD cap.
Remove the OAD(Overrunning Alternator Decoupler) pulley (A) using the special tool.

5.
6. Unsolder the 3 stator leads (A).

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 ENGINE ELECTRICAL SYSTEM

Remove the 4 through bolts (A).

7.
Disconnect the rotor (A) and bracket (B).

8.
Reassembly
Reassemble in the reverse order of disassembly.
  
1 • When reassembling OAD pulley, replace with new OAD cap.
.
Inspection
[Rotor]
1. Check that there is continuity between the slip rings (C).

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 ENGINE ELECTRICAL SYSTEM

2. Check that there is no continuity between the slip rings and the rotor (B) or rotor shaft (A).
3. If the rotor fails either continuity check, replace the alternator.
[Stator]
Check that there is continuity between each pair of leads (A).

1.
2. Check that there is no continuity between each lead and the coil core.
3. If the coil fails either continuity check, replace the alternator.

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2.6 Starting System Description

The starting system includes the battery, starter, solenoid switch, ignition switch, inhibitor switch
(A/T), clutch pedal switch (M/T), ignition lock switch, connection wires and the battery cable.
When the ignition key is turned to the start position, current flows and energizes the starter
motor's solenoid coil. The solenoid plunger and clutch shift lever are activated, and the clutch
pinion engages the ring gear. The contacts close and the starter motor cranks. In order to prevent
damage caused by excessive rotation of the starter armature when the engine starts, the clutch
pinion gear overruns.
Troubleshooting
  
• The battery must be in good condition and fully charged for this troubleshooting.

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 ENGINE ELECTRICAL SYSTEM

Description
The starting system includes the battery, starter, solenoid switch, ignition switch, inhibitor switch
(A/T), clutch pedal switch (M/T), ignition lock switch, connection wires and the battery cable.
When the ignition key is turned to the start position, current flows and energizes the starter
motor's solenoid coil. The solenoid plunger and clutch shift lever are activated, and the clutch
pinion engages the ring gear.The contacts close and the starter motor cranks. In order to prevent
damage caused by excessive rotation of the starter armature when the engine starts, the clutch
pinion gear overruns. In conjunction with the ISG function, the starter motor must do a great deal
more work. Therefore, the starter motor is configured for a significantly higher number of start
cycles. The components of the starter motor have been adapted to the higher requirements.

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 ENGINE ELECTRICAL SYSTEM

1.Solenoid
2.Brush
3.Armature
4. Overrun clutch

Specification
Item Specification
Rated voltage 12 V, 0.9 kW
The number of pinion teeth 10
Performance Ampere Max. 60 A
[No-load, 11.5 V] Speed Min. 5,500 rpm

2.6.1Starter Components and Components Location

Components

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 ENGINE ELECTRICAL SYSTEM

1.Screw 7.Leverplate
2.Fronthousing 8.Leverpacking 13.Brushholder
3.Stopring 9.Magnetswitchassembly 14.Brush(+)
4.Stopper 10.Armatureassembly 15.Rearbracket
5. Overrunning clutch 11. Yoke assembly 16.Throughbolt
6. Lever 12. Brush (-) 17. Screw

2.6.1.1 Circuit Diagram

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 ENGINE ELECTRICAL SYSTEM

2.6.2 Starter Repair procedures

Removal
1. Disconnect the battery negative terminal.
Remove the battery tray.
2. (Refer to Engine Electrical System - "Battery")
Remove the air duct and air cleaner assembly.
3. (Refer to Engine Mechanical System - "Air Cleaner")
Disconnect the starter cable (B) from the B terminal on the solenoid then disconnect the connector from
the S terminal (A).

4
.
5. Remove the 2 bolts holding the starter, then remove the starter (A).

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 ENGINE ELECTRICAL SYSTEM

Installation
Install in the reverse order of removal.

Starter installation bolt: 49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)
1.
Disassembly
Disconnect the M-terminal (A) on the magnet switchassembly.

1.
After loosening the 2 screws (A), detach the magnet switch assembly (B).

2.
3. Loosen the brush holder mounting screw (A) and the trough bolts (B).

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 ENGINE ELECTRICAL SYSTEM

Remove the rear bracket (A) and brush holder assembly (B).

4.
Remove the yoke (A).

5.
6. Remove the packing (A), lever plate (B), lever (C), armature (D).

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Press the stopper (A) using a socket (B).

7.
After removing the stop ring (A) using stopper pliers (B).

8.
9. Remove the stop ring (B), stopper (A), over running clutch (C) and armature (D).

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• Using a suitable pulling tool (A), pull the over running clutch stopper (C) over the stop ring (B).

Reassembly
1. Reassemble in the reverse order of disassembly.
Inspection
Starter Solenoid Inspection
1. Disconnect the lead wire from the M-terminal of solenoid switch.
Connect the battery as shown. If the starter pinion pops out, it is working properly.
  
• To avoid damaging the starter, do not leave the battery connected for more than 10 seconds.

2.
3. Disconnect the battery from the M terminal.
If the pinion does not retract, the hold-in coil is working properly.
  

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• To avoid damaging the starter, do not leave the battery connected for more than 10 seconds.

Disconnect the battery also from the body. If the pinion retracts immediately, it is working properly.
  
• To avoid damaging the starter, do not leave the battery connected for more than 10 seconds.

4.
Free Running Inspection
1 Place the starter motor in a vise equipped with soft jaws and connect a fully-charged 12-volt battery to
. starter motor as follows.
2. Connect a test ammeter (150-ampere scale) and carbon pile rheostats shown is the illustration.
Connect a voltmeter (15-volt scale) across starter motor.

3.

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4. Rotate carbon pile to the off position.

5. Connect the battery cable from battery's negative post to the starter motor body.
6. Adjust until battery voltage shown on the voltmeter reads 11volts.
Confirm that the maximum amperage is within the specifications and that the starter motor turns
smoothly and freely.
Items Current (Max.) Speed (Min.)
7 ISG type 95 A 3,400 rpm
. Non-ISG type 95 A 2,500 rpm
Armature
1. Remove the starter.
2. Disassemble the starter as shown at the beginning of this procedure.
Inspect the armature for wear or damage from contact with the permanent magnet. If there is wear or
damage, replace the armature.

3
.
Check the commutator (A) surface. If the surface is dirty or burnt, resurface with emery cloth or a
lathe within the following specifications, or recondition with #500 or #600 sandpaper (B).

4
.
5. Check the commutator diameter. If the diameter is below the service limit, replace the armature.

Commutator diameter
Standard (New) : 29.4 mm (1.1575 in)
Service limit : 28.8 mm (1.1339 in)

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Measure the commutator (A) runout.

If the commutator runout is within the service limit, check the commutator for carbon dust or brass
A. chips between the segments.
B. If the commutator run out is not within the service limit, replace the armature.

Commutator runout
Standard (New) : 0.05mm (0.0020in.) max
Service limit : 0.10mm (0.0039in.) max

6.
7 Check the mica depth (A). If the mica is too high (B), undercut the mica with a hacksaw blade to the
. proper depth. Cut away all the mica (C) between the commutator segments. The undercut should not be
too shallow, too narrow, or v-shaped (D).

Commutator mica depth

Standard (New) : 0.5 mm (0.0197 in.)
Limit : 0.2mm (0.0079 in.)

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Check for continuity between the segments of the commutator. If an open circuit exists between any
segments, replace the armature.

8
.
Check with an ohmmeter that no continuity exists between the commutator (A) and armature coil core
(B), and between the commutator and armature shaft (C). If continuity exists, replace the armature.

9
.
Starter Brush
1. Brushes that are worm out, or oil-soaked, should be replaced.

Bruch length
Standard : 12.3 mm (0.4843 in)
Service linit : 5.5 mm (0.2165 in)

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To seat new brushes, slip a strip of #500 or #600 sandpaper, with the grit side up, between the
commutator and each brush, and smoothly rotate the armature. The contact surface of the brushes
• will be sanded to the same contour as the commutator.
Starter Brush Holder
Check that there is no continuity between the (+) brush holder (A) and (-) plate (B).
If there is continuity, replace the brush holder assembly.

1.
Overrunning Clutch
Slide the overrunning clutch along the shaft.
1. Replace it if does not slide smoothly.
2 Rotate the overrunning clutch both ways.
. Does it lock in one direction and rotate smoothly in reverse? If it does not lock in either direction of it
locks in both directions, replace it.

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If the starter drive gear is worn or damaged, replace the overrunning clutch assembly. (the gear is not
available separately)
Check the condition of the flywheel or torque converter ring gear if the starter drive gear teeth are
3. damaged.
Cleaning
Do not immerse parts in cleaning solvent.
1 Immersing the yoke assembly and/or armature will damage the insulation wipe these parts with a cloth
. only.
Do not immerse the drive unit in cleaning solvent.
2. The overrun clutch is pre-lubricated at the factory and sol-vent will wash lubrication from the clutch.
3. The drive unit may be cleaned with a brush moistened with cleaning solvent and wiped dry with a cloth.

Inspection
1. Turn ignition switch OFF and disconnect the negative (-) battery cable.
2. Remove the fuse box cover.
Remove the starter relay (A).

3.
Using an ohmmeter, check that there is continuity between each terminal.
Terminal Continuity
4 30 - 87 NO
. 85 - 86 YES

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Apply 12V to terminal 85 and ground to terminal 86.

Check for continuity between terminals 30 and 87.

5.
6. If there is no continuity, replace the starter relay.
7. Install the starter relay.
8. Install the fuse box cover.

2.7 Cruise Control System

Description
The cruise control system is engaged by the cruise "ON/OFF" main switch located on right of
steering wheel column. The system has the capability to cruise, coast, accelerate and resume
speed.
It also has a safety interrupt, engaged upon depressing brake or shifting select lever.
The ECM is the control module for this system. The main components of cruise control system
are mode control switches, transmission range switch, brake switch, vehicle speed sensor, ECM
and ETS motor that connect throttle body.
The ECM contains a low speed limit which will prevent system engagement below a minimum
speed of 40km/h (25mph).
The operation of the controller is controlled by mode control switches located on steering wheel.
Transmission range switch and brake switch are provided to disengage the cruise control system.
The switches are on brake pedal bracket and transmission. When the brake pedal is depressed or
select lever shifted, the cruise control system is electrically disengaged and the throttle is
returned to the idle position.
Cruise main switch (CRUISE)

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The cruise control system is engaged by pressing the cruise "ON/OFF" main switch. Pressing the
cruise "ON/OFF" main switch again releases throttle, clears cruise memory speed, and puts
vehicle in a non-cruise mode.
Set/Coast switch (SET/–)
The "SET/–" switch located on right of steering wheel column has two functions.
The set function - Push the "SET/–" switch and release it at the desired speed. The SET indicator
light in the instrument cluster will illuminate. Release the accelerator pedal. The desired speed
will automatically be maintained.
The coast function - Push the "SET/–" switch and hold it when the cruise control is on. The
vehicle will gradually slow down. Release the switch at the desired speed. The desired speed will
be maintained.
Push the "SET/–" switch and release it quickly. The cruising speed will decrease by 2km/h or
1mph.
Resume/Accel switch (RES/+)
The "RES/+" switch located on right of steering wheel column has two functions.
The resume function - If any method other than the cruise “ON/OFF” main switch was used to
cancel cruising speed temporarily and the system is still activated, the most recent set speed will
automatically resume when the "RES/+" switch is pushed. It will not resume, however, if the
vehicle speed has dropped below approximately 40km/h (25mph).
The accel function - Push the "RES/+" switch and hold it when the cruise control is on. The
vehicle will gradually accelerate. Release the switch at the desired speed. The desired speed will
be maintained.
Push the "RES/+" switch and release it quickly. The cruising speed will increase by 2km/h or
1mph.
Cancel switch (CANCEL)
The cruise control system is temporarily disengaged by pushing the "CANCEL" switch.
Cruise speed canceled by this switch can be recovered by pushing the "RES/+" switch.

System Block Diagram

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2.7.1 Cruise Control Switch Schematic Diagrams

Circuit Diagram

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Inspection
[Measuring Resistance]
1. Disconnect the cruise control switch connector from the control switch.

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Measure resistance between terminals on the control switch when each function switch is ON
(switch is depressed).
Function switch Terminal Resistance
SET - 3-5 550?±5%
RES + 3-5 880?±5%
2 CANCEL 3-5 330?±5%
. CRUISE 3-5 1.4k?±5%
If not within specification, replace switch.

2.7.2 Cruise Control Switch Repair procedures

Removal
1. Disconnect the negative (-) battery terminal.
Remove the steering wheel assembly.
2. (Refer to Steering System - "Steering Wheel")
Remove the screw from the steering cover.

3.
4. Remove the steering back cover (A).

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Remove the steering remote control connector (A).

5.
6. Remove the steering remote control (A) after loosening the screw.

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Installation
1. Install in the reverse order of removal.

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