6-2

INTAKE HEATER

CIRCUIT DIAGRAM

Intake Heater System Circuit Diagram LAOM9

COMPONENTS

01 Battery ASSY 49 Cable

24 Heater ASSY intake 50 Strap, bond
24A Gasket, intake heater 53 Sensor. water temperature
31 Cable BL Stopper, battery
32 Battery case BZ Washer
33 Cable EK flange, intake
(L/intake heater)
KALM20
Intake Heater Components
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INTAKE HEATER REMOVAL

1. Battery negative terminal disconnection

2. Air cleaner hose disconnection

3. Ventilation hose disconnection

Disconnecting the Hose KAL1-33

4. Intake pipe removal

5. Intake heater removal Removing the Intake Pipe KAL28-13

(1) Intake heater gasket
(2) Intake heater
(3) Intake heater gasket

INTAKE HEATER INSTALLATION

The installation procedure is the reverse of the

removal procedure.
Air cleaner pipe set nut
T = 138 kg-cm (9.98 ft-lb)
[13.53 Nm]

Removing the Intake Heater KAL3-32

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PREHEATING TIMER INSPECTION

1. Preheating indicator lamp lighting time

measurement
(1) Disconnect the water temperature
sensor connector.

Disconnecting the Conductor KALS59

(2) Turn the engine switch to ON, and
measure the preheating indicator lamp
lighting time.
Standard: 20 seconds (12V)
(Only 11Z engine),
20 seconds (24 V)

Caution:
Do not repeat this operation since the high
power consumption may cause excessive
battery discharge.

(3) Reconnect the water temperature sensor

connector. Preheating Indicator Lamp LAOS154

2. Afterheating function check

(1) Disconnect the water temperature
sensor connector.
(2) Start the engine and measure the
duration of current conduction between
the preheating timer terminal
Standard: 70 seconds

Caution:
Do not repeat since the power consump-
tion is high.
Afterheating Check G-13-2
Reconnect the water temperature sensor
(3) connector.

3. Open-circuit Detecting Function Check

Check that the preheating indicator
(1) lamp comes on and relay (for after-
heating) is set to off when the relay (for
afterheating) open-circuit detection ter-
minal connector is disconnected.

Open-circuit Detecting Function Check F1058

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4. Water Temperature Sensor Inspection

(1) Measure the resistance between water
temperature sensor terminals.
Standard:
Ω
-20°C 16.2 ± 1.6 kΩ
Ω
20°C 2.45 ± 0.24 kΩ
Ω
80°C 0.322 ± 0.032 kΩ

Inspecting the Water Temperature Sensor F2763

Sensor Characteristic Curve B6202

INTAKE HEATER INSPECTION

1. Intake heater inspection:

(1) Inspect continuity in the intake heater.
Standard: Continuity

Inspecting the Intake Heater KAL3-14

INTAKE HEATER RELAY INSPECTION

(1) Check continuity between the following
connectors.
Standard:
g E Continuity
Ω)
(approx. 14Ω
+B G No continuity

(2) Apply the battery voltage between

terminals g and E, and inspect the
function.
Standard:
Inspecting the Heater Relay B2997
+B G Continuity
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STARTING MOTOR

COMPONENTS

Starting Motor Components KALM21

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ITEMS TO BE PREPARED

STARTING MOTOR REMOVAL

1. Disconnect the battery negative - terminal.

Disconnecting the Battery Negative KAL34-2

- Terminal
2. Disconnect the starting motor wiring con-
nector.

Disconnecting the Starting Motor Wiring KAL34-4

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3. Remove the starting motor.

(1) Disconnect the lead from terminal 30.
(2) Set Nut
(3) Bond strap

Removing the Set Nut KAL34-6, 9

(4) Starting motor

Removing the Set Nut KAL34-10

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DISASSEMBLY

1. Disconnect the lead wire from the magnet

switch.

Disconnecting the Lead Wire KAHS91

2. Yoke removal
(1) Through bolts
(2) Yoke ASSY

3. End frame removal Removing the Yoke KAHS92

(1) Screws
(2) End frame

4. Brush removal
(1) Use long-nose pliers and raise the posi-
Removing the End Frame KAHS93
tive side brush spring.

Caution:
Carefully operate so as not to damage
the brush and commutator.

Removing the Brush KAHS94

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5. Armature removal

Caution:
Do not let the armature fall.

Removing the Armature KAHS95

6. Housing removal
(1) Screws
(2) Housing ASSY

Removing the Housing KAHS96

7. Clutch removal

Removing the Clutch KAHS97

8. Steel ball removal

Caution:
Do not lose the steel ball.

Removing the Steel Ball KAHS98

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9. Idle gear removal

Removing the Idle Gear KAHS99

10. Retainer and roller removal

Caution:
Carefully operate so as not to drop the
retainer and roller.

Retainer and roller KAHS100

11. Coil spring removal.

Removing the Spring KAHS101

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INSPECTION

1. Armature coil grounding test

(1) Check the insulation between the
commutator and armature coil.
Standard: No continuity

2. Armature coil short-circuit test Armature Coil Grounding Test Z5260

(1) Use the armature tester. While placing
the steel plate parallel with the armature.
Standard:
The steel plate shall neither be
attracted
nor vibrate.

Caution:
Thoroughly eliminate deposits on the
armature surface.

Armature Coil Short-Circuit Test Z5261

3. Armature coil open-circuit test
(1) Check continuity between segments.
Standard:
Continuity between all segments

Armature Coil Open-Circuit Test B1416

4. Commutator inspection
(1) Inspect radial runout.
Limit: within 0.05 mm (0.002 in)

Inspecting the Commutator Z5256

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(2) Inspect the outside diameter.

Standard: 36 mm (1.42 in)
Limit: 35 mm (1.38 in)

Inspecting the Commutator Outside Diameter Z5257

(3) Inspect the undercut depth between

segments.
Standard: 0.7 mm (0.028 in)
Limit: 0.2 mm (0.008 in)

Inspecting the Undercut M5044

5. Field coil open-circuit test

(1) Check the continuity between the field
coil brush and terminal C.
Standard: Continuity

Field coil Open-Circuit Test M5047

6. Field coil grounding test

(1) Check the insulation between the field
coil brush and field.
Standard: No continuity

Field Coil Grounding Test M5048

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7. Brush inspection
(1) Inspect the contact surface roughening
and brush length.
Standard: 20.5 mm (0.81 in)
Limit: 13.0 mm (0.51 in)

Caution:
Measure the brush length at the center
(concave portion).

(2) At the time of contact surface correc-

tion or brush replacement, use sand Inspecting the Brush ST0017, 0018
paper wrapped around the commutator
for surface correction.

8. Brush and spring inspection

(1) After checking smooth brush spring
movement, measure the installed load,
Standard: 3200 ~ 4000 g (7.1 ~ 8.8 lb)
[31.4 ~ 39.2 N]
Limit: 2200g (4.9 lb)
[21.6 N]

Inspecting the Brush Spring S4116

9. Brush holder inspection

(1) Check the insulation between the posi-
tive + and negative - brush holders.
Standard: No continuity

Inspecting the Brush Holder ST0062

10. Clutch and gear inspection

(1) Check the gear for wear and damage.
(2) Check that the gear is locked when
rotated direction (counter clockwise)
and that it rotates smoothly when it
is rotated in the reverse direction
(clockwise).

Inspecting the Clutch and Gear ST0020

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11. Bearing inspection and replacement

(1) No abnormality or seizure shall occur
when rotated with a finger force
(2) No abnormal sound shall be heard when
rotated quickly.
(3) Replace the bearing when any ab-
normality is found.

Inspecting the Bearing C0842, 0843

(4) Use the SST to remove the bearing.

SST 09286-46011

Replacing the Bearing B1419

(5) Use a press to fit the bearing.

Press-Fitting the Bearing B1420

12. Magnet switch inspection

(1) Check continuity between 2 terminal
50 and 1 terminal C.
Standard: Continuity

Inspecting the Magnet Switch F2703

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(2) Check continuity between 2 terminal

50 and 1 the magnet switch body.
Standard: Continuity

Inspecting the Magnet Switch F2702

ASSEMBLY

1. Steel ball installation

(1) Coat high-temperature grease on the ball
and put it into the clutch shaft hole.

Installing the Steel Ball B1423

2. Idle gear and clutch assembly
(1) Coat high-temperature grease on the idle
gear and clutch.
(2) Assemble the clutch, roller, retainer
and idle gear with the starting motor
housing.

Assembling the Idle Gear and Clutch ST0063

3. Starting motor housing assembly

(1) Coat high-temperature grease on the
return spring, and assemble it with the
magnet switch.
(2) Assemble the starting motor housing
and magnet switch.

Assembling the Starting Motor Housing ST0225

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4. Armature installation
(1) Coat high-temperature grease on the
armature bearing, and install the arma-
ture to the starting motor yoke.

Installing the Armature ST0237

5. Brush holder installation
(1) Raise the brush spring with a screw-
driver, and install the brush holder to
the starting motor yok
(2) Pull up the spring and install the brush
to the brush holder.

Installing the Brush Holder ST0039

6. End frame installation

(1) Match the end frame notch 1 with the
lead wire grommet 2 .
(2) Use the screws (two) to fix the end
frame.

Installing the End Frame KAHS102

7. Yoke installation
(1) Install the felt washer on top of the
armature shaft bearing.

Installing the Felt Washer ST0103

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(2) Match the yoke notch 1 with the

protrusion of the magnet switch, and
assemble the yoke and magnet switch.

Installing the Yoke KAHS103

(3) Install two through bolts.

Installing the Through Bolts ST0348

8. Lead wire connection to terminal C
(1) Use a nut to connect the lead to terminal
C.

Connecting the Lead Wire to Terminal C ST0347

INSPECTION

Caution:
Carry out each test in a short time (3 to 5
seconds).

1. Pull-in test
(1) Make sure that the illustrated connec-
tion causes the pinion gear to come out.

Pull-in Test ST0227

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2. Holding coil performance test

(1) Make sure that the pinion gear stays at
the protruded position after disconnect-
ing the wiring from terminal C from the
pull-in test state.

Inspecting the Holding Coil ST0228

3. Plunger return test

(1) Check that the pinion gear retracts
when the wiring is disconnected as
illustrated from the holding coil perfor-
mance test state.

Return Test ST0229

4. No-load test
(1) Firmly fix the starting motor with a
vise.
(2) Since a big current flows in the leads
during the no-load test, use thick
lead wires.
(3) Read the ammeter when the indication
is stabilized.
Standard: (24V) 90A or less
(12V) 180A or less

No-load Test F2698

INSTALLATION

The installation procedure is the reverse of the

removal procedure.

Caution:
Check that there is no incorrect or omitted
wiring before connecting the battery nega-
tive terminal.

Installing the Starting Motor F4998

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STARTING MOTOR RELAY

INSPECTION

1. Continuity inspection
Terminals Continuity
St E Yes
B Mg No
Replace the relay if defective.

Inspecting the Continuity (24 V) F2705

Inspecting the Continuity (12 V) ST0064

2. Function check
(1) Check that the circuit between terminals
Mg and B is closed when the battery
voltage is applied to terminals St and E.

Checking the Function (24 V) F2706

Checking the Function (24V) ST0108