16-1

GROUP 16

ENGINE
ELECTRICAL
CONTENTS

CHARGING SYSTEM . . . . . . . . 16-3 REMOVAL AND INSTALLATION <4G69> 16-15

DISASSEMBLY AND REASSEMBLY . . 16-16
INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-18
GENERAL INFORMATION . . . . . . 16-3

SERVICE SPECIFICATIONS. . . . . 16-4

STARTING SYSTEM . . . . . . . . 16-20

SPECIAL TOOLS. . . . . . . . . . . . . . 16-5

GENERAL INFORMATION . . . . . . 16-20

ON-VEHICLE SERVICE. . . . . . . . . 16-6 SERVICE SPECIFICATIONS . . . . . 16-21

ALTERNATOR OUTPUT LINE VOLTAGE
DROP TEST . . . . . . . . . . . . . . . . . . . . . 16-6 STARTER MOTOR ASSEMBLY . . 16-22
OUTPUT CURRENT TEST . . . . . . . . . . 16-7 REMOVAL AND INSTALLATION <4G63> 16-22
REGULATED VOLTAGE TEST . . . . . . . 16-9 REMOVAL AND INSTALLATION <4G69> 16-23
WAVEFORM CHECK USING AN STARTER MOTOR ASSEMBLY
OSCILLOSCOPE. . . . . . . . . . . . . . . . . . 16-10 INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-24
DISASSEMBLY AND REASSEMBLY . . 16-26
ALTERNATOR ASSEMBLY . . . . . 16-13 INSPECTION . . . . . . . . . . . . . . . . . . . . . 16-27
REMOVAL AND INSTALLATION <4G63> 16-13 Continued on next page
16-2

IGNITION SYSTEM . . . . . . . . . . 16-30 DETONATION SENSOR CHECK . . . . . 16-36

IGNITION SECONDARY VOLTAGE
WAVEFORM CHECK USING AN OSCILLOSCOPE
GENERAL INFORMATION . . . . . . 16-30 <4G63>. . . . . . . . . . . . . . . . . . . . . . . . . . 16-36

SERVICE SPECIFICATIONS. . . . . 16-32 IGNITION COIL. . . . . . . . . . . . . . . . 16-40

REMOVAL AND INSTALLATION <4G63> 16-40
SPECIAL TOOL . . . . . . . . . . . . . . . 16-32 REMOVAL AND INSTALLATION <4G69> 16-41

ON-VEHICLE SERVICE. . . . . . . . . 16-33 CAMSHAFT POSITION SENSOR . 16-41

IGNITION COIL (WITH BUILT-IN POWER REMOVAL AND INSTALLATION. . . . . . 16-41
TRANSISTOR) CHECK <4G63> . . . . . . 16-33
IGNITION COIL (WITH BUILT-IN POWER CRANKSHAFT POSITION SENSOR 16-42
TRANSISTOR) CHECK <4G69> . . . . . . 16-33 REMOVAL AND INSTALLATION <4G63> 16-42
RESISTIVE CORD CHECK <4G63> . . . 16-34 REMOVAL AND INSTALLATION <4G69> 16-43
SPARK PLUG CHECK AND CLEANING
<4G63> . . . . . . . . . . . . . . . . . . . . . . . . . 16-35
SPARK PLUG CHECK AND CLEANING
DETONATION SENSOR . . . . . . . . 16-44
<4G69> . . . . . . . . . . . . . . . . . . . . . . . . . 16-35 REMOVAL AND INSTALLATION <4G63> 16-44
CAMSHAFT POSITION SENSOR CHECK 16-36 REMOVAL AND INSTALLATION <4G69> 16-45
CRANK ANGLE SENSOR CHECK . . . . 16-36
 ENGINE ELECTRICAL
CHARGING SYSTEM
16-3
CHARGING SYSTEM
GENERAL INFORMATION
M1161000100373
The charging system uses the alternator output to The average output voltage fluctuates slightly with
keep the battery charged at a constant level under the alternator load condition.
various electrical loads. When the ignition switch is turned on, current flows in
OPERATION the field coil and initial excitation of the field coil
occurs.
Voltage When the stator coil begins to generate power after
the engine is started, the field coil is excited by the
output current of the stator coil.
The alternator output voltage rises as the field
Approximately current increases and it falls as the field current
14.4 V
decreases. When the battery voltage (alternator "S"
terminal voltage) reaches a regulated voltage of
approximately 14.4 V, the field current is cut off.
Time When the battery voltage drops below the regulated
AKX00183 AC
voltage, the voltage regulator regulates the output
Rotation of the excited field coil generates AC voltage to a constant level by controlling the field
voltage in the stator. current.
This alternating current is rectified through diodes to In addition, when the field current is constant, the
DC voltage having a waveform shown in the alternator output voltage rises as the engine speed
illustration. increases.

SYSTEM DIAGRAM
<4G63>
Alternator

Stator coil
Engine-ECU
<M/T> or
Engine-A/T-ECU
<A/T>
G

Field coil S
L
+

FR Ignition switch
Battery
Voltage regulator Charge warning light

AK100054 AG
16-4 ENGINE ELECTRICAL
CHARGING SYSTEM

<4G69>
Alternator

Stator
coil

Engine-ECU
<M/T> or
Engine-A/T-ECU
<A/T>
Field coil
G
S
+
L
FR Ignition
switch Battery
Charging
Voltage regulator warning
light –

AK301529 AC

ALTERNATOR SPECIFICATIONS
Item 4G63 4G69
Type Battery voltage sensing Battery voltage sensing
Rated output V/A 12/100 12/110
Voltage regulator Electronic built-in type Electronic built-in type

SERVICE SPECIFICATIONS
M1161000300377

Item Standard value Limit

Alternator output line voltage drop (at 30 A) V − maximum 0.3
Regulated voltage ambient −20°C 14.2 − 15.4 −
temperature at voltage regulator V 20°C 13.9 − 14.9 −
60°C 13.4 − 14.6 −
80°C 13.1 − 14.5 −
Output current − 70 % of normal output current
 ENGINE ELECTRICAL
CHARGING SYSTEM
16-5
SPECIAL TOOLS
M1161000600301

Tool Number Name Use

MB991502 MUT-II sub assembly Checking the idle speed

B991502

MB991955 MUT-III sub assembly Checking the idle speed

A A: MB991824 A: Vehicle
B: MB991827 communication
C: MB991910 interface (V.C.I.)
D: MB991911 B: MUT-III USB cable
MB991824 E: MB991825 C: MUT-III main harness
B F: MB991826 A (Vehicles with CAN
communication
system)
D: MUT-III main harness
MB991827 B (Vehicles without
CAN communication
C
system)
DO NOT USED E: MUT-III measurement
adapter
F: MUT-III trigger
MB991910
harness
D

MB991911

MB991825

MB991826

MB991955

MB991519 Alternator test harness Checking the alternator

("S" terminal voltage)
16-6 ENGINE ELECTRICAL
CHARGING SYSTEM

ON-VEHICLE SERVICE

ALTERNATOR OUTPUT LINE VOLTAGE DROP TEST

M1161000900380

Ammeter (clamp-type)

Alternator

Voltmeter (digital-type)

Battery
"B" terninal

AK203361AD

This test determines whether the wiring from the 5. Connect a digital-type voltmeter between the
alternator "B" terminal to the battery (+) terminal alternator "B" terminal and the battery (+)
(including the fusible line) is in a good condition or terminal. [Connect the (+) lead of the voltmeter to
not. the "B" terminal and the connect the (-) lead of the
1. Always be sure to check the following before the voltmeter to the battery (+) cable].
test. 6. Reconnect the negative battery cable.
• Alternator installation 7. Connect the MUT-II/III
• Drive belt tension
8. Leave the hood open.
(Refer to P.11A-8, GROUP 11A − On-Vehicle
Service.) <4G63> 9. Start the engine.
(Refer to P.11C-8, GROUP 11C − On-Vehicle 10.With the engine running at 2,500 r/min, turn the
Service.) <4G69> headlamps and other lamps on and off to adjust
• Fusible link the alternator load so that the value displayed on
• Abnormal noise from the alternator while the the ammeter is slightly above 30 A.
engine is running Adjust the engine speed by gradually decreasing
2. Turn the ignition switch to the "LOCK" (OFF) it until the value displayed on the ammeter is 30
position. A. Take a reading of the value displayed on the
3. Disconnect the negative battery cable. voltmeter at this time.
4. Connect a clamp-type DC test ammeter with a Limit: maximum 0.3 V
range of 0 − 150 A to the alternator "B" terminal NOTE: When the alternator output is high and the
output wire. value displayed on the ammeter does not
NOTE: The way of disconnecting the alternator decrease until 30 A, set the value to 40 A. Read
output wire and of connecting the ammeter is the value displayed on the voltmeter at this time.
possibly not found the problem that the output When the value range is 40 A, the limit is
current is dropping due to the insufficient maximum 0.4 V.
connection between terminal "B" and the output
wire.
 ENGINE ELECTRICAL
CHARGING SYSTEM
16-7
11.If the value displayed on the voltmeter is above 12.After the test, run the engine at idle.
the limit value, there is probably a malfunction in 13.Turn off all lamps.
the alternator output wire, so check the wiring 14.Turn the ignition switch to the "LOCK" (OFF)
between the alternator "B" terminal and the position.
battery (+) terminal (including fusible link).
15.Remove the MUT-II/III.
If a terminal is not sufficiently tight or if the 16.Disconnect the negative battery cable.
harness has become discolored due to
overheating, repair and then test again. 17.Disconnect the ammeter and voltmeter.
18.Connect the negative battery cable.

OUTPUT CURRENT TEST

M1161001000409

Load

Ammeter
Voltmeter (clamp-type)

– +

Ignition switch Charging indicator

B
FR
L
S
G

Alternator
Engine-ECU
<M/T> or
Engine-A/T-ECU
<A/T>
Battery

AK304240 AB

This test determines whether the alternator output (Refer to P.11A-8, GROUP 11A − On-Vehicle
current is normal. Service.) <4G63>
1. Before the test, always be sure to check the (Refer to P.11C-8, GROUP 11C − On-Vehicle
following. Service.) <4G69>
• Alternator installation • Fusible link
• Battery (Refer to P.54A-6, GROUP 54A − Battery • Abnormal noise from the alternator while the
− On-Vehicle Service.) engine is running.
NOTE: The battery should be slightly discharged. 2. Turn the ignition switch to the "LOCK" (OFF)
The load needed by a fully-charged battery is position.
insufficient for an accurate test. 3. Disconnect the negative battery cable.
• Drive belt tension
16-8 ENGINE ELECTRICAL
CHARGING SYSTEM

CAUTION Limit: 70 % of normal current output

Never use clips but tighten bolts and nuts to NOTE: .
connect the line. Otherwise loose connections • For the nominal current output, refer to the
(e.g. using clips) will lead to a serious accident Alternator Specifications.
because of high current. • Because the current from the battery will soon
4. Connect a clamp-type DC test ammeter with a drop after the engine is started, the above step
range of 0 − 150 A to the alternator "B" terminal should be carried out as quickly as possible in
output wire. order to obtain the maximum current output
value.
NOTE: The way of disconnecting the alternator
• The current output value will depend on the
output wire and of connecting the ammeter is
electrical load and the temperature of the
possibly not found the problem that the output
alternator body.
current is dropping due to the insufficient
• If the electrical load is small while testing, the
connection between terminal "B" and the output
specified level of current may not be output
wire.
even though the alternator is normal. In such
5. Connect a voltmeter with a range of 0 − 20 V cases, increase the electrical load by leaving
between the alternator "B" terminal and the earth the headlamps turned on for some time to
[Connect the (+) lead of the voltmeter to the "B" discharge the battery or by using the lighting
terminal, and then connect the (-) lead of the system in another vehicle, and then test again.
voltmeter to the earth]. • The specified level of current also may not be
6. Connect the negative battery cable. output if the temperature of the alternator body
7. Connect the MUT-II/III or the ambient temperature is too high. In such
8. Leave the hood open. cases, cool the alternator and then test again.
9. Check that the reading on the voltmeter is equal 12.The reading on the ammeter should be above the
to the battery voltage. limit value. If the reading is below the limit value
and the alternator output wire is normal, remove
NOTE: If the voltage is 0 V, the cause is probably
the alternator from the engine and check the
an open circuit in the wire or fusible link between
alternator.
the alternator "B" terminal and the battery (+)
terminal. 13.Run the engine at idle after the test.
10.Turn the light switch on to turn on headlamps and 14.Turn the ignition switch to the "LOCK" (OFF)
then start the engine. position.
11.Immediately after setting the headlamps to high 15.Remove the MUT-II/III.
beam and turning the heater blower switch to the 16.Disconnect the negative battery cable.
high revolution position, increase the engine 17.Disconnect the ammeter and voltmeter.
speed to 2,500 r/min and read the maximum 18.Connect the negative battery cable.
current output value displayed on the ammeter.
 ENGINE ELECTRICAL
CHARGING SYSTEM
16-9
REGULATED VOLTAGE TEST
M1161001100398

Load
Ammeter (clamp-type)

Ignition switch Charging indicator

MB991519 Black

B
FR
L Alternator
S
G

Blue
Red Yellow
Battery
Engine-ECU
<M/T> or
Engine-A/T-
ECU <A/T>
Voltmeter (digital-type)

AK304241AB

This test determines whether the voltage regulator 4. Use the special tool Alternator test harness
correctly controlling the alternator output voltage. (MB991519) to connect a digital voltmeter
1. Always be sure to check the following before the between the alternator "S" terminal and earth
test. [Connect the (+) lead of the voltmeter to the "S"
• Alternator installation terminal, and then connect the (-) lead of the
• Check that the battery installed in the vehicle is voltmeter to a secure earth or to the battery (-)
fully charged. terminal].
(Refer to P.54A-4, GROUP 54A − Battery − 5. Connect a clamp-type DC test ammeter with a
On-Vehicle Service.) range of 0 − 150 A to the alternator "B" terminal
• Drive belt tension output wire.
(Refer to P.11A-8, GROUP 11A − On-Vehicle NOTE: The way of disconnecting the alternator
Service.)<4G63>
output wire and of connecting the ammeter is
(Refer to P.11C-8, GROUP 11C − On-Vehicle possibly not found the problem that the output
Service.)<4G69> current is dropping due to the insufficient
• Fusible link
connection between terminal "B" and the output
• Abnormal noise from the alternator while the wire.
engine is running
6. Reconnect the negative battery cable.
2. Turn the ignition switch to the "LOCK" (OFF)
position. 7. Connect the MUT-II/III
3. Disconnect the negative battery cable. 8. Turn the ignition switch to the "ON" position and
check that the reading on the voltmeter is equal to
the battery voltage.
NOTE: If the voltage is 0 V, the cause is probably
an open circuit in the wire or fusible link between
the alternator "S" terminal and the battery (+)
terminal.
16-10 ENGINE ELECTRICAL
CHARGING SYSTEM

9. Turn all lamps and accessories off. 14.After the test, lower the engine speed to the idle
10.Start the engine. speed.
11.Increase the engine speed to 2,500 r/min. 15.Turn the ignition switch to the "LOCK" (OFF)
12.Read the value displayed on the voltmeter when position.
the alternator output current alternator becomes 16.Remove the MUT-II/III.
10 A or less. 17.Disconnect the negative battery cable.
13.If the voltage reading conforms to the value in the 18.Disconnect the ammeter and voltmeter.
voltage regulation, then the voltage regulator is 19.Connect the alternator output wire to the
operating normally. alternator "B" terminal.
If the voltage is not within the standard value, 20.Remove the special tool, and return the connector
there is a malfunction of the voltage regulator or of to the original condition.
the alternator. 21.Connect the negative battery cable.
Voltage Regulation Table
Standard value:
Inspection terminal Voltage regulator ambient Voltage V
temperature °C
Terminal "S" −20 14.2 − 15.4
20 13.9 − 14.9
60 13.4 − 14.6
80 13.1 − 14.5

WAVEFORM CHECK USING AN OSCILLOSCOPE

M1161001200179

MEASUREMENT METHOD Connect the oscilloscope special patterns pick-up to

the alternator "B" terminal.
Alternator

CH1

"B" terminal AK100002 AC

 ENGINE ELECTRICAL
CHARGING SYSTEM
16-11
STANDARD WAVEFORM
Observation Conditions
Function Special pattern
Pattern height Variable
Variable knob Adjust while viewing the waveform.
Pattern selector Raster
Engine speed Curb idle speed

(V)

0.4

0.2
Voltage at
alternator 0
"B" terminal
–0.2

–0.4

Time

AKX00189AG

NOTE: when the voltage waveform reaches an excessively

high value (approximately 2 V or higher at idle), it
often indicates an open circuit due to a brown fuse
between alternator "B" terminal and battery, but not a
defective alternator.

AKX00190

The voltage waveform of the alternator "B" terminal

can undulate as shown in the illustration. This
waveform is produced when the regulator operates
according to fluctuations in the alternator load
(current), and is normal for the alternator. In addition,
16-12 ENGINE ELECTRICAL
CHARGING SYSTEM

EXAMPLE OF ABNORMAL WAVEFORMS

NOTE: .
1. The size of the waveform patterns differs largely, depending on the adjustment of the variable knob on the
oscilloscope.
2. Identification of abnormal waveforms is easier when there is a large output current (regulator is not
operating). (Waveforms can be observed when the headlamps are illuminated.)
3. Check the conditions of the charging warning lamp (illuminated/not illuminated). Also, check the charging
system totally.

Abnormal waveform Problem cause

Example 1 Open diode

AKX00191

Example 2 Short in diode

AKX00192

Example 3 Broken wire in

stator coil

AKX00193

Example 4 Short in stator

coil

AKX00194
 ENGINE ELECTRICAL
CHARGING SYSTEM
16-13
ALTERNATOR ASSEMBLY
REMOVAL AND INSTALLATION <4G63>
M1161001400667

Pre-removal Operation Post-installation Operation

• Under Cover Removal (Refer to GROUP 51, Under Cover • Drive Belt Installation (Refer to GROUP 11A, Crankshaft
P.51-19). Pulley P.11A-16).
• Drive Belt Removal (Refer to GROUP 11A, Crankshaft • Drive Belt Tension Adjustment (Refer to GROUP 11A,
Pulley P.11A-16). On-vehicle Service P.11A-8).
• Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-19).

1 7

11 ± 1 N·m
13 ± 1 N·m
44 ± 10 N·m
12 ± 2 N·m 9

N2
4 22 ± 4 N·m
(Engine oil) 23 ± 3 N·m

6
8.8 ± 1.0 N·m

AC301643 AB

Removal steps Removal steps (Continued)

1. Oil level gauge and guide <<A>> 5. Harness connector
2. O-ring 6. Water pump pulley
3. Detonation sensor harness 7. Alternator connector
connector and clamp 8. Alternator brace
4. Power steering oil pressure hose <<B>> 9. Alternator assembly
clamp
16-14 ENGINE ELECTRICAL
CHARGING SYSTEM

REMOVAL SERVICE POINT Move the lock lever of the ABS-ECU connector as
<<A>> HARNESS CONNECTOR shown in the illustration, and then disconnect the
DISCONNECTION harness connector.

Lock lever <<B>> ALTERNATOR ASSEMBLY REMOVAL

Remove the alternator assembly from above the
vehicle.

AC200022AE
 ENGINE ELECTRICAL
CHARGING SYSTEM
16-15
REMOVAL AND INSTALLATION <4G69>
M1161001400678

Pre-removal Operation Post-installation Operation

• Under Cover Removal (Refer to GROUP 51, Under Cover • Drive Belt Installation (Refer to GROUP 11C, Crankshaft
P.51-19). Pulley P.11C-17).
• Drive Belt Removal (Refer to GROUP 11C, Crankshaft • Drive Belt Tension Check (Refer to GROUP 11C,
Pulley P.11C-17). On-vehicle Service P.11C-8).
• Under Cover Installation (Refer to GROUP 51, Under
Cover P.51-19).

1
11 ± 1 N·m

5
14 ± 3 N·m

4
3
49 ± 9 N·m

49 ± 9 N·m
8
11 ± 1 N·m
49 ± 9 N·m

7 6
44 ± 10 N·m AC309557AB

Removal steps Removal steps (Continued)

1. A/C compressor assembly • Timing belt lower cover (Refer to
connector GROUP 11C, Timing Belt
2. A/C compressor assembly P.11C-36).
connector clamp 8. Alternator mounting bracket
3. Alternator connector
4. Alternator terminal REMOVAL SERVICE POINT
5. Connector bracket <<A>> ALTERNATOR ASSEMBLY REMOVAL
6. Harness bracket
Remove the alternator assembly from above the
<<A>> 7. Alternator assembly
vehicle.
16-16 ENGINE ELECTRICAL
CHARGING SYSTEM

DISASSEMBLY AND REASSEMBLY

M1161001600199

1
4
3

5
7 6

12
10
9

8
14

13

11

AK202845 AB

Disassembly steps Disassembly steps (Continued)

<<A>> 1. Front bracket assembly <<C>> 8. Stator
<<B>> 2. Alternator pulley 9. Plate
>>B<< 3. Rotor <<C>> >>A<< 10. Regulator assembly
4. Rear bearing 11. Brush
5. Bearing retainer 12. Rubber packing
6. Front bearing 13. Rectifier
7. Front bracket 14. Rear bracket
 ENGINE ELECTRICAL
CHARGING SYSTEM
16-17
DISASSEMBLY SERVICE POINTS CAUTION
<<A>>FRONT BRACKET ASSEMBLY REMOVAL • Use a 180 − 250 W soldering iron, and finish
unsoldering within four seconds. Diodes will
be damaged by heat if unsoldering time is too
long.
• Avoid applying undue force to the diode
leads.
1. Unsolder the stator leads from the main diode of
the rectifier assembly when the stator is removed.
2. When removing the rectifier assembly from the
regulator assembly, undo the soldered points on
AK202718 the rectifier assembly.

CAUTION REASSEMBLY SERVICE POINTS

Do not insert the screwdriver blades too deep.
Doing so could damage the stator coil. >>A<<REGULATOR ASSEMBLY INSTALLATION
Insert the blades of screwdrivers between the front
bracket assembly and stator core, and pry and
separate them with the screwdrivers.
Wire
<<B>>ALTERNATOR PULLEY REMOVAL

AK202779 AB

Rear bracket

Brush
AK202714

CAUTION Wire
Perform operation carefully not to damage the
rotor.
Clamp the rotor in a vise with the pulley facing up to
AK202830 AB
remove the pulley.
After installing the regulator assembly, insert a piece
<<C>>STATOR / REGULATOR ASSEMBLY of wire through the hole in the rear bracket while
REMOVAL pressing the brush to keep the brush against
movement.
Rectifier Solder
assembly NOTE: Holding the brush with the wire facilities
installation of the rotor.

Solder
AK202778 AB
16-18 ENGINE ELECTRICAL
CHARGING SYSTEM

>>B<<ROTOR INSTALLATION 3. If continuity is present, replace the rotor.

STATOR

Wire

AK202779 AB

Remove the brush holding wire after the rotor has

been installed. AK202716

INSPECTION 1. Check the continuity between coil leads.

M1161001700129
If there is no continuity, replace the stator.
ROTOR

AK202717
AK202735

2. Check the continuity between coil and core.

1. Measure the resistance between the two slip rings
of the rotor coil to check the continuity between If there is no continuity, replace the stator.
them.
RECTIFIER ASSEBMLY
Replace the rotor if the resistance is not within the
standard value range.
Standard value: 3 − 5 Ω
2. Check the continuity between the slip rings and
core.

AK202803

1. Check the condition of the (+) heat sink by

checking continuity between the (+) heat sink and
each of the stator coil lead connecting terminals.
AK202736 If continuity is present for both terminals, the
diode is shorted. Replace the rectifier assembly.
 ENGINE ELECTRICAL
CHARGING SYSTEM
16-19

BRUSH

Protrusion
length

AK202802

2. Check the condition of the (−) heat sink by

AK202808 AB
checking continuity between the (−) heat sink and
each of the stator coil lead connecting terminals. 1. Measure the length of the protrusion of the brush.
If continuity is present in both directions, the diode Replace the brush if the protrusion length is
is shorted. Replace the rectifier assembly. shorter than the limit.
Limit: 2 mm minimum
2. Unsolder the lead of the brush. The brush will
come out, becoming ready for removal.

Solder

AK202804

3. Check the condition of the diode trio by testing

continuity of each of the three diodes using a
circuit tester connected to both sides of the diode. AK202834 AB

Connect in a polarity and then reverse the polarity 3. Install a new brush by pushing it into the holder as
for each test. shown in the drawing and soldering the lead.
If continuity exists or no continuity exists for both
polarities, the diode is defective. Replace the
rectifier assembly if any of the diodes is defective.
16-20 ENGINE ELECTRICAL
STARTING SYSTEM

STARTING SYSTEM
GENERAL INFORMATION
M1162000100268
If the ignition switch is turned to the "START" When the ignition switch is returned to the "ON"
position, current flows in the pull-in and holding coils position after starting the engine, the starter clutch is
provided inside magnetic switch, attracting the disengaged from the ring gear.
plunger, When the plunger is attracted, the lever An overrunning clutch is provided between the pinion
connected to the plunger is actuated to engage the and the armature shaft, to prevent damage to the
starter clutch. starter.
On the other hand, attracting the plunger will turn on
the magnetic switch, allowing the "B" terminal and
"M" terminal to conduct. Thus, current flows to
engage the starter motor.
SYSTEM DIAGRAM

Holding coil Plunger

Pull-in coil
Lever

B Overrunning clutch

Ignition switch M
Pinion gear
S

+ Armature

Battery

Brush
Yoke

AK202970 AB
 ENGINE ELECTRICAL
STARTING SYSTEM
16-21
STARTER MOTOR SPECIFICATIONS
Item Specification
Type Reduction drive with planetary gear
Rated output kW/V 1.4/12
Number of pinion teeth 8

SERVICE SPECIFICATIONS
M1162000300079

Item Standard value Limit

Pinion gap mm 0.5 − 2.0 −
Commutator run-out mm 0.05 0.1
Commutator diameter mm 29.4 28.8
Undercut depth mm 0.5 0.2
16-22 ENGINE ELECTRICAL
STARTING SYSTEM

STARTER MOTOR ASSEMBLY

REMOVAL AND INSTALLATION <4G63>
M1162001000725

Pre-removal and Post-installation Operation

• Resonator and Air Intake Duct Removal and Installation
(Refer to GROUP 15, Air Cleaner P.15-3).
• Under Cover Removal and Installation (Refer to GROUP
51, Under Cover P.51-19).

18 ± 3 N·m
4 9.0 ± 2.0 N·m
3
30 ± 3 N·m
1
49 ± 9 N·m

AC301550 AB

Removal steps REMOVAL SERVICE POINT

1. Starter cover <<A>> STARTER ASSEMBLY REMOVAL
2. Starter connector Remove the starter assembly from above the
3. Clutch release cylinder connecting
vehicle.
bolts
4. Clutch hose clamp
<<A>> 5. Starter assembly
6. Starter cover bracket
 ENGINE ELECTRICAL
STARTING SYSTEM
16-23
REMOVAL AND INSTALLATION <4G69>
M1162001000639

Pre-removal and Post-installation Operation

• Air Duct Removal and Installation (Refer to GROUP 15,
Air Cleaner P.15-4).
• Exhaust Manifold Heat Protector Removal and Installation
(Refer to GROUP 15, Exhaust Manifold P.15-11).

30 ± 3 N·m

2
3

12 ± 2 N·m 1

6 49 ± 9 N·m 9.0 ± 2.0 N·m

AC305106 AC

Removal steps REMOVAL SERVICE POINT

1. Starter cover <<A>> STARTER ASSEMBLY REMOVAL
2. Harness clamp Remove the starter assembly from above the
3. Starter connector
vehicle.
4. Starter terminal
<<A>> 5. Starter assembly
6. Starter cover bracket
16-24 ENGINE ELECTRICAL
STARTING SYSTEM

STARTER MOTOR ASSEMBLY INSPECTION

M1162001100227
PINION GAP ADJUSTMENT
MAGNETIC SWITCH PULL-IN TEST

Switch
S
M S
B
battery
M
B
Battery
Starter Wire
motor
Starter Wire
motor
AKX01238 AF

AKX01242 AE
1. Disconnect the field coil wire from the M-terminal
of the magnetic switch. 1. Disconnect the field coil wire from the M-terminal
2. Connect a 12-volt battery between the S-terminal of the magnetic switch.
and M-terminal. CAUTION
CAUTION This test must be performed quickly (in less than
This test must be performed quickly (in less than 10 seconds) to prevent the coil from burning.
10 seconds) to prevent the coil from burning. 2. Connect a 12-volt battery between the S-terminal
3. Set the switch to "ON", and the pinion will move and M-terminal.
out. 3. If the pinion moves out, the pull-in coil is good. If it
doesn't, replace the magnetic switch.

Stopper MAGNETIC SWITCH HOLD-IN TEST

S
M
Pinion B
Battery
Pinion gap
AKX00198 AC
Starter Wire
4. Check the pinion-to-stopper clearance (pinion motor
gap) with a feeler gauge.
AKX01244AE
Standard value: 0.5 − 2.0 mm
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 body.
3. Manually pull out the pinion as far as the pinion
stopper position.
AKX00199
4. If the pinion remains out, everything is in order. If
5. If the pinion gap is out of specification, adjust by the pinion moves in, the hold-in circuit is open.
adding or removing gasket(s) between the Replace the magnetic switch.
magnetic switch and front bracket.
 ENGINE ELECTRICAL
STARTING SYSTEM
16-25
FREE RUNNING TEST Current: maximum 95 Amps

Ammeter
A MAGNETIC SWITCH RETURN TEST
S
Carbon-pile
rheostat
M B
S
Battery
Starter V M
motor Voltmeter B
Battery

AKX01246 AE Starter Wire

motor
1. Place the starter motor in a vise equipped with
soft jaws and connect a fully-charged 12-volt AKX01248 AE

battery to the starter motor as follows: 1. Disconnect the field coil wire from the M-terminal
2. Connect a test ammeter (100-ampere scale) and of the magnetic switch.
carbon pile rheostat in series between the positive
CAUTION
battery terminal and starter motor terminal.
This test must be performed quickly (in less than
3. Connect a voltmeter (15-volt scale) across the 10 seconds) to prevent the coil from burning.
starter motor.
2. Connect a 12-volt battery between the M-terminal
4. Rotate the rheostat to full-resistance position.
and body.
5. Connect the battery cable from the negative
battery terminal to the starter motor body. WARNING
6. Adjust the rheostat until the battery positive
Be careful not to get your fingers caught
voltage shown on the voltmeter is 11 V. when pulling out the pinion.
7. Confirm that the maximum amperage is within the 3. Pull the pinion out and release. If the pinion
specifications and that the starter motor turns quickly returns to its original position, everything is
smoothly and freely. operating properly. If it doesn't, replace the
magnetic switch.
16-26 ENGINE ELECTRICAL
STARTING SYSTEM

DISASSEMBLY AND REASSEMBLY

M1162001200224

12
15 13
10
11
14
2 20

5.8 ± 1.6 N·m 19

18 5.8 ± 1.6 N·m
1 17 3.4 ± 1.0 N·m
4
16
3

21

7 5
9

AK304532 AB

Disassembly steps Disassembly steps (Continued)

1. Screw 12. Packing B
<<A>> 2. Magnetic switch 13. Plate
3. Screw 14. Planetary gear
4. Bolt 15. Lever
5. Rear bracket <<B>> >>A<< 16. Snap ring
6. Brush holder <<B>> >>A<< 17. Stop ring
7. Rear bearing 18. Overrunning clutch
8. Armature 19. Internal gear
9. Yoke assembly 20. Planetary gear shaft
10. Ball 21. Front bracket
11. Packing A
 ENGINE ELECTRICAL
STARTING SYSTEM
16-27
DISASSEMBLY SERVICE POINTS STARTER MOTOR PARTS CLEANING
<<A>> MAGNETIC SWITCH REMOVAL Never clean in a solvent such starter motor parts as
the magnetic switch, brush holder, and armature.
B terminal S terminal If they are soaked in a solvent, their insulation
could be impaired. When these parts require
cleaning, wipe off contamination with cloth.
Field coil
M terminal lead 1. Never soak the drive unit in a solvent. If it is
washed in a solvent, the grease having been
packed in the overrunning clutch at the factory will
be washed out. Wipe the drive unit with cloth if it
requires cleaning.
AK202890 AB
REASSEMBLY SERVICE POINTS
CAUTION >>A<< STOP RING/SNAP RING INSTALLATION
Do not clamp the yoke assembly with a vise.
Disconnect the lead from the M terminal of the
magnetic switch.

<<B>> SNAP RING/STOP RING REMOVAL

Overrunning Stop ring
Socket wrench clutch
Stop ring

Stop ring Pinion Gear

Snap ring AK202911 AB
Overrunning
clutch Use a suitable puller to pull the stop ring until it gets
over the snap ring.

INSPECTION
AK202790 AB M1162001300179
COMMUTATOR
1. Apply a long socket wrench of an appropriate size
to the stop ring and strike the wrench to drive out
the stop ring toward the pinion gear side.

Snap ring
Snap ring
pliers Pinion gear

Overrunnning
clutch

AK202712

1. Support the armature with a pair of V block and

AK202791 AB turn it to measure the runout of the surface not
rubbed by the brushes using a dial gauge.
2. Remove the snap ring with snap ring pliers, then
Standard value: 0.05 mm or less
remove the stop ring and overrunning clutch.
Limit: 0.1 mm
16-28 ENGINE ELECTRICAL
STARTING SYSTEM

Push the brush into the brush holder to make sure

that the spring is working on the brush.
If the spring is not working, replace the brush holder.

OVERRUNNING CLUTCH

AK202715
Free
2. Measure the diameter of the commutator.
Standard value: 29.4 mm
Limit: 28.8 mm Lock

AK202710 AB

Undercut 1. Make sure that the pinion cannot be turned

Segment
counterclockwise and can be turned clockwise
Mica
freely.
2. Check the pinion for abnormal ware and damage.

BRUSHES

AK202711 AB

3. Measure the depth of the undercut between

segments.
Brush
Standard value: 0.5 mm height
Limit: 0.2 mm

BRUSH HOLDER
AK202846 AB

1. Check the commutator contacting surface of each

brush for abnormal roughness. Also check the
height of the brush. Replace the brush holder if
the height is lower than the limit.
Limit: 7.0 mm
2. When the contact surface of the brush is rectified
or the brush holder is replaced, recondition the
AK202897
contact surface with sandpaper wrapped around
the commutator.
 ENGINE ELECTRICAL
STARTING SYSTEM
16-29
ARMATURE COIL MAGNETIC SWITCH
1. Check the armature coil for short circuit as
follows:
A
Growler

M terminal

AK202891 AB

1. Coil open circuit test

AK202733 AB
• Check that there is continuity between the M
2. Set the armature in a growler. terminal and body A.
• If there is no continuity, replace the magnetic
CAUTION
switch.
Clean the surface of the armature thoroughly
before performing the test.
3. While holding a thin strip of iron against the B terminal
armature in parallel with its axis, turn the armature
slowly. The armature is normal if the iron strip is
not attracted to the armature or it does not vibrate.

M terminal

AK202892 AB

2. Contact fusion check

• Check that there is no continuity between the B
terminal and M terminal.
• If there is continuity, replace the magnetic switch.
AK202734

4. Check the insulation between commutator B terminal

segments and armature coils. The armature coils
are properly insulated if no continuity is present.

M terminal

AK202893 AB

3. Switch contact check

• Push the indicated end of the magnetic switch
with a strong force to close the internal contacts.
AK202713 Without releasing the switch end, check that
there is continuity between the B terminal and M
5. Check continuity between a segment and another. terminal.
There is no open circuit in the tested coil if there is • If there is no continuity, replace the magnetic
continuity. switch.
16-30 ENGINE ELECTRICAL
IGNITION SYSTEM

IGNITION SYSTEM
GENERAL INFORMATION
M1163000100335

<4G63> The engine-ECU <M/T> or engine-A/T-ECU <A/T>

This system is equipped with two ignition coils (A and turns the two power transistors inside the ignition
B) with built-in power transistors for the No. 1 and coils alternately on and off. This causes the primary
No. 4 cylinders and the No. 2 and No. 3 cylinders currents in the ignition coils to be alternately
respectively. interrupted and allowed to flow to fire the cylinders in
Interruption of the primary current flowing in the the order 1-3-4-2.
primary side of ignition coil A generates a high The engine-ECU <M/T> or engine-A/T-ECU <A/T>
voltage in the secondary side of ignition coil A. The determines which ignition coil should be controlled
high voltage thus generated is applied to the spark by means of the signals from the camshaft position
plugs of No. 1 and No. 4 cylinders to generate sensor which is incorporated in the camshaft and
sparks. At the time that the sparks are generated at from the crank angle sensor which is incorporated in
both spark plugs, if one cylinder is at the the crankshaft. It also detects the crankshaft position
compression stroke, the other cylinder is at the in order to provide ignition at the most appropriate
exhaust stroke, so that ignition of the compressed timing in response to the engine operation
air/fuel mixture occurs only for the cylinder which is conditions. It also detects the crankshaft position in
at the compression stroke. order to provide ignition at the most appropriate
In the same way, when the primary current flowing in timing in response to the engine operation
ignition coil B is interrupted, the high voltage thus conditions.
generated is applied to the spark plugs of No. 2 and When the engine is cold or operated at high
No. 3 cylinders. altitudes, the ignition timing is slightly advanced to
provide optimum performance.
When the automatic transmission shifts gears, the
ignition timing is also retarded in order to reduce
output torque, thereby alleviating shifting shocks.
SYSTEM DIAGRAM

Air flow sensor

Intake air temperatur

sensor
Ignition
Engine coolant switch
Ignition coil B Ignition coil A
temperature sensor

Engine-ECU
Camshaft position
<M/T> or
sensor
Engine-A/T-
ECU <A/T>
Crank angle sensor Battery

Barometric pressure
sonsor Spark plug

Detonatoin sensor
Cylinder No. 2 3 4 1
Ignition switch-ST

AK101074 AF
 ENGINE ELECTRICAL
IGNITION SYSTEM
16-31
IGNITION COIL SPECIFICATION
Item Specification
Type Molded 2-coil

SPARK PLUG SPECIFICATIONS

Item Specification
NGK IGR6A11

<4G69> The engine-ECU <M/T> or engine-A/T-ECU <A/T>

This system is equipped with four ignition coils with determines which ignition coil should be controlled
built-in power transistors for each of the cylinders. by means of the signals from the camshaft position
Interruption of the primary current flowing in the sensor and the crank angle sensor. It also detects
primary side of an ignition coil generates a high the crankshaft position, in order to provide ignition at
voltage in the secondary side of ignition coil. The the most appropriate timing in response to the
high voltage thus generated is applied to the spark engine operation conditions.
plugs to generate sparks. The engine-ECU <M/T> or When the engine is cold or running at high altitudes,
engine-A/T-ECU <A/T> turns the power transistors the ignition timing is slightly advanced to provide
inside the ignition coils alternately on and off.This optimum performance. Furthermore, if knocking
causes the primary currents in the ignition coils to be occurs, the ignition timing is gradually retarded until
alternately interrupted and allowed to flow to fire the knocking ceases.
cylinders in the order 1-3-4-2.
SYSTEM DIAGRAM

Ignition
Air flow sensor switch
Battery
Barometric pressure
sonsor
Intake air temperatur
sensor
Engine coolant
temperature sensor
Engine-ECU
Accelerator pedal <M/T> or
position sensor Engine-A/T-
Camshaft position ECU <A/T>
sensor
Ignition coil
Crank angle sensor
Ignition switch-ST
Detonatoin sensor
Vehicle speed signal
Inhibitor switch
Spark plug

Cylinder No. 2 3 4 1

AK303631 AB
16-32 ENGINE ELECTRICAL
IGNITION SYSTEM

IGNITION COIL SPECIFICATION

Item Specification
Type Molded 4-coil

SPARK PLUG SPECIFICATIONS

Item Specification
NGK LZFR6AI

SERVICE SPECIFICATIONS
M1163000300209

IGNITION COIL <4G63>

Item Standard value
Secondary coil resistance kΩ 8.5 − 11.5

SPARK PLUG
Item Standard value Limit
Spark plug gap mm 4G63 1.0 − 1.1 1.3
4G69 0.7 − 0.8 1.2

RESISTIVE CORD <4G63>

Item Standard value Limit
Resistance kΩ − Maximum 19

SPECIAL TOOL
M1163000600200

Tool Number Name Use

MD998773 Detonation sensor Detonation sensor
wrench removal and installation
 ENGINE ELECTRICAL
IGNITION SYSTEM
16-33
ON-VEHICLE SERVICE

IGNITION COIL (WITH BUILT-IN POWER TRANSISTOR) CHECK <4G63>

M1163001200409
Check by the following procedure, and replace if PRIMARY COIL AND POWER
there is a malfunction. TRANSISTOR CONTINUITY CHECK
SECONDARY COIL RESISTANCE CHECK NOTE: .
•

+ –

1.5 V

– + 1 2 3

AKX01264 AK202356 AE

Measure the resistance between the high-voltage An analogue-type circuit tester should be used.
terminals of the ignition coil. • Connect the negative (-) prove of the circuit tester
Standard value: 8.5 − 11.5 kΩ to terminal No. 1.
CAUTION
This test must be performed quickly (in less
than 10 seconds) to prevent coil from burning
and power transistor from breakage.
Connect and disconnect 1.5 V battery between
terminal No. 2 and No. 3, and observe the ohmmeter
whether there is continuity or not.
1.5 V power supply Continuity between 1 −
between 2 − 3 2
When current is flowing Continuity
When current is not
flowing No continuity

IGNITION COIL (WITH BUILT-IN POWER TRANSISTOR) CHECK <4G69>

M1163001200391
Check by the following procedure, and replace if 3. Connect the ignition coil connector.
there is a malfunction. 4. Earth the side electrode of the spark plug and
SECONDARY COIL RESISTANCE CHECK crank the engine.
NOTE: It is impossible to check the secondary coil 5. Check that spark is produced between the
through the continuity check as a diode is integrated electrodes of the spark plug.
in the secondary coil circuit of this ignition coil. 6. If no spark plug is produced, replace the ignition
Accordingly, check the secondary coil in the following coil with a new one and recheck.
procedure. 7. If spark is produced with the new ignition coil,
1. Disconnect the ignition coil connector. replace the old one as it is faulty. If no spark is
2. Remove the ignition coil and install a new spark produced again, the ignition circuit is suspected
plug to the ignition coil. as faulty. Check the ignition circuit.
16-34 ENGINE ELECTRICAL
IGNITION SYSTEM

PRIMARY COIL AND POWER CAUTION

TRANSISTOR CONTINUITY CHECK This test must be performed quickly (in less
NOTE: . than 10 seconds) to prevent coil from burning
•
and power transistor from breakage.
Connect and disconnect 4.5 − 9.0 V battery between
+ – terminal No. 2 and No. 3, and observe the ohmmeter
whether there is continuity or not.
4.5 – 9 V
4.5 − 9 V power supply Continuity between 1 −
– + 1 2 3
between 2 − 3 2
When current is flowing Continuity
When current is not
flowing No continuity
AK202356 AD

An analogue-type circuit tester should be used.

• Connect the negative (-) prove of the circuit tester
to terminal No. 1.

RESISTIVE CORD CHECK <4G63>

M1163001400146
Measure the resistance of the all spark plug cables.
1. Check cap and coating for cracks.
2. Measure resistance.
Limit: Maximum 19 kΩ

AKX00382
 ENGINE ELECTRICAL
IGNITION SYSTEM
16-35
SPARK PLUG CHECK AND CLEANING <4G63>
M1163004300405

CAUTION 3. Check the plug gap and replace if the limit is

When pulling off the spark plug cable from the exceeded.
plug always hold the cable cap, not the cable. Standard value: 1.0 − 1.1 mm
1. Remove the spark plug cables. Limit: 1.3 mm
2. Remove the spark plugs. CAUTION
CAUTION Be careful not to allow foreign matter in
• Do not attempt to adjust the gap of the iridium cylinders.
plug. 4. Clean the engine plug holes.
• Always use a plug cleaner and finish cleaning 5. Install the spark plugs.
within 20 seconds. Do not use wire brushes.
Otherwise, the iridium and platinum tip may
be damaged.

Iridium tip

Platinum tip
AKX01327AD

SPARK PLUG CHECK AND CLEANING<4G69>

M1163004300416
1. Remove the spark plugs. 2. Check the plug gap and replace if the limit is
CAUTION exceeded.
• Do not attempt to adjust the gap of the iridium Standard value: 0.7 − 0.8 mm
plug. Limit: 1.2 mm
• Always use a plug cleaner and finish cleaning CAUTION
within 20 seconds. Do not use wire brushes. Be careful not to allow foreign matter in
Otherwise, the iridium tip may be damaged. cylinders.
3. Clean the engine plug holes.
4. Install the spark plugs.

Iridium tip

AKX00383 AN
16-36 ENGINE ELECTRICAL
IGNITION SYSTEM

CAMSHAFT POSITION SENSOR CHECK

M1163004400264
Check the camshaft position sensor circuit if (Refer to P.13B-179, GROUP 13B − Troubleshooting
self-diagnosis code, No. P0340 is shown. − Inspection procedure for diagnosis code.) <4G69>
(Refer to P.13A-142, GROUP 13A − Troubleshooting
− Inspection procedure for diagnosis code.) <4G63>

CRANK ANGLE SENSOR CHECK

M1163004500324
Check the crank angle sensor circuit if self-diagnosis (Refer to P.13B-169 GROUP 13B − Troubleshooting
code, No. P0335 is shown. − Inspection procedure for diagnosis code.) <4G69>
(Refer to P.13A-131 GROUP 13A − Troubleshooting
− Inspection procedure for diagnosis code.) <4G63>

DETONATION SENSOR CHECK

M1163002900058
Check the detonation sensor circuit if self-diagnosis (Refer to P.13B-166, GROUP 13B − Troubleshooting
code, No. P0325 is shown. − Inspection procedure for diagnosis code.) <4G69>
(Refer to P.13A-127, GROUP 13A − Troubleshooting
− Inspection procedure for diagnosis code.) <4G63>

IGNITION SECONDARY VOLTAGE WAVEFORM CHECK USING AN OSCILLOSCOPE

<4G63>
M1163001700233

MEASUREMENT METHOD 2. Clamp the spark plug cable with the trigger
1. Clamp the secondary pickup around the spark pickup.
plug cable. NOTE: Clamp the trigger pickup to the same
NOTE: . spark plug cable clamped by the secondary
• The peak ignition voltage will be reversed pickup.
when the spark plug cables No. 2 and No. 4,
or No. 1 and No. 3 cylinders are clamped.
• Because of the two-cylinder simultaneous
ignition system, the waveforms for two
cylinders in each group appear during
waveform observation (No. 1 cylinder - No. 4
cylinder, No. 2 cylinder - No. 3 cylinder).
However, waveform observation is only
applicable for the cylinder with the spark plug
cable clamped by the secondary pickup.
• Identifying which cylinder waveform is
displayed can be difficult. For reference,
remember that the waveform of the cylinder
attached to the secondary pickup will be
displayed as stable.
 ENGINE ELECTRICAL
IGNITION SYSTEM
16-37
STANDARD WAVEFORM

Observation Conditions
Function Secondary
Pattern height High (or Low)
Pattern selector Raster
Engine revolutions Curb idle speed

Spark line (point A)

kV

Ignition voltage
(point D)

Secondary
ignition voltage
wave pattern
Wave dampling reduction section (point B)

Dwell section

Point C

Time

AKX00278AD
16-38 ENGINE ELECTRICAL
IGNITION SYSTEM

Observation Conditions (The only change from above condition is the pattern selector.)
Pattern selector Display

kV

NO. 2 cylinder
NO. 1 cylinder NO. 3 cylinder NO. 4 cylinder ignition noise
ignition noise

Secondary ignition
voltage wave pattern Time
0
2 Newtral section

AKX01275 AC

WAVEFORM OBSERVATION POINTS

Point A: The height, length and slope of the spark line show the following trends (Refer to abnormal
waveform examples, 1, 2, 3 and 4).
Spark line Plug gap Condition of Compression Concentration Ignition Spark plug
electrode force of air mixture timing cable
Length Long Small Normal Low Rich Advanced Leak
Short Large Large wear High Lean Retarded High
resistance
Height High Large Large wear High Lean Retarded High
resistance
Low Small Normal Low Rich Advanced Leak
Slope Large Plug is fouled − − − −
Point B: Number of vibration in reduction vibration section (Refer to abnormal waveform example 5)
Number of vibrations Coil and condenser
3 or more Normal
Except above Abnormal
Point C: Number of vibrations at beginning of dwell section (Refer to abnormal waveform example 5)
Number of vibrations Coil
5 − 6 or higher Normal
Except above Abnormal
Point D: Ignition voltage height (distribution per each cylinder) shows the following trends.
Ignition Plug gap Condition of Compression Concentration Ignition Spark plug
voltage electrode force of air mixture timing cable
High Large Large wear High Lean Retarded High
resistance
Low Small Normal Low Rich Advanced Leak
 ENGINE ELECTRICAL
IGNITION SYSTEM
16-39
EXAMPLES OF ABNORMAL Example 3
WAVEFORMS • Wave characteristics
Spark line is low and long, and is sloping.
However, there is almost no spark line
distortion.
• Cause of problem
Spark plug gap is fouled.

AKX00280

Example 1
• Wave characteristics
Spark line is high and short.
• Cause of problem AKX00283

Spark plug gap is too large.

Example 4
• Wave characteristics
Spark line is high and short.
Difficult to distinguish between this and abnormal
waveform example 1.
• Cause of problem
Spark plug cable is nearly falling off (Causing a
dual ignition).

AKX00281

Example 2
• Wave characteristics
Spark line is low and long, and is sloping.
Also, the second half of the spark line is distorted.
This could be a result of misfiring.
• Cause of problem
Spark plug gap is too small. AKX00284

Example 5
• Wave characteristics
No waves in wave damping section.
• Cause of problem
Layer short in ignition coil.

AKX00282
16-40 ENGINE ELECTRICAL
IGNITION SYSTEM

IGNITION COIL
REMOVAL AND INSTALLATION <4G63>
M1163004000493

10 ± 2 N·m
3.0 ± 0.5 N·m

1 2
4
4
3
2
3
5
25 ± 4 N·m

AC301786 AB

Removal steps Removal steps (Continued)

1. Rocker cover centre cover 4. Ignition coil
2. Ignition coil connector 5. Spark plug
3. Spark plug cable
 ENGINE ELECTRICAL
IGNITION SYSTEM
16-41
REMOVAL AND INSTALLATION <4G69>
M1163004000501

Pre-removal and Post-installation Operation

Resonator Removal and Installation (Refer to GROUP 15,
Air Cleaner P.15-4).

10 ± 2 N·m

2
1

25 ± 5 N·m

AC305115AD

Removal steps Removal steps (Continued)

1. Ignition coil connectors 2. Ignition coils
3. Spark plugs

CAMSHAFT POSITION SENSOR

REMOVAL AND INSTALLATION
M1163003400517

<4G63>

2
1

3N
8.8 ± 1.0 N·m

AC301556 AB

Removal steps Removal steps (Continued)

1. Camshaft position sensor 2. Camshaft position sensor
connector connection 3. O-ring
16-42 ENGINE ELECTRICAL
IGNITION SYSTEM

<4G69>

11 ± 1 N·m

2
AC304319
AC302233
3N AC305127 AC

Removal steps Removal steps (Continued)

1. Camshaft position sensor 2. Camshaft position sensor
connector connection 3. O-ring

CRANKSHAFT POSITION SENSOR

REMOVAL AND INSTALLATION <4G63>
M1163003500514

3.0 ± 0.5 N·m

22 ± 4 N·m
6

1
8.8 ± 1.0 N·m

2
8 22 ± 4 N·m
4

3
7
8.8 ± 1.0 N·m

49 ± 9 N·m 5 49 ± 9 N·m

AC301612
 ENGINE ELECTRICAL
IGNITION SYSTEM
16-43
Removal steps REMOVAL SERVICE POINT
1. Power steering pressure switch <<A>> POWER STEERING OIL PUMP ASSEMBLY
connector REMOVAL
2. A/C compressor connector
Remove the power steering oil pump assembly from
3. A/C compressor connector clamp
<<A>> 4. Power steering oil pump assembly
the bracket with the hose attached.
5. Power steering oil pump bracket NOTE: Place the removed power steering oil pump
6. Rocker cover centre cover assembly in a place where it will not be a hindrance
7. Crankshaft position sensor when removing and installing and secure it with a
8. Crankshaft position sensor cord or wire.
connector bracket

REMOVAL AND INSTALLATION <4G69>

M1163003500525

Pre-removal and Post-installation Operation

Timing Belt Lower Cover Removal and Installation (Refer to
GROUP 11C, Timing Belt P.11C-36).

2
1

8.5 ± 0.5 N·m

AC305391 AD

Removal steps
1. Timing belt lower cover bracket
2. Crankshaft position sensor
16-44 ENGINE ELECTRICAL
IGNITION SYSTEM

DETONATION SENSOR
REMOVAL AND INSTALLATION <4G63>
M1163002800631

CAUTION
Do not drop or hit the detonation sensor against other components. Internal damage may result, and
the detonation sensor will need to be replaced.

<Intake side>

2
23 ± 2 N·m
AC301657AB

Removal steps Use special tool detonation sensor wrench

1. Detonation sensor connector (MD998773) to remove the detonation sensor.
connection
<<A>> >>A<< 2. Detonation sensor INSTALLATION SERVICE POINT
REMOVAL SERVICE POINT >>A<< DETONATION SENSOR INSTALLATION

<<A>> DETONATION SENSOR REMOVAL Detonation

sensor
Detonation
sensor

MD998773

MD998773 AC100807 AC

AC100807 AC
Use special tool detonation sensor wrench
(MD998773) to tighten the detonation sensor to the
specified torque.
 ENGINE ELECTRICAL
IGNITION SYSTEM
16-45
REMOVAL AND INSTALLATION <4G69>
M1163002800642

CAUTION
Do not drop or hit the detonation sensor against other components. Internal damage may result, and
the detonation sensor will need to be replaced.
Pre-removal and Post-installation Operation
Air Cleaner Removal and Installation (Refer to GROUP 15,
Air Cleaner P.15-4).

23 ± 2 N·m
1
5

11 ± 1 N·m

31 ± 3 N·m

3
AC302234
AC305130 AD

Removal steps Removal steps (Continued)

1. Detonation sensor connector 4. Intake manifold stay
connection <<A>> >>A<< 5. Detonation sensor
2. Detonation sensor clamp 6. Detonation sensor connector
3. Harness clamp bracket
16-46 ENGINE ELECTRICAL
IGNITION SYSTEM

REMOVAL SERVICE POINT INSTALLATION SERVICE POINT

<<A>> DETONATION SENSOR REMOVAL >>A<< DETONATION SENSOR INSTALLATION

Detonation Detonation
sensor sensor

MD998773 MD998773

AC100807 AC AC100807 AC

Use special tool detonation sensor wrench Use special tool detonation sensor wrench
(MD998773) to remove the detonation sensor. (MD998773) to tighten the detonation sensor to the
specified torque.