Starter testing Launch System Component Locations Note: Left hand drive model shown; the location on the right-hand drive model is similar. 1. Battery 2. Shift selector switch 3. Starter Note: Before testing, the ambient temperature...
Starter Replacement 1. Disconnect the negative cable from the battery. 2. Disconnect the starter cable from the B terminal on the solenoid, then disconnect the BLACK/WHITE wire from the S terminal. 1. 10x1.25 mm, 44 Nm (4.5 kgf/m); 2. 10 x...
Checking the starter brushes Measure the length of the brushes. If the length of the brushes is greatly reduced due to wear, replace the brushes (or brush holder assembly). Note: In order for the new brushes to snap into place after being installed...
Starter Freewheel Check 1. Move the freewheel on the shaft. Does she move freely? If not, replace it. 2. Rotate the freewheel in both directions. Does it lock in one direction and rotate freely in the opposite direction? If it doesn't block in...
Checking and testing the starter rotor 1. Check the rotor for wear or damage due to contact with the field winding. Replace rotor if necessary. 2. Check the surface of the switch and its diameter. If the surface is dirty or burnt, abrade it with emery cloth...
Starter brush holder test 1. Make sure there is no conduction between the positive and negative brush holders. If there is continuity, replace the brush holder assembly. 1.Positive holder (+) brushes 2. Negative holder (-) brushes 3.Positive...
Starter Assembly Note: Refer to the figure above for assembly. 1. Pry off the brush springs with a screwdriver, then slide the brushes approximately halfway out of the holders and release the springs to lock the brushes in that...
Checking the operation of the starter 1. Disconnect the wire from the M terminal. 2. Connect as shown below using as large a wire as possible (preferably the same as used in cars). 3. Connect the battery as shown. If the starter gear extends, the starter is...
Ignition system — basic information Note: Left hand drive model shown; the location on the right-hand drive model is similar. Ignition timing control system: 1. high voltage wires; 2. spark plugs; 3. distributor Wiring diagram (ignition system)
Checking and adjusting the ignition timing 1. Check the idle speed. and adjust if necessary. 2. Remove the 2-pin diagnostic connector (BROWN and BLACK wires), then insert a shorting jumper into it (P/N 07PAZ-0010100). 3. Start the engine. Maintain rpm at 3000...
Replacing the ignition distributor Withdrawal 1. Disconnect the connector from the distributor. 2. Disconnect the high voltage wires from the distributor cap. 3. Turn out fixing bolts from the distributor, then remove the distributor from a head of...
Ignition distributor repair 1. back cover; 2. distributor slider; 3. cover seal. believe in damage; 4. distributor cap. check for cracks, wear, damage and dirt. clean or replace.; 5. magnetic shield; 6. ignition coil; 7. distributor housing. check...
Ignition Coil Testing Using an ohmmeter, measure the resistance between the terminals. If the resistance is out of specification, replace the ignition coil. Note: Resistance varies with coil temperature: nominal values are given at 20°C....
Inspection and testing of high voltage wires 1. Carefully disconnect the high voltage wires by pulling on the rubber boot. Do not bend wires; You can break them from the inside. 2. Check the condition of the high voltage wire terminals. If any terminal is rusty,...
Checking spark plugs 1. Check electrodes and ceramic insulator: Burning or wear of the electrodes can occur due to: early ignition Loose spark plug Too high thermal range spark plugs Insufficient cooling Candle fouling can occur due to:...
Charging system — basic information Note: Left hand drive model shown; the location on the right-hand drive model is similar. Location of components: 1. rechargeable battery; 2. fuse/relay box under the hood (with built-in electrical load detector (ELD);...
Generator replacement 1. First disconnect the cable from the negative battery terminal, then from the positive. 2. Remove the harness holder from the top bracket. 3. Disconnect 4- (or 3-) connector and terminal B wire from the generator. 4....
Rectifier test (Denso) Note: Diodes allow current to flow in one direction and prevent it from flowing in the opposite direction. Since the alternator rectifier consists of eight diodes (four couples), it is required to test the conductivity...
Rectifier Testing (Mitsubishi) Note: Diodes allow current to flow in one direction and prevent it from flowing in the opposite direction. Since the alternator rectifier consists of six diodes, conduction testing in both directions is required with an...
Generator Repair (Denso) Note: Separating the pulley, drive side housing and rotor is only required when replacing the front bearing. Loosen the pulley with tools as shown. Use an impact wrench if necessary. 1. rear bearing; 2. rotor; 3....
Generator repair (Mitsubishi) Note: Remove the pulley only when replacing the front bearing. Loosen the pulley locknut with 10mm and 22mm socket wrenches. Use an impact wrench if necessary. 1. Caution: Do not allow grease or oil to come into contact...
Testing the Generator Control System (Models KG, KE, KQ and KU) Testing the generator control system (models KG, KE, KQ and KU) Note: Before testing with the fault indicator lamp (MIL) check if the electrical load detector unit is working properly (ELD).
Generator/regulator testing Generator/regulator testing Caution: Use caution when testing as the radiator and condenser fans will come on without warning while the engine is running.
Removing the rectifier (Mitsubishi) 1. Remove the four through bolts. 2. Heat the rear bearing housing with a 1000W hair dryer for about five minutes (50-60°C). 3. Separate the rear housing from the drive shaft side of the housing by inserting a flat head...
Checking the alternator brushes (Denso) 1. Remove the end cap, then remove the brush holder by unscrewing the two screws. 2. Measure the length of the brushes with a caliper. Generator brush length: Standard (new): 10.5 mm Limit wear: 1.5 mm 3. If the length...
Checking the alternator brushes (Mitsubishi) 1. Separate the drive shaft side housing from the rear housing as described above. 2. Separate the rear housing from the stator/rectifier assembly by removing the four screws and terminal nut from the rear housing ( see...
Testing the slip rings of the generator rotor 1. Check the resistance between slip rings. 2. It should be 1.8-3.0 ohms. If the resistance is normal, go to step 2. If the resistance is out of specification, replace the alternator. 3. Verify that there is no...
Generator stator testing 1. Check for continuity between each pair of leads. 2. Make sure there is no continuity between the leads and the coil core. 3. If the coil fails the continuity test, replace the alternator.
Rear Bearing Replacement (Mitsubishi) 1. Press out the rear bearing. Make sure the tips of the puller arms are thin enough to fit between the bearing and slip rings. Do not reinstall a removed bearing. 2. Press in the new bearing using a hand press. Apply...
Alternator assembly (Mitsubishi) 1. Press the brushes, then insert the pin or drill (about 1.8 mm in diameter) and fix them in this position. 2. Heat up the rear bearing housing in the rear housing. Once heated, proceed with assembly immediately before...
Checking and adjusting the alternator drive belt Note: When installing a new belt, first adjust the deflection or tension to the values for the new belt, then adjust the deflection or tension to the values for the used belt by starting the engine and letting it run...
Engine Electrical Specifications Engine Electrical Specifications *1: When installing a new belt, adjust the deflection to the values for the new belt. Start the engine, let it run for 5 minutes and shut it off. Re-adjust the deflection or tension to...