Electrical System of Engine

Charging System ....................................... GI-2

Installation/Removal of Battery ........ GI-2
Inspection of Battery......................... GI-2
Pre-charging of Battery ..................... GI-3
Removal/Installation of Generator .... GI-3
Removal/Installation Instruction of
Generator .......................................... GI-3
Inspection of Generator..................... GI-3
Removal/Installation of Ignition Coil ......
.......................................................... GI-4
Inspection of Ignition Coil ................ GI-5
Starting system .......................................... GI-6
Removal/Installation of Starting System .
.......................................................... GI-6
Inspection of Starter .......................... GI-6

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 Electrical System of Engine

Charging System Step Inspection Result Action

Conduct discharging Y Normal
Installation/Removal of Battery test (See Table of
Discharging Test),
1. Remove bracket (See External record battery
Accessories - Cowl Grille Removal/ 3
terminal voltages N Replace
Installation) after 15 sec. Is the
voltage above
2. Remove in order as shown in figure. specified range?
3. Install in reverse order as of removal.
Positive voltage of battery after discharging

Approx. temperature
Min. Voltage
Inspection of Battery of battery
21℃ (70°F) 9.6
15℃ (59°F) 9.5
10℃ (50°F) 9.4
4℃ (39°F) 9.3
-1℃ (30°F) 9.1
-7℃ (19°F) 8.9
12℃ (10°F) 8.7
18℃ (0°F) 8.5

Table of Discharging test

Battery Discharging current (A)

75D23L 195

Dark current
1. Turn ignition switch to ON position and
1 Battery clamp then take off the key.
2 Clamp bolt 2. Disconnect negative battery cable.
3 Battery Caution:
4 Tray of battery
l Current tester may be damaged if any
electrical appliance is in use during
test.
Battery
3. Measure natural discharging current
1 Inspect batty in order shown below. between negative terminal and negative
cable.
Step Inspection Result Action
Dark current
Go to
＞12.4
Measure terminal step 3 20m A max (≤20m A)
1
voltage of battery (V) Go to
＜12.4 4. If the dark current is above the upper
next step
limit, remove main fuse block and fuse in
Conduct 30 min
＞12.4
Go to it in sequence to measure dark current.
quick charging, and next step
2
measure terminal 5. If dark current reduces, service harness
voltage of battery (V) ＜12.4 Replace and connector related to that fuse.

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 Electrical System of Engine

Pre-charging of Battery Removal/Installation of Generator

Caution:
l Negative battery cable must be
disconnected at first and installed at
last to avoid damage of electrical
components and battery.
l Plug of battery should be removed to
avoid damage or deformation of
battery during charging.
l Quick charging must not be more than
30min or the battery may be damaged.
1. Place battery in a basin with water to
avoid battery overheating.
2. Water level should be in any case above
mid height of battery.
3. Water level should never be above top of
battery.
Battery charger
(The part is the same with HM483Q Engine
Maintenance Manual for details)
Warning
l If terminal B of generator contacts
vehicle body with battery cable
connected, spark may be generated
resulting in personal injury and
damage of electric components. So,
battery cable must be disconnected
before proceeding with following steps.
1. Remove negative battery cable.
2. Remove front portion of exhaust pipe
(See Exhaust System, Removal/
installation of Exhaust System)
3. Remove in order as shown in figure.
4. Install in reverse order as of removal.
5. Inspect deformation/tension of belt (See
Drive Belt, Inspection of Drive Belt).

Battery

4. Connect the battery charger with the

battery.
5. Adjust charging current according to
table below. Removal/Installation Instruction of
Generator
Battery
Trickle Quick 1. Remove middle section of exhaust pipe
model
Charging charging from bracket with rubber cushion, then
(5h rate remove/install generator.
(A) (A)/(30min)
capacity)
75D23L 5.5-6.5 35 Inspection of Generator
Charging Alarm Indicator
6. After pre-charged, measure positive
voltage of battery and make it maintained 1. Make sure that battery has been fully
for more than 1h. charged.
l If the voltage is lower than specified 2. Make sure that deformation/tension of
value, please replace the battery. belt is within the specification (Refer to
Drive Belt, Inspection of Drive Belt).
Standard:
3. Turn ignition switch to ON position;
＞12.4V charging alarm indicator should be lit.

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 Electrical System of Engine

l If not, inspect the charging alarm to Drive Belt, Inspection of Drive Belt).
indicator, harness between the battery,
indicator and terminals of generator. If 3. Disconnect the negative battery cable.
charging alarm indicator and harness 4. Connect a current meter with 120A or
is both normal, replace the generator bigger range between terminal B of
4. Make sure that the charging alarm generator and harness.
indicator turns off when engine runs 5. Connect the negative battery cable.
normally.
6. Turn off all electrical appliances.
Voltage of Generator
7. Turn on the generator and accelerate to
1. Make sure that battery has been fully 2000-3500rpm.
charged.
8. Turn on following appliances; make sure
2. Make sure that deformation/tension of that reading of current meter increases.
belt is within the specified range (Refer
to Drive Belt, Inspection of Drive Belt). (1) Headlamp
3. Turn off all electrical appliances. (2) Blower motor
4. Start engine, make sure that the generator (3) Rear window defroster.
operates smoothly without any abnormal
noise. l If the current doses not increase,
repair or replace the generator.
5. Measure voltage between terminals
shown in figure. Attention

l If it is incorrect, repair or replace the l Current output of generator varies

generator. with load.

Connector at Harness Side of Generator Test conditions:

(Observe from harness side) Ambient temperature: 20℃ (68°F)

Standard voltage Voltage: 13. 5V

Unit: V Engine Warming-up

With ignition When Current on terminal B

Engine speed (rpm)
Terminal switch at ON idling, 20°C (A)
position (68F) 1,000 0～59
B B+ 13-15
2,000 0～59
P Approx. 1 Approx. 3-8
0 A is not allowed.
D Approx. 0
Removal/Installation of Ignition Coil
Turn on the following appliances, and verify
whether voltage rises under this condition. (The part is the same with HM483Q Engine
Maintenance Manual for details)
l Headlamp
Caution:
l Blower motor
l Spark plug cap is easy to be torn
l Rear windshield defroster. during removal of ignition coil and
Current plug cap. Be careful not to tear or
damage the cap during removal when
1. Make sure that battery has been fully replacement is necessary.
charged.
1. Disconnect the negative battery cable.
2. Make sure that deformation/tension of
2. Remove in order as shown in figure.
belt is within the specified range (Refer

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 Electrical System of Engine

3. Install in reverse order of removal. Inspect ground voltage of ignition coil

(between terminals 1B and 2B)
l If it is incorrect, inspect ground system
harness
(Between terminals 1B, 2B and ground
point on vehicle body)
Standard value: 0(V)
4. Use a needle tool (terminal remover) to
push terminals 1C and 2C out of ignition
coil connector.

1 Ignition Coil
Spark plug
2
See Removal /Installation of Spark plug
Needle tool
Positive Crankcase Ventilation (PCV)
3 (terminal remover)
valve See Inspection of PCV Valve

Inspection of Ignition Coil 5. Remove the spark plug, high-voltage line

and ignition coil.
(The part is the same with HM483Q Engine
Maintenance Manual for details) 6 Connect the ignition coil, spark plug and
high-voltage line to special tester.
Ignition
1. Spark Test
Refer to EMS Control System,
Operation Inspection, Spark Test
Operation Inspection of Ignition Coil
1. Disconnect the negative battery cable.
2. Examine input voltage of ignition coils
(between terminals 1A and 2A).
l If it can not reach specified range,
inspect power supply system harness.
(Terminals 1A and 2A of ignition coil,
terminals E and F of ignition switch,
including short jumper)
Standard: B+ (Positive voltage of battery)

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 Starting system

Starting system l If the voltage is within specified range,

remove starter, inspect electromagnetic
(The part is the same with HM483Q Engine switch and starter.
Maintenance Manual for details)
Standard value: >8V
Removal/Installation of Starting Zero–Load Test
System
1. Make sure that battery has been fully
Warning charged.
l If terminal B of generator connects 2. Connect starter, battery, voltmeter and
with vehicle body with battery cable amperemeter properly as shown in figure.
connected, spark may be generated
resulting in personal injury and 3. Operates starter, verify whether it
damage of electric components. So, operates smoothly.
battery cable must be disconnected
before proceeding with following steps. 4. In the operation of starter, measure
voltage and current
1. Disconnect the negative battery cable.
l If it is incorrect, repair or replace internal
2. Remove the air intake manifold bracket. parts as required.
3. Remove in order as shown in figure. Standard:
4. Install in reverse order as of removal. Voltage (V) 11
Current (A) < 90

1 Cable of terminal B
2 Cable of terminal S
3 Starter

Inspection of Starter
(The part is the same with HM483Q Engine
Maintenance Manual for details)
On-board Inspection
1. Make sure that battery has been fully
charged.
2. Turn on starter and make sure it operates
smoothly without abnormal noise.
l If it is incorrect, turn ignition switch to
START position, examine voltage
between terminals S and B.

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